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EKS 314
Operating Manual
225 pgs6.87 Mb0

Jungheinrich EKS 314 Operating Manual

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EKS 314
05.05 -
Operating manual Manual de instrucciones
52032020
07.08
u E
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0108.USA
Foreword
Safe operation of the industrial truck requires specialist knowledge, which is acquired from this Operating Manual, from the training required by OSHA under 29 CFR
1910.178, and by training operators in factory installations and their functions. Safe operation of the industrial truck requires knowledge that can be acquired from this ORIGINAL OPERATING MANUAL. The information is set out concisely and in a clear format. The chapters are organized alphabetically, each starting at page 1. The page identifier consists of the chapter letter and page number. For example: Page B2 is the second page of Chapter B.
Various types of industrial trucks are described in this Operating Manual. When operating the truck and carrying out maintenance work, make certain you use the description corresponding to your vehicle type.
Safety instructions and important information, and their relative importance, are indicated by the following safety warning symbols and indicator words:
QwD This message indicates a hazardous situation that, if not avoided, will result
in death or serious injury. The instructions, safety precautions, actions, or procedures relating to this message must be observed to avoid the risk of death or serious injury.
QwW This message indicates a hazardous situation that, if not avoided, could
result in death or serious injury. The instructions, safety precautions, actions, or procedures relating to this message must be observed to avoid the potential risk of death or serious injury.
QwK This message indicates a situation that may lead to minor or moderate injury
if disregarded. The instructions, safety precautions, actions, or procedures relating to this message must be observed to avoid the risk of minor or moderate injury.
IMPORTANT This message appears if special precautionary measures are needed to
ensure that the correct action is taken or to prevent damage to or malfunction of the industrial truck or a component.
NOTICE This message appears if special information, instructions, or indications are
needed with regard to procedures, equipment, tools, pressures, loads, and other special data.
t Indicates component fitted as standard.
o Indicates optional extra.
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It is impossible for the manufacturer to foresee every possible operational circumstance that could involve a potential danger. For that reason, the warnings in this manual and on the equipment itself do not encompass all possible circumstances. If you use a tool, procedure, working method, or operating technique not expressly recommended by the manufacturer, you must make sure yourself that it does not present a safety risk to you or to anyone else. You must also ensure that the product will not be damaged or made unsafe through operation, lubrication, maintenance, or the chosen repair measures. The information, technical data, and illustrations contained in this document are based on the information available at the time of publication. Specifications, torques, pressures, measurements, settings, illustrations, and all other data are subject to change at any time. These changes relate to the performance of the product. Before executing a task, you should request the most up-to-date and comprehensive information from the manufacturer / dealer. You can also obtain additional copies of the manual from your dealer.
In the interests of technical advancement, the manufacturer reserves the right to make changes, while retaining the essential features of the type of vehicle described, without correcting this Operating Manual at the same time.
Copyright
Copyright of this operating manual remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Phone: +49 (0) 40/6948-0
www.jungheinrich.com
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Table of Contents
A Following the rules- common sense and the law
B Recognize and avoid the hazards
C Correct use and application of the truck
D Truck Description
1 Application ........................................................................................... D 1
2 Assemblies and Functional Description ..............................................D 3
2.1 Truck ................................................................................................... D 4
3 Standard Version Specifications ......................................................... D 5
3.1 Performance data ................................................................................ D 5
3.2 Dimensions (as per data plate) ........................................................... D 7
3.3 Mast version ........................................................................................ D 8
3.4 US Standards ...................................................................................... D 8
3.5 Conditions for application .................................................................... D 9
4 Identification points, warning labels and data plates ........................... D 10
4.1 Truck data plate .................................................................................. D 12
4.2 Capacity .............................................................................................. D 12
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E Operation
1 Controls and Displays ......................................................................... E 1
1.1 Operating and display equipment on control panel ............................. E 1
1.2 Display unit controls and displays ....................................................... E 2
1.3 Truck operational status symbols ........................................................ E 6
2 Starting up the truck ............................................................................ E 7
2.1 Attaching the safety restraint belt ........................................................ E 8
2.2 t To prepare the truck for operation .................................................. E 9
2.3 o Preparing the truck for operation with an additional access code ... E 10
2.4 Setting the time ................................................................................... E 11
2.5 Operator specific settings .................................................................... E 12
3 Travelling, Steering, Braking ............................................................... E 13
3.1 Travelling ............................................................................................. E 13
3.2 Steering ............................................................................................... E 14
3.3 Braking ................................................................................................ E 14
3.4 Negotiating narrow aisles .................................................................... E 15
3.5 Lifting – Lowering – outside and inside the rack lanes ........................ E 19
3.6 Diagonal travel .................................................................................... E 19
3.7 Order picking and stacking .................................................................. E 20
3.8 Park the truck securely ........................................................................ E 22
4 Important general issues affecting safe operation
and use of the industrial truck ............................................................. E 23
4.1 Training, certification and permission to operate the truck .................. E 23
4.2 Truck damage and repair .................................................................... E 25
4.3 Load Issues ......................................................................................... E 26
4.4 Work environment ............................................................................... E 27
4.5 Safety devices and warning labels ...................................................... E 29
4.6 Lifting of persons ................................................................................. E 30
4.7 Emergency stop device ....................................................................... E 32
4.8 Driver's cab emergency lowering ........................................................ E 32
5 Operation of the truck .......................................................................... E 33
5.1 Safety regulations for the truck operator ............................................. E 33
5.2 General operation of the truck ............................................................. E 33
5.3 Make sure your truck is properly equipped ......................................... E 36
5.4 Load and transport safety ................................................................... E 37
5.5 Avoid overturn and tipover .................................................................. E 38
5.6 Attend and secure your truck .............................................................. E 39
5.7 Lifting of persons ................................................................................. E 39
5.8 Slack chain safety device override ...................................................... E 41
5.9 Travel cutout override (o) ................................................................... E 41
5.10 Lift limit override (o) ......................................................................... E 41
5.11 Aisle end safety device (o) ................................................................. E 42
5.12 Wire Guidance emergency operation (Error 144) ............................... E 43
5.13 Recovering the truck from a narrow aisle / Moving the truck
without a battery .................................................................................. E 44
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F Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ F 1
2 Battery type ......................................................................................... F 2
3 Charge the battery .............................................................................. F 3
4 Battery removal and installation .......................................................... F 4
5 Check the battery condition, the acid level and acid density ............... F 6
6 Battery discharge indicator .................................................................. F 6
G Truck Maintenance + Troubleshooting
1 Operational safety and environmental protection ................................ G 1
2 Safety regulations applicable to truck maintenance ............................ G 1
3 Servicing and inspection ..................................................................... G 6
4 EKS 314 maintenance checklist .......................................................... G 7
5 Lubrication schedule ........................................................................... G 10
5.1 Fuels, coolants and lubricants ............................................................. G 11
6 Maintenance and Repairs ................................................................... G 12
6.1 Preparing the truck for maintenance and repairs ................................ G 12
6.2 Securing the driver’s position carriage and mast ................................ G 13
6.3 Lift Chain Servicing ............................................................................. G 13
6.4 Inspecting the lift chains ...................................................................... G 13
6.5 Hydraulic oil ......................................................................................... G 14
6.6 Hydraulic hoses ................................................................................... G 14
6.7 Checking electrical fuses .................................................................... G 15
6.8 Recommissioning the truck after cleaning or maintenance work ........ G 16
7 Decommissioning the industrial truck .................................................. G 16
7.1 Operations to be performed prior to decommissioning ....................... G 16
7.2 Measures to be taken during decommissioning .................................. G 17
7.3 Recommissioning the truck after decommissioning ............................ G 17
8 Safety inspections at regular intervals and after exceptional events .. G 18
9 Final de-commissioning, disposal ....................................................... G 18
10 Troubleshooting .................................................................................. G 19
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H Transport and Commissioning
1 Transport ............................................................................................. H 1
2 Lifting by crane .................................................................................... H 1
2.1 Crane points ........................................................................................H 3
2.2 Lifting the battery by crane .................................................................. H 3
2.3 Securing the truck during transport ..................................................... H 3
2.4 Basic truck transport safety ................................................................. H 4
2.5 Mast transport safety ........................................................................... H 5
2.6 Mast assembled .................................................................................. H 5
3 Commissioning .................................................................................... H 7
3.1 Moving the truck without a battery ...................................................... H 7
3.2 Installing/removing or erecting/folding the mast .................................. H 7
4 Commissioning .................................................................................... H 7
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A Following the rules- common sense and
the law
In 1998, OSHA reported on its thorough study of industrial truck use. This report may be found at Federal Register/ Vol. 63, No. 230. In its report, OSHA explained its many reasons for carefully defining the duties of employers to train their employees in the use of industrial trucks, and the duty of untrained persons not to operate indus- trial trucks except in controlled, training circumstances. The report addresses how critically important the training required by the OSHA regulations is for the safety of people and things wherever industrial trucks are operated. 29 CFR sec. 1910.178. In simple terms, careful training before operation of an industrial truck is critical and must occur before truck operation because accidents resulting in injury, death or property damage almost always result from disregard of the basic risks inherent in truck use or disregard of safety rules and procedures created to reduce or eliminate those risks. The training required by OSHA is designed to address those risks. The evidence provided by OSHA in its report reveals that the law’s operator training re- quirements for employers and operators are grounded in experience and goog judg- ment. Jungheinrich has provided an industrial truck which complies with 29 CFR 1910.178, and ASME B56.1. Jungheinrich representatives are available to assist and answer any questions which may arise concerning the capacities, operation, use and main- tenance of the truck. According to OSHA, people do not start out with the knowledge and skills they need to safely operate a powered industrial truck, and therefore, they need formal training and practice to gain the knowledge and to master the skills they need to safely oper- ate an industrial truck. Consequently, having an industrial truck which complies with the law and standards fulfills only one half of the safety equation. It is, therefore, up to you, the operator, and your employer, to fulfill your responsibilities by obeying all national, state and local laws and regulations concerning training and the safe oper- ation of industrial trucks - not just because it is the law, but because it also makes common safety sense.
Only trained and certified persons may operate an industrial truck.
Training programs must comply with OSHA requirements and address, at least, all of the topics listed there.
The user portion of ASME B56.1 is recommended to employers and operators for careful review and observance.
“Safe operation is the responsibility of the operator“ ASME B56.1-2003, Part II sec. 5.1.1.
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B Recognize and avoid the hazards
In its 1998 study of industrial truck use, OSHA identified a nummber of ways acci- dents regularly occur and described why they occur. OSHA concluded that untrained and poorly trained operators pose significant risks to themselves and those working in their vicinity. According to OSHA, the major cause of accidents with industrial trucks and their resulting injuries and deaths is improper or unsafe operation. It is no surprise, therefore, that when OSHA reviewed its files, it discovered that accidents almost always occur as a result of situations or actions the operator, or the employer and the operator, were in a position to influence or control for the better. A simple re- view of the accident causes identified by OSHA proves this observation. Out of 208 industrial truck accidents studied, which involved 184 deaths or serious injuries, fully 50% were caused by a load problem, including overload, instability, falling load or im- proper lifting of load. Similarly, 25% involved overturn/tipover of the truck. Falls of the truck from a platform or trailer, or of lifted persons from the truck, accounted for ano- ther 20% of accidents. Although ’no training’ accounted for about 4% of the accidents, OSHA properly noted that many of the accidents could have been equally caused by improper training - for example, an overturn accident may also have been the result of no, or poor, training of the operator about load balance. Other less frequent, but equally employer and operator - controllable accident causes include speeding and use of improper equipent.
It is therefore critically important to:
– Complete the training and operator certification process before beginning work with
an industrial truck.
– Always be in competent physical, mental and emotional condition before operating
an industrial truck.
– Understand and observe safe loading and handling practices- know your machine
capacities and work within them.
– Avoid circumstances which can lead to overturn or tipover- this includes, for ex-
ample, understanding center of gravity and following sound loading and load mo- vement practices, and constant area awareness of edges, curbs, dropoffs and other surface details.
– Never carry passengers or lift people without specific training, the correct truck,
equipment and procedures.
– Always follow traffic rules and always be aware of the location of co-workers, other
trucks and your physical surroundings.
The manufacturer declines all responsibility for the consequences of dismantling the truck or making any modification which is outside the manufacturer’s control.
The manufacturer’s responsibility is limited to the configuration of the equipment de- scribed in the conformance certificate. The manufacturer is absolved from their re- sponsibility if there are modifications, additions or use of equipment from another sup- plier, in which case the user assumes the manufacturer’s responsibility.
These operating instructions become invalid if the machine is modified by a company which is not part of our company group, even if original spare parts are used and our company logo remains displayed on the equipment.
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C Correct use and application of the truck
NOTICE These operating instructions include all the information needed for transport,
first start-up, normal use, servicing and maintenance of the described industrial truck, in accordance with ASME B56.1-2003, UL 583 and ANSI Z535.4-2002. Read these instructions carefully to ensure proper and safe use of the truck.
The industrial truck described in these operating instructions is suitable for lifting and transporting loads and must be used, operated and maintained according to the law and the information provided in these operating instructions. Any use of the truck not authorized by law or these instructions is a misuse of the truck and beyond the inten- ded design of the truck. Such misuse can lead to death and/or serious injury to per- sons and damage to equipment and property. Overloading caused by excessively heavy or unbalanced loads is an example of misuse of the truck which must be avo- ided. The maximum allowable load is indicated on the identification plate and load di- agram label shown on the truck. The industrial truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty at- mospheres prevail.
These operating instructions must be kept as long as the vehicle is in use.
Duties of the user: A user of an industrial truck may be one of several persons depending on the context referred to in these operating instructions- it includes the truck owner, any person lea- sing or renting the truck and the operator, as referred to in ASME B56.1- 2003. Users will usually be employers, and the truck operators will often be their employees for purposes of OSHA regulations. Every user must know and follow the applicable rules and regulations concerning industrial truck use and operation. The operator instruc- tions are for all users, and are directed toward and should be provided to the persons who will actually operate the industrial truck. The user and operator must ensure that the truck is not abused and used only within its design limits so that all danger to life and limb of the operator, and third parties, is avoided. The user and operator must also ensure that the accident prevention regu- lations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must ensure that all who will operate this truck have read and understood these operating instructions and have fulfilled all training and certification required by law before performing any work with the truck.
The user and operator are advised that when functions on industrial trucks are auto- mated (for example rail-guided or inductively-guided trucks), the operation of the ve- hicle is changed which may result in modified performance characteristics, mainte- nance procedures, and additional safety precautions. The addition of any automatic function to a manned industrial vehicle requires the evaluation of the impact of the automation on all other functions. It maybe necessary to automate other functions to some degree.
