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EJC 14

Jungheinrich EJC 14, EJC 16, EJC-Z 14, EJC-Z 16 Operating Instructions Manual

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Page 1
Operating instructions
10004249
EJC/EJC-Z 14/16
G
06.98 -
01.06
Page 2
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
f
Used before safety instructions which must be observed to avoid danger to personnel.
m
Used before notices which must be observed to avoid material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment. o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
Page 3
0108.GB
Page 4
I 1
0401.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Description of application .................................................................... B 1
2 Assembly groups ................................................................................. B 2
3 Technical data ..................................................................................... B 3
3.1 Performance data EJC 14/16 / EJC-Z 14/16 ....................................... B 3
3.2 Dimensions EJC 14/16 ........................................................................ B 3
3.3 Dimensions EJC-Z 14/16 .................................................................... B 4
3.4 EN standards ...................................................................................... B 6
3.5 Conditions for application .................................................................... B 6
4 Location of instruction labels and identification labels ........................ B 7
4.1 Truck identification label ...................................................................... B 8
4.2 Load capacity ...................................................................................... B 8
4.3 Load capacity, wheel-arm lifting device .............................................. B 9
4.4 Label/Order/Inventory/Service No. ...................................................... B 9
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 First commissioning ............................................................................ C 2
3 Moving the truck without own drive ..................................................... 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 Open battery hood .............................................................................. D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with stationary battery charger .......................... D 3
4.2 Recharging the battery with integrated battery charger (o) ................ D 4
5 Removing and installing the battery .................................................... D 7
5.1 Remove battery by lifting it upwards
(truck without wheel-arm lifting device) ............................................... D 7
5.2 Remove battery by lifting it upwards
(truck with wheel-arm lifting device) .................................................... D 8
5.3 Lateral battery change (o) .................................................................. D 9
6 Combined instrument .......................................................................... D 10
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0401.GB
I 2
EOperation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of controls and indicating instruments .............................. E 2
3 Putting vehicle in operation ................................................................. E 4
4 Operation of the fork lift truck .............................................................. E 5
4.1 Safety regulations applicable when operating the truck ...................... E 5
4.2 Driving, steering, braking .................................................................... E 6
4.3 Picking up or lowering load units ......................................................... E 9
4.4 Safe parking of the truck ..................................................................... E 11
4.5 Fault location ....................................................................................... E 11
F Maintenance of the fork lift truck
1 Operational safety and environmental protection .................................F 1
2 Safety regulations applicable to truck maintenance .............................F 1
3 Servicing and inspection ......................................................................F 3
4 Maintenance checklist ..........................................................................F 4
5 Lubrication schedule ...........................................................................F 6
5.1 Fuels, coolants and lubricants ..............................................................F 7
6 Notes on maintenance .........................................................................F 8
6.1 Preparation of the truck for servicing and maintenance operation .......F 8
6.2 Open the battery hood .........................................................................F 8
6.3 Open the front hood .............................................................................F 8
6.4 Check hydraulic oil level .......................................................................F 9
6.5 Check the transmission oil level ...........................................................F 9
6.6 Exchanging the coarse sieve ...............................................................F 9
6.7 Checking the electric fuses ..................................................................F 10
6.8 Recommissioning the truck ..................................................................F 11
7 Decommissioning the fork lift truck ......................................................F 11
7.1 Operations to be performed prior to decommissioning ........................F 11
7.2 Measures to be taken during decommissioning ...................................F 11
7.3 Recommissioning the truck ..................................................................F 12
8 Safety checks to be performed at regular
intervals and following any untoward incidents
(D: Accident prevention check according to VBG 36) ......................F 12
Page 6
A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating 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 ope- rating 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 conside- red 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 opera- ting duties. The user must ensure that the truck is not abused and only used within its design li- mits 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 app- lies 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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0600.GB
A 2
Page 8
B 1
0401.GB
B Truck description
1 Description of application
The truck is a four-wheel electric lift truck with control shaft and controlled drive wheel. It is conceived for lifting and transporting palleted goods on level ground. Either open- ground pallets or trolleys can be picked up. A wheel-arm lifting device is available as an option, extending the ground clearance during transports on uneven ground. The nominal load capacity can be found on the identification label. The load capacity in relation to lifting height and load centre distance is specified on the load capacity label.
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0401.GB
B 2
2 Assembly groups
Pos. EJC
14/16
EJC-Z
14/16
Description
1 ttKey switch
2 ooCombined instrument
(battery discharge monitor and operating hour meter)
3 ttControl shaft with control shaft head
4 tt“Shunt driving” button
5 ttDriving regulator
6 ttCollision-guard button
7 ttHoist frame
8 ttProtective pane
9 ttBattery hood 10 ttMaster switch (emergency stop) 11 o-Battery charger 12 ttLifting device 13 ttFront hood 14 ttSupporting wheel 15 ttDrive wheel 16 ooDocument case
1
15
2
3
4
55
6
10
9
11
13
14
12
7
8
16
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B 3
0401.GB
3 Technical data
A
Specification of technical data according to VDI 2198. Technical modifications and supplements reserved.
