Conhersa ET-1000 User Manual

ALL-TERRAIN ELECTRIC LIFTER ET-1000

USER’S MANUAL

Edition: December 2009

USER’S MANUAL

INDEX

1. MAIN COMPONENTS 1.1

2. SAFETY INSTRUCTIONS 2.1

3. CONTROL SWITCHES AND INDICATORS 3.1

4. SWITCH ON AND WORK 4.1

5. LOADING AND UNLOADING 5.1

6. SERVICE AND CARE 6.1

7. LONG WAREHOUSING 7.1

8. TECHNICAL SPECIFICATIONS 8.1
 2008 CONHERSA

1. MAIN COMPONENTS

1. Chassis

2. Front wheels

3. Fork Grouping

4. Fence

5. Hydraulic Cylinder

6. Chains

7. Pulley

8. Electric braking

9. Motor drive wheel

10. Handle

1.1

11. Batteries

12. Batteries charger

13. Hydraulic pump

14. Main contactor

15. Electronic controller

16. Load indicator

17. Plug

18. Emergency stop

1.2

2. SAFETY INSTRUCTIONS

Etiquettes 2.2
All-terrain lifter: safety 2.4
Daily inspections 2.5
All-terrain lifter operator 2.9
Movement in ramps and special areas 2.10
All-terrain lifter transportation 2.12
Testing 2.13
Noise level 2.13
Dangerous environment 2.13

2.1

ETIQUETTES

2.2

WARNING

WARNING

Keep hands, feet and body
away from masts and forks.
Danger of trapping betwee fix
and mobile parts.

CAUTIONS WHILE CHARGING
BATTERIES

1. Charge batteries at an open-air
area, away from flames, fumes
and sparks. Batteries’ gasses
may be explosives

2. Do not smoke around the
charging area.

3. Do not disconnect the
connector during the process of
charging. Danger of sparks.

Do not stand on nor under the
forks.

2.3

ALL-TERRAIN LIFTER:
SAFETY

USE UNDER INSTRUCTIONS
The All-terrain Lifter may only be

used under instructions included
in this manual.

WARNING

This Lifter may only be used to
transport and placement of
charges and palletised
materials, as per the
instructions of this Manual.

WARNING

Should you wish to use it for
different purposes, you may

ask for CONHERSA’S

agreement and, if necessary,
your local authorities in order
to avoid risks.

WARNING

In case of malfunction, switch
off and contact our technical
service.

2.4

DAILY INSPECTIONS

Befote using, following
inspections shall be followed:

1. Brake: When releasing handle,
make sure that the machine is
restrained and you can not
move it.

2. Forks: Visual inspection. Verify
correct lift and descent. No
damage in forks.

3. Hydraulic circuit: Verify possible
looses (leaks) in pipe and
cylinder.

4. Wheels: Verify tyres state.
Tigthen bolts. Verify wheels
pressure.

6. Bettery: Correct battery charge
level: >20%.

7. Horn: check..

8. Lifting: With forks unloaded,
verify correct lifting and
descent.

9. Travel: Pressing the death­man, verify correct movement
forward and reverse.

10. Visual inspection of chains
and pulleys. Verify unloaded
that the stress is equal in both
chains.

WARNING

In case of malfunction, switch
off, inform to whom it may
concerní, and contact the
technical service.

BRAKE
When releasing handle, verify

that speed controller returns to
neutral position and brake is
inmediately actioned. A clicking
sound will be noticed.

Push the Lifter to make sure that
it is well braked and you can not
move it.

5. Control instruments: Switch on
key. Verify batteries’ light
indicatiors lights on.

2.5

FORKS AND CHAINS
Lift the security bolt by hand. Put

it down back again, and verify
that it stays well placed over the
security fence and can not be
moved unintentionally.

Forks must be placed in
symmetry as per the axe.

To tighten the chains, adjust the
screw placed at the end of the
chains (A) with its bolts.

WARNING

In case of adjusting the chains,
verify that bolts are well tighten
(A)

2.6

DELANTERAS

TRASERA

Size

3.00-8”

4.00-8”

Solid

Superelastic

Superelastic

front

rear

HYDRAULIC CIRCUIT

RUEDAS

BATTERY CHARGE LEVEL
Verify oil level in the deposit.
Verify in case of possible oil

losses (leaks)

Turn the key to ON position.

Verify charge level in the

indicador. If level is under 20%,

charging is needed.