NOTICE If these Operating Instruction are not observed the warranty becomes void.
The same applies if improper work is carried out on the device by the customer and/or third parties.
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Mounting of attachments: The mounting or installation of any attachments and modifications and/or additions to hardware or software which will interfere with, or supplement, rated capacity, safe op- eration, any emergency control or device, or any other function of the truck is only per- mitted with approval of the proposed modifications or additions by the manufacturer. When such approval is granted, capacity, operation, and maintenance instruction pla- tes, tags, or decals must be changed accordingly. If necessary, the approval of local authorities must also be obtained. Approval obtained from local authorities does not render manufacturer approval of the modifications or additions unnecessary.
If the truck is equipped with attachment(s) including fork extensions, the user shall see that the truck is marked to identify the attachment(s), show the approximate weight of the truck and attachment combination, and show the capacity of the truck with attachment(s) at maximum elevation with load laterally centered. When modifications involve rebuild and repair of the basic unit, they shall be made in accordance with the manufacturer‘s established criteria and procedures.
The basic functions of the truck are:
– steering (guidance) – travel – control and sensing – lifting/load manipulation
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Identification plate: We highly recommend that the data from the identification plate be copied onto the diagram below to ensure that this important data is available to the operator and that these instructions are not inadvertently used with any other product.
The user is responsible for confirming that all identification plates and caution and in- struction markings are in place and legible (refer to section “Identification points and data plates“ in chapter D).
QwW Industrial truck use is subject to certain hazards that cannot be completely
eliminated by mechanical means. Those risks can, however, be minimized by the exercise of intelligence, care and common sense. Operators must, therefore, be competent, careful, physically and mentally fit, and thoroughly trained in the safe operation of the equipment and load handling.
for type "E" industrial trucks with type "E" battery
Built in compliance with ASME B 56.1
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General instructions for Users and Operators
QwW The following are general instructions which apply to all users, including
company management, department heads, operators, transporters and employees who work in the vicinity of industrial trucks. The user is responsible for safe operation of this truck, and both employer and operator must work together to enforce and follow the safety regulations which apply to use of the truck.
1. These instructions must be read before using the truck and followed when the truck is in use
2. The user and operator must ensure that the truck is used only for the purpose for which it has been designed. The user and operator must NOT:
– allow abnormal use of the truck – disable the safety devices – overload or operate the truck outside the load graph
(refer to section “Capacity“ in chapter D) – use the truck as a crane – use the truck to lift or carry people – lock a control in position – ignore standard practices for handling and manipulating loads – transport loads over people’s head – push or pull loads with the truck – engage in games or horseplay with the truck such as racing, or ’chicken’ – carry unbalanced loads
3. The user and operator must check the strength of the floors (to avoid damaging them), the racks, and in general all the corridors and areas where the truck will or may be used.
4. Read the instructions on the plates attached to the truck and make sure that they remain legible
5. Keep these instructions available for all operators in an accessible location on the truck
6. Make sure that only trained, certified and responsible persons, capable of safe operation of the truck, are allowed to operate the truck.
7. Make sure that the truck cannot be tampered with when it is not in use
8. Never use a truck which does not appear to be in good working condition
9. Never use the truck to carry a load or apply a force which exceeds its maximum operating load
10. Never use the truck for a purpose for which it is not intended
11. Read the truck safety regulations and apply them rigorously
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12. The manufacturer declines all responsibility for the consequences of dismantling the truck or making any modification which is outside the manufacturer’s control
13. The manufacturer’s responsibility is limited to the configuration of the equipment described in the conformance certificate. The manufacturer is absolved from their responsibility if there are modifications, additions or use of equipment from another supplier, in which case the user assumes the manufacturer’s responsibi- lity
14. These operating instructions become invalid if the machine is modified by a com- pany which is not part of our company group, even if original spare parts are used and our company logo remains displayed on the equipment
15. The conditions of your workplace, and other unusual operating conditions may require additional safety precautions and special operating instructions
16. Supervision is an essential element in the safe operation of powered industrial trucks
17. Batteries must comply with the minimum/maximum battery weight range shown on the truck identification plate
18. Floor and wheel locks (if provided) are intended only to hold the truck in a desi- red position on a level surface
QwW Serious hazards are overloading, load instability, obstruction to the free
passage of the load, collision with objects or pedestrians, poor maintenance, and use of equipment for purposes it was not intended or designed. Changes in load(s), dimension(s), coupling types(s) and/or position(s), and floor surface condition(s) or battery weights may affect rated capacities and safe operation. Only stable or safely arranged loads shall be handled.
The operator is responsible for proper loading, load stability and securement. The operator shall, as necessary, verify that the load remains stable and secure.
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D Truck Description
1 Application
The EKS 314 is an electric stockpicker. It is designed to be used on level surfaces to transport and pick goods. The floor surface must comply with the following require- ments:
Floor specifications
QwW In order to prevent accidents due to operation on uneven floor surfaces the
following floor surface tolerances must not be exceeded.
Max. permitted height differences (h) across the aisle:
Floor planeness / tolerances lengthwise to the tracks for both height classes
– Floor has to be oil and grease resistant. – Floor leakage resistance RE is not permitted to pass 10
6
Ω.
– Floor surface must be carefully finished to eliminate all short floor waves.
Axle width (S)
up to 1 m
up to 40 inch
more than 1,0 m
up to 1,5 m
more than 40 inch
up to 59 inch
more than 1,5 m
up to 2,0 m
more than 59 inch
up to 79 inch
more than 2,0 m
up to 2,5 m
more than 59 inch
up to 98 inch
Max. permitted height difference between outer tracks (SP) VNA truck lift height </= 6 m / </= 236 inch VNA truck lift height > 6,01 m / > 236 inch
2,0 mm
0.08 inch
2,5 mm
0.10 inch
3,0 mm
0.12 inch
3,5 mm
0.14 inch
1,5 mm
0.06 inch
2,0 mm
0.08 inch
2,5 mm
0.10 inch
3,0 mm
0.12 inch
Distance of measuring points
1,0 m /
39.34 inch
2,0 m /
78.68 inch
3,0 m /
118.02 inch
4,0 m /
157.36 inch
Max. permitted tolerance/ planeness Bulk sample as limit value
2,0 mm
0.08 inch
3,0 mm
0.12 inch
4,0 mm
0.16 inch
5,0 mm
0.20 inch
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D 2
Open bottom pallets or pallets with transverse boards can be lifted inside or outside the area of the load wheels or roll cage.
Loads can be stacked and unstacked and transported over long distances.
The driver's cab is raised together with the load lifting device to provide excellent vis- ibility and easy access to the rack levels to be operated.
The racks must be suitable for the EKS 314. The following safety distances specified by the manufacturer must be observed:
QwW In order to prevent accidents, whenever a truck is used in rack system aisles
(rail guided) a safety distance of at least 3.54 inch / 90 mm between either side of the truck and the racks must be maintained. In case of inductively / wire guided trucks a safety distance of at least
4.92 inch/ 125 mm is recommended.
The ground surface must comply with the floor specifications mentioned above. Guide rails must be provided in the narrow aisles for the rail guidance system. Vulkollan guide rollers attached to the truck chassis guide the truck between the guide rails. A guidance wire must be routed in the ground for the inductive / wire guidance (WG) system. The signals from the wire are received on the chassis and processed in the on-board computer.
The capacity is shown on the data plate, for example:
Travel direction definition:
To indicate travel directions, the following orientations will be used in this manual:
Type Capacity Load center of gravity
EKS 314 3000 lbs / 1360 kg 23.6 inch / 600 mm
Left
Right
Drive direction
Load direction
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2 Assemblies and Functional Description
Item Description
1 t Mast 2 t Overhead guard 3 t Safety gates 4 t Safety restraint belt 5 t Control panel 6 t Height-adjustable driver’s position 7 t Chassis 8 t Foot switch/deadman switch 9 t Pallet clamp
t = Standard equipment o = Optional Equipment
1
2
4
3
6
7
5
8
9
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2.1 Truck
Safety mechanisms: Side mounted safety gates (3). The driver is also secured by a
safety restraint belt (4). The overhead guard (2) protects the driver from falling ob- jects. The Emergency Disconnect switch immediately cuts out all truck movements in haz- ardous situations. Safety gates (3) on either side of the cab disable all truck move- ments as soon as they are opened. Travelling, lifting and lowering can only be activated when the foot switch (8) is pressed.
Drive: Vertical, heavy-duty threephase motor (asynchronous), hence easy and rapid main- tenance. The motor is mounted directly onto the single-wheel driving gear
Brake system:
The truck can be braked gently and wear-free by pulling back the travel control button or steering in the opposite direction. This feeds energy into the battery (operating brake).
The electromagnetic spring pressure brake acting on the drive motor serves as a parking brake and handbrake.
Steering:
Particularly smooth steering with threephase drive system. The handy steering wheel is integrated within the control panel. The position of the steered drive wheel is shown in the display unit. The steering angle is +/- 90°, offering maximum maneuverability in narrow aisles.
With the mechanical rail guidance (RG) system the drive wheel is set to the forward position at the press of a button.
In wire guidance (WG) mode, steering is automatically assumed by the truck control- ler when it detects the guidance wire, and manual steering is deactivated.
Controls and displays:
The functions are activated via ergonomic thumb and finger movement to ensure fa- tigue-free operation without straining the wrists; sensitive application of travel and hy- draulic movements to spare and position the goods exactly. Integrated information display unit for all important driver information such as steering wheel position, overall lift, truck status reports (e. g. faults), service hours, battery ca- pacity, time and wire guidance status etc.
Hydraulic system:
All hydraulic movements are controlled by a maintenance-free AC motor with a flang- ed low emission gear pump. Oil is distributed via magnetic switch valves. The varying oil requirements are controlled by the speed of the motor. During a lowering operation the hydraulic pump drives the motor which then acts as a generator (regenerative lowering). The energy produced is then fed back to the battery.
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Electrical System:
Service laptop connection interface:
– To configure all the key truck data (limit position damping, lift cutout, retardation
and acceleration patterns, cut-outs etc.) rapidly and reliably. – To read out the error log to analyse fault causes. – To simulate and analyse program operations. – Provides simple functional extension by releasing code numbers.
The controller is fitted with a CAN Bus and a continually measuring sensor system.
The controller provides smooth start-up and braking of the load in all limit positions through limit position and intermediate cushioning.
Highly efficient threephase technology with energy retention for the drive and lift mo- tors provides high travel and lift speeds and better use of energy.
The MOSFET threephase controller provides smooth starting for all movements.
For drive battery options see section “Battery type“ in chapter F.
3 Standard Version Specifications
NOTICE Technical data specified in accordance with the german standart „Type
sheets for industrial trucks“. Technical modifications and additions reserved.
3.1 Performance data
RG: Rail Guidance WG: Wire Guidance FR: Free Range
Description EKS 314
Q Capacity (where c= 23.6 inch (600 mm)) 3000 lbs 1360 kg
c Load center of gravity distance 23.6 inch 600 mm
Travel speed without load (RG) 6.0 mph 9.6 km/h Travel speed with load (RG) 6.0 mph 9.6 km/h Travel speed without load (WG) 4.7 mph 7.5 km/h Travel speed with load (WG) 4.7 mph 7.5 km/h Travel speed without load (FR) 6.0 mph 9.6 km/h Travel speed with load (FR) 6.0 mph 9.6 km/h Lift speed without load 1.21 ft/s 0.37 m/s Lift speed with load 1.21 ft/s 0.37 m/s Lowering speed with load 1.15 ft/s 0.35 m/s Lowering speed without load 1.12 ft/s 0.34 m/s
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D 6
h
12
h
15
h
3
h
6
h
1
h
4
l
2
b
5
b
1
b6b
10
l
1
W
a
l
m
1
m
2
h
7
xy
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3.2 Dimensions (as per data plate)
1)
ZT mast performance data measured for 600 DZ.
Description EKS 314
h
1
Mast height (retracted)
1)
109.5 inch 2780 mm h3Lift
1)
236.2 inch 6000 mm h4Mast height (extended)
1)
327.6 inch 8320 mm h6Height above overhead guard 91.3 inch 2320 mm h7Height 8.3 inch 210 mm
h12Truck height raised
1)
244.5 inch 6210 mm
h15Stockpicking height
1)
307.5 inch 7810 mm
Ast Working aisle width for pallets 39.4 x
47.2 inch (1000 x 1200 mm) trans.
55.1 inch 1400 mm
b1Chassis width 39.4 inch 1000 mm b5Distance between forks, outer 22.7 -31.3 inch 576 -794 mm b6Width across guide rollers 51.2 inch 1300 mm
b10Width across front axle 42 inch 1067 mm
l1Overall length w.o. load 118.5 inch 3010 mm l2Length incl. fork shank 76.4 inch 1940 mm
l Fork length 42 inch 1067 mm
WaTurning radius 66.1 inch 1680 mm
m1Ground clearance below forks 0.98 inch 25 mm m2Ground clearance from center of
wheelbase
2.56 inch 65 mm
x Load distance 7.5 inch 190 mm y Wheelbase 59.8 inch 1520 mm
Net weight incl. battery, w.o. load 7672.1 lb 3480 Kg
Page 25
0108.USA
D 8
3.3 Mast version
3.4 US Standards
Continuous sound pressure level at ear:
58 db(A)
as per ASME B56.11.5 test procedures ASME
NOTICE 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: a
w,zS
= 3.65 ft/s2 (1.11 m/s2).
NOTICE The swinging acceleration acting on the body in its operating position is the
linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Description EKS 314 (TL/ZT)
h1Retracted height 91.3 - 189 inch 2320 - 4800 mm h3Lift 118.1 - 315 inch 3000 - 8000 mm h4Extended height 209.5 - 406.3 inch 5320 - 10320 mm h6Height above overhead guard 91.3 inch 2320 mm
h12Truck height raised 126.4 - 323.2 inch 3210 - 8210 mm h15Stockpicking height 189.4 - 386.2 inch 4810 - 9810 mm
Description EKS 314 (TL/DZ)
h1Retracted height 91.3 - 137 inch 2320 - 3480 mm h3Lift 137.8 - 315.4 inch 3500 - 8010 mm h4Extended height 229.1 - 406.7 inch 5820 - 10330 mm h6Height above overhead guard 91.3 inch 2320 mm
h12Truck height raised 146.1 - 323.6 inch 3710 - 8220 mm h15Stockpicking height 209.1 - 386.6 inch 5310 - 9820 mm
Page 26
D 9
0108.USA
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit values for electromagnetic emis- sion and interference immunity as well as testing of static electricity discharge accord- ing to the following table:
Resistance
The following thresholds apply to industrial trucks / systems:
NOTICE Very powerful electromagnetic fields may affect the performance of the truck.
