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EJE KmS 16

Jungheinrich EJE KmS 16 Operating Instructions Manual

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Page 1
Operating instructions
50114146
EJE KmS 16
G
02.01 -
02.01
Page 2
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
f
Used before safety instructions which must be observed to avoid danger to personnel.
m
Used before notices which must be observed to avoid material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment. o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
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0108.GB
Page 4
I 1
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Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
2.1 EN standards ...................................................................................... B 3
2.2 Conditions for application .................................................................... B 3
3 Identification locations and identification plates .................................. B 4
3.1 Truck identification plate ..................................................................... B 5
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery ................................................... D 4
6 Combined instrument (o) ................................................................... D 5
EOperation
1 Safety regulations governing the operation of the fork-lift truck .......... E 1
2 Description of the operating controls and indicating instruments ........ E 2
3 Starting up the truck ............................................................................ E 4
4 Operation of the fork-lift truck .............................................................. E 6
4.1 Safety regulations applicable when operating the truck ...................... E 6
4.2 Driving, steering, braking .................................................................... E 7
4.3 Picking up and setting down loads ...................................................... E 10
4.4 Order picking up to the second level (o) ............................................ E 10
4.5 Safe parking of the truck ..................................................................... E 11
5 Fault location ....................................................................................... E 11
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I 2
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance Check - list ..................................................................... F 4
5 Lubrication Schedule ........................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Description of the servicing and maintenance operations ................... F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ...................................................................... F 8
6.2 Opening the battery hood .................................................................... F 8
6.3 Opening the front hood ....................................................................... F 8
6.4 Checking the hydraulic oil level ........................................................... F 9
6.5 Checking the electric fuses ................................................................. F 10
6.6 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and
following any untoward incidents (D: Accident
prevention check according to VBG 36) .............................................. F 12
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A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating instructions and must always be heeded. National regulations are fully applica- ble.
The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these ope- rating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A “user” within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the opera- ting duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The same app- lies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
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A 2
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B Truck description
1Application
The truck is an electrically driven, three-wheeled lifting trolley controlled by means of a control shaft and provided with a driver standing platform. The truck is designed for use on level surfaces for transporting and order-picking goods and is able to pick up, outside the load-bearing wheel range, pallets with open bases or lateral boards, as well as trolleys. Access to the second order-picking level is available as optional equipment in the form of a step in the backrest and a step-on battery cover. The capacity of the truck is 1600 kg at a load centre distance of 600 mm.
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B 2
2 Assemblies
Item Designation Item Designation
1 o Combined instrument 9 t Collision guard 2 t Controller 10 t Motor brake 3 t Master switch 11 t Electric system 4 t Hydraulic pump 12 t Lifting linkage 5 t Hydraulic oil reservoir 13 t Load-bearing wheel support 6 t Drive motor 14 t Driver standing platform 7 t Supporting wheel 15 t Lifting cylinder 8 t Driven wheel 16 t Control shaft
t= Standard equipment o = Optional equipment
1
2
3
4
5
6
7
8 9 7
10
11
12
13
14
16
15
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2.1 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0.62m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit val- ues for electromagnetic emission and interference immu- nity as well as testing of static electricity discharge ac- cording to prEN 12895 and the references to other standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
2.2 Conditions for application
Ambient temperature
- during operation: 5°C to 40°C
A
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5°C or in cold stores respectively with extreme temperatures or humidity changes.
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B 4
3 Identification locations and identification plates
A
The capacity label (18) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded. The load distribution label (19) stip- ulates that the load on the fork is to be approximately uniform.
Item Designation
17 Label “CAUTION: Low-voltage electronics” 18 Capacity Qmax 19 Load distribution 20 Label “Caution, pushbutton operation” 21 Truck identification plate 22 Identification label, battery 23 Accident prevention inspection label (
D
only)
24 Attachment point of hooks for transportation by crane
22
18
17
24
19
20
Q
max
1600
kg
mV
1,5 V
21
23
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3.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial no. (26) of the truck.
