Jungheinrich Electric Reach Truck ETR230, ETR235, ETR335D, ETR340, ETR345 Workshop Service Manual

05.15 - 05.15 51423150 ETR 230/235 Operating Instructions u

3 Foreword Notes about 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 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 industrial truck and carrying out maintenance work, make certain you use the description corresponding to your industrial truck type. See www.osha.gov web site for more information on Regulations (Standards – 29 CFR) Powered industrial trucks – 1910.178. 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: DANGER! Danger indicates a 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.

4 NOTICE Notice is used to address practices not related to personal injury. Z 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

5 Copyright Copyright of this operating manual remains with Jungheinrich AG. Distributed by MCFA 2121 W. SAM HOUSTON PARKWAY N. HOUSTON, TX 77043-2305 FAX: 713-365-1414

7 Table of contents A Compliance with regulations - Legal requirements and com- mon sense............................................................................... 11 B Recognition and avoidance of risks ........................................ 13 C Proper use............................................................................... 15 1 General .................................................................................................... 15 2 Proper use ............................................................................................... 15 3 Permissible usage conditions .................................................................. 15 4 Duties of the operator .............................................................................. 16 5 Adding attachments or optional equipment ............................................. 17 6 General instructions for operating personnel and the owner ................... 18 7 Stability .................................................................................................... 20 D Know Your Industrial Truck ..................................................... 21 1 Description of indicators and controls...................................................... 21 2 Overview of components ......................................................................... 23 3 Display unit .............................................................................................. 24 3.1 Battery discharge indicator ...................................................................... 26 3.2 Battery discharge monitor ........................................................................ 26 4 Technical data ......................................................................................... 27 4.1 Performance data .................................................................................... 27 4.2 Weights.................................................................................................... 28 4.3 Wheels..................................................................................................... 28 4.4 Dimensions .............................................................................................. 29 4.5 Battery ..................................................................................................... 31 4.6 US standards ........................................................................................... 32 4.7 Usage conditions ..................................................................................... 34 4.8 Electrical requirements ............................................................................ 34 5 Position of Labels and Nameplates ......................................................... 35 5.1 Overview of labels and nameplates......................................................... 35 5.2 Nameplate ............................................................................................... 37 5.3 Load capacity plate of the industrial truck ............................................... 38

8 E Operation ................................................................................ 41 1 Important general issues affecting safe operation and use of the industrial truck .................................................................................................. 41 1.1 Training, certification, and approval to operate the industrial truck ......... 41 1.2 Damage and repairs to the industrial truck .............................................. 44 1.3 Issues related to the load ........................................................................ 45 1.4 Operating environment ............................................................................ 46 1.5 Safety devices and warning labels .......................................................... 50 2 Setting the display unit ............................................................................ 51 2.1 Display (4 Inch) ........................................................................................ 51 2.2 Button allocation of the display ................................................................ 53 2.3 Symbols in the display ............................................................................. 55 2.4 Setting the time........................................................................................ 56 3 Preparing the industrial truck for operation.............................................. 57 3.1 Daily checks before startup ..................................................................... 57 4 Starting the industrial truck ...................................................................... 58 4.1 Safety regulations for industrial truck operators ...................................... 58 4.2 Operation of the industrial truck............................................................... 64 4.3 Safe loading and transporting.................................................................. 67 4.4 Reduce risk of a tipover ........................................................................... 69 4.5 Supervising and securing the industrial truck .......................................... 71 4.6 Preparing for operation ............................................................................ 72 4.7 Emergency stop....................................................................................... 73 4.8 Travel direction definition......................................................................... 74 4.9 Driving ..................................................................................................... 75 4.10 Braking .................................................................................................... 78 4.11 Steering ................................................................................................... 81 4.12 Adjusting the forks ................................................................................... 82 4.13 Lifting ....................................................................................................... 83 4.14 Tilting ....................................................................................................... 85 4.15 Sideshifter (o) ......................................................................................... 86 4.16 Reach/Retract Forks................................................................................ 87 4.17 Lifting, transporting, and putting down load ............................................. 88 4.18 Operating attachments ............................................................................ 91 4.19 Operating the pantograph........................................................................ 92 4.20 Emergency lowering ................................................................................ 93 4.21 Parking the industrial truck ...................................................................... 94 5 Optional equipment (o) ........................................................................... 95 5.1 Keyless access systems .......................................................................... 95 5.2 General information about operation with keyless access systems ........ 95 5.3 Starting up the keypad............................................................................. 95 5.4 Operation of the display unit .................................................................... 97 F Battery - maintenance, charging, and changing...................... 101 1 Safety instructions for handling acid-filled batteries ................................ 101

9 1.1 General information for handling batteries .............................................. 102 2 Charging the battery ................................................................................ 103 3 Removing and installing the battery ........................................................ 104 3.1 Removing the battery .............................................................................. 104 3.2 Installing the battery ................................................................................ 105 G Industrial truck maintenance ................................................... 107 1 Operating safety and environmental protection ....................................... 107 2 Safety regulations for maintenance ......................................................... 108 3 Maintenance and inspection .................................................................... 112 4 Maintenance check list ............................................................................ 113 4.1 Operator .................................................................................................. 113 4.2 Customer service..................................................................................... 115 5 Fluid and lubrication chart ....................................................................... 118 5.1 Handling fluid safely ................................................................................ 118 5.2 Lubrication chart ...................................................................................... 120 5.3 Fluids ....................................................................................................... 122 6 Description of maintenance and service tasks ........................................ 123 6.1 Preparing the industrial truck for maintenance and servicing .................. 123 6.2 Check the hydraulic oil level .................................................................... 124 6.3 Checking the electrical fuses ................................................................... 126 7 Long term shutdown of the industrial truck .............................................. 128 7.1 Actions to be taken before shutting down the industrial truck ................. 129 7.2 Actions to be taken during shutdown....................................................... 129 7.3 Restarting the industrial truck after shutdown ......................................... 131 8 Permanent decommission and disposal .................................................. 132 H Transport and initial startup..................................................... 133 1 Handling by crane.................................................................................... 133 2 Transport ................................................................................................. 134 3 Initial startup ............................................................................................ 135 3.1 Check the supporting rollers/casters before starting up the vehicle ........ 136

Jungheinrich Electric Reach Truck ETR230, ETR235, ETR335D, ETR340, ETR345 Workshop Service Manual

You're Reading a Preview

Recently Viewed