GMR STAMA Micro, STAMA Parker, STAMA Multi, STAMA Evo, STAMA Mini Operating Instructions Manual

...
GMR maskiner a/s Saturnvej 17 DK-8700 Horsens
Tel. +45 7564 3611 www.gmr.dk
DK GB DE
SE
Registration of Use ............................................................. 3
EU declaration of conformity .............................................. 5
General information ............................................................ 6
Safety requirements ........................................................... 7
Operating ............................................................................ 9
Maintenance ..................................................................... 10
Lead-acid batteries ............................................................11
Lithium-ion batteries ......................................................... 18
Marking/labelling............................................................... 23
Customer services and claims.......................................... 24
Operating Instructions
STAMA Micro, Parker, Mini, Multi,
Evo, Maxi EL
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Registration of Use
Page 3
Operating Instructions
GB
Registration for use:
Machine number
Delivery date
Model
End user
Address
Dealer
STAMA manufactures quality machines for professional users. The warranty period on our machines is 12 months from the purchase date, and covers any material or manufacturing defects. Any parts that have suffered damage as a result of material and production faults will be replaced by GMR maskiner a/s at no charge. Compensation will not be given for consequential damage or wearing parts.
A condition for the processing of claims is that this registration for use is submitted to GMR maskiner a/s no later than 1 month after delivery to the user.
This can be done on our website at www.gmr.dk
or by lling in and forwarding or scanning the form below to: GMR maskiner a/s
Saturnvej 17 DK-8700 Horsens stensballe@gmr.dk
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
EU declaration of conformity
Page 5
Operating Instructions
GB
EU declaration of conformity
Manufacturer: GMR maskiner a/s
Saturnvej 17, 8700 Horsens, Denmark
Tel.: +45 7564 3611
hereby declares that
machine: STAMA
machine no.:
date:
is in conformity with the applicable requirements of:
Directive 2006/42/EC of the European Parliament and of the European Council of 17 June 2006 on the approximation of the laws of the Member States relating to machinery.
Signature:
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
General information
Page 6
Operating Instructions
GB
Please read the Operating Instructions before you start to use your new STAMA truck.
If you are in any doubt, contact the dealer.
Use only original STAMA parts in your electric truck. To order original parts, contact your dealer or GMR maskiner a/s directly.
The truck is fully assembled and tested at the factory. It is ready for use.
The STAMA truck is a product, the design of which is based on the practical experiences of users, e.g. graveyards and housing associations.
General comments
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Safety requirements
Page 7
Operating Instructions
GB
The truck starts smoothly and continues to accelerate until it reaches maximum speed.
Acceleration
Intended use
Normal use
The truck is intended to carry stone, gravel, soil, branches and waste.
Max last, Micro = 350 kg Max last Parker = 500 kg Max last, Mini = 750 kg Max last, Multi, Evo and Maxi = 1000 kg
The operator must sit on the seat when driving. The truck stops if contact with the seat is interrupted for more than 1 second.
Light The operator must ensure that there is sufcient light when driving the
truck so that potential obstacles are clearly visible.
Maximum speed Micro 12 km/h
Parker and Mini 15 km/h Mini 15 km/h Multi and Evo 20 km/h Maxi 16 km/h
The top speed is electronically controlled and can be lowered. Contact GMR maskiner.
Trailer total weight Without park brake With park brake
Mini and Parker 350 kg 700 kg Multi 500 kg 1000 kg Maxi 500 kg 1000 kg Evo 970 kg 1940 kg
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Safety requirements
Page 8
Operating Instructions
GB
Vibrations There are no signicant vibrations as the machine is electrically
powered.
Disposal When disposing of the truck, the battery should be recycled. The
remainder of the truck should be disposed of by a scrap dealer.
WARNING Moving parts
Take care not to allow people or objects to get crushed when tipping the truck bed.
WARNING Safety guards
When the truck is in operation, all safety guards must be secured.
WARNING Maintenance
Before starting maintenance work, bring the truck to a complete standstill to ensure that there is no danger of personal injury due to moving parts.
The truck speed should be adapted to the conditions, i.e. reduce speed at corners and in narrow passages. There is a risk that the truck may overturn when travelling on an incline. Never drive on an incline of more than 20° across the direction of travel. When travelling fully loaded down a steep hill, the truck must travel at very slow speed (tortoise mode). If you drive too fast down a hill, the truck may (worst case) run out of control. Make sure the brakes are in good working order at all times.