Item Designation Item Designation
25 Type 32 Drive power in kW 26 Serial No. 33 Customer no. 27 Rated capacity in kg 34 Min./max. battery weight in kg 28 Battery: Voltage V
Ampere hours Ah
35 Empty weight without battery in kg
29 Manufacturer 36 Year of manufacture 30 Order no. 37 Manufacturer logo 31 Load centre distance in mm
25
26
27
28
29
30
32
36
35
34
33
31
37
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B 6
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1 1
C 1
0201.GB
C Transportation and commissioning
1 Transportation by crane
f
Ensure that only lifting gear of adequate capacity is used (for weight of the truck refer to the truck identification label).
– Park the truck and render it safe (refer to chapter E).
A
The truck chassis and the fork are provided with hoisting points (1) to be used when the truck is to be lifted and transported by crane.
m
Secure the hoisting gear to the hoisting points (1) ensuring that the hoisting gear will not slip.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– If necessary, install the battery. Do not damage the battery cable.
(refer to chapter D). – Charge the battery (refer to chapter D). – Commission the truck as detailed
(refer to chapter E).
A
When the truck is parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
1 1
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C 2
3 Moving the truck with the drive unit inoperative
f
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as fol- lows:
– Ensure that the truck cannot accidentally move. – Set the master switch to position “OFF”. – Set the key switch to position “OFF” (“0”) and remove the key. – Unlock the cover locks (2), open and set down the front hood (3). – Slacken the lock nuts (4) and tighten the
screws (5).
The brake has now been released and the truck can be moved.
f
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition.
– Loosen the screws (5) by approx. 5 mm
and lock by tightening the lock nuts (4).
The brake is now applied again.
5
4
2
3
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D Battery - Servicing, recharging, replace-
ment
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by qualified personnel. The instructions contained in this operating manual, and the instructions of the manufacturer of the battery and of the battery recharging station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when han- dling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharg- ing. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- minals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a non- skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- tional environmental protection regulations or waste disposal provisions. The manu- facturer’s specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be dam- aged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into con- tact with battery acid. Spilled battery acid must be immediately neutralized.
m
Only batteries with closed tray may be used.
f
Battery weight and dimensions have considerable influence on operational safety of the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.
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D 2
2 Battery types
Depending on the truck version, the truck will be supplied with different battery types.
The battery weights can be seen from the battery identification plates.
f
Battery weight and dimensions have considerable influence on operational safety of the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.
3 Exposing the battery
f
Park the truck and render it safe (Refer to chapter E).
– Release the cover by depressing the lock (1), fold the battery cover (2) forward and
release the cover safety mechanism (3) r.
The truck is equipped with a PzS-battery. The battery is now exposed and the re- quired operations may be performed.
Battery type Battery compartment (185 mm) 24 V-PzS-batteries 2 PzS 180 Ah L 24 V-PzS-batteries 2 PzS 220 Ah L 24 V-PzS-batteries 2 PzS 270 Ah L
1
3
2
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f
The battery connector and socket must only be connected or disconnected with both the truck and the battery charger switched off.
– Withdraw the battery connector (4). – Remove any insulating matting from
the batteries.
4 Charging the battery
– Expose the battery (refer to section 3).
f
During the recharging operation the tops of the battery cells must be exposed to ensure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging opera- tion, check all cable connections and plugged connections for visible damage.
– Connect the charging cable of the battery charger to the battery connector. – Recharge the battery observing the instructions provided by the battery supplier
and by the battery charger supplier.
f
All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
4
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D 4
5 Removing and installing the battery
– Expose the battery (refer to section 3). – Push the battery against the frame in
order to relieve the battery support (5).