Likewise, equipment that is highly sensitive to electromagnetic fields may in turn be affected by the truck. Ensure that truck emissions will not affect the operation of any nearby equipment.
NOTICE Electrical or electronic components and their arrangement may only be
modified after written approval by the manufacturer has been obtained.
3.5 Conditions for application
Ambient temperature:
- during operation: 41 °F (+5 °C) to 104 °F (+40 °C) 24-hour ambient temperature average: max. 77 °F (25 °C) max. humidity in interior rooms 70%, no condensation
NOTICE Industrial trucks must be specially equipped and approved for continuous use
in environments with temperatures below 41 °F (5 °C) or in cold stores respectively with extreme temperatures or humidity changes.
Ambience condition Test Unit
1.1 Frequency Electromagnetic field
Amplitude modulation
27-1000 *
10 80
MHz
V/m (unmodulated, rms)
% AM (1kHz)
1.2 Frequency Electromagnetic field
Pulse modulation
900 ± 5
10 50
200
MHz
V/m (unmodulated, rms)
% duty cycle
Hz freq. of recurrence
1.3 Static electricity discharge 4 contact
8 air
discharge
kV (discharge voltage)
* The frequency range has been extended to include low frequencies in the
wiring.
Page 27
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D 10
4 Identification points, warning labels and data plates
QwW Warnings and notices such as load diagrams, strap points and data plates
must at all times be legible. Replace if necessary.
Item Description
1 “Pressurized hydraulic system” warning 2 “Emergency drain” decal 3 “Electrical system” warning 4 “Electric voltage” warning 5 “Charger” warning 6 “Explosive gases” warning 7 “Min. battery size” warning
NOTICE Continued on the next page
9
7
1
3
4
2
16
13
14
D (mm)
11
15
9
16
18
8
6
8
3
9
12
8
19
5
10
17
for type "E" industrial trucks with type "E" battery
Built in compliance with ASME B 56.1
Page 28
D 11
0108.USA
Item Description
8 “Danger of trapping” warning
9 Strapping points for lifting by crane 10 Truck data plate 11 Capacity plate 12 “Trapped / Crushed“ warning 13 “Danger of crashing” warning 14 “Only authorized specialist personnel, hazard listing” notice 15 “Danger when dismantling the pallet clamp” warning 16 Jack contact points 17 Serial number (engraved in chassis underneath the battery cover) 18 “Emergency drain key” decal 19 “Add hydraulic oil” notice
9
7
1
3
4
2
16
13
14
D (mm)
h3 (mm) Q (kg)
11
15
9
16
18
8
6
8
3
9
12
8
19
5
10
17
for type "E" industrial trucks with type "E" battery
Built in compliance with ASME B 56.1
Page 29
0108.USA
D 12
4.1 Truck data plate
NOTICE For queries relating to the truck or spare parts orders, please state the truck
serial number (21).
4.2 Capacity
The capacity plate (11) gives the capacity (Q in lbs / kg) of the truck as a function of the load center of gravity distance (D in inch / mm) and lift height (h3 in inch / mm) in tabular form.
Item Description Item Description
20 Option 29 Manufacturer's logo 21 Serial number 30 Max. lift height 22 Load center distance 31 Residual lift capacity 23 Year of manufacture 32 Battery weight min. 24 Battery ID 33 Max. Battery capacity 25 Hour Rate 34 System voltage
26 Battery weight max. 35
Weight of truck without battery
+/- 5% 27 Nominal power 36 Rated capacity 28 Manufacturer 37 Model
for type "E" industrial trucks with type "E" battery
Built in compliance with ASME B 56.1
20
21 22
23 24
25 26 27
28
29
37
36 35 34
33 32
31
30
D (mm)
h3 (mm) Q (kg)
D (inch)
h3 (inch) Q (lbs)
11
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1005.USA
E Operation
1 Controls and Displays
1.1 Operating and display equipment on control panel
Item Control / Display Function
1 Travel control button t Controls the travel direction and speed of the
truck 2 Hydraulic control switch t Lifting and lowering of main lift 3 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched
on by unauthorized personnel 4 “Warning” (Horn) button t Sounds Horn, Activates a warning 5 EMERGENCY DISCON-
NECT switch
t Interrupts the main supply, all truck movements
are disabled 6 Buttons (F1 - F5) t Activate or confirm the function related to the
symbol displayed above it 7 Display unit t Operating information and warning message
display 8 “Cancel sub-menu”
switch (F0)
t Sets the menu to the basic display
9 Switch for
“palletclamp”
t Fixes (clamps) and loosens the pallet.
10 Steering wheel t Steers the truck in the required direction
t = Standard equipment o = Optional Equipment
5
1
7910 4 38
6
2
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E 2
1.2 Display unit controls and displays
Upper range symbols
Item Symbol Control /
Display
Function
11 Displays possible
travel speeds: Turtle Rabbit
t
Creep mode Max. travel speed
12 “Guidance wire recog-
nition” display
WG Sensors which have recognized the
guidance wire have a dark background
13 Steering angle display
changes with display – “Tracking on”
– “Wire guided”
– “Deviation from
guidance wire”
t
RG
WG
WG
WG
WG
Indicates the current steering angle with reference to the center position
After selecting “Rail guidance” the steer- ing angle display permanently shows the centre position
The steering angle display fades and is replaced by guidance wire symbols
– when the truck is tracked onto the
guidance wire (inductive guidance)
– when the truck is automatically guided
by the guidance wire
– when the truck deviates without guid-
ance from the guidance wire and auto- matic guidance
11
12
13 14 15 16 17
19
2021
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1005.USA
14 Display for
“Overall lift” “Referencing re-
quired” display: Main lift - lift
Main lift - lower
Pallet clamp open
Pallet clamp closed
Pallet clamped
t Displays the height of the forks
Requests operating position to raise
Requests operating position to lower
Appears when the pallet clamp is open
Flashes when the pallet clamp is closed
but the pallet is not clamped.
Appears when a pallet is clamped
15 Display for
service hours
t Displays the number of service hours
since the truck was commissioned 16 “Time” display t Shows the time 17 Battery discharge-
indicator
t Displays the battery charge condition
(residual capacity as a percentage) 20 Option o 21 Option o
RG = Rail guidance WG = Wire / inductive guidance
Item Symbol Control /
Display
Function
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1005.USA
E 4
Lower range symbols and switches
Activate switch (6) under the respective symbols (19) displayed, or confirm the relat- ed function. The symbol will be given a dark background.
Symbol Control or Display Function
Warnings
“Slack chain safety de- vice” display
t Displayed when the slack chain safety de-
vice engages
“Slack chain safety de- vice override” switch
Overrides the slack chain safety device to lift the driver's position freely
“Fwd./Rev. travel only” display
t Displayed when lift cutout is actvated due to
low battery capacity and only forward or re- verse travel is possible.
Switch for Acknowledge lift cutout due to battery discharge”
Confirms lift cutout due to low battery ca- pacity and releases travel (the Fwd./Rev. Travel Only display has a dark background)
Display for “Lift limit”
o Displayed when the lift limit is activated
“Lift limit override”switch Overrides the lift limit (display has a dark
background). Observe the maximum pas- sage heights
“Lower limit” display o Indicates that the automatic lowering limit
has been activated.
“Lowering limit override” switch
Overrides the lowering limit, controlled by hydraulic control button
“Travel cutout” display o Indicates that automatic, height dependent
travel cutout has been activated
“Travel cutout override” switch
Overrides the automatic, height dependent travel cutout
“Aisle endsafety device” display (option)
o Indicates that the aisle end safety device
has been activated. The truck brakes.
Select “Warning sub- menu” display
o Indicates that several warnings (e.g. slack
chain safety device height dependent lift cutout) have been issued.
Quit “warnings” sub- menu.
Displays individual warnings
Quit “warnings” sub- menu.
o Indicates that the sub-menu can be quit.
“Cancel warnings sub- menu” switch
Sets the “warnings” sub-menu to the stand- ard menu
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1005.USA
Guidance systems
“Guidance on” display not active
“Guidance on” display active
t
RG
WG
Displays automatic guidance in the aisle:
Rail guidance display (drive wheel set to forward position)
Indicates that inductive / wire guidance is activated
“Guidance on” switch RGWGSets the drive wheel to forward position
Activates the alignment (and frequency selection (for multifrequen- cy)
Displays “Select Fre- quency 1” (similar to oth- er frequencies) (“Guidance on” sub- menu)
oWGIndicates that guidance is possible via Fre-
quency 1
“Select Frequency 1” switch (similar to other frequencies)
Activates guidance through frequency 1 (automatically quits the sub-menu after 1 second)
“Special attachment” dis- play
o Indicates that the special attachment can
be controlled
“Special attachment”switch
Activates control of the special attachment, controlled via the hydraulic control button
t = Standard equipment o = Optional Equipment
RG = Rail guidance WG = Wire / inductive guidance
Symbol Control or Display Function
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E 6
1.3 Truck operational status symbols
The operational status of the truck when it is switched on is indicated by symbols in the display unit.
Safety gates open
Foot switch not pressed
When the following symbols are displayed you must carry out a reference movement in accordance with the display, i.e. the Main Lift must be raised approx. 10 cm/3.94 inch and then lowered again. This is the only way for the controller to release all the truck movements at full speed.
Referencing: lift - raise
Referencing: lift - lower
Lift cutout for referencing
QwW When disabling the lift cutout the driver must look
out for obstacles when the mast is extended.
Pressing the “lift cutout override” switch disables the lift cutout.
Page 36
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1005.USA
2 Starting up the truck
QwW Before the truck can be commissioned, operated or a load unit lifted, the
driver must ensure that there is nobody within the hazardous area (see section “Safety regulations governing the operation of the industrial truck“ in this chapter).
NOTICE Negotiating slopes and inclines: It is forbidden to operate this truck on
slopes and inclines.
NOTICE The truck must not be used to tow a trailer.
Checks and operations to be performed before starting daily work
– Check the whole of the outside of the truck for signs of damage and leaks. – Check the battery attachment and wire connections for damage, make sure they
are secure. – Check the battery connector - make sure it is secure. – Check the overhead guard for damage. – Check the load lifting device for visible damage such as cracks, bent or severely
worn load forks. – Test pallet clamp operation. – Check the load wheels for damage. – Make sure the load chains are evenly tensioned. – Make sure all safety mechanisms are correct and working. – Test the operating and parking brake. – For rail guidance systems check the guide rollers - make sure they are smooth and
not damaged. – Check the belt for damage and wear.
QwW It is forbidden for more than one person to enter the driver’s cab at a time.
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E 8
2.1 Attaching the safety restraint belt
QwD Check the safety restraint belt (27) and the eye (25), safety rope (24),
karabiner hooks (23, 26) and attachment point (22) on the overhead guard daily for wear and damage. If the belt system (23 – 27) is damaged, do not use the truck under any circumstances. The belt must be immediately replaced after an accident (catching a person) or if it is damaged or worn. Any damage must be reported to a supervisor. All warnings on the belt must be read and observed.
QwD Attach and fasten the safety restraint belt as soon as you get on the platform
and before starting other work.
– Attach the safety restraint belt (27) to your body. – Attach the safety rope (24) and karabiner hook (23) to the overhead guard. – Attach the safety rope (24) and karabiner hook (26) to the eye (25) of the safety
restraint belt (27).
23
26
27
25
24
22
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1005.USA
2.2 t To prepare the truck for operation
– Attach the belt system
(see section “Attaching the safety restraint belt“ in this chapter). – Close the safety gates securely on both sides. – Turn the EMERGENCY DISCONNECT switch (5) to release it. – Put the key in the key switch (3) and turn it clockwise. – Test the warning device (horn) (4). – Test the operating and parking brakes. – Carry out a test movement on the lift mast to adjust the height display.
QwW Press the EMERGENCY DISCONNECT switch (5) immediately if the truck
starts to move or lift when it is switched on.
NOTICE Brief steering movements caused by steering referencing are permissible.
54
8
7
3
6
Page 39
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E 10
2.3 o Preparing the truck for operation with an additional access code
– Attach the belt system
(see section ”Attaching the safety restraint belt” in this chapter). – Close the safety gates securely on both sides. – Turn the EMERGENCY DISCONNECT switch (5) to release it. – Put the key in the key switch (3) and turn it clockwise. – In the display unit (7) you are required to enter a 5 digit code / pin via the five func-
tion buttons (6)
NOTICE Press function key F0 (8) to assign to the five function keys (6) the digits 0 -
4 or 5 -9 for entering the code/pin.
NOTICE Unless the correct code/pin is entered, none of the truck's functions will
operate
NOTICE A maximum of 10 different code/pins can be set.
– Test the warning device (horn) (4). – Test the operating and parking brakes. – Carry out a test movement on the lift mast to adjust the height display.
NOTICE After a factory-set interval, you will be required to enter in the display a 5 digit
code / pin using the five function buttons (6).
QwW Press the EMERGENCY DISCONNECT switch (5) immediately if the truck
starts to move or lift when it is switched on.
NOTICE Brief steering movements caused by steering referencing are permissible.
54
8
7
3
6
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1005.USA
2.4 Setting the time
Selecting the “Set Time” menu:
Press switch 8, the display changes to the sub menu.
NOTICE Truck movements are inhibited in this truck
menu.
Now press switch 30 twice; the “Set Time” menu now ap- pears in the display unit.
Setting the time:
NOTICE Truck movements are inhibited in this truck menu.
Simultaneously press switch 30:
– and 31: to set the time forward by an hour. – and 32: to set the time back by an hour. – and 33: to set the time forward by a minute. – and 34: to set the time back by a minute.
The set time (35) is then shown in the display unit.
Quitting the “Set Time” menu:
Press switch 8, the display changes to the sub menu.
Now press switch 34, the display changes to the “Truck Functions” sub menu.
30
34
8
v,a
8
30
31
33
32
34
13:22
35
Page 41
1005.USA
E 12
2.5 Operator specific settings
Selecting the “Operator Specific Settings” menu:
Press switch 8, the display changes to the sub menu.
NOTICE Truck movements are inhibited in this truck
menu.
Now press switch 33; the “Operator Specific Settings” menu now appears in the display unit.