Max. incline in direction of travel:
about 40% over a distance of 0.5 metres
about 20% over a distance of 1-2 metres
about 15% over a distance of 3-5 metres
If the incline is steeper and the truck fully loaded, there is a risk that the truck will stall on the incline and (worst case) may roll backwards.
Speed, slopes and in-
clines
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Operating
Page 9
Operating Instructions
GB
Preparation
Before starting, check that:
The battery is fully charged
The battery electrolyte density is correct
The battery is clean
There is no battery error or operating fault
Turn the main switch. Micro truck: the main switch is on the right-hand side of the vehicle under the truck bed. Mini truck: the main switch is to the right of the steering column. Multi truck: the main switch is on the
back of the seat box. On the Maxi truck the main switch is on the left­hand side of the vehicle under the seat box. Turn and hold the ignition key on the dashboard in that position until the display lights up and the hydraulic pump has accumulated servo pressure.
Pre-start inspection
Pre-start inspection
Operating
Direction of travel Read the "Preparation" section before operating the truck.
Select direction of travel – forward or reverse – using the selector on the dashboard. Regulate speed using the foot pedal. The foot pedal also acts as an engine brake (release pressure on the foot pedal).
Release the foot pedal. The motor brakes. If you need to brake harder, use the foot brake.
Stopping
Unloading/tipping
Activate switch on the dashboard. Unloading/tipping starts.
To stop the truck and all its moving parts, turn the ignition switch to the OFF position and then turn the main switch anticlockwise.
Emergency stop
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Operating
Page 10
Operating Instructions
GB
To prevent unnecessary breakdowns and excessive wear-and-tear, your truck should be maintained at regular intervals.
Electric motor
NEVER use a high-pressure/steam cleaner to clean the motor as this can cause condensate to form.
The truck must be serviced twice a year by a GMR-approved technician.
If the truck does not work properly, read the alarm code and contact an authorised technician.
Error code:
14 Main relay does not crank due to pump start 16 / 22 Electronics overheating 28 Operating motors overheating 17 / 23 Battery voltage low 39 Main relay does not crank 47 Error in start sequence, forward/reverse selector switch
and accelerator, seat switch released
To cancel the error, try switching the forward/reverse selector switch to neutral. Then switch the ignition switch to OFF and restart. If there is an alarm code in the display all the time, you must contact an authorised workshop.
For a full list of error codes in English, contact GMR maskiner.
The hydraulic system is generally maintenance-free. However, you
should replace hydraulic uid once a year or after 500 operating hours. We recommend Shell Tellus Artctic 32 Hydraulic uid.
Hydraulic system
Gear motor
Lubricating mechanical
parts
Grease the ball bearings about six times a year.
Type SAE 80W90 gear oil must be changed after 500 hours of operation or at least once a year. Micro, Parker and Mini 0.25 litres Multi, Evo and Maxi 0.50 litres
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Lead-acid batteries
Page 11
Operating Instructions
GB
WARNING Risk of personal injury/death
The charging of lead-acid batteries can be hazardous, due to the formation of explosive hydrogen gas.
Lead batteries
WARNING Risk of personal injury/death
Flames and sparks are not permitted in the vicinity of the battery. Power down the mains supply contact before releasing the charger clamp.
WARNING Risk of personal injury/death
Some internal parts of the charger carry live current and represent a risk of personal injury. The charger frame must therefore only be opened by specially
qualied personnel.
COMMENT Important information
The charger is not suitable for domestic use or for
use in ofces or similar electrical environments.
The battery charger is an automatic, microprocessor controlled
charging unit, which is intended specically to charge open lead-acid batteries. Charging specications according to DIN 41774.
General comment
The charger must be located in a dry, well-ventilated space.
• The charger should be connected to the mains power supply ­It must be earthed and fused. Connect in accordance with the
specications on the charger type plate.
• The charger can be adjusted to the appropriate mains voltage. (This may only be performed by an authorised technician. If the charger frame is opened, the guarantee will be considered null and void).
• The charger may only be adjusted when the unit is powered down.
Installation
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Lead-acid batteries
Page 12
Operating Instructions
GB
Depending on type and production year, your truck will have one of two different types of battery charger.
Function
SMC-HF 600/800
Curtis 1621
• Connect the battery. Switch on the mains supply. The POWER ON diode is lit when the unit is charging.