Raise the battery support
– by the eyes, – push it a little distance into the chas-
sis, – lift and withdraw it.
f
Batteries with open poles, or open cell bridges, must be covered with a rubber mat to prevent short-circuiting. When us- ing a crane in battery replacing opera- tions, ensure that the crane is of adequate capacity (refer to the battery weight indicated on the battery identifi- cation plate located at the battery trough). The battery must be lifted vertically to pre- vent crushing of the battery trough. Lifting hooks must be applied in such a way that, with the lifting gear slack, they will not drop on to the battery cells.
– Secure the lifting gear. – Lift out the battery.
f
When replacing batteries, ensure that a battery of the same type is fitted. Additional weights must not be removed and their position must not be changed.
– Installation is in the reverse order of operations.
f
Following reinstallation of the battery, visually check all leads and connectors for damage and prior to the recommissioning of the truck check
– that the battery support is locked and – that the battery hood is safely locked.
5
5
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0201.GB
6 Combined instrument (o)
Battery discharge indicator: The charging con-
dition of the battery is indicated in 10% incre- ments by means of ten bars shown on the battery symbol (6).
With progressive depletion of the battery, the illu- minated bars will go out from the top downwards.
m
When using maintenance-free batteries, the in- strument must be set so that the “T” symbol (9) will appear next to the operating hour display. When this setting is not performed, the battery might suffer damage caused by exhaustive dis- charge. Setting of the instrument should be performed by the manufacturer’s service staff.
An advance “Caution” symbol (7) will appear at a residual battery capacity of
- 30% in the case of standard batteries and
- 50% in the case of maintenance-free
batteries. Battery recharging is now advisable.
The advance “Caution” symbol (7) will go out and a flashing “STOP” symbol (8) will appear at a re- sidual battery capacity of
- 20% in the case of standard batteries and
- 40% in the case of maintenance-free
batteries. After a period of 5 minutes, the “STOP” symbol (8) will remain permanently lit. Battery recharging is now required.
Battery discharge monitor: As soon as the “STOP” symbol (8) is permanently displayed, the lifting function of the truck will be automatically switched off.
A
Lifting will only become possible again after the battery has been recharged to at least 70%.
Hour meter: The hour meter (10) integrated into the battery discharge indicator shows the total operating time of the travelling and lifting movements.
A
In the operative condition, the digit after the comma will flash.
h
h
h
STOP
T
T
T
6
7
8
9
10
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D 6
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E 1
0201.GB
E Operation
1 Safety regulations governing the operation of the fork-lift truck
Driving permission: The fork-lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his rep- resentative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork-lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork-lift truck dur- ing working time. He must forbid unauthorised persons to drive or operate the fork-lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork-lift truck or on the attach- ments must immediately be brought to the notice of the person in charge. Fork-lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork-lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A „danger area“ is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork-lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also in- cludes the area within reach of falling loads or falling/lowering truck attachments.
f
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork-lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
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E 2
2 Description of the operating controls and indicating instruments
Item Operating control or
indicating instrument
Function
1 Combined instrument
o
Shows the residual capacity of the battery, as well as the accumulated operating hours of the truck (refer to chapter D).
2 Control shaft
t
Steering and braking. Swivelling of control shaft into the braking
range B: The truck is mechanically braked.
Swivelling of control shaft into the driving range F: The mechanical brake is released and the truck is ready to travel (slow speed).
3 Key switch
t
Switching the control current on and off. When the key is removed from the key switch, the truck cannot be operated by un- authorized persons.
4 Operating key “Lowering”
t
Lowering the fork at a fixed speed.
5 Operating key “Lifting”
t
Raising the fork at a fixed speed.
6 Operating key “Horn”
t
Giving audible warning signal.
7 Operating key
t
Without function.
8 Controller
t
Controlling the direction of travel, as well as the travelling speed (refer to section 4.2).
9 Master switch
t
Switching the current supply on and off.
10 Control shaft adjustment
o
Locking the control shaft
11 Key-controlled operation -
pedestrian mode
o
Slow travel in direction - V -
12 Key-controlled operation -
pedestrian mode
o
Slow travel in direction - R -
13 Operating key - Slow travel
t
Not operated: slow speed. Operated: normal travelling speed.