Settings in the “Operator Specific Settings” menu:
NOTICE Truck movements are inhibited in this truck menu.
The operator can adjust the settings in
– Acceleration Travel
– Apron speed
– Aisle speed
– Steering wheel transmission
between 1 (weak) and 8 (strong).
Switch 31 weakens the chosen function and switch 33 intensifies it.
The setting is transfered to the program by switch 32.
When the next function is to be set, you can use switch 30 (back) or switch 34 (forward) to do this.
Quitting the “Operator Specific Settings” menu:
Press switch 8, the display changes to the sub menu.
Now press switch 34, the display changes to the “Truck Functions” sub menu.
30
33
8
v,a
34
a
v
v
v
OK
+
-
8
30
31
33
32
34
Page 42
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1005.USA
3 Travelling, Steering, Braking
EMERGENCY DISCONNECT
– Press the EMERGENCY
DISCONNECT switch (5) down.
All truck movements are inhibited.
The operation of the switch must not
be affected by any objects placed in its
way.
3.1 Travelling
The truck can be driven in 3 modes: Free travel, with wire or rail guidance. The operating mode employed depends on the guidance system of the racking sys- tem in use.
IMPORTANT Do not drive the truck unless the panels are closed and properly locked.
The foot switch must be kept depressed for travel.
3.1.1 Travelling in apron field
– Close the safety gates. – Turn the EMERGENCY
DISCONNECT switch (5) to release it. – Put the key in the key switch (3) and
turn it clockwise; the “operational” dis-
play lamp will be lit. – Apply the foot switch (37). – Carry out a test run, see Page E6. – Raise the main lift with the hydraulic
control button (2) until the forks are
clear of the ground. – Slowly turn the travel control button (1)
with your right thumb.
Turning in drive direction (F)
= Forward travel
Turning in load direction (R)
= Reverse travel – You can control the travel speed by
continuing to turn or by adjusting the
travel control button. – Use the steering wheel (10) to steer
the truck in the required direction.
5
3
10
1
2
F
R
37
F
R
Page 43
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E 14
3.2 Steering
Use the steering wheel to steer the truck outside narrow aisles. The position of the drive wheel is shown in the display unit (13).
3.3 Braking
NOTICE The truck’s braking characteristics depend largely on the ground conditions.
The driver must take this into consideration when handling the truck.
The truck can be braked in three different ways:
- with the operating brake
- with the foot switch.
- with the EMERGENCY DISCONNECT switch
3.3.1 Braking with the operating brake
While travelling, set the travel direction switch to the zero position or the opposite trav- el direction; the traction current controller will cause the truck to brake.
3.3.2 Braking with the foot switch
Releasing the foot switch causes the truck to brake.
NOTICE This type of braking can only be used as a parking brake and not as an
operating brake.
3.3.3 Braking with the EMERGENCY DISCONNECT switch
Applying the EMERGENCY DISCONNECT switch will cause the truck to brake to a halt.
IMPORTANT The EMERGENCY DISCONNECT switch must only be used in emergency
situations.
13
Page 44
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1005.USA
3.4 Negotiating narrow aisles
IMPORTANT It is forbidden for unauthorized personnel to enter narrow aisles (truck lanes
in racking systems with safety distances < 500 mm / 19.7 inch) or for personnel to cross through them. These work areas must be marked and identified accordingly. Carry out a daily inspection of the safety mechanisms on the truck or the racking sysem to avoid hazards and protect personnel. These must not be rendered ineffective, misused, adjusted or removed. Immediately report and rectify any faulty safety devices.
NOTICE Before entering a narrow aisle, the driver must look for people or other trucks
in the aisle. Never enter a narrow aisle where there are people or other trucks. If there are people in the aisle, stop the truck immediately.
NOTICE Only enter narrow aisles in trucks which are designated for this purpose. If a
narrow aisle is equipped with a non-mechanical wire guidance system, and the guidance system is faulty or switched off, the truck may only be removed from the narrow aisle at creep speed.
Page 45
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E 16
3.4.1 Rail guidance truck
Rail guidance trucks are equipped with sensors which activate aisle recognition when they enter the racking lanes.
– Approach the aisle at reduced speed so that the truck
is aligned with the narrow aisle and is within the demar-
cation.
NOTICE Observe the notices attached along the route.
– Slowly enter the narrow aisle.
Ensure that the truck guide rollers enter the narrow aisle guidance rails.
– Press the “guidance on” (32) switch. – The “guidance on” display light (38) changes to active mode. – The drive wheel is automatically set forward. The steering angle display (13) shows
the steering angle permanently in the center position after alignment. Manual steer-
ing is disabled. – The travel control button (1) is used to change travel speed and direction. – Continue to travel along the narrow aisle at your required speed.
IMPORTANT Press the push button (32) to leave the rail
guidance. The display (38) changes to non-active mode. The truck is now also free to move.
QwW You can only change from automatic to manual
steering once the truck has completely left the narrow aisle.
32
38
13
32
3813
Page 46
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1005.USA
3.4.2 Wire guidance trucks
QwW When starting or continuing the truck after the wire guidance has been
deactivated, note the position of the drive wheel as manual steering is now activated again.
QwW If an automatically guided truck is switched off, the wire guidance is no
longer active when the truck is switched on again. This situation can create a risk of accidents! When you continue to travel a warning is sounded and the speed is reduced. Apply push button (32) to re-activate the wire guidance (“Wire guidance active” light (38) goes on) and re-align the truck.
QwW During alignment, the rear part may veer out when it reaches the guidance
wire (42).
– .Approach the guidance wire (42) at an angle
and at reduced speed.
When aligning, the truck should not be parallel to the guidance wire. The optimum approach angle is between 10° and 50°.
Tracking should preferably be in the load direc- tion, as this involves less time and distance.
– When the truck is close to the guidance wire,
switch on the wire guidance with push button
(32).
The “guidance on” display light (38) changes to active mode.
When the guidance wire has been reached the truck is automatically guided.
When the guidance wire is reached tracking automatically ensues at reduced speed. The steering angle display (13) changes to “Track- ing On” (43). The audible tracking signal sounds.
40
41
42
32
38
13
32
3843
Page 47
1005.USA
E 18
Inductive automatic steering takes over the steering of the truck and applies it to the guidance wire.
Tracking is complete once the truck has been led precisely to the guidance wire (42). “Tracking on” (43) changes to “guidance wire applied” (44). The tracking signal no longer sounds. The track is now automatically guided.
Turn the travel selection switch (1) to change travel speed and direction.
IMPORTANT Press the push button (32) to quit the
guidance wire. The display (38) changes to non-active mode. In addition, the ”guidance wire applied” (44) display changes to the steering angle display (13). The truck is now free to move again.
QwW You can only change from automatic to manual steering once the truck has
completely left the narrow aisle.
32
38
44
1
2
F
R
32
3813
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1005.USA
3.5 Lifting – Lowering – outside and inside the rack lanes
QwW There is a risk of injury when the driver’s cab and the load lifting device are
lowered. There must be nobody in the danger zone.
Lift – Lower (Main Lift)
– Apply the foot switch. – At the same time, turn the hydraulic control button (2) “up”
- in drive direction (L) = lower
- in load direction (R) = raise or At the same time, turn the hydraulic control button (2) “down”
- in drive direction (R) = raise
- in load direction (L) = lower
NOTICE The lift and lower speeds are proportional to the degree of turn of the
hydraulic control switch.
NOTICE If the line break safety device actuates at a non-permitted lowering speed
(Error: Er 287), determine the cause and if there no leakage in the hydraulic system, briefly raise the Main Lift and then lower it again.
3.6 Diagonal travel
QwW Diagonal travel (simultaneous travel and lifting/lowering) is possible when
you press the hydraulic control button (2) while simultaneously depressing the travel control button (1).
L
R
Raise (R)
Lower (L))
2 “up“
2 “down“
Page 49
1005.USA
E 20
3.7 Order picking and stacking
Collecting, transporting and depositing loads
IMPORTANT Before picking up a load unit the driver must make sure that it has been
correctly palletized and does not exceed the truck’s capacity. Observe the load diagram.
– Check the fork distance for the pallet and adjust if necessary.
t Adjusting the forks
To pick up the load securely, the forks must be as far apart as possible and centrally positioned with respect to the fork carriage. The load center of gravity must be cen- trally aligned between the forks.
– Raise the forks (45) slightly – Push the forks (45) into the correct position on the fork carriage.
.
45
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1005.USA
3.7.1 Picking up a load from the front.
IMPORTANT Before collecting the load the driver must ensure that the pallet clamp is open.
– Apply the foot switch (37). – Drive the truck slowly. – Slowly insert the forks into the pallet until
the fork shank touches the load or the pal- let.
– Raise the load slightly. – Clamp the load by pressing the “Pallet
Clamp” switch (9).
– Check on the display (7) in the control pan-
el that the load has been clamped.
– Slowly reverse the truck.
IMPORTANT The ground surface must be in good
condition to ensure this works correctly.
3.7.2 Transporting a load
– Apply the foot switch (37). – Always transport a load outside the rack aisle as low as possible, allowing for
ground clearance.
– Always transport loads with both forks. When transporting heavy loads always en-
sure that both forks carry an equal weight.
– Gradually accelerate. – Drive at constant speed. – Always be prepared to brake. Only stop suddenly in emergency situations. – Reduce speed accordingly at narrow bends.
9 7
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3.7.3 Depositing a load
– Drive the truck carefully up to the storage location.
IMPORTANT Before a load can be deposited, the driver must ensure that the storage
location is suitable for storing the load (size and capacity).
– Apply the foot switch (37). – Raise the load lifting device so that the
load can be taken to the storage loca- tion without striking any objects.
– Carefully push the load into its storage
location.
– Open the pallet clamp by pressing the
“Pallet Clamp” switch (9).
– Check on the display (7) in the control
panel that the pallet clamp is open.
– Carefully lower the load lifting device
so that the forks are clear of the load.
IMPORTANT Avoid placing the load down
suddenly to avoid damaging the load and the load lifting device.
– Carefully remove the load lifting de-
vice from the load.
– Fully lower the load lifting device.
3.8 Park the truck securely
When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
QwW Do not park the truck on an incline. In special cases the truck may need to be
secured with blocks or chocks.
NOTICE Select a parking place where nobody will collide with the forks.
– Always park the truck with the mast completely lowered. – Lower the forks to the ground. – Set the key switch to “0” and remove the safety key.
9 7
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4 Important general issues affecting safe operation and use of the industrial
truck
4.1 Training, certification and permission to operate the truck
Permission to operate: Industrial trucks shall be operated only by persons who have
been trained in the operation of trucks and who have demonstrated pursuant to 29 CFR 1910.178 to their employer their capability of safely and competently operating the truck and moving and handling loads, and who have been expressly authorized by their employer or his representative to operate the truck.
Operators must be qualified in terms of visual, auditory, physical and mental ability at the time of operation in order to operate the truck safely.
Prohibition of unauthorized use: The operator is responsible for the industrial truck during working time and he/she must forbid unauthorized persons to drive or operate the industrial truck.
Operator training: Personnel who have not been trained to operate powered indus- trial trucks may operate a truck for the purposes of training only, and only under the direct supervision of the trainer. This training should be conducted in an area away from other trucks, obstacles and pedestrians.
The operator training program must comply with 29 CFR 1910.178 and shall include instruction with and careful study of the manufacturer’s operating instructions and procedures, the owner’s regulations for the site where the trainee will operate the in- dustrial truck, the area’s operating conditions and the particularities of the industrial truck to be operated by the trainee. All new operators must participate in the training program, regardless of their former experience.
The training program communicate or provide for the following:
– The importance of careful selection of the operator, considering their physical qual-
ifications, job attitude and aptitude.
– An emphasis on safety of stock, equipment, operator, and other personnel, includ-
ing citing of rules and why they were formulated.
– The basic fundamentals of industrial trucks and components as related to safety,
i.e. loading, mechanical limitations, stability, braking force etc.
– An introduction to equipment, control locations and functions, explanations of how
they work when used properly, and problems when used improperly.
– Supervised practice designed to simulate actual operations, i.e. loading, etc., which
the operator will be authorized to perform.
– Refresher courses, which may be condensed versions of the primary course, and
periodic, “on-the-job“ operator evaluation.
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The operator’s main responsibility lies in the safe operation of the powered industrial truck according to the instructions imparted in the training program.
Operation not complying to the safety regulations or improper operation or mainte- nance of a powered industrial truck may lead to:
– Death or severe injuries of the operator or others; – Damage to the industrial truck or other material damage.
The training program shall emphasize safe and proper operation to avoid injury to the operator and others and prevent property damage, and shall cover the following are- as:
1. Fundamentals of the powered industrial truck(s) the trainee will operate, includ- ing:
– Characteristics of the powered industrial truck(s), including variations between
trucks in the workplace; – Differences between the truck and the automobile; – Significance of nameplate data, including rated capacity, warnings, and
instructions affixed to the industrial truck; – Operating instructions and warnings in the operating manual for the truck, and
instructions for inspection and maintenance to be performed by the operator; – Type of motive power and its characteristics; – Method of steering; – Braking method and characteristics, with and without load; – Visibility, with and without load, forward and reverse; – Load handling capacity, weight and load center; – Stability characteristics with and without load, with and without attachments; – Controls-location, function, method of operation, identification of symbols; – Load handling capabilities; forks, attachments; – Fueling and battery charging; – Guards and protective devices for the specific type of truck; – Other characteristics of the specific industrial truck;
2. Operating environment and its effect on truck operation, including:
– Floor or ground conditions, including temporary conditions; – Fueling and battery charging facilities; – Application of “classified” industrial trucks in areas rated as potentially
endangered by fire or explosion as per ANSI/NFPA 505 definition; – Narrow aisles, doorways, overhead wires and piping, and other areas of limited
clearance; – Areas where the truck may be operated near other powerde industrial trucks,
other vehicles, or pedestrians; – Use and capacity of elevators; – Other special operating conditions and hazards that may be encountered.
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3. Operation of the powered industrial truck, including:
– Proper preshift inspection and approved method for removing from service a
truck that is in need of repair; – Load handling techniques: Lifting, lowering, picking up, placing, tilting; – Traveling, with and without loads, turning corners; – Parking and shutdown procedures; – Other special operating conditions for the specific application.
4. Operational safety rules and practices including:
– Provisions of this manual in section “Operation of the truck“ in this chapter; – Other rules, regulations, or practices specified by the employer at the location
where the powered industrial truck will be used.