• When the charging level reaches 2.43 V per cell, the charger reduces charging to a pre-programmed voltage charge level and the next diode lamp lights up. The charger charges at constant voltage for about 60% of the main charging period.
• Then the pulsed maintenance charging phase starts. A green diode lights up.
The battery is now fully charged.
Recharging
• If the battery does not reach 2,43 V per cell after 10 hours of recharging, switch off the charger. The lower red diode lamp lights up. The red diode lamp indicates that there is an error or that charger safety is compromised.
• If the total charging time exceeds 16 hours, the charger switches to maintenance charging.
• In the event of a power cut, the charging timer is interrupted. The timer restarts when the power is resumed. The charger's charging diode lamp is extinguished during a power cut.
Operating errors
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Normal operation
Page 13
Operating Instructions
GB
Before charging
Don't forget to switch the charger off or press the pause button each time you connect or disconnect the battery to/from the charger. To avoid sparks, power down the charger before disconnecting the charger and battery connectors.
Drive the machine close to the charger. The charger and battery connectors must be within easy reach of each other.
Turn ignition switch to 0. Cut the power.
Connect the charger connector to the battery connector on the machine.
Switch on the charger.
Check that the charger starts to charge. The Red lamp lights up (NB: on some chargers, this lamp is Yellow).
The charging process is optimal at room temperature. If the battery is to be stored for a longer period of time, it should be fully charged before storage.
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Normal operation
Page 14
Operating Instructions
GB
After charging
Don't forget to switch off the charger or press the pause button each time you connect or disconnect the battery to/from the charger. To avoid sparks, power down the charger before disconnecting the charger and battery connectors.
Check that the charger has fully charged the battery. The Green lamp is lit.
Power down the charger or press the pause button.
Disconnect the charger connector from the battery connector.
COMMENT: Never pull on the cables.
Wipe the battery and close the battery lid. Connect the battery connector to the truck and drive.
Check battery uid level at least every 14 days. If necessary, top up the battery uid.
ALWAYS top up after charging.
NEVER top up before charging.
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Max. Min.
Lead-acid batteries
Page 15
Operating Instructions
GB
Manual top-up
with battery uid
COMMENT: NEVER add acid to the battery, only battery uid.
Do not store battery uid in a metal container. To top up, use equipment
made of plastic or other non-conductive material, which can also withstand contact with water and acid.
If the acid level is too high, there is a risk that it will spill over during charging, which may damage the battery or underlay. If the battery has toppled or if acid has leaked from it, contact GMR maskiner a/s.
Always keep the battery clean and avoid acid spills. If metal parts are tainted with acid, clean them. To protect them from further adverse effects, lubricate with acid-free Vaseline.
Boards and separators must always be covered by the acid. Never top up with
more battery uid than indicated on the
drawing.
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Normal operation
Page 16
Operating Instructions
GB
The battery lling system (BFS) caps work best when water pressure is
0.3-2.0 bar, which corresponds to water column pressure when pouring
from a height of 3-20 metres.
If the pressure is too low, the caps may fail to close at the correct level in
the cells and continue to ll. The battery will then overow, which affects
electrolyte density and may damage the battery box and underlay.
The canister must be placed at least three metres above the cell caps, preferably higher.
T-cylinder for water connection
Degassing cylinder
Fluid cylinder
Valve cylinder
Indicator cylinder
Automatic top-up with a
BFS and water caniste
COMMENT Important information
If a battery has overowed, the electrolyte level
must be regulated. This must be only be done by Exide Batteriservice, Motive Force. Call +45 702 78
702. Contact GMR maskiner a/s to order electrolyte regulation
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Normal operation
Page 17
Operating Instructions
GB
Position the canister at the correct height and check the BFS system regularly. If you do not, your battery may get damaged.
The battery manufactur-
er's guarantee provisions
For further information about the different types of batteries,
click: http://www.gnb-nordic.com/anden-info/garanti/motive/
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Lithium batteries
Page 18
Operating Instructions
GB
The lithium battery pack contains a number of individual LFP cells. The pack has a nominal voltage of about 3.3 V per cell. This is the safest type of lithium battery on the market.
LFP batteries have a at discharge curve, i.e. the voltage remains at
about 3.2 V until the battery is about 80% discharged, after which the voltage diminishes sharply. To minimise the risk of damage and prolong the lifetime of the batteries, we recommend that they are never more than 80% discharged.