14 Deadman switch, with
lockable control shaft
o
Not operated: Truck is braked Operated: Brake is released.
t
= Standard equipment
o
= Optional equipment
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1 3
5
4
13 (14)
11
12
6
9 10
2
78
V
R
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E 4
3 Starting up the truck
f
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
Checks and operations to be performed before starting daily work
– Visually check the entire truck (especially the wheels and the lifting device) for vis-
ible damage.
Switching on the truck
– Step onto the standing platform. – Push down the control shaft adjusting lever (10) (o), swivel the control shaft to the
desired position and release the control shaft adjusting lever again. – Pull out the master switch (9). – Insert the key in the key switch (3) and turn the key clockwise towards the “I” posi-
tion until reaching the stop. – Check the warning signal (horn) (6) for correct functioning. – Check the controller (8) for correct functioning (refer to section 4.2).
The truck is now ready for operation.
The combination instrument (1) (o) shows the available battery capacity.
– Check the service and counter-current brake for correct function (refer to section
4.2).
A
Operating key (7) without function.
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6
10
9
1 3
7
8
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E 6
4 Operation of the fork-lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially allo-
cated for truck traffic must be used. Unauthorised persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local con- ditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must al- ways observe an adequate braking distance between the fork-lift truck and the vehi- cle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not per- mitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork-lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork-lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork-lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driv- er ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork-lift truck driver has to sat- isfy himself accordingly before driving into lifts or on to loading platforms. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift together with the fork-lift truck must only enter the lift after the fork-lift truck has come safely to a standstill, and must leave the lift before the fork-lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork car- riage, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork-lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
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4.2 Driving, steering, braking
Emergency stop
– Depress the master switch (9).
This will switch off all electrical functions.
Driving
m
Do not drive the truck unless the hoods are closed and locked in the stipulated man- ner.
– Start up the truck (refer to section 3).
Swivelling control shaft:
A
Operating key “Slow travel” (13) not operated = slow speed,
operated = normal travelling speed.
– Swivel the control shaft (2) into the travelling range “F”. – Rotate the controller (8) to the required travelling direction (V or R).
Lockable control shaft: (o)
– Depress the deadman switch (14). – Rotate the controller (8) to the required travelling direction (V or R).
A
The more the controller is turned, the more the travelling speed will increase.
The truck will now start in the selected direction.
V
R
0
9
2
B
B
F
V
R
13 (14)
8
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E 8
Steering
– Swivel the control shaft (2) to left or right.
The position of the control shaft corresponds to the position of the steered driven wheel.
Braking
f
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The truck may be braked in three ways:
– either by counter-current braking, – or by means of the service brake. – using the generator brake
Counter-current braking:
– Turn the controller (8) into the opposite travelling direction until the truck has come
to a standstill. – Release the controller.
The truck is now braked by counter-current.
Swivelling control shaft
Braking by means of the service brake:
– Swivel the control shaft (2) into one of the braking ranges “B”, or release the control
shaft altogether.
The drive motor will then be braked by means of the motor brake.
A
When the control shaft is released, it will automatically swivel into the upper braking range “B”. When the truck is parked, the motor brake will act as a parking brake.
Braking by means of the generator brake (coasting):
– Release the controller (1) - the controller assumes the zero position.
Depending on the setting, the truck is braked by the generator braked, coasting to a stop.
Lockable control shaft (o)
Braking by means of the service brake:
– Release the deadman switch (14).
The drive motor will then be braked by means of the motor brake.
A
When the truck is parked, the motor brake will act as a parking brake.
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Key-controlled operation - Control shaft (o)
A
The truck can be controlled in the key-operated mode with the operator walking on either side of the truck. The max. travelling speed is then reduced. (slow speed).
