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Summary of Contents for EVERUN ERT1500
- Page 1 Everun Telescopic Loader Operation Manual ERT1500 Qingdao Everun Machinery Co., Ltd.
- Page 2 Store the manual with care, including after having fully re ad the document,to ensure that you canrefer to it in the future and clarify any doubts . Should you have any difficulty understanding thismanual, or any paragraph in the manual, contact your Official ERT1500 Representative orDealer.
- Page 3 INTRODUCTION The manual consists of five sections: Section 1：GENERAL INFORMATION Section Section 2：SPECIAL SAFETY INFORMATION SectionSection 3：OPERATING INSTRUCTIONS Section 4：PERIODIC MAINTENANCE OPERATIONS SectionSection 5：DIAGRAMS AND CHARTS Section 1, “GENERAL INFORMATION”, includes general information on the main parts of themachine. This section also lists details of part references and technical characteristics, etc. Section 2, “SPECIAL SAFETY INFORMATION”, is aimed at personnel in charge of the correct operation of the machine, repairs and maintenance, and, for companies with a large number ofmachines, the safety manager.
- Page 4 In this case, contact your Official ERT1500 Representative or Dealer to clarify any doubts or obtain another version of this manual.
- Page 5 In this case, contact your Official ERT1500 Representative or Dealer to clarify any doubts or obtain another version of this manual.
- Page 6 HOW TO IDENTIFY YOUR MACHINE 1. MACHINE DIRECTIONS The terms right, left, forward and back, when used in this manual, refer to these positions from the operator’s seat looking forwards. These references will be particularly useful to identify the differ-ent machine parts(front, rear, etc.) mentioned in this manual.
- Page 7 HOW TO IDENTIFY THE MACHINE IMPORTANT: Check that the instructions manual is the right version for the machine in question.Please indicate model number, date of purchase and frame and serial number when consultingERT1500 or your dealer for any matter. This information can be found on the identification plate. We recommend you make a record of these numbers in the spaces provided below for handy reference and keep it in your files.
- Page 8 - Lifting people. Should the forklift be used to lift people, obtain information on applicable legislation as per each country and take the appropriate precautionsor consult an authorized ERT1500 dealer. Any other use should be considered outside of the intended use and therefore improper.
- Page 9 - Operating on slopes steeper than recommended. - Using accessories or equipment for purposes other than those intended. - Using accessories or equipment not authorized or manufactured by ERT1500. - Operating in locations with a risk of fire or explosions.
- Page 10 MAIN PARTS 1 - bucket 2 - Fork carriage for accessories and tools3 - Horizontal arm 4 - Headlights and signal lights5 - Engine cover 6 - Wheel 7 - Driver’s seat with seat belt 8 - Steering wheel 9 - Front axle...
- Page 11 DESCRIPTION OF THE MAIN PARTS HYDROS TATICTRANS MISSION This is an assembly of components enabling the movement of the machine. Theassembly mainly consists of: -variable-flow hydrostatic pump connected to the combustion engine via an elastic coupling. - a hydraulic unit fitted on the differential pinion of the front axle. - two radial piston hydrostatic motors, one on each wheel, for the rear axle.
- Page 12 - these methods are safe, i.e. they satisfy the standards and descriptions mentioned in thissection of the manual. - these methods do not cause direct or indirect damage to the machine, making it unsafe. If in doubt, always ask! Contact your Official ERT1500 Representative or Dealer should you haveany questions.
- Page 13 PREREQUIS ITES FOR PERSONNEL You are th e “KEY” to the safety so think... - Before you begin using a forklift that you are not familiar with, you should read this operator manualcarefully and consult your superior if you have any doubts. PREREQUIS ITES FOR OP ERATORS Operators which use the machine occasionally or regularly (e.g.
- Page 14 PREREQUIS ITES FOR PERSONNEL YPersonnel in charge of the maintenance of the machine must be qualified, and have received mechanical training in the maintenance of earth moving machines in general,and must necessar- ily satisfy the following prerequisites: 1. PHYSICAL RE QUIRE MENTS Operators must have normal hearing and visual abilities, satisfactory coordination and he ability toexecute the functions required to maintain the machine in a safe manner,as specified in this manual 2.INTELLECTUAL REQUIRE MENTS AND ATTITUDES...
- Page 15 WORK AND MAINTENANCE CLOTHING The appropriate equipment and material for the function in question and the prevention of accidents must be used when operating the machine or carrying out maintenance or repair operations. The final equipment will be selected on the basis of the assessment of risk for each work station; however,generally speaking, the following recommendations apply: comfortable close fitting work suit or other clothing which cannot be caught in moving components.