Charge during approximately 10

hours (See procedure on page

5.1).

2.7

CONTROL INSTRUMENTS AND
CLAXON

Turn on the key. Verify light
indicador i son.

.

HANDLE

Verify correct claxon function

2.8

Unloaded, press lifting button to
verify that forks go up correctly.

Press down button to verify that
forks go down smoothly.

Pressing the death-man system,
turn slighty the hanle to verify that
the blocked brake is self-released
(an audible clicking sound must
be heard), and that the Lifter
comences to move gentil.

Verify both, forward and reverse.

 Contact key

 Death-man system.

 Forward-reverse.

 Claxon.

 Down-forks button.

 Up-forks button.

LIFTER OPERATOR

USER’S KNOWLEDGE

WARNING

While using, this manual’s

instructions shall be observed,
as well as local/national legal
dispositions.

SAFETY CLOTHING

Each site’s observations should

also be observed while using the
lifter.

For example:

WARNING

For clothing, observation of the
national rules and obligations
is as must.

Clothes should be tight enough

to avoid traps. If necessary in

the working site, user should

also wear protective glasses,

helmet, gloves, and whatever

required.

2.9

MOVEMENT IN RAMPS
AND SPECIAL AREAS

WARNING

Using the lifter et-1000 for
transporting goods in ramps is
strictly forbidden.

Only permitted with the lifter
unloaded, if necessary.

WARNING

Do not turn in ramps.
Movement in ramps is delicate:
pay maximum attention and
care.

WARNING

Caution when moving on the
truck surface. Please make
sure that the truck is stopped.

Ramp should be firmly placed

on the ground in order to avoid

unexpected movements.

Pay maximum attention during

the loading and unloading of

the lifter on the truck.

2.10

The ramp used to place the
lifter onto the truck must be
resistant enough to bear the
lifter, taking into account the
vertical movement of the lifter.

MOVEMENT
Visibility
Do not drive forward when the

load does not permit complete
visibility. In that case, drive
backward, except when driving
into a service lift, where entering
backwards is forbidden.

If visibility difficulties remain,
another operator should indicate
the correct direction. In this case,
drive slowly and handle with care.

Verify that working area is
lightened enough.

2.11

TRANSPORT OF THE
LIFTER

WARNING

1. Unloaded, put forks in the

upper position.

2. Confirm that in and out

angles do not interfere with
the ground or transport
platform.

3. When using a wooden made

bridge between platform and
dock, make sure that the
planks can bear the lifter.

6.Switch off and release

contact key.

4. Use only the lifting hangers

to lift the lifter. (see picture)

2.12

NOISE LEVEL

Less than 70 dB (A)

TESTING

After transport or a long
warehousing period, functional
testing is necessary.

Three tests:

1. Daily inspection test. (See page

2.5), to be made by users.

2. Dynamic tests, to be made by

the technical service.

2.1. Movement test.
Confirm that the lifter moves

towards the correct forward­reverse switch, and confirm
that the blocking brake works
properly.

With the lifter loaded, press
up and down buttons to make
sure of correct work.

2.2. Piling test.

2.3. Descending speed test.
Confirm that descending

speed is not more than 0.6
m/s.

3. Hold load test.
With the machine off, fully loaded

with the forks up, confirm that the
forks don’t move down at all, or
they move down but not faster
than 10mm/min.

NOISE LEVEL

DANGEROUS

ENVIRONMENT

WARNING

Use of lifter in dangerous

environment is strictly

forbidden.

A dangerous environment may

cause fire or explosions

because of dust, fumes or

gasses.

Lift completely and descent
the load at maximum speed
several times.

2.13

3. CONTROL SWITCHES AND INDICATORS

 Contact key
 Handle
 Security anti-trapping button
 Battery charge indicator
 Emergency stop

3.1

HANDLE SWITCHES

Contact key

Contact key is located at the
lower part of the handle.

It has two positions:

- Connected

- Disconnected

When connected, the batteries
light indicator will turn on.

When disconnected, all circuits
are off.

Forward-reverse switch.

It is the red switch. It may be
pressed either with the left or the
right hand.

When releasing, it comes back to
the neutral position.

Buttons for lifting and descending
the forks.

They are located at the centre of
the handle.

When pressing, the forks start to
move, and they stop just when
buttons are released.

