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
© 2004 CONHERSA
1. MAIN COMPONENTS
Chassis
c
d Front wheels
e Fork grouping
f Hydraulic cylinde r
g Handle
h Motor drive wheel
i Hydraulic motor pump
1.1
j Electronic controller
k Electric braking
l Batteries
11 Load indicator
12 Claxon
13 Emergency stop
c Chassis
d Front wheels
e Fork grouping
f Hydraulic cylinde r
g Handle
h Motor drive wheel
i Hydraulic motor pump
j Electronic controller
k Electric braking
l Batteries
11 Load indicator
12 Claxon
13 Emergency stop
1.2
2. SAFETY INSTRUCTIONS
Etiquettes 2.2
Hand pallet truck safety 2.4
Daily inspections 2.5
Hand pallet truck operator 2.9
Movement in ramps and special areas 2.10
Transport of the pallet truck 2.12
Testing 2.13
Noise level 2.13
Dangerous environment 2.13
2.1
ETIQUETTES
2.2
CAUTIONS WHILE LOADING
BATTERIES
1. Load batteries at an open-air
area, away from flames, fumes
and sparks. Battery’s gasses
may be explosives
2. Do not smoke around the
loading area.
3. Do not switch off during
loading: danger of sparks.
WARNING
Do not stand on the forks.
WARNING
Keep hands, feet and body
away from masts and forks.
Danger of trapping between fix
and mobile parts.
2.3
HAND PALLET TRUCK
SAFETY
USE UNDER INSTRUCTIONS
Hand pallet truck may only be
used under instructions included
in this manual.
WARNING
This hand pallet truck may only
be used to transport palletised
materials.
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.
In case of handle malfunction,
press red button, switch off
and contact our technical
service.
WARNING
2.4
DAILY INSPECTIONS
Before using, following
inspections shall be followed:
1. Brake: When releasing handle,
make sure that hand pallet
truck 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.
Tighten bolts. Verify wheels
pressure.
5. Control instruments: Switch on
key. Verify battery’s light
indicators lights on.
6. Battery: Correct charge level
(20% at least).
7. Claxon: Verify well function.
8. Lifting: With forks unloaded,
verify correct lifting and
descent.
9. Connected: Pressing the deadman, verify correct forward and
reverse.
WARNING
In case of malfunction, switch
off, inform to whom it may
concern, and contact technical
service.
BRAKE
When releasing handle, verify
that speed controller returns to
neutral position and brake is
immediately blocked. (When
blocking, a sound must be
noticed).
Push the pallet truck to make
sure that it is well blocked and
you can not move it.
2.5
FORKS
Lift the fork by hand and place it
where needed.
Forks must be placed in
symmetry as per the axe.
The own friction of the for ks avoid
of not intended displacement.
2.6
HYDRAULIC CIRCUIT
Verify oil level in the deposit.
Verify in case of possible oil
losses (leaks).
WHEELS
FRONT REAR
Measure 155R13” 4.00-8”
Pressure 2,7 bar Super elastic
front
BATTERY CHARGE LEVEL
Turn the key to ON position.
Verify charge level in the
indicator. If level is under 20%,
batteries must be charged.
Connect the charger for
approximately 10 hours (See
procedure on page 5.1).
rear
2.7
CONTROL INSTRUMENTS AND
CLAXON
Turn on the key. Verify battery
light indicator is on
Verify claxon by pressing the
claxon button.
HANDLE
Unloaded, press lifting and
descending buttons to verify that
forks go up and down correctly.
Press the dead-man function,
press smoothly the forwardreverse switch and verify that the
blocked brake is self-released (an
audible sound is heard), and the
truck commences to move gently.
Verify both, forward and reverse.
Contact key.
c
d Dead-man function
e
Forward-reverse throttle
f Claxon.
g Forks down button
h Forks up button
2.8
HAND PALLET TRUCK
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
pallet truck.
