03.12 06.1351212330 ECR 327 / 336 Operating Instructions u ECR 336
ECR 327
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Foreword
Notes to the Operating Instructions
All forklift truck users should be familiar with their Local, Regional, and National regulations. United States users should be familiar with the Occupational Safety and Health Administration (OSHA) regulations and standards, and ANSI/ITSDF B56.1, Safety Standard for Low Lift and High lift Lift Trucks.
Safe operation of the industrial truck requires special knowledge, which is acquired from these Operating Instructions, from the training required by OSHA under 29 CFR 1910.178, and by training operators in factory installations and their functions. Safe operation of the industrial truck also requires knowledge that can be acquired from these ORIGINAL OPERATING INSTRUCTIONS. Information is set out concisely and in a clear format. The chapters are arranged by letter and the pages are numbered sequentially.
Various types of industrial trucks are described in these Operating Instructions. When operating the vehicle and carrying out maintenance work, make certain you use the description corresponding to your vehicle type.
See www.osha.gov web site for more information on Re
See www.itsdf.org web site for more information on the B56.1 Safety Standards for Low Lift and High Lift Trucks.
Safety instructions and important information together with their relative importance are indicated by the following safety warning symbols and indicator words:
Safety instructions and markings
Safety instructions and important information together with their relative importance are indicated by the following safety warning symbols and indicator words:
DANGER!
Danger indicates an hazardous situation which, if not avoided, will result in death or serious injury.
WARNING!
Warning indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION!
Caution indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTE
Notice is used to address practices not related to personal injury.
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This message appears if special information, instructions, or indications are needed with regard to procedures, equipment, tools, pressures, loads, and other special data.
t Denotes standard equipment
o Denotes optional equipment
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Z
It is impossible for the manufacturer to foresee every possible operational circumstance that could involve a potential danger. For that reason, the warnings in this manual and on the equipment itself do not encompass all possible circumstances. If you use a tool, procedure, working method, or operating technique not expressly recommended by the manufacturer, you must make sure yourself that it does not present a safety risk to you or to anyone else. You must also ensure that the product will not be damaged or made unsafe through operation, lubrication, maintenance, or the chosen repair measures.
The information, technical data and illustrations contained in this document are based on the information available at the time of publication. Specifications, torques, pressures, measurements, settings, illustrations, and all other data are subject to change at any time. These changes relate to the performance of the product. Before executing a task you should request the most up-to-date and comprehensive information from the manufacturer. Up-to-date information can be obtained from your dealer. You can also obtain additional copies of the manual from your dealer.
In the interests of technical advancement, the manufacturer reserves the right to make changes, while retaining the essential features of the type of vehicle described, without amending these Operating Instructions at the same time.
Copyright
Copyright of this operating manual remains with Jungheinrich AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Phone: +49 (0) 40/6948-0
www.jungheinrich.com
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ATable of contents
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ACompliance with regulations - Legal requirements and common sense...............................................................................11 BRecognition and avoidance of risks .........................................13 CProper use...............................................................................15 1General............. ............15 2Proper use............... ..............16 3Permissible usage conditions..................................................................17 4Duties of the operator.......... ............18 5Installing attachments and/or attaching accessory parts.........................19 6General instructions for operating personnel and the owner ...................20 7Nameplate............. ............22 DDescription of vehicle...............................................................23 1Description of use....................................................................................23 1.1Vehicle models and rated load capacities ..............23 2Description of components and functions................... ............24 2.1Overview of components..... ............24 2.2Functional description.......... ............25 3Technical data.........................................................................................27 3.1Performance data................ ............27 3.2Dimensions.............. ..............28 3.3Electromagnetic Compatibility (EMC)......................................................31 3.4Usage conditions.............. ............32 4Position of labels and nameplates............ ..............33 4.1Nameplate...............................................................................................34 4.2Label - warning regarding coasting while the "Pedestrian" jog button right is held down............................................................................................35 4.3Label - Danger battery......... ............35 4.4Label - warning regarding risk of injuries......... ............35 4.5Label - warning regarding the minimum size of the battery.....................36 4.6Label - warning regarding coasting.......... ..............36 4.7Label - warning regarding risk of injuries and parking the vehicle...........37 4.8Label - Load capacity Qmax....................................................................38 4.9Label - attention battery charger............ ..........38 4.10Label - warning regarding coasting while the "Pedestrian" jog button left is held down............................................................................................38 4.11Label - warning regarding electrical devices.............. ............39 4.12Stability....................................................................................................40