5. Operational training practice, including:
– If feasible, practice in the operation of powered industrial trucks shall be
conducted in an area separate from other workplace and personnel; – Training practice shall be conducted under the supervision of the trainer; – Training practice shall include the actual operation or simulations performance
of all operating tasks such as handling, maneuvering, traveling stopping,
starting, and other activities under the conditions that will be encountered in the
use of the truck.
6. Testing, retraining, and Enforcement
– During training, performance and oral and/or written tests shall be given by the
employer to measure the skill and knowledge of the operator in meeting the
requirements of the Standard. Employers shall establish a pass/fail
requirement for such tests. Employers may delegate such testing to others but
shall remain responsible for the testing. Appropriate records shall be kept. – Operators shall be retrained when new equipment is introduced, existing
equipment is modified, operating conditions are changed, or an operator’s
performance is unsatisfactory. – The user shall be responsible for enforcing the safe use of the powered
industrial truck according to the provisions of this Standard.
NOTICE Information on operator training is available from such sources as powered
industrial trucks manufacturers, government agencies dealing with employee safety, trade organizations, and safety consultants.
4.2 Truck damage and repair
Damage and defects: Damage or defects noted on the industrial truck or on the at-
tachments must immediately be brought to the notice of proper responsible person. Industrial trucks that cannot be safely operated (e.g. due to worn wheels or defective brakes) must not be used until they have been properly repaired.
Repairs: Operators are not allowed to make any repairs or modifications to the indus- trial truck without specific training and authorization to do so. Under no circumstances must the operator change or modify the setting of switches or safety devices or appli- ances or render them ineffective.
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4.3 Load Issues
Sensors: If a load exceeds the width and/or the length of the truck, the user should
require that sensors in the direction of travel covering the maximum moving width and/or length be provided to prevent contact between the load and any obstruction.
Stability: When operated as intended, industrial high lift trucks meeting the manufac- turer requirements of ASME B56.1-2003 are stable. Truck instability can result from, among other things, untrained or improper operation, poor maintenance, poorly main- tained travel ways and work areas.
Among others, the following factors may also affect truck and load stability: Ground and floor conditions (such as ice, oil, or water), speed, loading (even without a load, industrial trucks equipped with attachments may behave like partially loaded industri- al trucks), battery weight, dynamic and static forces and operator’s judgment.
Use only batteries whose weight falls within the minimum/maximum battery weight range indicated on the identification plate for industrial trucks (see section “Truck data plate“ in chapter D).
The operator shall be responsible for the load stability and retention. The operator must verify the stability of the load as necessary to ensure its safe retention.
The operator must adjust to special operating conditions. The stability of an industrial truck is determined using extensive tests defined in ASME B56.1-2003 and, does not take into account industrial truck operation on inclines or the transporting of off-center loads.
Some customers may have stability requirements defined for generic application dif- fering from manufacturer requirements provided by ASME B56.1-2003. However, the customers co-operating with the manufacturer must use the stipulations of ASME B56.1-2003, para. 7.6 as a guideline for his own, more strict requirements. Changes are only permitted with written approval of the proposed modifications or ad- ditions by the manufacturer.
Load backrest extension: If the type of load presents a hazard the user shall equip the truck with a vertical load backrest extension manufactured according to manufac- turer requirements and ASME B56.1-2003.
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4.4 Work environment
Danger area: A “danger area” is the area within which persons are endangered by
the traveling or lifting movements of the industrial truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling / lowering truck attachments.
QwW Unauthorized persons must be required to leave the danger area. The driver
must give a warning signal whenever a situation presenting danger to persons might develop. The industrial truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
The employer is responsible for rating any atmosphere or any area hazard under ANSI/NFPA 505 and providing appropriate operator training on the subject.
Industrial trucks operated in danger areas and batteries used in such areas must be approved and match the requirements of ANSI/NFPA 505.
Industrial trucks and application areas must be marked required by ANSI/NFPA 505.
Stopping distance: The stopping distance of an industrial truck, depends on many factors, including other traffic and pedestrians, the amount of free space available, the ground construction and the stability of the load(s).
Caution should be exercised with changed environments. Changes in weather, sur- face conditions, or applications may effect the truck’s stopping distance; speeds loads, brake settings, and/or operation should be adjusted accordingly.
Aisles and obstacles: Permanent aisles, roadways or passageways and floors must be appropriately dedicated or marked as required by ANSI Z535.2.
Restricted areas of truck operation require identification and/or marking.
In nonrestricted areas, the floor space boundary required for the truck and its load and/or train shall be clearly marked, including the clearance necessary for turns and maneuver.
Doors which open automatically and blind corners shall have suitable audible and/or visual alarms to anticipate the approach of the truck and to allow for door actuation. Passive devices such as mirrors are recommended also.
A minimum clearance of 1.5 ft (450mm) should be maintained between obstructions and trucks (including loads). All other areas having reduced clearance shall be des- ignated as restricted areas and be clearly marked by signs, stripes, lights, or other designations.
– Automatic truck guide paths should not be routed through doorways frequented by
personnel unless the opening is wide enough for personnel to remain outside the guide path clearance aisle. Also, opening and closure of powered or nonpowered doors shall be accomplished in a manner that alerts or restricts personnel near the doorway.
– In order to minimize the possibility of blocking the complete closing of a fire door,
the truck will respond to a signal such as an input from a limit switch and/or heat sensor and stop prior to the fire door.
– System planning and design should not have a normal stop location where a truck
or its load would block a fire door closure.
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Parts of loads, machines, material or construction facilities permanently or temporar- ily projecting into the normal operating area must be protected, clearly and visibly marked or clearly visible.
Illumination of operating areas: Operating areas must be sufficiently illuminated as per ANSI/IES RP7 see also, 29 CFR 1910.178 (h) regarding auxiliary directional light- ing.
The user is responsible for equipping an industrial truck with working lights if the op- erating conditions require so.
Sound: Powered industrial trucks may increase the working environment sound lev- el. The customer/employer is responsible for noise assessment of the workplace and consideration of and meeting the operator’s need for ear protection.
Dock plates: Dock plates (loading aisles) must not be driven on.
Trucks with/without trailers and railroad cars: It is forbidden to use the industrial
truck in trucks, on trailers or railroad cars. In addition, railroad cars or trailers must not be moved with a powered industrial truck unless it has been specially designed and equipped for this purpose.
Floors and floor conditions: Areas of use for industrial trucks shall be smooth and level, free of gaps, floor drains, etc.
The floor shall be maintained to keep them free of debris and liquids which hinder safe operation of the truck.
Ramps and inclines in the area of truck use are forbidden.
Travel surface: The surface over which the truck system operates shall be main- tained to ensure that the traction required for travel, steering, and braking perform- ance can be met under reasonably anticipated environmental conditions.
Truck identification plate capacities and ratings are based on level, dry surfaces hav- ing a minimum coefficient of friction with the driven and brake wheel of 0.6. Surface conditions which deviate from this standard may adversely affect truck safety and re- quire appropriate truck derating.
Physical environment: The physical environment, including temperature, humidity, ambient weather, air quality (e.g. explosive, particulates, and/or gaseous constitu- ents) shall be a part of the truck design criteria. Changes in the environment shall be evaluated to verify there is no adverse effect on the truck’s safety systems.
Radiated emissions: Many types of devices may emit energy, such as electromag- netic, electrostatic, or optical, that could affect the operation of the vehicle system. Likewise, vehicle systems may emit energy that could affect other systems and/or personnel. Users should seek guidance from the truck manufacturer if interference is suspected. The conditions acceptable for the truck system installation shall be defined by user and truck manufacturer agreement.
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4.5 Safety devices and warning labels
Safety devices and warning labels: The safety devices, warning labels and warning
notes described in these operating instructions must always be used and obeyed.
1. (Overhead) guards
– Industrial trucks with and without driver, including order picking industrial trucks
must be equipped with a(n) (overhead) guard manufactured according to
manufacturer requirements as per ASME B56.1-2003. – The (overhead) guard is to protect the driver from dropping objects but cannot
provide protection against every possible impact. As consequence, it should
not be regarded as a replacement for sound power of judgment and care during
loading, handling, and stacking, etc. – In co-operation with the manufacturer, the owner may stipulate the use of a
reinforced (overhead) guard or one with a smaller opening. – Good judgment and care shall be exercised in handling of loads extending
above the mast.
2. Exceptions
– The standard overhead guard height and the vertical free space below the
overhead guard may be reduced to allow operation with an overhead guard if
overhead obstacles restrict the entire industrial truck lowering height.
Changes are permitted only after written approval by the manufacturer has
been obtained.
Warning devices: Every industrial truck must feature a signal horn, whistle, gong or other acoustic device(s) for use by the operator.
The user must decide whether or not the operating conditions require the industrial truck to be equipped with additional acoustic or visual devices such as working lights or flash lamps, and is responsible for implementing and maintaining such devices.
The user shall advise the manufacturer of the desired interval(s) for all additional acoustic or visual devices so that the user’s needs may met as fully as possible.
Signs, warning devices, and other safety devices should be used as required to alert and to protect the personnel from contact with the truck or items actuated by the truck. This includes equipment that is designed to interact with the truck system.
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4.6 Lifting of persons
Lifting of persons: The transport or lifting of persons other than the operator is for-
bidden without special training and an approved work platform. The following meas- ures to protect personnel must be taken if a working platform is used to lift persons with industrial trucks designed and intended for handling goods:
– The working platform must the manufacturer requirements provided in
ASME B56.1-2003; – Provide protection for personnel in their normal working position on the platform
against potentially dangerous moving parts of the industrial truck; – Ensure that the required retaining devices such as banisters, chains, ropes, safety
belt(s) with link(s), or drop dampers, etc. are in place and used as intended; – Ensure that the lifting device moves smoothly over the entire lifting height, both
empty and loaded, and that all lift cut-out devices and stops, if applicable, are func-
tioning; – An overhead guard must be installed where required by operating conditions; – Any safety belt, link or drop damper that has been permanently deformed or other-
wise damaged must be replaced.
Whenever an industrial truck is equipped with a working platform (except high lift in- dustrial trucks with moving driver’s cabin), the measures for the owner as defined in ASME B56.1-2003 and the following measures for personnel protection must be tak- en:
– Provide a platform meeting the manufacturer requirements as per ASME B56.1-
2003; – Only permit its use on a truck which complies with the requirements as per ASME
B56.10-1992 (manually propelled high lift industrial trucks); – Attach the platform fixtures and securely fasten the platform to fork carrier or fork; – Fork carriers and/or forks used for lifting persons and carrying the platform must be
protected against turning; – The lifting mast must remain perpendicular – do not operate it in a laterally tilted
position; – The platform must remain level and centered and not tilted forward or backward
during lifting; – The industrial truck must be level and firmly positioned; – Set all travel controls to neutral and apply the parking brake; – Before lifting persons mark the work area with cones or other devices to warn of
work by elevated personnel; – Lift and lower persons smoothly and carefully, and only upon express request; – Avoid overhead obstacles and power lines; – Keep your hands and feet away from all controls not in use; – Move the industrial truck and/or the platform slowly and make minor horizontal
movements only if persons are on the platform, and do this upon request only; – Rotary devices attached to industrial trucks must be mechanically locked to prevent
any movement; – A trained operator must be present in position to control the industrial truck or he
must be available to operate the controls. The parking brake must be applied if the
driver is not in position;
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– The overall weight of platform, load and persons must not exceed half of the carry-
ing capacity indicated on the identification plate of the industrial truck carrying the
platform; – The persons must remain on the platform floor. It is not permitted to use banisters,
planks, ladders, etc. on the platform to extend the reach or to reach greater heights; – Persons and equipment on the platform must not project from the available space; – Adequate room for personnel shall be provided so that personnel and/or equipment
do not extend over the edge of the platform or require that personnel sit or stand on
equipment being lifted; – The platform must be lowered to the ground for persons to enter or to leave. Never
attempt to climb over any industrial truck parts to enter or leave the platform, or at-
tempt to climb in and out of the plattform while the plattform is elevated.
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4.7 Emergency stop device
When the automatic emergency stop mechanism applies (e.g. if the wire guidance is lost, electric steering fails) the truck brakes to a halt. Before starting again, the cause of the error must be identified and corrected. Start the truck again in accordance with manufacturer’s instructions contained in these operating instructions (see ”Starting up the Truck” in Chapter E).
4.8 Driver's cab emergency lowering
QwW When using emergency lowering, make sure that nobody is present in the
danger zone. If a second person is used to lower the load handler via the emergency lowering device, this person must consult with the driver. Both people must be in a safe area to avoid danger. The driver’s cab must not be lowered when the load handler is in the rack. The truck may only be started again once the error has been localized and corrected.
If necessary, a second person can be deployed to lower the cabin from the ground.
– Lift up the battery panel and take the Allen key from the bracket (48) to the vent
slots (48) in the battery compartment. – Insert the Allen key into the hole (46). – Slowly open the drain valve (47) using the Allen key. – The cabin will lower.
46
47
48
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5 Operation of the truck
5.1 Safety regulations for the truck operator
Operator’s responsibility: This equipment can be dangerous if not used properly.
The operator is responsible for working safely with the truck.
The operator shall abide by applicable safety rules and practices as provided in this manual, the required operator training, the employer and required by law.
The operator must develop safe working habits and be conscious of hazardous situ- ations in order to protect himself, other employees, the industrial truck, and other goods.
The operator must be familiar with all controls, truck functions and gauges before op- erating the truck.
Manually operated functions and motions of the truck must be performed only at speeds which allow control to be maintained.
Before operating the industrial truck, operators must have read and understood the manufacturer’s Operating Instructions of the industrial truck in question, and they must adhere to the safety instructions described below.
Before operating the industrial truck, operators must be familiar with special or unu- sual operating conditions which require additional safety measures or special operat- ing procedures.
5.2 General operation of the truck
Inspections to be performed by the operator: Prior to each shift and before oper-
ating the industrial truck, its condition must be inspected; this applies in particular to the following items:
– Wheels and casters; – Warning and safety devices –Guards; –Lights; –Battery; – Controls; – Lift systems; – Load-carrying attachments; – Chains; – Limit switches; – Brakes; – Floor or wheel lock(s); – Tilt protection devices – Steering;
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If the inspection reveals that the industrial truck needs repair, and therefore is in an unsafe condition, or could tend to become unsafe, the proper responsible person must be immediately informed of the truck’s need for repair and the industrial truck must not be operated again until it has been repaired.
If the industrial truck exhibits any safety defects during operation, the proper respon- sible person must be immediately informed of this circumstance and the industrial truck must not be operated again until it has been repaired.