- Page 16 SAFETY STANDARDS WORKING AREA The forklift should only be used by authorized and duly trained personnel. Depending on the work are a, remember..- If there is a risk of fire or explosion in the working area, either because of goods stored or because of possible fluid or gas leaks, check that the forklift is fitted with a sufficient degree of fire protec- tion.
- Page 17 PRIOR PREPARATION WHEN STARTING UP THE FORKLIFT Place the machine in its working position and check that the machine is on the level.Before starting operations: -Check that maintenance operations are carried out carefully, and that the specified time intervals are applied (see section 4 on “MAINTENANCE”).
- Page 18 ·cuts or loose threads on the belt. ·wear or damage to fittings, including anchor points. ·incorrect functioning of the seat belt buckle or retracting roller. ·loose seams or stitching. -Check that all covers, locks and other safety elements are correctly positioned. The removal of safety devices such as the engine cover is prohibited with the exception of for maintenance purposes.
- Page 19 DURING WORK AND MAINTENANCE When operating the forklift, do not forget to ... - Keep hands, feet and the whole body in general inside the area provided for the operator. - Pay special attention to work on slopes, move slowly, avoid being situated crosswise and do not operate slopes which exceed the recommended gradient.
- Page 20 To prevent this we recommend the following: · Try to remain within the operator cab. · Grasp the steering wheel firmly Push feet firmly against the floor plate of the cab. · Try to keep as far away from the point of impact as possible. Take care when loading and unloadingthe forklift... - If concrete spills onto the road surface, remove it before it hardens.
- Page 21 -The manufacturer will not be held responsible for any incidences or accidents caused by the use ofnon- original spare parts or by repairs carried out by unauthorized workshops. - When replacing tyres, ensure that they are the correct replacements and follow the tyre manufactur- er’s safety instructions.
- Page 22 -When completing an operation, do not leave the machine in a otentiallydangerous configuration. - Be environmentally friendly. When changing oil, fluids, tyres, batteries, etc., take the used materials to the corresponding recycling centres. If you handle or scrap silencers or catalytic silencers which contain mineral fibre- based absorbent materials, protect your skin with the appropriate gloves and clothing and take the materials to approved disposal sites for this class of materials.
- Page 23 DURING WORK AND MAINTENANCE When operating the forklift, do not forget to ... - Keep hands, feet and the whole body in general inside the area provided for the operator. - Pay special attention to work on slopes, move slowly, avoid being situated crosswise and do not operate slopes which exceed the recommended gradient.
- Page 24 PARKING THE FORKLIFTAND CUTTING THE ENGINE When leaving the forklift... -Turn theengine off and switch off the ignition. Place the horizontal arm in the horizontal position. - Place all controls in the neutral (standby) position. - Put the parking brake on. - Block all mechanisms which impede use of the forklift by unauthorized persons;...
- Page 26 PREAMBLE This section aims to supply the operator with a basis to gradually learn howto operate the forklift. Learn to use and predict the reactions of the forklift. Once seated in the driver’s cab and having made preliminary adjustments, the operator must identify and learn the position of the different controls and instruments.
- Page 27 A device is fitted enabling the seat to be moved forward or back to adjust the distance from the pedals. To adjust the seat, turn the lever (1 ) and push the seat in the desired direc-tion. Once in position, release the lever and ensure that the seat remains blocked in the selected position.
- Page 28 CONTROL PANEL 1 - The dashboard 2 - Wiper controller 3 - The steering wheel 4 - Light switch 5 - Risk control system 6 - Cigarette lighter 7 - Engine controls 8 - The fuse...
- Page 29 ENGINE CONTROLS A:Neither circuit is supplied. You may remove the key and the engine is stopped. B:Circuits are supplied, ready to start the engine. Engine oil pressure, battery charge and pre-heating lamps all light up. If the pre-heating lamp is lit, this indicates that the pre-heating resistances are operational and heating the combustion chamber to a temperature which will enable the firing of the vaporised diesel fuel.Wait until this light goes out before starting the engine.
- Page 30 WARNING LIGHT FUNCTION A - Differential lock B - Warning lamp C - Emergency light D - headlamps E - Working light F - Heat...
- Page 31 START-UP BEFORE STARTING THE ENGINE - Check tyre pressure and condition. - Familiarise yourself with the controls and ensure that they function correctly. - Verify that steering operates freely. - Activate the throttle pedal various times to ensure it operates freely. It must return to the originalposition when released.