8 EOperation.................................................................................41 1Important general issues affecting safe operation and use of the industrial truck..................................................................................................41 1.1Training, certification, and approval to operate the industrial truck.........41 1.2Damage and repairs to the industrial truck................. ............44 1.3Issues related to the load........................................................................45 1.4Operating environment............................................................................46 1.5Safety devices and warning labels............... ............49 2Operating the industrial truck...................................................................50 2.1Safety regulations for industrial truck operators....... ..............50 2.2General operation of the industrial truck....... ............51 2.3Safe loading and transporting..................................................................54 2.4Preventing tipping............. ............56 2.5Attended/unattended parking and securing of the industrial truck...........58 2.6Lifting people........... ..............58 3Description of indicators and controls.... ..........59 3.1Description of indicators and control elements........................................59 3.2Battery Discharge Indicator (BDI)............. ..............61 4Starting the industrial truck. ..........62 4.1Daily checks and actions before startup..................................................62 4.2Preparing for operation........ ............63 4.3Switching off and securing the industrial truck........... ............64 5Operation of the industrial truck.................. ............65 5.1Safety regulations applicable when operating the industrial truck...........65 5.2Emergency Stop, driving, steering and braking.......................................68 5.3Picking up, transporting, and putting down loads....... ............77 6Optional equipment...... ............79 6.1Tiller lock mode.......................................................................................80 6.2Keypad.................. ............82 FBattery - maintenance, charging, and changing......................85 1Safety instructions for handling acid-filled batteries................................85 2Battery types.................. ............87 3Uncovering the battery........ ............88 4Charging the battery................................................................................89 5Removing and installing the battery................ ............91 6Battery extraction from the side............. ..........92 6.1"Side battery extraction" removal............................................................92 6.2Installation "Side battery extraction"..... ..........93 GIndustrial truck maintenance and troubleshooting...................95 1Operating safety and environmental protection.......................................95 2Safety regulations for maintenance.......... ..............97 3Maintenance and inspection....... ............102 4Maintenance check list............................................................................103 4.1Operator................ ..........103
9 4.2Customer service.....................................................................................105 5Consumables and lubrication chart.......... .......109 5.1Handling consumables safely ..................................................................109 5.2Lubrication chart......................................................................................111 5.3Consumables........... ..........112 6Description of maintenance and servicing jobs.......................................113 6.1Preparing the industrial truck for maintenance and servicing..................113 6.2Opening the drive hood...........................................................................114 6.3Remove the engine hood........................................................................114 6.4Check the hydraulic oil level................ ..........116 6.5Checking the electrical fuses...................................................................118 6.6Restarting the industrial truck after maintenance and servicing work.....120 7Extended shutdown of the industrial truck......... ..........121 7.1Measures required before shutdown.......................................................122 7.2Actions to be taken during shutdown............ ..........123 7.3Restarting the industrial truck after shutdown.......... .......124 8Safety check after time and unusual events............................................125 9Permanent decommissioning and disposal....... ..........126 10Troubleshooting.......................................................................................127 10.1Industrial truck does not move........ ..........127 10.2Load cannot be raised........... ..........127 HTransport and initial startup.....................................................129 1Handling by crane. ..........129 2Transport.................................................................................................130 3Initial startup.......... ..........131 3.1Check the supporting rollers/casters before starting up the vehicle........132
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ACompliance with regulations - Legal requirements and common sense
In 1998, OSHA produced a report on its wide-ranging study into the use of powered industrial trucks in industry. This report was published in the US Federal Register/ Vol. 63, No. 230.
In this report OSHA sets out the many reasons why employers are required to train their employees in connection with the use of powered industrial trucks and why untrained personnel must be prohibited from using industrial trucks except in controlled operating conditions such as a training session.