LFP battery discharge curve at different temperatures
Voltage (V)
Discharged capacity (%)
LFP batteries have a longer lifetime than conventional lead-acid batteries. They can withstand more than 3,000 70% depth of discharge (DOD) cycles. The voltage of LFP batteries must not fall under 2.5 V per cell. If voltage falls below this level, the cells may be irreparably damaged.
Battery lifetime
The battery pack (LFP = Lithium Ferro
phosphate)
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Lithium batteries
Page 19
Operating Instructions
GB
Battery management
system
BMS = Battery Management
System
The lithium-ion battery pack is tted with BMS, a system which monitors
the voltage in each individual battery cell. A combined battery sensor/
balancing unit is tted to the top of each cell.
The PCB is tted directly onto the cell's + and - terminals and has two functions:
1. The board constantly monitors cell voltage so that it remains within the permitted range (2.6-4 V). If voltage is within the permitted range, a green diode lamp lights up, The unit's output signals to the main monitoring system that everything is in good working order.
2. The unit also helps to balance the cells while the battery pack is recharging. When the charge voltage exceeds 3.6 V, the unit starts to deduct balancing energy from + to - , increasing to 1 ampere when maximum voltage (4.0 CV) is achieved. When the PCB is balancing (deducting power), a red diode lamp lights up (at the same time as the green one). The red diode lamp on the sensors does not signal that there is an error.
Stama trucks with reset
button (until 2014)
The PCB outputs are daisy chained and monitored by a micro-controller-based (MCU) monitoring system.
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Lithium batteries
Page 20
Operating Instructions
GB
There are two diode lamps on the MCU:
The green diode lamp indicates that there is a 12 V supply to the PCB.
As long as the monitoring circuit is intact, the MCU ensures that a small 12 V relay remains connected. The 12 V relay supplies all remaining units which take energy from the battery, e.g. the key switches, main and pump relays.
The MCU monitors the cell circuit. If the circuit is broken, the red diode
lamp ashes. After 10 seconds, the relay is disconnected and the red
diode lamp lights up.
The MCU is disconnected if the main switch is disconnected.
The red diode lamp indicates that the monitoring circuit is broken, i.e. that there is a problem with at least one of the cells.
MCU diode lamps
A break in the MCU circuit can be caused by a cell with excessively low voltage. If this is the case, recharge the battery. Press reset button
briey.
Resetting the MCU
Insufcient cell voltage
Open main switch If there is a break in the MCU circuit caused by the main switch having
been opened, just press the reset button briey. The truck does not
need recharging.
If the MCU is triggered during charging, the charging voltage may be too high or the battery imbalanced. Try pressing the reset button repeatedly. If one of the red cell sensor diode lamps lights up much earlier than the others, the voltage in this cell is too high. The cell may be damaged.
If the cell is damaged, contact GMR maskiner a/s.
Excessive charging voltage or imbalanced battery
Stama trucks with no reset button (after 2014)
Stama trucks which do not have a reset button are tted with a simple
BMS, in which the MCU is replaced by a simple BMS relay, which requires no resetting. If all the battery sensors light up green, the BMS relay is activated and the machine can be started. If just one of the sensors does not light up green, the relay is not activated and the batteries will not be excessively discharged.
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Lithium batteries
Page 21
Operating Instructions
GB
The battery charger charges all the batteries serially and simultaneously to a charge voltage of 3.65 V per cell. The charger charges constantly until the desired voltage level is achieved. Then the charge voltage is reduced until full starting voltage is achieved. The starting voltage is maintained until the charger is switched off. Before the charge voltage is reached, all the cell sensors' red diode lamps should light up.
The battery pack is fully charged in seven hours.
Lithium-ion batteries should not be subjected to charge voltage over a prolonged period of time because constant high charge voltage reduces battery capacity. Disconnect the charger when the batteries are fully charged.
During storage, the battery discharges 3% a month and, to avoid reaching full depth of discharge, it must therefore be recharged at least every six months. Lithium batteries are maintenance-free.
Lithium-ion battery charger
Lithium batteries can withstand frost, and can be used down to minus 20 °C, though with reduced capacity.
Cold
• If they are corroded, clean cell terminals with a dry brush.
• Keep electrical connections dry at all times.
If you have a question or need more information material, contact GMR maskiner a/s.
COMMENT Important information
To avoid irreparable damage, NEVER allow lithium batteries to discharge completely.
CAUTION Damage to machinery or attachments
Do not open the cells as this can ultimately (worst case) cause irreparable damage.