3.1 Performance data EJC 14/16 / EJC-Z 14/16
3.2 Dimensions EJC 14/16
Description EJC 14
EJC-Z 14
EJC 16
EJC-Z 16 Q Nominal load capacity 1400 1600 kg C Load centre distance at standard fork length 600 600 mm
Driving speed with / without load 6.0 / 6.0 6.0 / 6.0 km/h Lifting speed with / without load 15 / 23 14 / 23 cm/s Lowering speed with / without load 40 / 40 40 / 40 cm/s Max. hill-climbing ability with / without load 8 / 16 7 / 16 %
Description Version
1)
EJC 14 EJC 16
h
1
Overall height (depending on mast)
2)
1700 - 2600 1700 - 2600 mm
h
2
Free lifting capacity
3)
100 100 mm
h
3
Lifting height (depending on mast)
short
long
2500 - 4300 2500 - 5350
2400 - 4200 2400 - 5250
mm
h
4
height with mast protruded (depending on mast type)
7)
short
long
2981 - 4781 2981 - 5831
2931 - 4731 2931 - 5781
mm
h
5
Free lifting capacity (double-lifting device)
4) 8)
(depending on mast type)
1219 - 2119 1169 - 2069 mm
h
13
Fork lowered 90 90 mm
y Wheel base
short
long
1217 1357
1217 1357
mm
l
1
Truck length (= l2 + l)
6)
short
long
1836 1976
1836 1976
mm
l
2
Length of front section
5) 6)
short
long
686 826
686 826
mm
B Truck width 800 800 mm
b
5
Overall distance of fork 560 560 mm
m2Ground clearance 30 30 mm
A
st
Working corridor width
5) 6)
800 x 1200 longitudinal
short
long
2140 2278
2140 2278
mm
A
st
Working corridor width
5) 6)
800 x 1200 longitudinal (according to VDI)
short
long
2277 2416
2277 2416
mm
W
a
Turning circle for shunt driving (raised control shaft)
short
long
1428 1567
1428 1567
mm
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0401.GB
B 4
3.3 Dimensions EJC-Z 14/16
1)
“short/long” version refers to the length of the battery compartment (see chap. D)
2)
for ZT hoist frame with 100 mm free lifting capacity (h2) : (h1) = + 50 mm
3)
onyl telescope hoist frame (ZT)
4)
only ZZ and DZ hoist frame
5)
with load guard: (l2)= + 15 mm
6)
with DZ hoist frame: (l2) = + 38 mm (EJC 14) + 43 mm (EJC 16)
7)
with LSG + 610 mm (EJC 14) + 560 mm (EJC/EJC(-Z)16)
8)
with LSG - 610 mm (EJC 14) - 560 mm (EJC 16)
9)
Wheel-arm lifting height with lowered wheel arm
Description Version1)EJC-Z 14 EJC-Z 16
h1Overall height (depending on mast)
2)
1700 - 2600 1700 - 2600 mm
h2Free lifting capacity
3)
100 100 mm
h3Lifting height (depending on mast) short
long
2500 - 4300 2500 - 5350
2400 - 4200 2400 - 5250
mm
h4height with mast protruded
7)
(depending on mast type)
short
long
2981 - 4781 2981 - 5831
2931 - 4731 2931 - 5781
mm
h5Free lifting capacity (double-lifting de-
vice) (depending on mast type)
4) 8)
1219 - 2119 1169 - 2069 mm
h13Fork lowered 90 90 mm
y Wheel position (lowered/lifted) short
long
1457/1397 1597/1537
1457/1397 1597/1537
mm
l
1
Truck length (= l2 + l)
6)
short
long
1868 2008
1868 2008
mm
l2Length of front section
5) 6)
short
long
718 858
718 858
mm
B Truck width 830 830 mm
b
5
Overall distance of fork 560 560 mm
m2Ground clearance
9)
20 20 mm
AstWorking corridor width
5) 6)
800 x 1200 longitudinal
short
long
2171 2310
2171 2310
mm
AstWorking corridor width
5) 6)
800 x 1200 longitudinal (according to VDI)
short
long
2348 2487
2348 2487
mm
WaTurning circle for shunt driving
(raised control shaft) Wheel arms lowered/raised
short
long
1668/1608 1807/1747
1668/1608 1807/1747
mm
h31Lifting height of wheel-arm 122 122 mm
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B 5
0401.GB
h
4
h
3
h
1
l
2
l
1
l
c
y
Q
h
5
h2h
31
h
13
b
5
A
st
W
a
B
m
2
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0401.GB
B 6
3.4 EN standards
Continuous sound level: 65 dB(A)
according to prEN 12053 as stipulated in ISO 4871.
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity dischar- ge according to prEN 12895 and the references to other standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.5 Conditions for application
Ambient temperature:
- during operation 5 °C to 40 °C
A
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.
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B 7
0401.GB
4 Location of instruction labels and identification labels
Item Description
17 Load capacity wheel-arm lifting device 18 Load capacity 19 Prohibition sign “Do not transport other persons” 20 Truck identification label 21 Limit-stop for crane loading (21a only EJC-Z) 22 Prohibition sign “Keep away from under the load lifting device” 23 Prohibition sign “Do not put your hands through the hoist frame” 24 UVV control label 25 Identification label, battery 26 Warning sign “Caution: Low-voltage electronics”
18
17
22
26
21
23
24
19
20
25
21a
kg
kg mm kg
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
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0401.GB
B 8
4.1 Truck identification label
A
In the event of queries relating to the truck or spare part orders, please state the serial no. (28) of the truck.
4.2 Load capacity
f
The label (18) includes a table indicating the loading capacity (Q in kg) in relation to the load centre di- stance (D in mm) and the lifting height (H in mm).
The arrow-shaped markings on the inner mast (40) and outer mast (41) show the driver when he has reached the lifting height limits that is defined on the load capacity label (18).