For example:
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.
WARNING
For clothing, observation of the
national rules and obligations
is as must.
2.9
MOVEMENT IN RAMPS
AND SPECIAL AREAS
WARNING
Using the electric rough terrain
hand pallet truck for
transporting goods in ramps is
strictly forbidden.
Only permitted with the pallet
truck unloaded, if necessary.
WARNING
Do not turn in ramps.
Movement in ramps is delicate:
pay maximum attention and
care.
WARNING
Caution when moving on a
truck surface. Please make
sure that the truck is stopped.
The ramp used to place the
hand pallet truck onto the truck
must be resistant enough to
bear the hand pallet truck.
Ramp should be firmly placed
on the ground in order to avoid
unexpected movements.
Pay maximum attention during
the loading and unloading of
the hand pallet truck on the
truck.
2.10
ENTRY IN SERVICE LIFTS
Elevation of the pallet trucks in
service lifts should only occur
when the service lift has enough
power and has been designed for
this purpose.
WARNING
Make sure that the service lift
is powerful enough –see the
service lift weight capacity- to
load the pallet truck.
Do not operate nor work with
the pallet truck inside the
service lift.
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.
Make sure that the pallet truck
does not touch the sides of the
service lift, and that it is well
placed in order to avoid
unexpected movements.
Operators should never get into
the service lift before the pallet
truck. Get out of the lift always
before the pallet truck.
2.11
TRANSPORT OF THE
PALLET TRUCK
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. (see picture)
3. When using a wooden made
bridge between platform and
dock, make sure that the
planks can bear the pallet
truck.
4. Use only the lifting hangers
to lift the pallet truck. (see
picture)
6.Switch off and release
contact key.
2.12
TESTING
2.3. Descending speed test.
NOISE LEVEL
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 pallet truck
moves towards the correct
forward-reverse switch, and
confirm that the blocking
brake works properly.
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
Less than 70 dB (A)
DANGEROUS
ENVIRONMENT
WARNING
Use of pallet truck in
dangerous environment is
strictly forbidden.
With the pallet truck loaded,
press up and down buttons to
make sure of correct work.
2.2. Piling test.
Lift completely and descent
the load at maximum speed
several times.
A dangerous environment may
cause fire or explosions
because of dust, fumes or
gasses.
2.13
3. CONTROL SWITCHES AND INDICATORS
c Contact key.
d Handle.
e Security button.
f Battery charge indicator.
g Fuses
h 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 swit ch.
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.
c Contact key
d Dead-man function
e
Forward-reverse throttle
f Claxon
g Forks down button
Dead-man function
Placed at both sides of the
handle. Must be pressed to allow
the machine moving forwardreverse.
3.2
h Forks up button
CONTROL INDICATORS
WARNING
Claxon
The claxon is located next to the
up and down buttons.
Battery charge level 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
The fuses are located in the
electronic controller.
The fuses may only be
changed by the specialized
personnel.
Replace the fuses by others
with similar characteristics.
WARNING
When the pallet truck is not
being used, make sure to turn it
off.
3.3
4. SWITCH ON AND WORK
c Contact key
Dead-man function
d
e forward-reverse throttle
f Claxon
g Forks down button
h Forks up button
4.1
SWITCH ON AND WORK
WARNING
Before using the pallet truck,
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 pallet
truck: you should not be able to
move it.
2. Disconnect the emergency
stop
3. Turn on the key without
pressing the throttle.
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.
WARNING
When leaving the pallet truck,
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.
4.2
Movement on slopes (ramps)
Movement on slopes with the
machine loaded is strictly
forbidden.
5. LOADING AND UNLOADING
LOADING
Adjust the forks in symmetry as
per the pallet truck 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 smoothl y 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 pallet truck
loaded should be made with
special care and attention. If the
load height does not allow proper
visibility, the pallet truck must be
driven forward, except when
entering into the service lifts,
where it is strictly forbidden.