- Page 32 START-UP For safety reasons when starting the forklift, the operator must be seated with the seat belt fastened, the parking brake must be applied, and the operator must check that the joystick and the FNR switch are in the neutral position. Insert the key into the starter switch and turn it to position (B) until the pre-heat indicator turns off, press the throttle pedal a 1/4 of the way and turn the key to position (C) until the engine starts.Do not hold this position for more than 15 seconds.
- Page 33 START THE ENGINE USING AN EXTERNAL SOURCE DANGER When starting the engine using an external source of energy, by connecting to the battery of another machine, check that the two resources do not enter into contact to avoid the possi bleprotection of sparks. The batteries emit a flammable gas which sparks could ignite, leading to the battery exploding.
- Page 34 The use of oils with suitable SAE viscosity in view of ambient temperatures is recommended for coldstarts. Consult the instructions and maintenance manual of the manufacturer of the engine for this purpose. Cold starting the engine: -Set the FNR switch to neutral. -Select the starter switch to ignition and wait until the resistance pre-heating indicator goes out.Press the accelerator pedal to the floor and start the engine by turning the starter switch to the start position.
- Page 35 SE OF THE FORKLIFT DANGER Always exit the driver’s cab backwards. Make sure that your boots and hands are clean and dry. Hold on to the supports and handles to avoid falling or tripping. Set the parking brake whenever the forklift stops, to prevent any undesired movements. This chapter defines a few techniques and procedures for the use of the machine equipped with a standard fork in safe conditions.
- Page 36 ELECTRIC HAZARDS Pay special attention to electric lines. Check the position, ensuring that no part of the forkliftmoves less than 6 metres from any electric line. WARNING To ensure maximum safety when using the forklift,always weigh the loads to be handled.Refer to the load chart located inside the cab, to the right of the driver.
- Page 37 HANDLING LOADS ADJUSTMENT OF FORKS The forks must be adjusted in terms of width depending on the load to be handled. Proceed asfollows: Floating forks (standard configuration): - Loosen the attachment screws (1 ). - Lift the forks and slide over the bolts until the desired distance is reached. - Re-tighten the attachment screws (1 ).
- Page 38 UNBALANCED LOADS - Identify the centre of gravity of the load. When handling packaged loads, this may be actually marked on the box. - Place the forklift to move the centre of gravity of the load to the centre of the forks. - Grip/release the load.
- Page 39 - Pay special attention to work on slopes, move slowly, avoid being situated crosswise and do notoperate slopes which exceed the recommended gradient. A slope within the recommended gradient does not mean that this slope can be manoeuvred on with absolute safety under any load, terrain or handling conditions.
- Page 40 PARKING AND NON-OPERATIONAL MACHINES SHORT STOPS Whenever the forklift is parked, either at the end of the day or in order to carry out any maintenancework, it should be parked on level ground. Apply the forklift’s parking brake. Run the engine at idle for 1 minute, if the forklift has been working at full load.
- Page 41 press the throttle pedal a 1/4 of the way and turn the key to position (C) until the engine starts. Do not hold this position for more than 15 seconds. If the engine does not start repeat the previous oper- ations. Wait for 30 seconds between each try.
- Page 42 jets. Finish by wiping with a clean cloth. WASHING THE ENGINE Wash the engine after having covered the air suction filter to protect against water. ELIMINATION ELIMINATION OF BATTERIES ENVIRONMENTAL PROTECTION Dispatch all used batteries to the appropriate recycling centres. Should leaks of substances such as acid or lead occur, which may be dangerous for individuals or the environment, take the emergency action required to reduce impact.
- Page 43 Check and ensure that the hour counter remains operational to ensure the correct definition of maintenance intervals. Should the scheduled maintenance standards indicat- ed in this manual not be complied with, the ERT1500 warranty will automatically be cancelled.
- Page 44 LUBRICANTS ,SAFETY AND HYGIENE STANDARDS HYGIENE Should oils come into extended contact with the skin, this may cause irritation.Therefore, it is recommended to use protective goggles and rubber gloves. After having handled oils it is recommended that you wash your hands carefully using water and soap. STORAGE Always store oils in a closed location out of the reach of children.
- Page 45 SCHEDULED MAINTENANCE - In maintenance operations only use original ERT1500 spare parts. This is the only way to guarantee that your forklift will re main as technically efficient as when it was purchased. - On this forklift as with any other, there are parts and systems which are subject to wear and misalignment, which may affect reliability and operator safety, the environment and the area, e.g.