Item Designation Item Designation
27 Type 34 Drive power in kW
28 Serial No. 35 Customer no.
29 Rated capacity in kg 36 Min./max. battery weight in kg
30 Battery: Voltage V
Ampere hours Ah
37 Dead weight without battery in kg
31 Manufacturer 38 Year of manufacture
32 Order no. 39 Manufacturer logo
33 Load centre distance in mm
27
28
29
30
31
32
34
38
37
36
35
33
39
18
41
40
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B 9
0401.GB
4.3 Load capacity, wheel-arm lifting device
Trucks with a wheel-arm lifting device are provided with an extra label (17) indicating the permissible assignment to wheel-arm lifting device and main lifting device.
4.4 Label/Order/Inventory/Service No.
A
This label contains the Full Service No. and is only handed out when a service con- tract is being concluded.
Item Description
42 Order no. 43 Inventory No. 44 Full Service No.
42
43
44
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0401.GB
B 10
Page 18
C 1
0401.GB
C Transportation and commissioning
1 Transportation by crane
f
Only use lifting equipment with sufficient bearing capacity (loading weight see identi- fication label on truck). If trucks are to be lifted that are provided with a wheel-arm lifting device, be careful not to protrude the lifting cylinders while the truck is being lifted. If the device is com- pletely protruded, there is the risk that the cylinder protection is being released due to overloading.
A
A hoisting point (1) is provided at the hoist frame for loading the truck with the help of hoisting gear. Trucks that are provided a with wheel-arm lifting device, have two more hoisting points (2) for loading.
– Park the truck and render it safe
(refer to chapter E).
– Attach the hoisting gear to the stop (1)
on the hoisting mast.
– In case of trucks that are provided with
a wheel-arm lifting device, the hoisting gear can also be attached to the stops (2) on the vehicle chassis.
m
Secure the hoisting gear to the hoisting points ensuring that the hoisting gear will not slip! The hoisting gear must be atta- ched in such a way that it does touch any add-on parts while the truck is being lif- ted. Trucks with wheel-arm lifting device must hang horizontally or slightly incli- ned in the direction of the lifting device.
1
2
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0401.GB
C 2
2 First commissioning
m
The truck must only be operated on battery current. Rectified alternate current will da- mage the electronics. Cables connected to the battery (towing cable) must be less than 6 meters in length.
f
It is prohibited to hoist loads when the truck is operated via a towing cable with an external battery.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check whether the equipment is complete and in perfect condition. – If required, mount the battery, make sure not to damage the battery cable
(see chapter D).
A
At trucks with an optionally built-in battery charger, adjust the characteristics (loading cam) (see chapter D).
– Load the battery (see chapter D). – If required, check whether the settings of the combined instrument correspond to
the battery (see chapter D).
– Commission the truck as prescribed
(see chapter E).
A
If the truck is parked for longer periods, the running surfaces of the wheels may be flattened. However, this flattening will disappear quickly when the truck is being driven.
Page 20
C 3
0401.GB
3 Moving the truck without own drive
f
This type of operation is prohibited on slopes and inclinations.
If the truck must still be moved after a fault has occurred, proceed as follows:
– Set master switch to “OFF” position. – Set key switch to “0” position and re-
move the key. – Secure the truck against rolling away. – Open and remove front hood
(see chapter F). – Turn the screws (3) anticlockwise until
you reach the limit stop.
The solenoid brake is triggered. The truck can now no longer be moved.
f
If you reached the target location, reset the brake system to its original condition! The truck must not be parked with released brake!
– Return the screws (3) anticlockwise until they touch the limit stop.
The original brake condition is restored.
Page 21
0401.GB
C 4
Page 22
D 1
0401.GB
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 handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery re- charging. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- minals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a non- skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- tional environmental protection regulations or waste disposal provisions. The manu- facturer’s specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be dama- ged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into con- tact with battery acid. Spilled battery acid must be immediately neutralized.
m
Only batteries with closed tray may be used.
f
Battery weight and dimensions have considerable influence on operational safety of the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.
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0401.GB
D 2
2 Battery types
The vehicle is equipped with different battery types depending on the type. The battery weights are specified on identification label of the battery.
m
When changing / assembling the battery, make sure that it is properly fixed in the bat- tery compartment the truck.
The following table shows the standard battery combinations and battery capacities:
Depending on the battery type, also high-performance or maintenance-free batteries can be used.
3 Open battery hood
– Park the truck and render it safe (refer to chapter E). – Set master switch (2) to “OFF” position. – Open the battery hood (1).
f
The battery hood (1) is held in place by its own weight.
Truck type 24V - Pz... - battery
EJC 14 EJC 14
EJC /-Z 14 / 16
2 PzB 126 Ah 2 PzB 150 Ah 2 PzB 180 Ah
EJC /-Z 14 / 16 EJC /-Z 14 / 16
3 PzS L 270 Ah 3 PzS L 330 Ah
2
1
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D 3
0401.GB
4 Charging the battery
As default, the truck is to be loaded with a stationary battery charger. The truck wit- hout wheel-arm lifting device can optionally be supplied with an integrated battery charger.
m
For recharging the battery, the truck has to parked in-doors in a sufficiently ventilated environment.
4.1 Charging the battery with stationary battery charger
– Park the truck and render it safe (refer to chapter E).
m
Connection / disconnecting battery connector and socket as well as pressing the ma- ster switch (2) may only be performed with truck and battery charger being switched off.
– Expose the battery (refer to section 3).
f
During the recharging operation the tops of the battery cells must be exposed to en- sure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed.
– Pull battery connector (3) from the plug and socket connection of the truck. – Remove insulation mat from battery, if necessary. – Connect the charging cable (4) of the battery recharging station with the battery
connector (3) and switch on the battery charger.
m
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
Page 25
0401.GB
D 4
4.2 Recharging the battery with integrated battery charger (o)
f
The battery charger must not be opened. If it is damaged, it has to be exchanged.