CAUTION Damage to machinery or attachments
Lithium batteries must be at least +5 ˚C before
they may be recharged. If colder batteries are charged they can be permanently damaged.
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Lithium batteries
Page 22
Operating Instructions
GB
Battery indicator
If the word SYNCHRONIZE ashes in the display, the battery charge
level reading is invalid. This happens if the indicator has been disconnected from the battery. Fully recharge the battery to ensure that the indicator measures correct battery charge level. SYNCHRONISE disappears from the display.
Displays
Battery power (voltage)
Current power consumption or charging.
Minus - is consumption
Ampere hours used since charging
Battery power remaining (%)
Remaining operating hours at current consumption
Battery alarm The battery indicator is set to the relevant size of battery. This must not
be changed except by agreement with GMR.
When the batteries have only a few percent of full power remaining, the indicator triggers an alarm ((%)), and the truck runs at reduced speed. The truck should be recharged.
Like an electricity meter, the battery indicator measures power entering and leaving the lithium-ion battery. The battery indicator also calculates power reserves. The indicator is always connected to the battery – even when the main switch is OFF.
1. CHARGE: Recharge the battery!
2. Numerical eld
5. Battery charge level
6. Charging indicator
7. Battery alarm
8. Unit of measurement
9. SYNCHRONIZE: Battery indicator is not synchronised correctly
10. Next view
11. Menu button (not normally used)
12. Previous view
GMR maskiner a/s
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Care for the ground
www.gmr.dk
Type:
kW:
No.:
Kg.
Marking/labelling
Page 23
Operating Instructions
GB
The truck is marked with various labels and signs. These must remain on the truck at all times. If labels and signs are damaged or obscured by paint, they must be replaced. New labels and signs are available from the manufacturer or contact your dealer.
Warning signs The machine carries warning signs.
Labels and signs:
Type plate/serial number plate ­machine number and
other specications
CE label The CE label indicates that the truck complies with the
EC Machinery Directive, and states production year.
Other labels The truck also carries the manufacturer's own labels (logos, etc.)
and a technical data label.
GMR maskiner a/s
Side 24
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Operating Instructions
GB
Customer services and claims
Claims The warranty period on GMR machines is 12 months from the purchase
date, and covers any material or manufacturing defects. These parts will be replaced by GMR maskiner a/s free of charge. Consequential damage and wear and tear will not be replaced.
Any components which are not manufactured by GMR maskiner a/s are included under the terms of the warranty to the extent authorised by the supplier of the parts in question. GMR maskiner a/s reserves the right to assign a claim of this kind to the relevant supplier and not to reach a decision until the relevant supplier has responded.
The following must be observed when working on a claim:
• report the claim to GMR maskiner before the repair is started
agree a time period with GMR maskiner for qualied technicians to carry out the repair
any labour costs will only be approved at a xed net price.
If GMR maskiner a/s has not authorised repair work in advance, any invoice submitted for repair work will not be approved.
At GMR maskiner a/s' request, before the claim can nally be handled,
any parts that were replaced must be sent carriage paid to the factory.
GMR maskiner a/s retains the exclusive right to determine the extent to which a part shall be replaced or repaired.
The warranty does not cover:
• normal wear and tear or damage which has resulted from inadequate maintenance.
• damage caused by collision.
non-compliance with the product's technical specications or if the product is used for a purpose other than that described in the user manual.
If the product is altered or if non-original spare parts are used, all rights under the warranty will be rendered void.
The purchaser does not have the right to require that design changes on future models are implemented in a pre-existing machine.
GMR maskiner a/s
Side 25
STAMA Micro, Parker, Mini, Multi, Evo, Maxi EL
Operating Instructions
GB
Customer services and claims
In the event
of a complaint:
Complaints must be registered directly with GMR maskiner a/s. Complete a complaint report, stating the machine type, production number and date of its delivery to the customer, and send it to us. This is done via the dealer login on our website www.gmr.dk. If questions arise about claims on imported machines, we reserve the right to present the claim to the manufacturer before making any decision about whether the claim can be accepted.
Our machinery is subject to the EC Machinery Directive and quality assured within the European Union. We make every effort to comply with these requirements and do our utmost to supply high quality machinery.
Horsens, 01.06.2017 GMR maskiner a/s
Copyright, GMR maskiner a/s © Saturnvej 17 DK-8700 Horsens
www.gmr.dk
01032018
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