 Contact key

 Dead-man function

 Forward-reverse throttle

 Claxon

 Forks down button

Dead-man function
Placed at both sides of the

handle. Must be pressed to allow
the machine moving forward­reverse.

3.2

 Forks up button

CONTROL INDICATORS

Claxon

Claxon is located next to the up
and down buttons.

Battery charge indicator

It has a display, showing the %
battery level.

Two things to know:

1. When turning the key on, the

display indicates the battery
level.

2. Shows the error code in case of

electronic fault.

Fuses

Te fuses are located in the
electronic controller and in the
hydraulic pump.

WARNING

Fuses should only be replaced
by specialized personnel.

Replace the fuses by similar
ones.

WARNING

When the lifter is not being

used, make sure to turn it off.

3.3

4.1

4. SWITCH ON AND WORK

 Contact key
 Dead-man function
 Forward-reverse throttle
 Claxon
 Forks down button
 Forks up button

SWITCH ON AND WORK

WARNING

Before using the lifter, please
read carefully all the security
instructions of this user’s
manual, pages 2.2 to 2.13 of
this manual.

1. Confirm that the blocking brake

is on by pushing the lifter: you
should not be able to move it.

2. Disconnect the emergency

stop

3. Turn on the key without

pressing the throttle.

5.1

WARNING

If the blocking brake does not
work, do not turn on the key.

4. Make sure that there is enough
battery charge by checking the
indicator.

5. Confirm that your way is clear,
and press the dead-man
function, and the forward­reverse throttle smoothly
towards the required way.

Movement

While moving, the forks must be
at their top position.

Turn

The closer you turn, the slowest
the speed should be, in order to
avoid unexpected load
movements.

Movement on slopes (ramps)

Movement on slopes with the
machine loaded is strictly
forbidden.

WARNING

When leaving the lifter, put
down the forks and remove the
contact key.

If error “CODE 23” appears,
two causes:

1. Forward-reverse throttle has
been pressed without using the
dead-man function, or

2. the temperature thermal switch
of the motor has reached and
excessive heating, due to an
intensive work. Turning off the
machine during 20 minutes
should be enough to cool the
machine.

5. LOADING AND
UNLOADING

LOADING
Adjust the forks in symmetry as

per the lifter axe. The more
separated the forks are, the more
stability there is.

Face the load frontally and stop
just before. Adjust forks height to
enter into the pallet to be loaded
correctly.

Move forward smoothly under the
pallet, and when stopping, make
sure that the blocking brake is

automatically activated (blocking
sound should be noticed)

Lift the load. Make sure it remains
stable. Press forward or reverse
and move slowly.

TRANSPORT
Moving with the lifter loaded

should be made with special care
and attention. If the load height
does not allow proper visibility,
the lifter must be driven forward,
except when entering into the
service lifts, where it is strictly
forbidden.

UNLOADING
Move towards the unloading area

slowly.
Verify that, when stopping, the

automatic blocking brake is on
(blocking sound).

Put down the forks to unload.

Move reverse to get away from
the pallet.

When restarting again, make sure
that the forks are in the top
position to avoid any obstacle
while moving.

5.1

6. SERVICE AND CARE

Classification of maintenance works 6.2
Maintenance to be made by the technical service 6.2
Maintenance to be made by users 6.3

6.1

CLASSIFICATION OF
MAINTENANCE WORKS

There are two types of maintenance
works:

1. Technical service: Only to be
made by the technical service.

2. User: To be made by the lifter
users (qualified worker)

WARNING

User should not make any
reparations nor maintenance
when technical service is
required.

Some operations may be
dangerous and should only be
made by the technical service.

MAINTENANCE TO BE MADE
BY THE TECHNICAL
SERVICE

The following operations should
only be made by our technical
service:

1. Batteries condition control.

2. Change batteries.

3. Change hydraulic oil.

4. Adjust motor pump.

5. Maintenance of the electronic
control.

6. Change fuses.

MAINTENANCE TO BE
MADE BY THE USER

As well as the daily inspections (see
page 2.5), the worker must carry on
with the following:

1. Change the front tyres.

2. Charge batteries.

3. Batteries electrolyte level control.

4. Lifter cleaning.

5. Emergency forks descent.

6.2

MAINTENANCE TO BE
MADE BY THE USER

WARNING

Before any maintenance, turn
off the key.

Confirm that the automativ
blocking brake is on.