A
Due to safety reasons, intermediate positions are available between the regulation positions “1” to “6” of the switch (7). If the truck is delivered without battery, an intermediate position is pre-selected as de- fault. The red light-emitting diode (5) flashes - the battery cannot be recharged.
Select charging curve in the integrated battery charger
Use switch (7) at the battery charger to adjust the charging curves to the appropriate battery according to the following table.
m
The power plug must be pulled before the corresponding charging curve is to be ad- justed!
Provided that a battery is connected, a new setting can be acknowledged via the LEDs (cf., indicator) which will then be immediately effective.
Position of switch (7) selected charging curves (characteristics)
1 Wet batteries: 100 - 300 Ah
2 Maintenance-free: 100 - 140 Ah
3 Maintenance-free: 150 - 200 Ah
4 Maintenance-free: 210 - 300 Ah
5F r e e
6F r e e
6
7
5
Page 26
D 5
0401.GB
Adjusting the charging curve
The charging curve can be adjusted by performing the following steps:
Starting the recharging process with integrated battery charger
– Park the truck and render it safe (refer to chapter E).
f
During the recharging operation the tops of the battery cells must be exposed to en- sure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed.
Mains supply
Line voltage: 230 V (+10/-15%) Line frequency: 50 Hz / 60 Hz
The power plug (8) of the battery charger can be found in the battery compartment.
– Expose the battery (refer to section 3). – Remove insulation mat from battery, if necessary. – Pull out master switch (2) (position “ON”). – Connect power plug (8) with a power socket.
Connect the battery This permits to use the battery
charger as an adjustment aid
Turn the adjustment switch to the right (i.e. clockwise) until it touches the limit stop.
The red LED flashes fast no valid
charging curve sel- ected
Turn the adjustment switch to the left (i.e. anticlockwise) until it tou- ches the limit stop.
After 3 seconds the green LED flashes only once
charging curve 1 selected
Select the desired charging curve by turning the adjust- ment switch to the right
The red LED starts to flash in the intermediate positions. If a valid charging curve is sel- ected, the green LED starts to flash in the relevant switch po- sition.
8
Page 27
0401.GB
D 6
A
The master switch (2) may only be operated with truck and battery charger being swit- ched off.
The flashing LED indicates the charging status and/or a fault (flashing codes see ta- ble “LED display”).
A
If the power plug (8) is connected to the mains, all electric functions of the truck are interrupted (electric driving lock). No operation of the truck is possible.
– Pull plug (8) from the power socket and place it in the battery compartment.
A
The recharge procedure is automatically continued after a power failure. The recharge procedure can be interrupted by pulling the power plug and can be con- tinued in steps.
f
The mains cable must not be damaged. Before commissioning the truck, the battery hood must be properly closed.
Charging times
The time required for recharging depends on the capacity of the battery.
LED display
Fill-up charge
The fill-up charge begins automatically after the recharge procedure has ended.
Partial recharging
The battery charger is designed in such a way that it automatically adapts to the char- ging status of partially recharged batteries. This permits to reduce wear and tear of the battery.
Green LED (6)
(charging
status)
Red LED (5)
(fault)
Indication
is lit --- Recharge procedure is finished; battery is full.
(charging break, fill-up charge or equalization charge)
flashes slowly --- Charging process
flashes fast --- Indicates the start of a recharge procedure or that a
new charging curve was adjusted. The number of the flashing pulses corresponds to the adjusted charging curve.
--- is lit Excess temperature. Recharge process is interrup- ted.
--- flashes slowly Safety charging interval exceeded. Recharge pro- cess is interrupted. Disconnection from the mains is required for restarting the charging process.
--- flashes fast charging curve setting is invalid.
--- --- Power failure and/or no battery connected.
Page 28
D 7
0401.GB
5 Removing and installing the battery
– Expose the battery (refer to section 3).
f
The truck must stand horizontally. Batteries with exposed terminals or connectors must be covered with a rubber mat to prevent short-circuits. Place battery connector and battery cable in such a way that they do not get caught within the truck interior when the battery is pulled out.
f
When replacing batteries, ensure that a battery of the same type is fitted. Supplemen- tary weights may not be removed or changed in their position.
f
After reinstallation of the battery, visually check all leads and connectors for damage. Before commissioning the truck, the battery hood must be properly closed.
A
When changing the battery with the aid of a lifting gear, ensure that the lifting gear is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The battery must be lifted vertically to prevent crushing of the battery trough. The hooks are to be attached to the battery hoisting ears (9) that they cannot fall onto the battery cells when the hoisting gear is released.
5.1 Remove battery by lifting it upwards (truck without wheel-arm lifting device)
– Withdraw the battery connector. – Attach hoisting gear to the hoisting ears (9). – Lift out the battery.
The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.
9
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D 8
5.2 Remove battery by lifting it upwards (truck with wheel-arm lifting device)
– Withdraw the battery connector (3).
f
The battery cable of the truck must be laterally led outside. While removing the bat- tery, make sure that the cable is not squeezed.
– Attach hoisting gear to the hoisting ears (9). – Lift out the battery.
The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.
39
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D 9
0401.GB
5.3 Lateral battery change (o)
– Withdraw the battery connector. – Pull the locking mechanism (12) of the battery cover upwards while firmly holding
the battery cover (13). – Lift out the battery cover (13) and keep it in a safe location. – Position battery trolley next to the truck. – Push cautiously battery (11) from the truck onto the battery trolley / battery change
station.
f
Be careful not to place your fingers between partition wall of the truck and the battery. Heed the operating instructions of the battery change station.
Mounting the battery:
– Insert battery up to battery stop (10). – Press in the battery stop and keep it in that position. – Pull battery into the truck.