– Swivel the control shaft (2) into the driving range “F” ( refer to section 4.2). – Turn the controller (8) into the required travelling direction (V or R).
f
When controlling the truck in the key-operated mode, it must be ensured that the steering system is pointing straight ahead and that the operator cannot get caught be- tween the truck and an obstacle.
Key-controlled operation - Backrest (o)
A
The truck can be controlled in the key-operated mode with the operator walking on either side of the truck. The max. travelling speed is then reduced (slow speed).
– Depress operating key (11)
The truck will move in direction - V - – Depress operating key (12)
The truck will move in direction - R -
f
When controlling the truck in the key-operated mode, it must be ensured that the steering system is pointing straight ahead and that the operator cannot get caught be- tween the truck and an obstacle.
11
11
12
12
11
V
R
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E 10
4.3 Picking up and setting down loads
m
Before picking up a load, the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded.
– Pass the lifting device as far as possible under the load.
m
Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm).
Lifting and lowering
A
When operating the keys “Lifting” or “Lowering”, the lifting or lowering movement will be at a fixed speed.
Lifting
– Depress operating key “Lifting” (5). – Keep the operating key depressed until the required lifting height has been
reached.
A
When the limit stop is contacted at the end of the lifting movement, the pressure lim- iting valve will respond (noise emission).
Lowering
– Depress operating key “Lowering” (4).
m
Avoid impacting of the load to prevent damage to the load and racking.
4.4 Order picking up to the second level (o)
The driver standing platform is designed in such a way that by holding on to the han- dle and by using the step, the driver can climb on to the battery cover.
f
When performing order picking operations at the second level, the driver must hold on to the handle and not to the control shaft. No controls must be operated when en- gaged in order-picking activities.
5
4
5
4
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4.5 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered safe. Proceed as follows to render the truck safe:
– Park the truck on level ground. – Completely lower the fork. – Set the key switch (3) to position
“0” and remove the key from the switch.
– Set the master switch (9) to posi-
tion “Off”.
5 Fault location
This chapter enables the operator to locate and rectify minor faults and malfunctions, or the effects of operating errors, himself. When trying to locate a fault, proceed in the order as shown in the table.
A
If it was not possible to eliminate the fault by performing the remedial actions indicat- ed above, please inform the manufacturer’s service organisation as more intricate faults can only be rectified by specially trained and qualified service staff.
Fault Possible cause Remedial action Truck does
not move
– Battery connector not con-
nected.
– Master switch (emergency
stop) depressed. – Key switch in position “0”. – Battery exhausted.
– Fuse defective.
– Check the battery connector and con-
nect if necessary.
– Release the master switch.
– Set the key switch to position “I”. – Check the charging condition of the
battery and recharge if necessary.
– Check fuses F1 and 1F1.
Load can- not be lifted
– Truck not operative.
– Hydraulic oil level too low. – Fuse defective.
– Perform all remedial actions listed un-
der the fault “Truck does not move”. – Check the hydraulic oil level. – Check fuse 2F1.
3
9
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F Maintenance of the fork-lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To en- sure safe and reliable operation of the fork-lift truck, only spare parts of the manufac- turer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced
and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assign- ments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tip- ping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork- lift truck. Prior to commencing cleaning operations, all safety measures that are re- quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-oper- ated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak com- pressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
m
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis- sioning” must be performed.
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F 2
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be de- energised by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. The factory-mounted tyres must only be replaced by original spare parts of the manufacturer, since otherwise the specification of the data sheet cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy- draulic components, also renew the hoses in this hydraulic system.
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3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe op- eration of the fork-lift truck. The neglect of regular servicing intervals can lead to fork- lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal op- erating conditions. For applications in dusty environments, or involving large temper- ature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the re- spective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week M3 = every 500 operating hours, but at least every 3 months M6 = every 1000 operating hours, but at least every 6 months M12 = every 2000 operating hours, but at least every 12 months
A
The W1 maintenance intervals must be carried out by the operator / customer.