CHANGE FRONT WHEELS

Front wheels

1. Put a wooden chock under the
lifter to separate it from the
floor. Verify that lifter remains
stable

2. Release off the security ring
and take off the wheel.

3. Mounting process is the in
reverse sense. Try not to
damage bolt and ring when
fastening.

6.3

BATTERY CHARGE

WARNING

1. Charge the batteries in a
well ventilated area, away
from heating points and
sparks. (Gases of batteries
may be explosives)

2. Do not smoke in the
charging area.

3. Do not disconnect the
connector during the
charging process: risk of
sparks.

Suggestions for the battery charge

1. For a longer battery life, it
should be discharged at least
35% before charging.

2. To avoid deep discharge that
could cause lifeless, when
arriving to a 20% of battery
charge, the machine slows its
speed drastically.

Charging process

1. Move lifter close to an electric
socket (220 V).

2. Turn off the key.

3. Connect the provided cable
to the lifter and an electric
socket (220 V).

4. Verify that the yellow and
green lights of the left-hand­side case of the lifter are
lightened.

5. Leave charging cycle to

C

complete while the green light
flickers.

6. Batteries are completely
charged when the green light
is permanent.

7. Disconnect the cable, wind it
and keep it safe. .

8. Turn the contact key on and
confirm that all the battery
charge level is at 100%.

6.5

BATTERIES MAINTGENANCE

WARNING

1. Batteries maintenance must be
made by authorized personnel.

2. Always use gloves and
protective glasses.

3. Smoking in the area is
forbidden.

Maintenance frequency

Must be done at least twice a year
(if possible, before and after
summer )

1. Unfasten with a screwdriver the 8
screws (T) and the metal cover.

2. Take out the metal cover.
Batteries should now be seen.

3. Confirm that there are no
electrolyte leaks and no corrosion
on the tips.

4. Put aside the battery glasses
carefully (B), without touching the
connecting tips.

5. Verify that the electrolyte level is
correct. If necessary, fill in with
distilled water up to the nets.

6.5

CLEANING THE LIFTER

WARNING

Before cleaning, turn off the
key.

Verify that the blocking brake
is on.

Cleaning the handle.

Clean the dust with a brush.
Do not use water.
Finish with a dry cloth.

Cleaning the motor chassis

Clean the dust with a brush.
Do not use water.
Finish with a dry cloth.

Cleaning the forks grouping
guides.

Clean the dust with a brush.
Do not use water.
Finish with a dry cloth.

6.7

EMERGENCY DESCENT OF
THE FORKS

If the forks are suddenly blocked
in the top position, there is a way
of putting them down:

1. Turn off the key.

2. Open the box key where the
motorpump is located.

3. Verify that there are no
obstacles under the forks.

4. Take off the hexagonal cover
(B with a nº 13 key.

5. Faten the bolt with a 4mm
allen key tol et the fork go
down.

6.7

7. LONG WAREHOUSING

LONG TIME WAREHOUSING
When the lifter is not going to be

used for a long time, keep it in a
dry and clean place, and follow
the following instructions:

1. Clean the lifter as explained

before.

2. Charge the batteries

completely.

3. Place the lifter in a horizontal

position.

4. Dissemble the batteries and put

them in a dry and fresh place.

WARNING

When there is no inside area
available, place the lifter in a
horizontal area and cover it
completely with a waterproof
plastic cover.

For warehousing for a longer
period, please contact
technical service.

WARNING

Don not use a waterproof cover
made of vinyl: it may cause
static electricity and
subsequently produce flames
with the batteries gasses.

6.8

SERVICE DURING THE
WAREHOUSING

1. Charge batteries every two

months.

2. Make visual inspections to

verify that there is no corrosion.

3. Clean the dirty areas and apply

anticorrosion if needed.

POST-WAREHOUSING
SERVICES

1. Remove the grease of the
exposed areas of the hydraulic
cylinders.

2. Charge the batteries
completely.

3. Turn on the key to confirm
batteries are completely
charged

4. Go ahead with the tests of page

2.13

7.2

MAXIMUM FORWARD-REVERSE
SPEED

< 1,2 m/s
MAXIMUM LOAD PERMITTED

1.000 kg

MAXIMUM FORKS ELEVATION

1600 mm

8. TECHNICAL SPECIFICATINOS

In this plaque, located at the right hand side, following
information should be seen: Serial number, traction
motor, elevation motor, tyres pressure, etc.

MAIN PARAMETERS

WARNING

Do not try to exceed the above parameters.

8.1