The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.
Page 31
0401.GB
D 10
6 Combined instrument
Battery discharge indicator: The di-
scharging status of the battery is indica- ted by 10 beams on battery icon (14) re- presenting 10%-steps.
As the discharge proceeds, the beams go out from top to bottom.
m
If maintenance-free batteries are used, the instrument must be adjusted in such a way that the T icon (17) appears next to the operating hours indicator. If this setting is not selected, the battery may be damaged due to a complete dischar- ge. For adjusting the instrument, it is re- commended to consult the manufacturer service.
When a remaining battery capacity of
- 30% for standard batteries
- 50% for maintenance-free batteries is reached, a “CAUTION” icon (15) is in- dicated. Recharging the battery is recommen- ded.
When a remaining battery capacity of
- 20% for standard batteries
- 40% for maintenance-free batteries is reached, the “CAUTION” icon goes out and a flashing “STOP” icon (16) ap- pears. After 5 min., the “STOP” icon box lights up permanently. Recharging the battery is recommended.
Battery discharge monitor: When the “STOP” icon is permanently lit, the lifting function is switched off.
A
The lifting function can only be re-activated, when the connected battery is at least recharged by 70%.
Operating hour meter: The operating hour meter (18) is integrated in the battery di- scharge indicator and displays the overall operating time of all driving and lifting mo- vements.
A
The digit to the right-hand side of the decimal point is flashing when the device is ac- tive.
h
h
h
STOP
T
T
T
14
15
16
17
18
Page 32
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0401.GB
E Operation
1 Safety regulations governing the operation of the fork lift truck
Driving permission: The fork lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his re- presentative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork lift truck du- ring working time. He must forbid unauthorised persons to drive or operate the fork lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork lift truck or on the attach- ments must immediately be brought to the notice of the person in charge. fork lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also inclu- des the area within reach of falling loads or falling / lowering truck attachments.
f
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork lift truck must immediately be brought to a standstill if persons, although as- ked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
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E 2
2 Description of controls and indicating instruments
Pos. Controls or
indicating instrument respectively
EJC
14/16
EJC-Z
14/16
Function
1 Master switch
(Emergency Stop)
tt
The circuit is interrupted, all electric functions are switched off. The truck is compulsory braked.
2 Key switch
tt
Switches the control current on and off. When the key is removed from the key switch, the truck cannot be opera- ted by unauthorised persons.
3 Combined instrument
oo
Indicates the remaining capacity of the battery and the hours of operation that truck has already performed (see chapter D).
4 Control shaft
tt
Steering and braking the truck.
5 Button - Shunt driving
tt
If the control shaft is in the upper bra- king range, the braking function can be by-passed by pressing this button. The truck can only be mo- ved with reduced speed (shunt dri- ving).
6 Button - wheel arms
lowering
-t
Wheel arms are lowered with constant speed
7 Button - wheel arms
lifting
-t
Wheel arms are lifted with constant speed
8 Driving regulator
tt
Controls the driving direction driving speed.
9 Collision-guard
button
tt
Truck drives away from the operator and stops.
10 Button -
Lifting the lifting device
tt
Lifting the lifting device. The lifting speed can be continuously
adjusted with this key (adjustment ran- ge 8 mm).
11 Button -
Lowering the lifting de- vice
tt
Lowering the lifting device. The lowering speed can be conti-
nuously adjusted with this key (adjust- ment range 8 mm).
12 Button - warning signal
(horn)
tt
Trigger warning signal.
13 Terminal strip
tt
Depositing of freight documents.
14 Control lamp at the
battery charger
o-
Indicates the loading states (see chapter D).
15 Integrated battery
charger
o-
Used for recharging the battery
16 Document case
oo
Used for depositing documents
t
= Standard equipment
o
= Optional equipment
Page 34
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0401.GB
2
1
3
4
5
8
8
10
11
12
9
13
14
15
16
7
6
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E 4
3 Putting vehicle in operation
f
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
Checks and actions before routine start-up
– Visual inspection for damages of the whole truck (especially tyres and load carrying
devices). – Visual inspection of battery fixing and cable connections.
Starting up the truck
– Pull out master switch (1). – Put key into the key switch (2) and turn right until stop to position “I”.
The combined instrument (3) indicates the available battery capacity. – Check function of horn (12). – Check control shaft (4) for braking and driving function (see section 4.2).
The truck is now ready for operation.
2
1
3
4
12
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0401.GB
4 Operation of the fork lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially alloca-
ted for truck traffic must be used. Unauthorized persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local con- ditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must al- ways observe an adequate braking distance between the fork lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permit- ted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork lift truck driver has to sa- tisfy himself accordingly before driving into lifts or on to loading platforms. 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. Persons riding in the lift together with the fork lift truck must only enter the lift after the fork lift truck has come safely to a standstill, and must leave the lift before the fork lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carria- ge, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
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E 6
4.2 Driving, steering, braking
f
Increased attention has to be paid during driving and steering the truck, especially if movements outside of the truck contour are to be performed. It is not admissible to stay on the vehicle during driving.
Driving with load lifting devices or loads lifted higher than the ground clearance di- stance is only permitted when the load is to be picked up or to be lowered to the ground. From a certain type dependant lift height, the drive speed is automatically re- duced during lifting and increased again during lowering.
EMERGENCY STOP
– Push master switch (1) down.
All electric functions are switched off. The truck is compulsory braked.
Emergency stop
When the control shaft (4) is released, the truck is compulsory braked (emergency stop) - the control shaft (4) automatically swivels into the upper braking range (B).
f
If the control shaft (4) swivels only slowly into the braking position, it is required to per- form troubleshooting measures. For example, the return spring must be exchanged!