Repairs and adjustments must be performed only by certified and authorized persons and upon receipt of appropriate repair authority.
If authorized to charge the truck’s battery(s), check the electrolyte level for proper lev- el and the battery compartment vents for clear passage of air prior to plugging the charging units into its power source.
Open flames are prohibited when checking the electrolyte level of batteries.
General: Prior to starting the industrial truck, the operator must read the section “Starting up the truck ” in Chapter E.
Start and operate the industrial truck and its functions and attachments only from the dedicated driver’s seat/operating position.
Hands and feet must remain within the area or cabin designated for the operator. No part of the body may project from the industrial truck’s operator cabin.
Foot protection is recommended.
Never put parts of your body into the lifting device frame.
Never put parts of your body into the industrial truck’s reach mechanism or other at- tachments.
Understand the industrial truck’s limits and safely operate the industrial truck to pre- vent any personal injury. Pedestrians must be protected at all times.
– Never steer the industrial truck towards a person standing in front of an object. – Prior to performing a U-turn make sure no-one is present within the rear pivoting
range. – Pay particular attention at crossing aisles, doorways or other areas where pedes-
trians may cross the industrial truck’s travel path.
It is not permissible for persons to be present beneath an industrial truck’s lifted part or to walk underneath it, regardless of whether the industrial truck is empty or loaded.
No additional person may ride on powered industrial trucks unless a safe seat has been provided by the manufacturer.
Do not permit passengers to ride on the carriage or forks.
Good judgment and care must be exercised in handling of loads extending above the mast.
Only industrial trucks approved for use in areas rated as potentially dangerous may be used in such areas.
Do not attach anything to and do not modify the industrial truck.
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Driving lanes and work areas: Only such lanes and routes that are specially allo- cated for truck traffic may be used. Unauthorized persons must stay away from indus- tial truck work areas. Loads must be stored at places specially provided for this pur- pose only.
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 industrial truck and the ve- hicle in front and he must be in control of his truck at all times. Sudden stopping (ex- cept in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating ar- ea.
Obey all traffic regulations including applicable speed restrictions on the premises. Right hand traffic applies under normal traffic conditions. Maintain a safety clearance distance to the truck in front in relation to truck speed; always be the master of the truck.
Yield the right of way to pedestrians, rescue vehicles such as ambulances and fire fighting vehicles, and other (powered) industrial trucks is forbidden.
Overtaking or passing other industrial trucks driving in the same direction at cross- ings, in a blind angle or in other hazardous spots.
Reduce the speed or stop and sound the horn at lateral aisles and other places with restricted view.
Cross railroad tracks at an oblique angle if possible. When stopping short of a railroad track, maintain a clearance of a least 2 m/2.2 yards (6.6 ft) from the track.
Always face in the direction of travel.
Keep an unobstructed view on the travel path and observe other traffic, persons and safety clearances.
Drive with the load towards the rear if it obstructs your view to the front.
Operate the industrial truck at a speed that allows the truck to be safely stopped under all conditions.
Drive with the load lifting device or load in the lowest position possible. Lift the load for stacking purposes only. This does not apply to industrial trucks that are intended normally to be operated with the load or load-engaging means elevated.
Accelerate, stop, turn or reverse smoothly to avoid slippage of the load and/or tipping or turnover of the industrial truck.
Do not indulge in stunt driving or horseplay.
Be cautious and reduce the speed on wet and slippery floors.
Industrial trucks shall not enter elevators without a special permit. Do not exceed the elevator’s load capacity. Slowly approach the elevator and enter it squarely as soon as the elevator car has reached a horizontal position. Set the controls to the neutral position, shut off power and, if equipped, set the floor or wheel lock(s) as soon as the industrial truck is in the elevator car. It is recommended that all other persons leave the elevator before the industrial truck enters or leaves the elevator car.
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Avoid travelling over loose objects, debris or openings on the floor.
When negotiating turns, reduce speed to a safe level consistent with the operating environment, and turn the hand steering mechanism in a smooth, sweeping motion. Except when maneuvering at a very low speed, turn the hand steering mechanism at a moderate, even rate.
5.3 Make sure your truck is properly equipped
All industrial trucks with driver must be equipped with an overhead guard as protec- tion against dropping objects, unless all other following conditions are met:
1. The vertical mast movement is restricted to 1826 mm/72 inch or less above
ground;
2. The industrial truck is operated in an area where:
– the lower edge of a stacked load is not more than 1825 mm/72 inch and the
upper edge is not more than 3050 mm/120 inch from the ground during stacking;
– loads in the form of stable and preferably rigidly connected units or containers
are handled;
– protection against objects dropping from neighboring high-bay warehouse
areas is provided. An overhead guard is to protect the driver from dropping objects but cannot provide protection against any possible impact. As a consequence, an overhead guardshould not be regarded as a replacement for good judgment and care during handling of loads.
3. The industrial truck must be marked with its area of operation.
A load backrest extension must be attached to protect the operator against a load or parts dropping onto him.
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5.4 Load and transport safety
Nature of the loads carried: Only loads that have been safely and correctly secured
must be carried (see section “Capacity“ in chapter D).
Handle only stable or safely commissioned loads (see section “Order picking and stacking“ in chapter E) within the capacity of the truck.
– Proceed with particular care if off-center loads to be handled cannot be centered. – Handle only loads whose weight does not exceed the industrial truck’s carrying ca-
pacity. – If it is uncertain or doubtful whether a load exceeds the truck capacity, DO NOT
TRANSPORT IT! – Handle loads with load carrying-units only; it is not permitted to transport loads or
other objects in the driver’s cabin or other areas of the industrial truck unless the
owner has provided and marked an appropriate space for this purpose.
Consult the truck identification plate for the truck and attachment capacity and work within the capacities listed.
Be particularly careful when positioning and transporting loads using attachments. Empty industrial trucks equipped with attachments are to be operated like partially loaded industrial trucks.
The load must be completely picked up by the load carrying devices. The fork length should be at least two thirds of the load’s length.
QwW Handling loads suspended from a crane arm (boom) or another device may
induce dynamic forces which negatively affect the industrial truck’s stability and which may exceed the manufacturer requirements of ASME B56.1-
2003. Sudden acceleration, braking and turning may cause the load to oscillate and constitute a hazard.
When handling suspended loads:
– The carrying capacity defined by the manufacturer of industrial trucks equipped for
handling suspended loads must not be exceeded; – The load must be lifted perpendicularly and never be pulled horizontally; – The load must be transported such that the load bottom and the lifting mast are as
low as possible; – With the load lifted, maneuver the industrial truck slowly and carefully and restrict
such movements to allow lowering into the transport position only; – Wherever possible, use guide ropes to prevent the load from swinging.
Transport of liquids: When transporting liquids, the center of gravity may change depending on the movement of the truck, which may seriously affect stability. All nec- essary precautions must be taken during maneuvers, in particular acceleration, brak- ing and turning, and all sudden movements must be avoided.
Flattening of wheels: When the truck is parked for extended periods, the running surface of the tires will flatten. However, this does not affect the travel safety or sta- bility of the truck as the flattening will disappear after travelling for a while.
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5.5 Avoid overturn and tipover
Operating a industrial truck with counterweight, central controller and a seated driver on a stationary driver’s seat requires special safety measures such as:
1. An industrial truck, empty or loaded, may turn over if the driver fails to slow down
to a safe speed prior to taking a bend. Indications that an industrial truck was too fast while taking a bend are:
– Slipping tires; – Lateral inclination; – Lifting-off of a tire and – The necessity to take a firmer grip on the steering wheel to avoid slipping out
of the seat.
2. The probability of lateral turning over increases with each of the following condi-
tions or combinations of them:
– Over loading; – Driving with the load lifted; – Heavy braking or accelerating while taking a bend; – Off-center load; – Driving on uneven ground; – Driving at too high a speed.
3. Tipping forward can occur and its likelihood is increased under the following con-
ditions or combinations of them:
– Over loading; – Driving with a raised load; – Jamming the brakes when driving forward; – Sudden acceleration when reversing
4. The driver should stay with the industrial truck if it turns over laterally or in longi-
tudinal direction. The driver should take a firm grip and lean away from the point of impact.
5. The driver should stay with the industrial truck if it drops off a loading ramp or
ramp. The driver should take a firm grip and lean away from the point of impact.
– The user may have to take other and/or additional safety measures and define
special work instructions to meet the conditions if the environment constitutes a severe hazard or unusual operating conditions prevail.
If present, an active driver protection system or similar system must be used. The driver protection serves to prevent head and body injuries by squeezing between the industrial truck and the floor when the truck turns over. Such systems cannot, howev- er, guarantee protection against all possible injuries.
Visibility during travel: The driver must look in the direction of travel and must al- ways have a clear view of the route ahead. When loads blocking the view are carried, the industrial truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the industrial truck to give suitable warnings.
Negotiating slopes and inclines: It is prohibited to operate this truck on slopes or inclines.
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5.6 Attend and secure your truck
A powered industrial truck is considered to be under supervision, or attended, if the operator is at a distance of less than 8 m/8.8 yards (26 ft) from the industrial truck and it remains within his field of vision.
A powered industrial truck is considered not to be under supervision, or unattended, if the operator is at a distance of more than 8 m/8.8 yards (26 ft) from the industrial truck and it remains within his field of vision, or whenever the operator leaves the in- dustrial truck and it is outside his field of vision.
Before leaving the driver’s seat / operating position:
– Do not park the truck on an incline. – Bring the industrial truck to a complete stop; – Completely lower the load lifting device unless it is carrying a lifting platform;
When leaving the industrial truck unobserved (see section “Parking the truck secure- ly” in Chapter E):
– Never park the truck on an incline; – Bring the industrial truck to a complete stop; – Completely lower the load lifting device; – Set the keyswitch to the “0” position and remove the safety key; – Apply the main switch or the EMERGENCY DISCONNECT switch.
Access to fire protection aisles, stairways and fire protection systems must not be blocked by a parked truck.
5.7 Lifting of persons
In case a truck is not equipped with controls that can be operated from its load lifting device (not applicable e.g. for order pickers), it may only be used for lifting persons if it has been designed for such purpose by the manufacturer and if the following rules are observed:
– Check to see if it is rated for this service; – All position holding and stabilizing devices specified by the manufacturer shall be
in place and engaged; – Be certain that required restraining means such as the guardrail system are in
place and properly used; – Attach the platform fixtures and securely fasten the platform to fork carrier or fork; – Ensure that both the empty and loaded lifting device moves smoothly over the en-
tire lifting height and that all lift cut-out devices and stops, if applicable, are func-
tioning; – Ensure that the platform is level and centered and not tilted forward or backward
during lifting; – Ensure that the industrial truck is standing firmly and in a level position; – Set all travel controls to neutral position and apply the parking brake; – Before lifting persons mark the work area with cones or other devices to warn of
work by elevated personnel; – Lift and lower persons smoothly and carefully, and only upon express request; – Avoid overhead obstacles and power lines;
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– Keep your hands and feet away from all controls not in use; – Move the industrial truck and/or the platform slowly only for minor adjustments in
horizontal positioning when personnel are on the platform and only at their request; – Rotary devices attached to industrial trucks must be mechanically locked to prevent
any movement; – The parking brake must be applied if the operator is not in the operating position; – The overall weight of platform, load and persons must not exceed half of the carry-
ing capacity indicated on the identification plate of the industrial truck carrying the
platform; – The persons must remain on the platform floor. It is not permitted to use banisters,
planks, ladders, etc. on the platform to extend the reach or to reach greater heights; – Persons and equipment on the platform must not project from the available space; – The platform must be lowered to the ground for persons to enter or to leave. Never
attempt to climb over any industrial truck parts to enter or leave the platform, or at-
tempt to climb in and out of the plattform while the plattform is elevated.
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5.8 Slack chain safety device override
If the slack chain safety device has actuated, e.g. when position- ing the load handler, loosening or braking the lift chain, the “slack chain safety device” symbol (50) illuminates in the display unit. It is possible to raise the Main Lift if the slack chain safety device override switch (51) is depressed and held down while pressing the hydraulic control button. Travelling and lowering are now in- hibited.
Before starting again, diagnose and correct the problem that caused actuation of the device.
IMPORTANT The truck can only be started again when the problem has been corrected.
5.9 Travel cutout override (o)
If travel is inhibited from a certain lift height (the “Travel cutout override” symbol (52) appears in the display), and the position of the truck relative to the rack must be adjusted to load or unload goods, press the “unlock travel” switch (53) and apply the travel control button as described in “Travelling”. This allows you to trav- el at crawl speed.
5.10 Lift limit override (o)
If local conditions require, an automatic lift cutout wich limits max- imum lift height can be fitted for safety reasons. The display unit shows the "Lift Cutout Override" symbol (54).
IMPORTANT Lift cutout only becomes effective after a test run has
been carried out. You can tell when this is the case, because the actual height is shown in the display unit. Pressing the “lift cutout override” switch (55) disables the lift cutout.
QwW When disabling the lift cutout the driver must look out for obstacles when the
mast is extended.
NOTICE Lift cutout is re-activated each time the mast falls below the lift limit height.
The respective travel and lift limit switches are located in the control panel.
51
50
53
52
55
54
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5.11 Aisle end safety device (o)
Trucks with the aisle end safety device brake before the aisle exit or in the transfer aisle. There are two basic versions for this:
1. Braking to a halt
2. Braking to 2.5 km/h / 1.55 mph.
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
1. Braking to a halt:
When the truck passes over the aisle end safety magnets heading for the aisle end, it comes to a halt.
To continue traveling:
– Briefly release the foot switch and then apply it again
The truck can be driven out of the narrow aisle at max. 2.5 km/h / 1.55 mph.
2. Braking to 2.5 km/h / 1.55 mph:
When the truck passes over the aisle end safety magnets heading for the aisle end, it brakes to 2.5 km/h / 1.55 mph and can be driven out of the narrow aisle at this speed.
IMPORTANT In both cases the braking distance depends on the travel speed.
QwW Aisle end safety braking is an additional function designed to support the
operator, but which does not release him from his responsiblities, e.g. to monitor braking at the aisle end and if necessary to apply the brakes.
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5.12 Wire Guidance emergency operation (Error 144)
If in a wire guidance system the guiding antenna extends beyond the pre-determined range of the guidance wire, an emergency stop is immediately performed.
If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The “tracking on” display and the audible tracking signal however remain permanently on and hence warn the driver.