In the running-in phase of the truck, the following additional operations have to be car- ried out:
After the first 50 to 100 operating hours, at the latest after two months:
– Tighten pole screws of battery and check condition of the cell connectors. – Perform visual inspection of the electronic and mechanic components. – Check transmission for leakages. – Check screw connections and mechanical safety retentions for tight fit. – Check the wheel nuts for security and retighten, if required. – Change all hydraulic filters. – Check the hydraulic connections for leakages and retighten, if necessary.
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F 4
4 Maintenance Check - list
Maintenance intervals
standard =
t
WMMM
cold store =
k
13612
Chassis and super- struct.:
1.1 Check all load bearing elements for damage
t
1.2 Check all bolted connections
t
1.3 Check platform for correct functioning and damage
t
Drive unit: 2.1 Check the transmission for noises and leakage
t
2.2 Check the transmission oil level
t
2.3 Change the transmission oil
lt
Wheels: 3.1 Check for wear and damage
t
3.2 Check the wheel bearings and ensure secure fastening of wheels a)
lt
Steering: 4.1 Check the steering wheel play
t
Brake sy- stem:
5.1 Performance and adjustment check
lt
5.2 Check gas pressure spring for proper resetting function, for leaks and damage
t
5.3 Check the brake linings for wear
t
5.4 Check the brake linkage; adjust and grease, if necessary
lt
Lifting de- vice:
6.1 Performance and adjustment check
t
6.2 Perform sight check of rollers, sliding elements, and stops
lt
6.3 Check fork tines and fork carrier for wear and damage
lt
Hydraulic system:
7.1 Performance check
lt
7.2 Check all connections for leakage and damage b)
lt
7.3 Check hydraulic cylinders for leakage, damage and secure attachment
lt
7.4 Check the oil level
lt
7.5 Change hydraulic oil and filter cartridge c)
lt
7.6 Check the pressure relief valves for correct functioning
lt
Electrical system:
8.1 Performance check
t
8.2 Check all cables for secure connection and damage
t
8.3 Check the fuses for correct amperage
t
8.4 Check switches and trip cams for secure attachment and correct functioning
t
8.5 Check contactors and relays, replace wearing parts, if necessary
t
8.6 Check the warning installation for correct functioning
lt
Electric mo- tors:
9.1 Check the carbon brushes for wear
t
9.2 Check the motor for secure attachment
t
9.3 Clean motor housing by means of a vacuum cleaner and check the commutator for wear
lt
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a) Wheel bolts to be first checked for tightness after approx. 100 operating hours, tighten, if
necessary.
b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours;
tighten, if necessary.
c) First change after 500 operating hours.
A
The maintenance intervals refer to normal service conditions. In case of aggravated conditions, the intervals must be reduced as required.
Maintenance intervals
standard =
t
WMMM
cold store =
k
13612
Battery: 10.1 Check acid density, acid level and cell voltage
lt
10.2 Check the terminals for secure attachment and apply grease
lt
10.3 Clean battery connections, check for tight seat
lt
10.4 Check the battery cables for damage, renew, if necessary
t
Lubricati- on:
11.1 Grease the vehicle in accordance with the lubrication schedule
lt
General measure- ments:
12.1 Check the electrical system for a grounding fault
t
12.2 Check the driving speed and braking distance
t
12.3 Check the lifting and lowering speed
t
12.4 Check safety and shutdown devices
t
Demonstra- tion:
13.1 Perform a trial run under a nominal load
t
13.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible
lt
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F 6
5 Lubrication Schedule
g
Gliding surfaces
s
Grease nipples Filler plug hydraulic oil
b
Filler plug gear oil
a
Drain plug gear oil Cold store usage
1)
Compound cold store usage 1:1
B
1,4 l
B + C
1)
A + C
A
0,7 l
1)
E
F
E
F
E
F
E
F
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5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions are to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type ma- terials must be stored in adequate containers. They might be inflammable and, there- fore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be dis- posed of according to the regulations.