Driving
f
Do not drive the truck unless the hoods are closed and locked in the stipulated man- ner. When driving through swinging doors, etc., make sure that the doors do not trig- ger the collision-guard button (9).
– Commissioning the truck (see section 3). – Push the control shaft (4) into the driving range (F) and set the driving switch (8) to
the desired driving direction (V or R).
The truck starts to drive into the selected direction.
A
The driving speed can be continuously regulated with the driving switch (8).
0
R
R
V
B
F
B
V
4
8
9
1
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0401.GB
f
If the truck can only be moved with reduced driving speed, a defect has occurred which is influencing the safety of operation of the truck. It may be that the service bra- ke can only be used after pressing the EMERGENCY-STOP switch (1). The truck needs to be taken out of service and must be repaired by expert personnel (see chapter F).
Driving on slopes
m
The load must be transported pointing towards the mountain!
Securing the truck against “rolling downhill”:
If the driving switch is set to zero, the service brake is automatically triggered when the truck starts to roll downhill (the control system detects the unintended movement of the truck). The driving switch can be used to release the service brake and to select the desired driving speed and direction.
f
If the roll-off brake was deactivated by the service, only service brake and counterflow brake are available.
Steering
– Swivelling the control shaft to the left-hand or right-hand side.
Shunt driving
f
The driver must pay special attention if he uses the “Shunt driving” button (5).
The truck can be moved with its control shaft (4) in ver- tical position (e.g. in confined spaces / lifts):
– Press “Shunt driving” button (5). – Set the driving switch (8) to the desired driving direc-
tion (V or R).
The service brake is triggered. The truck changes to the slow-driving mode.
m
The service brake is only activated after releasing the “Shunt driving” button; in the Shunt driving mode, braking is only possible using the counterflow brake (driving switch (8)).
f
In case of danger, the truck can be immediately braked by releasing the “Shunt dri- ving” button (5).
4
885
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0401.GB
E 8
Braking
f
The braking effect of the truck is mainly depending on the road surface. This must be taken into account by the driver for his driving behavior.
The truck may be braked in three ways:
– Using the service brake (control shaft (4)), – Using dynamic braking (roll-off brake can be adjusted by the service), – Control with regenerative brake via the drive control (8).
A
For standard driving operations, only the dynamic brake and that counterflow brake are to be used, since these brake types are reduce wear and tear and help to save energy (energy return supply).
Braking with the service brake:
f
In case of danger, the truck must be braked with the service brake (control shaft (4)).
– Swivel control shaft (4) upwards or downwards into one of the braking ranges (B).
The drive motor is mechanically braked.
A
When the control shaft (4) is released, it swivels into the upper braking range (B).If the truck is parked, the service brake is used as parking brake
Dynamic braking (roll-off brake):
– After releasing the driving switch (8) - driving switch set to zero - the truck is braked
with the help of the dynamic brake (roll-off brake), depending on the selected set-
ting.
f
If the roll-off brake was deactivated by the service, only service brake and counterflow brake are available.
Braking with the counterflow brake:
m
If the control system or driving mechanism breaks down, the counterflow brake beco- mes ineffective.
– Do not turn the drive control (8) into opposite driving direction.
A
The braking effect depends on the position of the driving switch.
0
R
R
V
B
F
B
V
4
8
9
1
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0401.GB
4.3 Picking up or lowering load units
f
Before a load unit is picked up, the driver has to make sure that it is properly palletised and does not exceed the permitted bearing capacity of the truck. Do not grab into the hoist frame during lifting and lowering.
– Drive the truck with the fork tines as far as possible below the load unit.
It is not permitted to pick up long goods with the truck driving transversally below
the good.
A
The double-two lifting hoist frame (ZZ) and the triple-two hoist frame (DZ) the first lif- ting movement of the load carriage (free lifting capacity) is realised without changing the overall height with the help of a short free-lifting cylinder which is centrally arran- ged.
From a specific lifting height onwards (depending on the design), the driving speed is automatically reduced when the lifting movement is performed and increased when the lowering movement is started.
Lifting
– Press the “Lift the lifting device” button
(10) until the desired height has been
reached.
Lowering
– Press the “Lower the lifting device”
button (11) until the desired height has
been reached.
A
The lifting/lowering speed can be conti- nuously adjusted with this button (adju- stment range 8 mm).
Small button adjustment range = slow lifting / lowering Large button adjustment range = fast lifting / lowering
m
Avoid any abrupt lowering of the load unit.
10 11
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E 10
Wheel-arm lifting device (o)
A
The “Lift wheel arms” and “Lower wheel arms” can be used to perform the lifting or lowering movement with a fixed speed.
f
To ensure the stability of the truck, the wheel arms will be automatically lowered from a specific lifting height of the fork onwards, depending on the used hoist frame type. From this lifting height onwards, the wheel-arm lifting device can no longer be used. The lowering movement cannot be interrupted! (Danger of injuries)
Lifting the wheel arms
– Press the “Lift wheel arms” (7) button. – Keep the button pressed, until the
desired lifting height has been rea-
ched.
Lowering the wheel arms
– Press the “Lower wheel arms” (6) but-
ton. – Keep the button pressed, until the
desired lowering height has been rea-
ched.
Emergency lowering system
f
The emergency lowering system may only be used if there are no persons within the danger zone.
If the lifting device can no longer be lowered due to a defect in the lifting control sy- stem, the emergency lowering system has to be activated.
– Set key switch (2) to its “0” position
and set the master switch (1) to its
“OFF” position. – Pull the battery connector
(see chapter D). – Open the front hood
(see chapter F). – Loosen the screw on the valve group
(17).