Automatic EMERGENCY STOP
If during operation one of the monitors for steering control, steering system, wire guid- ance or the safety cutout for the traction electronic system or power electronic system actuates, the truck safety devices will cause the truck to stop.
To enable the truck to travel again after an EMERGENCY STOP, carry out the follow- ing:
– Determine the possible cause of the EMERGENCY STOP. – Press the EMERGENCY STOP switch and turn it again to release it. – Error E144 is displayed. – Apply inductive automatic steering. – Press the travel control button and carefully align the truck with the guidance wire. – Error E144 goes out.
QwW If the truck now starts, test that it works with manual steering and inductive
automatic steering.
Automatic EMERGENCY STOP
If, after an automatic EMERGENCY STOP and having rectified the problem, you can- not start the truck again, turn the key switch off and on again. Now perform a referencing action, see “Truck Operational Status Symbols” section in Chapter E. The truck is now operational again.
Manual EMERGENCY STOP
Manual EMERGENCY STOPS occur when the EMERGENCY STOP button is pressed. The truck is operational again once the EMERGENCY STOP button has been released.
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5.13 Recovering the truck from a narrow aisle / Moving the truck without a battery
QwW Before recovering the truck from a narrow aisle, disconnect the battery.
IMPORTANT This operation must only be performed by suitably trained maintenance
personnel.
IMPORTANT When the brakes are de-activated the truck must be parked on an even
ground as the brakes are no longer effective.
– Fully lower the mast.
NOTICE Seek assistance from another person. The other person must be trained and
familiar with recovery operations.
To recover the truck from the aisle, release the brakes.
5.13.1 Release the magnetic brake
QwK Remove the electronic compartment cover at the back.
– Screw in the setscrews (61) on the magnetic brake above the drive motor to release
it.
IMPORTANT When starting the truck again:
Check the brake retardation.
61
60
62
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5.13.2 Adjust the steering angle
QwW The battery must be
disconnected when adjusting the steering angle.
QwK Remove the electronic
compartment cover at the back.
Using an Allen key set the steered wheel to the required direction via the screw in the steering motor (63).
NOTICE It is advisable to relieve the
wheel by lifting / jacking up the truck if setting an angle greater than 4 degrees.
5.13.3 Emergency recovery in drive di- rection:
QwK Remove the electronic
compartment cover at the back.
– Release the magnetic brake – Guide the tow rope (67), tow force
> 5 tons, around the counter- weight (65) by the left or right sides of the antenna (66).
IMPORTANT Note the wire routing in the
drive compartment and the antenna (66)!
– Carefully and slowly pull the truck
out of the narrow aisle.
QwW After recovery, prevent the truck from accidentally moving.
To do this, unscrew the setscrews on the magnetic brake above the drive motor. If the brake is not working, place blocks or chocks underneath the wheels of the truck to prevent it from moving.
63
66
67
65
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5.13.4 Emergency recovery in load direction
QwK Remove the electronic compartment cover at the back.
– Release the magnetic brake – Lower the driver’s position carriage and attach the tow rope (70), tow force > 5 tons
to both mast suspensions (68,69).
– Guide the tow rope (70) around the side of the driver’s position carriage above the
safety gates at the front in the load direction.
– Carefully and slowly pull the truck out of the narrow aisle.
QwW After recovery, prevent the truck from accidentally moving.
To do this, unscrew the setscrews on the magnetic brake above the drive motor. If the brake is not working, place blocks or chocks underneath the wheels of the truck to prevent it from moving.
70
69
68
70
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F 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 (see section “Park the truck securely“ in chapter E).
To avoid damage to equipment or injury to personnel, battery changing and charging facilities and procedures shall be in accordance with ANSI/NFPA 505.
Battery types and charging facilities supplied or specified by the truck manufacturer (e.g. opportunity charging) but not referenced in ANSI/NFPA 505 shall be maintained in accordance with instructions supplied by the truck manufacturer.
Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by trained and authorized personnel. The instructions contained in this oper- ating 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 open flames are not permitted when han- dling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 78.7 inches (2 meters) of the truck parked for battery recharging. When charging the battery, 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.
QwW To avoid damage to equipment or injury to personnel, consult manufacturer’s
procedures when re-placing contacts in any battery connector.
Disposal of the battery: Batteries must only be disposed of as providedin federal en- vironmental protection regulations or waste disposal provisions. The manufacturer’s specifications for the disposal must be heeded.
IMPORTANT Before closing the battery hood, make sure that the battery cable cannot be
damaged.
QwW 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 contact with battery acid. Spilled battery acid must be immediately neutralized.
IMPORTANT Only batteries with closed tray may be used.
QwW Battery weight and dimensions have considerable influence on the
operational safety of the truck. Changing the battery equipment is not permitted without prior written approval by the manufacturer.
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2Battery type
Depending on the use, the truck is equipped with different types of batteries. The table below shows the capacity of the batteries and also the combinations used as standard equipment:.
The battery weights can be seen on the battery name plate.
QwW Only use a battery whose weight is within the minimum and maximum range
stated on the truck’s data plate
QwW Failure to comply with the prescribed battery weight range can render the
truck unstable.
Battery Type Order no. Truck Type
48 V 3 EPzS 465 520 362 92 EKS 314
48 V 3 PzW 420 520 362 93 EKS 314
48 V Duglas 500 Ah (Hermes) 520 362 94 EKS 314
48 V GNB 500 Ah (Hermes) 520 362 95 EKS 314
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3 Charge the battery
QwW Park the truck securely
(see section “Parking the Truck Securely” in Chapter E).
– Turn key switch (2) to "0" (zero). – Lift up the battery panel (4).
QwW Only connect and disconnect the battery connector and the socket when the
mains and charger are switched off.
– Remove the battery connector (5). – If necessary, remove the insulating mat from the battery.
QwW When charging, the tops of the battery cells must be exposed to provide
sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage.
– Connect the charger lead of the battery charger station with the battery connector. – Switch on the charger. – Charge the battery in accordance with the battery and charging station manufactur-
ers’ instructions.
QwW It is essential to follow the safety regulations of the battery and charger station
manufacturers.
4
1 2
3
3
5
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4 Battery removal and installation
QwW Only batteries with insulated cells and terminal connectors may be used.
When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position.
QwW The truck must be horizontal (industrial truck is standing straight on level
ground) in order to prevent the battery from falling out when the battery retainer is removed.
QwW Only connect and disconnect the battery connector and the socket when the
mains and charger are switched off.
– Turn key switch (2) to "0" (zero). – Lift up the battery panel (4). – Disconnect the battery (5). – Lift out the left and right side panels (3).
4
1 2
3
3
5
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– Undo the battery retainer (8) by moving the lever (9) down and remove the retainer. – Pull the battery (6) onto the side of the prepared battery trolley.
QwW Make sure the battery trolley is properly secured.
QwW After replacing/fitting the battery (6), make sure that the battery is well
secured in the battery compartment.
NOTICE The battery retainers (7, 8) can swap positions. This means that they can
both be fitted in either the left or right side of the truck’s chassis.
Assembly is the reverse order.
QwW To avoid pushing the battery (6) through on assembly, the battery retainer (7)
must first be plugged in on the opposite side.
QwW After installing again, check all cables and connectors for signs of visible
damage and before using the truck again check that:
– the battery retainer (8) is fitted and secured by the lever (9), – the right and left side sections (3) are securely fitted and the battery panel (4) is
firmly closed.
6
8
7
9
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5 Check the battery condition, the acid level and acid density
– The battery manufacturer’s maintenance instructions apply. – Check the battery housing for cracks and any spilled acid. – Remove any oxidation remains from the battery terminals and apply an acid-free
grease to the battery terminals.
– Unscrew the stops and check the acid level.
The acid level should be at least 10-15 mm / 0.39-0.59 inches above the top of the plates. Now close the stops.
– If necessary, re-charge the battery.
6 Battery discharge indicator
When you turn and release the EMER- GENCY DISCONNECT switch and turn the key in the key switch clockwise, the battery discharge indicator will show the residual capacity available. The display starts to flash when the battery reaches a residual capacity of 10% and at a re- sidual capacity of 0% lift cutout ensues.
For maintenance-free and special bat- teries the display and cutout points can be adjusted by authorized personnel by assigning parameters.
+-
50%
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G Truck Maintenance + Troubleshooting
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.
QwW Operation of powered and manually propelled industrial trucks may be
hazardous if maintenance is neglected or repairs, rebuilds, or adjustments are not performed in accordance with the manufacturer’s design criteria.
QwW Modifications of industrial truck assemblies, especially of the safety
installations, are not permitted. On no account must the operational speeds of the truck be changed.
IMPORTANT Only original spare parts have been certified by our quality assurance
service. To ensure safe and reliable operation of the industrial truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the after sales 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.
In unusual cases not covered by this manual consult the truck manufacturer.
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: Maintenance and repair work on all indus-
trial trucks and truck systems shall be performed by authorized and trained manufac- turer personnel only and shall be performed in conformance with the practices de- scribed in this chapter. In addition, maintenance and inspection shall be performed in accordance with the manufacturer’s and user’s recommendations. The service or- ganization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
It is the user’s responsibility to follow all procedures for safe maintenance of equip- ment. Records of maintenance activities performed should be kept.
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Lifting and jacking up: When an industrial 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 tipping over (use of chocks and/or blocks). Work underneath the raised load lifting de- vice must only be carried out when the fork is immobilized and supported by a chain of adequate strength (see “Securing the driver’s position carriage and mast” in sec- tion G).
NOTICE Jacking point see chapter D.
Cleaning operations: Do not use inflammable liquids when cleaning the industrial
truck. Before commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) must be taken. For battery-operated indus- trial trucks, the battery plug must be removed. Use only weak vacuum air, weak com- pressed air and non-conducting, antistatic brushes for the cleaning of electric or elec- tronic assemblies.
IMPORTANT If the industrial 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.
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 must be taken. For battery-operated industrial trucks, the truck must also be depow- ered by removing the battery plug.
Welding: To prevent damage to electric or electronic components, remove them from the industrial truck prior to welding.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.
Wheels: The quality of the wheels greatly affects the stability and the driving behavior of the industrial truck. To ensure compliance with the data sheet specifications, only use genuine spare parts from the manufacturer when replacing the originally mounted wheels. When replacing wheels, ensure that the industrial truck remains level (wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: Lift chains (when provided) shall be inspected regularly. Chain found to have cracked, broken, or missing link plates; to have protruding, turned or seized pins; or, to be significantly corroded, shall be replaced, in pairs if so provided. New chain anchor pins shall be installed when chains are replaced. The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Wire ropes: Wire ropes (when provided) shall be inspected regularly. Any rope found to have a marked reduction in diameter, excessive abrasion of outside wires, broken wires, damage, or, to be significantly corroded, shall be replaced.
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Hydraulic hoses: The hoses must be renewed every six years.
Maintenance and inspection safety rules: When lifting industrial trucks for repair
or inspection purposes, this must be done in a reliable, secured, and stable manner. Removing components such as counter weights or support pairs will change the cent- er of gravity position and may result in an instable state.
Before commencing inspection and repair:
– Lift the drive wheels until the are clear off the floor, disconnect the battery and use
chocks or other form-fit devices to prevent the industrial truck from moving; – Block load lifting device, inner mast(s) or frames before starting work on these com-
ponents; – Disconnect the battery before performing work on the electrical system; – Plug the charger’s connector into the battery socket only, never into the industrial
truck’s socket.
Operation of the industrial truck for performance testing must occur in a specified and restricted area with a safety clearance maintained.
1. Before starting the industrial truck, the operator must read the section “Starting
up the truck” in Chapter E.
2. When leaving the industrial truck unobserved (see section “Parking the truck
securely” in Chapter E):
– Never park the truck on an incline; – Bring the industrial truck to a complete halt; – Completely lower the load lifting device; – Set the keyswitch to “0” and remove the safety key; – Press the main switch or the EMERGENCY DISCONNECT switch;
Prevent fire hazards and make sure fire fighting facilities are available in the work ar- ea. The use of open flames to check the level of liquids or to check for spilt liquids, in particular of battery electrolytes, is not permitted. Open fuel pans or flammable cleansers to clean components must not be used.
Ensure sufficient ventilation of the work area and keep the workshop clean and dry.
Brakes, steering, control devices, warning systems, lighting, controllers, lifting cut out devices, protection and safety systems, lift devices, stops pf pivoted axles and frame components must be carefully and regularly inspected and kept in a safe condition.
Special trucks or devices designed and approved for hazardous area operation shall receive special attention to ensure that maintenance preserves the original, approved safe operating features.
All hydraulic systems should be regularly inspected and maintained. Hydraulic cylin- ders, valves, hoses, fittings, and other hydraulic components should be checked to ensure that drift or leakage has not developed to the extent that it would create a haz- ard.
The truck manufacturer's capacity, operation, and maintenance instruction plates, tags, and decals shall be maintained in legible condition.
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Batteries, motors, controllers, limit switches, protective devices, electrical conduc- tors, and connections must be inspected and maintained in conformance with good practice. Special attention shall be paid to the condition of electrical insulation.
To avoid injury to persons or damage to equipment, follow the battery manufacturer’s connecting procedures when replacing the contacts in any battery connector.
Trucks shall be kept in a clean condition to minimize fire hazards and facilitate detec- tion of loose or defective parts.
Modifications and/or additions to the truck and/or to hardware or software that affect rated capacity, safe truck operation, or any emergency control or device shall not be carried out without the manufacturer’s prior written approval. When such modifica- tions and/or additions are approved in writing by the manufacturer, all capacity, oper- ation, and maintenance instruction plates, tags, and decals must be changed accord- ingly.
Care shall be taken to ensure that all replacement parts are interchangeable with the original parts and of a quality and performance at least equal to that provided with the original equipment. All parts are to be installed following the manufacturer’s proce- dures.
Wheels, casters, floor or wheel locks, steering mechanisms, control mechanisms, fastening and warning devices, lights, lift overload devices, guards and safety devic- es, lift/lower mechanisms, and frame members shall be carefully and regularly in- spected and maintained in safe operating condition.
When changing batteries on battery-electric trucks, replacement batteries must have a weight that falls within the minimum/maximum range specified on the truck’s name- plate by the truck’s manufacturer.
Inspecting and repairing forks used on industrial trucks: Forks in current use must be inspected at least every 12 months (in case of single-sided traversing oper- ation), for a damage or permanent deformation. Heavy use will require more frequent inspections.
Carrying capacity of a single fork tine: For forks used in pairs of two (normal configu- ration) the rated carrying capacity of each tine must be at least half the industrial truck’s rated carrying capacity as specified by the manufacturer, and the load center distance (rated value) must be indicated on the truck’s identification plate.