Grease data
Code Order No. Supply Qty Designation Used for:
A 29 200 670 5.0 l H-LP 46, DIN 51524 Hydraulic system B 29 200 680 5.0 l CLP 100, DIN 51517 Transmission C 29 200 810 5.0 l H-LP 10, DIN 51524 Transmission,
hydraulic system E 29 201 430 1.0 kg Grease, DIN 51825 Lubrication F 29 200 100 1.0 kg Grease, TTF52 Lubrication
Code Saponification Dropp. point °CWorked pene-
tr. at 25 °C
NLG1 class Service temper-
at. °C E Lithium 185 265 - 295 2 -35 / +120 F — — 310 - 340 1 -52 / +100
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F 8
6 Description of the servicing and maintenance operations
6.1 Preparing the truck for the performance of servicing and maintenance opera- tions
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
– Park the truck and render it safe (refer to chapter E). – Disconnect the battery plug so that the truck cannot be started by unauthorised per-
sons (refer to chapter D).
f
When work has to be performed under the raised fork or under the jacked up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the fork or truck. When lifting the truck, the instructions contained in chapter „Transportation and commissioning“ have to be observed.
6.2 Opening the battery hood
Refer to chapter D.
6.3 Opening the front hood
– Park the truck and render it safe. – Unlatch the cover lock (1); the wrench is stored in the battery compartment. – Swivel the control shaft to the lower area. – Lift the hood (2) off and deposit it next to the truck.
A
Installation is in the reverse order of steps.
1
2
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6.4 Checking the hydraulic oil level
– Prepare the truck for the perform-
ance of servicing and maintenance operations (refer section 6.1).
– Open the front cover (refer section
6.3).
– Check the hydraulic oil level at the
hydraulic oil reservoir (3).
A
The hydraulic oil reservoir is provided with markings (4). With the fork in the lowered position, the oil level must be between the markings “max.” and “min.”.
– If necessary, top up to the “max.” marking using hydraulic oil of the prescribed spec-
ification (refer to hydraulic oil specification, section 5.1).
– Close the front cover, remove the key and place the key in the key compartment.
min
max
3
4
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F 10
6.5 Checking the electric fuses
– Prepare the truck for the performance of servicing and maintenance operations (re-
fer section 6.1). – Open the front cover (refer section 6.3). – Referring to the table, check all fuses for correct rating and replace, where required.
– Reinstall the front hood
(refer to chapter E).
Item Description Protection of: Value
5 F1 Total control fuse 10 A 6 1F1 Drive motor (in parallel to 1F10) 150 A 7 1F10 Drive motor (in parallel to 1F1) 40 A 82F1Pump motor 150 A 9 6F1 Discharge indicator/operating hour meter 10 A
10
9
8 7
6
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6.6 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
– Check the horn for proper functioning. – Check the master switch for correct functioning. – Check the brake for correct functioning. – Lubricate truck according to lubrication schedule.
7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
m
During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional meas- ures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck. – Check the brakes for correct function. – Check the hydraulic oil level and top up if required (refer to chapter F). – Apply a thin film of oil or grease to all parts not protected by a paint coating. – Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F). – Recharge the battery (refer to chapter D). – Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
m
Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
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F 12
7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck. – Lubricate the fork lift truck according to the lubrication chart (refer to chapter F). – Clean the battery. Grease the pole screws using pole grease and reconnect the
battery. – Recharge the battery (refer to chapter D). – Check if the gear oil contains condensed water and change if required. – Check if the hydraulic oil contains condensed water and change if required. – Start up the fork lift truck (refer to chapter E).
A
Battery-operated fork lift trucks: If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork lift truck has to be chek- ked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experi- enced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the in- spection of fork lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects. Apart from this, the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with specially qualified staff. As visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to it. This plaque indicates in which month of which year the next test will be due.
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