A
The required Allen key (2.5 mm) can be found at the valve group.
The lifting device is lowered.
– Retighten the screw (17) after the emergency lowering procedure has been perfor-
med.
f
The truck may only be retaken into service after the required troubleshooting measu- res were successfully performed.
67
17
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4.4 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
f
Do not park the truck on slopes! The lifting device must always be completely lowe- red.
– Bring control shaft (4) into brake position (B). – Lowering the lifting device. – Set key switch (2) to “0” position and remove the key. – Set master switch (1) to “OFF” position.
4.5 Fault location
This chapter helps the operator to locate and fix simple malfunctions or the results of operating errors him- or herself. The order of the work stated in the table must be ob- served for fault location.
f
If it is not possible to rectify the fault by performing the indicated “remedial actions”, please contact the Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
Fault Possible cause Remedy
Truck does not move
– Battery connector
not connected
– Check the battery connector
and reconnect it, if necessary – Master switch (EMERGENCY
STOP) pressed
– Release
master switch (EMERGENCY
STOP) – Key switch set to “0“ position – Set the key switch to position “I” – Battery voltage too low – Check the charging status of
the battery
and recharge, if necessary – Control shaft not swivelled into
driving range (F)
– Swivel control shaft into driving
range (F) – Faulty fuse – Check
fuses F1 and 1F1 – Truck battery charger is con-
nected
– Disconnect the truck battery
charger
from the mains
Load cannot be lifted
– Truck not ready for operation – Perform all troubleshooting
measures that are mentioned
under “truck does not drive” – Hydraulic oil level too low – Check hydraulic oil level – Faulty fuse – Check fuse 2F1 – load too high – Pay attention to the maximum
bearing capacity (see identifi-
cation label) – Discharge monitor is triggered
(STOP icon)
– Check the charging status of
the battery
and recharge, if necessary
Page 43
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E 12
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0401.GB
F Maintenance of the fork lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To en- sure safe and reliable operation of the fork lift truck, only spare parts of the manufac- turer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tip- ping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork lift truck. Prior to commencing cleaning operations, all safety measures that are re- quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope- rated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com- pressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
m
If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis- sioning” must be performed.
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F 2
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork lift trucks, the truck must also be depowe- red by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components, these have to be removed from the fork lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. The factory-mounted tyres must only be replaced by original spa- re parts of the manufacturer, since otherwise the specification of the data sheet cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubri- cation is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy- draulic components, also renew the hoses in this hydraulic system.
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0401.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork lift truck. The neglect of regular servicing intervals can lead to fork lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large tem- perature fluctuations or multiple-shift operation, the servicing intervals must be shor- tened accordingly.
The following servicing checklist indicates the operations to be performed and the re- spective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week M3 = every 500 operating hours, but at least every 3 months M6 = every 1000 operating hours, but at least every 6 months M12 = every 2000 operating hours, but at least every 12 months
A
The W1 maintenance intervals must be carried out by the operator / customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.
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0401.GB
F 4
4 Maintenance checklist.
Maintenance intervals
Standard = t WMMM Cold-storage depot = k 13612
Chassis/ Design:
1.1 Check all load bearing elements for damage t
1.2 Check all bolted connections t
Drive unit: 2.1 Check the transmission for noises and leakage t
2.2 Check the transmission oil level t
2.3 Change the gear oil kt
Wheels: 3.1 Check for wear and damage t
3.2 Check seating and attachment kt
Steering: 4.1 Check the steering clearance t Brake system:
5.1 Check for correct function and adjustment kt
5.2 Check the return spring for repositioning function and damage
t
5.3 Check the brake linings for wear t
5.4 Check the brake linkage; adjust and grease, if necessary
kt
Hoist frame: 6.1 Visual check of rollers, slide pieces and stops kt
6.2 Check fork tines and fork carrier for wear and damage kt
6.3 Check secure attachment of hoist frame t
6.4 Check lift chains and chain guide for wear, adjust and grease them.
t
6.5 Check the lateral clearance of the mast profiles and whether they are parallel to each other
t
6.6 Check safety devices for proper attachment and damages
kt
Lifting device: 7.1 Check function, wear and tear and adjustment t
7.2 Visual check of rollers, slide pieces and stops kt
7.3 Check fork tines and fork carrier for wear and damage kt
Hydr. system: 8.1 Check function kt
8.2 Check all connections for leakage and damage kt
8.3 Check hydraulic cylinders for leakage, damage and secure attachment
kt
8.4 Check the oil level kt
8.5 Change hydraulic oil kt
8.6 Change filter t
8.7 Check the pressure relief valves for correct functioning kt
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0401.GB
Maintenance intervals
Standard = t WMMM Cold-storage depot = k 13612
Electr. system:
9.1 Check function t
9.2 Check all cables for secure connection and damage t
9.3 Check the fuses for correct amperage t
9.4 Check switches and trip cams for proper functioning and seating
t
9.5 Check contactors and relays, replace wearing parts, if necessary
t
9.6 Check functioning of warning devices and safety circuits kt
Electric motors:
10.1 Check wear of carbon brushes t
10.2 Check the motor for secure attachment t
10.3 Suck out engine block, check wear of collector kt
Battery: 11.1 Check acid density, acid level and cell voltage kt
11.2 Check the terminals for secure attachment and apply pole grease
kt
11.3 Clean battery connections, check for tight fit kt
11.4 Check the battery cables for damage and replace, if necessary
t
Lubrication service:
12.1 Grease truck according to lubrication schedule kt
General mea- surements:
13.1 Check electrical system for short to ground t
13.2 Check driving speed and braking distance t
13.3 Check lifting and lowering speed t
13.4 Check safety facilities and switch-off devices t
Demonstrati- on:
14.1 Perform a trial run under a nominal load t
14.2 Demonstrate the truck to a person charged with inspec- tion upon completion of the maintenance of the truck
kt
Page 49
0401.GB
F 6
5 Lubrication schedule
g Slide faces
s Grease nipple
Filler neck for hydraulic oil
b Filler neck Gear oil a Drain plug Gear oil
1) Mixing proportion for application in cold-storage depots 1:1
2) Tandem load wheel
3) Filling level see “Check hydraulic oil level”
B
1,4l
MA=105Nm
B+C
1)
G
A A+C
1)
2)
3)
E F
E F
E F
Page 50
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0401.GB
5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type ma- terials must be stored in adequate containers. They might be inflammable and, the- refore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualitiies resp., except if mi- xing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be dis- posed of according to the regulations.