The report shows how extremely important a training program as required by the OSHA guidelines is for the safety of equipment and personnel in connection with the use of powered industrial trucks (29 CFR 1910.178).
In simple terms, thorough training prior to the use of an industrial truck is extremely important and must take place before an industrial truck is used, since accidents leading to injury and death or property damage are almost always the consequence of disregarding the underlying risks inherent in the use of industrial trucks or of ignoring safety instructions and safety precautions designed to minimize or eliminate such risks.
The training by OSHA is designed to address those risks. The evidence provided by OSHA in its report reveals that the operator training requirements for employers and operators are grounded in experience and good judgment.
Jungheinrich has provided an industrial truck which complies with 29 CFR 1910.178 and ANSI/ITSDF B56.1. Jungheinrich representatives are available to assist and answer any questions which may arise concerning the capacities, operation, use and maintenance of the truck.
According to the OSHA report, knowledge and skills to operate an industrial truck powered by an electric drive are not innate in human beings. Quite the contrary: This knowledge can only be acquired through theoretical and practical training. This means that having an industrial truck that complies with statutory regulations and standards is only one half of the safety equation.
It is up to you, the operator, and your employer to be aware of your responsibilities and of all national and regional regulations and laws governing training requirements and the safe use of powered industrial trucks, not only because the law requires it but because it is a matter of common sense.
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NOTE
Powered industrial trucks may only be operated by trained and tested persons. Training must meet OSHA requirements and address at least the topics mentioned here.
Employers and operators should pay special attention to the section in ANSI/ITSDF B56.1 concerning the operator.
"Safe operation is the responsibility of the operator" ANSI/ITSDF B56.1, Part II Section 5.1.1.
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BRecognition and avoidance of risks
In its 1998 investigation into the use of powered industrial trucks, OSHA determined the ways in which accidents commonly occur and the causes of these accidents. OSHA concluded that considerable risks to operators themselves and to other people in their immediate vicinity can be put down to the inadequate or non-existent training of operating personnel.
According to OSHA, incorrect and unsafe operation are the principal causes of accidents in connection with powered industrial trucks and the resulting injuries and fatalities. It is therefore no coincidence that in reviewing its own research, OSHA found that in almost all cases accidents were attributable to situations or actions which the operator, or the employer and the operator together, could have influenced or could have prevented.
This finding was confirmed by a simple check of the accident causes cited by OSHA. Of the 208 accidents investigated involving powered industrial trucks, 184 of which were fatal accidents or resulted in serious injuries, a full 50 percent of them were due to loading problems, including overloading, unstable loads, dropped loads, or incorrect lifting of loads.
25 percent of the cases involved the tipping or overturning of the industrial truck. A further 20 percent of the accidents were caused by the industrial truck falling from a platform or a trailer or by persons falling from an elevated position in an industrial truck. Although only 4% of the accidents were due to an absence of training and instruction, OSHA nevertheless noted that many accidents could also have been caused by inadequate training.
For example, the overturning of a vehicle could just as easily be caused by poor or inadequate instruction of the operator with regard to the loading of the industrial truck. Other, less frequent accident causes, which could nevertheless still have been avoided by employers and operators, were excessive speed and the use of inappropriate equipment.
The following measures are therefore of vital importance:
and aptitude-tested before working with a powered industrial truck.
lly, mentally, and emotionally capable of operating a powered industrial truck.
cal knowledge in relation to the safe loading and correct operation of the industrial truck. The capacity limits of the machine must be known and must never be exceeded.
ndustrial truck to tip or overturn must be avoided. Attention must be paid in this regard to shifting centers of gravity, correct loading and the safe transport of loads, and to defensive driving, taking account of edges, bends, slopes, and other driving conditions. aining and the correct type of truck, passengers should never be carried nor people lifted under any circumstances. Furthermore, the correct procedure for this must be observed.
ivers must always be aware of the position of colleagues and of other trucks and must pay attention to local conditions.
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• Thank you very much for reading the preview of the manual.
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