UNLOADING
Move towards the un loading area
slowly.
Verify that, when stopping, the
automatic blocking brake is on
(blocking soun d).
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 pallet
truck 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. Tyres air-pressure control.
2. Change the front tyres.
3. Charge batteries.
4. Batteries electrolyte level
control.
5. Pallet truck cleaning.
6. Emergency forks descent.
6.2
MAINTENANCE TO BE
MADE BY THE USER
WARNING
Before making any
maintenance, turn off the key.
Confirm that the automatic
blocking brake is on.
TYRES AIR-PRESSURE
CONTROL
From time to time, the airpressure control should be made
to confirm that it is correct.
Front tyres
1. Release valve screw-top.
2. Connect a manometer.
3. Correct pressure is 2,7 bar. If
it is less, add air with the
pump.
Pressure (bar)
Front 2,7
Rear Super elastic
CHANGE FRONT TYRES
Front tyres
1. Put a wooden chock under the
pallet truck to separate it from
the floor. Verify that pallet truck
remains stable.
2. Fasten the bolt with a wrench.
With the other hand, loosen the
nut with an 18 wrench, just up
to when there are only few
turns of the nut left.
6.3
NOTE: Do not tight the nut too
much: some pieces could be
damaged and turning the pallet
truck would be impossible.
3. With a nylon hammer or
wooden chock, hit the nut in
order to take it out.
4. Unscrew completely the nut
and release the bolt by hand.
5. Take out the wheel.
6. Once the wheels is taken out,
repair the puncture, change the
tyre, etc.
7. Assembling procedure should
be done all the way round.
Make sure not to damage the
nut when inserting.
6.4
BATTERY CHARGE
WARNING
3. Connect the prov ided cabl e to the
pallet truck and an electric socket
(220 V).
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 ar riving
to a 20% of battery charge, the
machine slows its speed
drastically.
Charging process
1. Move pallet truck close to an
electric socket (220 V).
2. Turn off the contact key.
4. Verify that the red light is on.
5. Batteries are completely charged
when the green light is
permanent.
6. Disconnect the cable, wind it and
keep it safe. .
7. Turn the contact key on and
confirm that all the battery charge
level is at 100%.
6.5
BATTERIES MAINTENANCE
1. Loosen with a screwdriver the
10 screws of the batteries
yellow metal box.
4. Put aside the top of the battery
glasses carefully, without
touching the connecting tips.
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).
5. Verify that the electrolyte level
is correct. If necessary, fill in
with distilled water up to the
nets.
2. Take out the top and front part
of the metal box.
3. Confirm that there are no
electrolyte leaks and no
corrosion on the tips.
6.6
CLEANING THE PALLET TRUCK
WARNING
Before cleaning, turn off the
key.
Verify that the blocking brake
is on.
Cleaning the handle.
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.
Clean the dust with a brush.
Do not use water.
Finish with a dry cloth.
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 right hand side box,
where the motor pump is
located.
3. Verify that there are no
obstacles under the forks.
4. Press the red button to make
the forks go down.
6.8
7. LONG WAREHOUSING
LONG TIME WAREHOUSING
When the pallet truck 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 pallet truck as
explained before.
2. Charge the batteries
completely.
3. Place the pallet truck in a
horizontal position.
4. Dissemble the batteries and put
them in a dry and fresh place.
5. Put the pallet truck on wooden
sticks in order to avoid damages
and deformations of the tyres.
WARNING
When there is no inside area
available, place the pallet truck
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.
7.1
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
8. TECHNICAL SPECIFICATIONS
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
MAXIMUM FORWARD-REVERSE
SPEED
MAXIMUM LOAD PERMITTED 1.200 kg
MAXIMUM FORKS ELEVATION 200 mm
WARNING
Do not overload the pallet truck.
Do not try to exceed the above parameters.
< 0,6 m/s
8.1
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