Grease Data
Code Order-no. Supply Qty Designation Used for:
A 29 200 670 5,0 l H-LP 46, DIN 51524 Hydraulic system B 29 200 680 5,0 l CLP 100, DIN 51517 Transmission C 29 200 810 5,0 l H-LP 10, DIN 51524 Transmission,
hydraulic system E 29 201 430 1,0 kg Grease, DIN 51825 Lubrication F 29 200 100 1,0 kg Grease, TTF52 Lubrication
Code Saponification Dropp.
point °C
Worked penetr.
at 25° C
NLG1 class Service tempe-
rat. °C
E Lithium 185 265-295 2 -35/+120
F -- -- 310-340 1 -52/+100
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6 Notes on maintenance
6.1 Preparation of the truck for servicing and maintenance operation
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
– Park the truck and render it safe (refer to chapter E). – Disconnect the battery connector to prevent accidental or unauthorised truck ope-
ration.
f
When work has to be performed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, the instructions included in chapter “Transportation and Commissioning” have to be observed.
6.2 Open the battery hood
See chapter D.
6.3 Open the front hood
– Turn the control shaft to the truck outer edge or incline it slightly. – Release the hood locking mechanism (1); the key (2) can be found in the battery
compartment.
– Raise the hood (3) and place it next to the truck.
A
Mounting is performed in reverse order .
1
4
3
2
5
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0401.GB
6.4 Check hydraulic oil level
– Prepare the truck for servicing and maintenance operations (refer to chapter F, sec-
tion 6.1). – Open the front hood (see section 6.3). – Check the hydraulic oil level of the hydraulic tank (see section 5).
A
There are markings on the hydraulic tank (see section 5). The oil level must be chek- ked with the lifting device being lowered.
– If required, top up with hydraulic oil with the required characteristics
(see section 6.4; see table)
A
Mounting is performed in reverse order.
6.5 Check the transmission oil level
– Prepare the truck for servicing and maintenance operations (see section 6.3). – Open the front hood (see section 6.2). – Loosen 2 x screws (5) using the key (2). – Remove carefully the wheel cover (4). – Check gear-oil level - oil level must reach the filler neck
(see section 5). – If required, top up with gear oil with the required characteristics (see section 5).
A
Mounting is performed in reverse order.
6.6 Exchanging the coarse sieve
– Preparation of the truck for servicing
and maintenance operations
(refer to chapter F, section 6.1). – Open the front hood (see section 6.2). – Loosen the screwed connection (6). – Pull off the connection (7) and remove
the coarse sieve. – Insert a new coarse sieve.
A
Mounting is performed in reverse order.
A
Tighten screwed connection (6) with max. 60
+10
Nm.
Marking Litre Lifting heights (h3)
EZTZZDZ
Upper edge approx. 10.5 - - - up to 5350
4 approx. 10 - - - - 3 approx. 8.3 - - up to 4300 up to 4300 2 approx. 6.8 - up to 4300 up to 3600 - 1 approx. 5.1 all up to 3200 up to 2500 -
6 7
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6.7 Checking the electric fuses
– Preparation of the truck for servicing and maintenance operations
(refer to section 6.1).
– Open the front hood
(see section 6.3).
– Referring to the table, check all fuses for correct rating and replace, where required.
Item Description Protection of: Value
8 F1 Total control fuse 10 A
9 1F1 Drive motor (in parallel to 1F10) 150 A 10 2F1 Pump motor 150 A 11 1F10 Drive motor (in parallel to 1F1) 40 A 12 6F1 Discharge indicator/operating hour meter 10 A
12
11
10 9
8
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0401.GB
6.8 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
– Check the horn for proper functioning. – Check the master switch for correct functioning. – Check the brake for correct functioning. – Lubricate truck according to lubrication schedule.
7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be par- ked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
m
During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional mea- sures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck. – Check the brakes for correct function. – Check the hydraulic oil level and top up if required (refer to chapter F). – Apply a thin film of oil or grease to all parts not protected by a paint coating. – Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F). – Recharge the battery (refer to chapter D). – Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
m
Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
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7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck. – Lubricate the fork lift truck according to the lubrication chart (refer to chapter F). – Clean the battery. Grease the pole screws using pole grease and reconnect the
battery. – Recharge the battery (refer to chapter D). – Check if the gear oil contains condensed water and change if required. – Check if the hydraulic oil contains condensed water and change if required. – Start up the fork lift truck (refer to chapter E).
A
Battery-operated fork lift trucks: If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork lift truck has to be chek- ked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experi- enced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the in- spection of fork lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects. Apart from this, the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with specially qualified staff. As visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to it. This plaque indicates in which month of which year the next test will be due.
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