- Page 46 MAINTENANCE OPERATIONS DANGER All maintenance interventions must be carried out with the engine stopped, the parking brakeset, the tools on the ground and the FNR switch in the neutral position. WARNING Before carrying out any maintenance operation requiring the hoisting of a component, e.g. the horizontal arm or the cab, attach the hoisted component in a stable and secure manner, before carrying out any action.
- Page 47 ACCESS TO ENGINE, CAB AND TANK COMPARTMENTS ENGINE COMPARTMENT You must open the engine protective cover to carry out any intervention inside the engine compartment. In addi- tion, the side walls of the rear wheel can be removed. The rear part of the cover is fitted with a lock. The inner right part of the cover is also fitted with a mechanical catch to hold the cover open.
- Page 48 The right side cover may be removed to simplify mainte- nance operations. An inspection gate also exists in each cab floor panel To access components located behind the right side cover: -Loosen the 4 attachmentscrews (A)located in the upper flap and remove the Cover HYDRAULIC FLUID AND FUEL TANK The fuel and hydraulic fluid tanks are located on the leftside of the...
- Page 49 Changingthe fuel pre-filter. Lift the cover and access the left side of the engine. Locate the fuel pre-filter.(B)Pre-filte r (C)Flanges Remove the fixing flanges brackets and thefilter. Ensure that the new filter is located in the correctdirection as indicated by the arrow marked on the filter housing. WARNING Always replace this component.
- Page 50 IMPORTANT Always maintain the fuel injection pump airvent plug closed, except when draining. The enginemay suddenly cut out if the plug is open. GREASE CAUTION Before injecting lubricating grease in the grease nipples, clean carefully to prevent, mud, dust or other foreign bodies mixing in the grease thereby reducing or even cancelling out lubrication properties.
- Page 51 Place and tighten the filling cap correctly and close the cover. A cooling system which requires coolant frequently indicates that there are leaks or engine prob-lems. See an authorized ERT1500 dealer. RADIATOR FINS Periodically check the radiator area for its cleanliness.
- Page 52 Be careful not to damage the radiators when cleaning the fins. Do not use any sharp object or tool thatcould damage the fins. The fins are purposely thin parts to allowefficient cooling. See an authorized ERT1500 dealer to check the correct performance of the cooling system. OIL TANK LEVEL CHECK DANGER Fine jets of pressurised hydraulic fluid canpenetrate the skin.Never use your...
- Page 53 4. Clean the base and cover the seal joint of the new filter element with clean oil. 5. Fill the new filter cartridge with clean hydraulic fluid. 6. Screw in the filter element once again and tighten by hand, do not use mechanical tools. WARNING Take particular care when tightening the filter cartridge in its support because if it is incor- rectly tightened, it could cause the suction circuit to take in external air causing transmission failure.
- Page 54 - Avoid placing metal objects on the battery. This could cause dangerous short circuits, especial- ly during recharging. - Given that electrolyte is highly corrosive, avoid any contact with the forklift chassis or with elec- tric or electronic components. Should contact occur, contact your authorized ERT1500 dealer.
- Page 55 (fig.1). If oils of different brand names are used, ensure that you completely empty the oil pan before adding the new oil. REF. recommends oil for Diesel engines REPSOL ERT1500 EFFICIENT Reference 461.00099.00. Lubricants , oils and filter cartridges...
- Page 56 FUEL Use automotive cleandiesel (class A), which preferably meets 98/70/EEC standard amended by stan- dard 2003/17 or the equivalent EN 590 standard. In Spain RD 1728/1999 applies. For the USA market, it must meet Grades 1D and 2D of the ASTM D975 standard, in supplies which do not meetthese standards,the sulphur content should never exceed 0.5% mass.
- Page 57 SCREWCHARACTERISTIC FINE 10.9 12.9 THREAD 24.5 M8×1 6289 M9×1 M10×1 M10×1.25 12.7 15.3 M12×1.5 12.4 14.8 M14×1.5 13.8 M16×1.5 M18×1.5 M18×2 M20×1.5 M22×1.5 M24×1.5 1270 M24×2 1220 M27×1.5 1850 M27×1.5 1800 M27×2 2560 M30× 1.5 2480 M30×2...
- Page 58 Tel: 0086-532 -809 97859 Fax: 0086-532-80993178 Website: www.everun.com Faceb ook: http s: / /ww w.f ac e boo k.c om/ eve run mac hin ery Address: Room 902, Yon gxin Int ern at ional Fin an ce Centre, No. 6 Qin Li ng Road, Qingdao, China...
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