Inspection: Forks must be carefully inspected regularly by trained personnel in order to detect damages, cracks, permanent deformations, etc. that might negatively affect safe application. Any fork that shows such a defect must be replaced or withdrawn from service and may not be returned to service unless it has been satisfactorily re- paired by the fork manufacturer or expert of equal competence.
1. Surface cracks: The fork, in particular the bottom and the weld seams that con-
nect all attachments to the fork body, must be subjected to a thorough visual inspection for cracks and, if deemed necessary, to a non-destructive material test for evidence of cracks. This inspection for cracks must cover all special fix- tures of the fork body to the fork carrier including bolted devices and forged fix- tures for hooks or shaft shaped load carrier receptacles. The forks must not be commissioned again if cracks are found.
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2. Straightness of fork blade and fork back: Verify the straightness of the upper fork
blade side and the fork back front. If the deviation from a straight line is more than 0.5% of the fork blade length and/or the fork back height, the fork must not be commissioned again until it has been appropriately repaired.
3. Fork angle (between the top of the fork blade and the fork back side facing the
load): Every fork deviating by more than 3 degrees from the genuine specifica- tion must not be recommissioned. The rejected fork must be realigned and tested.
4. Difference in fork tip height: Verify the height difference of a fork pair attached to
the fork carriage. If the fork tip height difference is more than 3% of the fork blade length, the fork must not be commissioned again until it has been appropri- ately repaired.
5. Position lock (if present in the original configuration): Check that the position lock
is in the proper condition and functions correctly. If any fault has been detected, the fork must not be commissioned again until it has been appropriately repaired.
6. Wear:
– Fork blade and fork back: Fork blade and fork back, in particular the area of the
fork stop must be thoroughly inspected for wear. The fork must not be commis- sioned again if the thickness is less than 90% of the original thickness (fork back).
– Position hook (if present in the genuine configuration): The load-bearing sur-
face of the upper hook and the retaining surfaces of both hooks must be in- spected for wear, cracks or other local deformations. In case of deformations resulting in too great a play between fork and fork carrier, the fork must not be commissioned again until it has been appropriately repaired.
7. Legibility of marking (when originally provided): If the fork marking is not clearly
legible, it shall be renewed per instructions from original supplier.
Repair and inspection:
– Repair: The decision whether or not a fork may be repaired for further use and the
repair itself are restricted to the fork manufacturer or an expert of equivalent com-
petence. Repair of superficial cracks or wear by forging is not recommended. Nec-
essary repairs requiring a realignment must be followed by the stipulated
appropriate heat treatment of forks. – Test load: After repair, except the repair or replacement of the position lock and/or
the identification plate, a fork may be commissioned again only if it has been suc-
cessfully subjected to the manufacturer tests as per ASME B56.1-2003; however,
the test load must be the capacity as indicated on the fork.
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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 industrial truck. The neglect of regular servicing intervals can lead to industrial truck failure and constitutes a potential hazard to personnel and equipment.
IMPORTANT Operating conditions for the industrial truck can have a significant impact on
the life of service components. We recommend that a customer consultant from Jungheinrich perform an on- site operational analysis and define maintenance intervals to minimize damage due to wear. The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, involving large temperature 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:
W = Every 50 service hours, at least weekly A = Every 500 service hours B = Every 1000 service hours, at least once a year, however C = Every 2000 service hours, at least once a year, however
NOTICE Servicing intervals W must be performed by the owner/user.
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4 EKS 314 maintenance checklist
Maintenance intervals
Standard = t WABC
Chassis/ Structure:
1.1 Check all load bearing components for damage t
1.2 Check screw connections t
1.3 Test the operator’s platform and check for damage t
1.4 Check that identification points, data plates and warning labels are legible and replace if necessary
t
1.5 Check tilt safety devices are present and secure t
1.7 Make sure decals are present, legible and valid t
1.8 Check battery panel and sides are secure t
1.9 Test battery panel attachment and check for damage t
Drive: 2.1 Lubricate the bearing between the drive motor and
transmission
t
2.2 Check transmission for noise and leakage t
2.3 Change transmission oil t
Wheels: 3.1 Check wheels for wear and damage t
3.2 Check and lubricate bearing and attachment t
Steering: 4.1 Test operation and setting of wheel position display t
4.2 Check the distance between the guide rollers and the rail guidance over the entire length of the rails. The play between the two guide rollers and the rails (measured over the axle) should be 0-5 mm/0-0.2 inches. The roll- ers should not jam.
t
Brake sys- tem:
5.1 Test operation and settings t
5.2 Check the brake lining wear t
5.3 Check brake mechanism, adjust and lubricate if necessary
t
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p) Replace hydraulic hoses after 6 years' operation
Maintenance intervals
Standard = t WABC
Hydraulic System
6.1 Test operation t
6.2 Check connections and ports for leaks and damage t
6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure
t
6.4 Check oil level t
6.5 Test hose guide and check for damage t
6.6 Check ventilation and discharge filter on hydraulic reser- voir
t
6.7 Replace ventilation and discharge filter on hydraulic res- ervoir
t
6.8 Replace hydraulic oil and filter cartridge t
6.9 Test pressure relief valves t
6.10 Make sure hydraulic hoses are sealed and check for damage. p)
t
6.11 Test line brake safety device t
Electrical System
7.1 Test static charge eliminator t
7.2 Test operation t
7.3 Make sure wire connections are secure and check for damage
t
7.4 Test the operation of the cable guides and check for damage
t
7.5 Test operation of warning devices and safety switches. t
7.6 Make sure sensors are fixed, not damaged, clean and operational
t
7.7 Test operation of instruments and displays t
7.8 Check contactors and relays; if necessary replace any worn parts
t
7.9 Check fuse ratings t
Electric Motors:
8.2 Check motor attachment t
Battery: 9.1 Check acid density, acid level and cell voltage t
9.2 Check terminals are securely attached, and apply grease
t
9.3 Clean battery connections, make sure they are secure t
9.4 Check battery cables for damage, replace if necessary. t
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e) IG: inductive guidance trucks
Maintenance intervals
Standard = t WABC
Lift mecha- nism:
10.1 Clean contact surfaces in the mast sections and apply grease.
IMPORTANT Attention: Secure Mast as necessary!
t
10.2 Check mast attachments (bearings and retaining screws)
t
10.3 Check lift chains and chain guide for wear, adjust and lu- bricate
t
10.4 Lubricate lift chains t
10.5 Visually inspect rollers, slide pieces and stops t
10.6 Check forks and fork carriage for wear and damage t
10.7 Check pallet clamp for wear and damage t
Safety Devices:
12.1 Check operator safety harness + belts for damage and wear, and test operation
t
12.2 Check safety harness retaining point for for damage and wear, and test operation
t
12.3 Check legibility of notices on safety restraint belt. t
Lubrication: 13.1 Lubricate the truck according to the lubrication schedule t General
Measure- ments:
14.1 Check electrical system for frame leakage t
14.2 Test travel speed and braking distance t
14.3 Test lift and lowering speeds t
14.4 Test safety devices and cutouts t
14.5 IG: Measure the current in the guidance wire, adjust if necessary e)
t
14.6 Check travel on the guidance wire, check maximum de- viation and adjust if necessary e)
t
14.7 Check tracking mode on the guidance wire for aisle tracking e)
t
14.8 Check wire guidance EMERGENCY STOP operatione) t
Demonstra- tion:
15.1 Test run with rated load t
15.2 When maintenance is complete, present the truck to the responsible person.
t
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5 Lubrication schedule
g
Contact surfaces a Transmission oil drain plug
s
Grease nipple c Hydraulic oil drain plug Hydraulic oil filler neck
G
E
B
E
H
A
E
G
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5.1 Fuels, coolants and lubricants
Handling lubricants: Lubricants must always be handled properly as per manufac-
turer’s instructions.
QwW Improper handling is injurious to health, life, and environment. Lubricants
must be stored in adequate containers only. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
When filling in lubricants use clean containers only. It is prohibited to mix lubricants of different grades or qualities, except if mixing is expressively prescribed in these op- erating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of lubricants and binding agent is to be disposed of according to the regulations.
* Plus 2% additive 68 ID (order no. 50307735)
QwD The vehicles are delivered from the factory with "HLP D22" hydraulic fluid or
with "Plantohyd 22 S + 2 % additive 68 ID“ biodegradable hydraulic fluid. An oil change from "Plantohyd 22 S" biodegradable hydraulic fluid to "HLP D22" hydraulic fluid is not permitted. The same applies to an oil change from"HLP D22" hydraulic fluid to "Plantohyd 22 S" biodegradable hydraulic fluid. Furthermore, operation with a mixture of "HLP D22“ hydraulic fluid and "Plantohyd 22 S" biodegradable hydraulic fluid is not permitted.
Code Order no. Quantity Capacity Description Used for
A
51037497
51037494
1,32 gal
(5 l)
0,26 gal
(1 l)
approx.
8.72 gal (33 l)
HLP D22 including 2% additive share 68 ID
Hydraulic system
51085361*
1,32 gal
(5 l)
Plantohyd 22 S (biodegradable hydraulic fluid)
B 50022968
1.32 gal (5 l)
0.66 gal (2.5 l)
SAE 80 EP API GL4 Transmission
E
14038650
0.9 lbs
(400 g)
cartridge
---
Lithium grease KP2K-30
General
29201430
2.2 lbs (1 kg)
G 29201280
2.2 lbs
(400 ml)
---
Chain spray Tunfluid LT 220
Mast track, Lift chains
H 50157382
2.2 lbs (1 kg)
0.9 lbs
(400 g)
Lithium grease K3K-20
Front wheel bearings
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6 Maintenance and Repairs
QwW Load bearing parts of the truck, e. g. chassis and mast, may only be welded
after consultation with the manufacturer.
6.1 Preparing the truck for maintenance and repairs
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 securely (see section “Park the truck securely“ in Chapter E). – Disconnect the battery to prevent the truck from being switched on accidentally – When working under a raised lift truck, block, support and secure it to prevent it
from lowering, tipping or sliding away.
– Remove the electronic compartment cover at the back.
QwW When work has to be performed under the lifted load lifting device or truck,
suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the industrial truck, the instructions contained in chapter “Transportation and commissioning” have to be observed. Secure the truck against rolling away when you work on the parking brake.
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6.2 Securing the driver’s position carriage and mast
The driver’s position carriage can be secured in the raised position.
– Raise the driver’s position carriage until the
threads (1,2) for the retaining bolts are free.
– Unscrew the retaining bolts from the attach-
ment (3).
– Plug retaining bolts in vertical holes (1,2)
and tighten. Make sure that one of the flat sides of the retaining bolts is facing up.
– Very slowly lower the driver’s position car-
riage/mast until it is positioned on the retain- ing bolts.
NOTICE The thread (1) for the retaining bolt
only exists for the DZ mast.
6.3 Lift Chain Servicing
IMPORTANT It is important that all lift chains and pivots are at all times kept clean and well
lubricated. Only lubricate discharged chains. A chain must be lubricated with particular care where it passes over a deflection pulley. Lift chains are safety- critical parts. Chains should not have any significant contamination. They should only be cleaned with paraffin derivatives e. g. petroleum or diesel fuels. Never clean chains with steam jet high pressure cleaners, cold or chemical cleaning agents.
6.4 Inspecting the lift chains
Unauthorized wear and external damage:
In accordance with official regulations, a chain is considered to be worn if it has ex- tended in length by 3% in the section which passes over the deflection pulley. For safety reasons, we advise replacing chains when they elongate by 2%. Chains should also be replaced immediately when visible damage is noted, as such damage leads to permanent breakage after a certain time.
IMPORTANT If the truck is fitted with two lift chains, both chains must always be replaced.
This is the only way to ensure even load distribution over the two chains. When replacing chains the connecting bolts between the chain anchor and the chain must be replaced. Only new original parts may be used.
1
3
2
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6.5 Hydraulic oil
– Prepare the truck for maintenance and repairs
IMPORTANT Oil must never be allowed to enter the drainage system or the soil. Used oil
must be preserved until it can be disposed of in the correct manner.
IMPORTANT Only fill or drain hydraulic oil when the mast is completely lowered.
Remove the electronic compartment cover at the back.
Draining oil:
Suction off the hydraulic oil with the dis- charge filter removed (4). If this is not possible, the hydraulic oil can be drained from the bottom of the hydraulic reser- voir after the oil drain screw (6a) has been unscrewed.
Adding oil:
Screw in the oil drain screw (6a). Re- plenish with new hydraulic oil up to the Max. mark on the dipstick (7). Screw the discharge filter backon.
QwD Note carefully which hydraulic fluid should be used. If
"Plantohyd 22 S" biodegradable hydraulic fluid is to be used, the hydraulic tank will have the warning label: "Only use biodegradable hydraulic fluid" (6b). In this case, only "Plantohyd 22 S" biodegradable hydraulic fluid may be used to fill the hydraulic tank.
QwD An oil change from "Plantohyd 22 S" biodegradable hydraulic fluid to "HLP
D22" hydraulic fluid is not permitted. The same applies to an oil change from"HLP D22" hydraulic fluid to "Plantohyd 22 S" biodegradable hydraulic fluid. Furthermore, operation with a mixture of "HLP D22“ hydraulic fluid and "Plantohyd 22 S" biodegradable hydraulic fluid is not permitted.
Checking the hydraulic oil level
When the mast is fully lowered, check that the hydraulic oil level is between the min. and max. markings on the dipstick (7). If this is not the case, add new hydraulic oil.
6.6 Hydraulic hoses
Hose lines must be replaced every six years, see Safety Regulations for Hydraulic Hose Lines ZH 1/74.
4
6a
7
6b
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6.7 Checking electrical fuses
QwW Electric fuses must only be checked and replaced by authorized personnel.
– Prepare the truck for maintenance and repairs
(see chapter G). – Remove the electronic compartment cover at the back. – Check the fuse rating and condition in accordance with the table; replace if neces-
sary.
Item Description Current circuit Rating / type
8 1F11 Three-phase current drive control 250 A
9 3F10 Three-phase current steering control 35 A 10 2F15 Three-phase current hydraulic control 400 A 11 F2.1 DC/DC converter U1 input 48 V 48 V 10 A 12 5F1 Lighting and special equipment 48 V 48 V 10 A 13 F3.1 DC/DC converter U1 output 24 V 24 V 10 A 14 F1.2 DC/DC converter U16 input 48 V 48 V 4 A 15 5F2 DC/DC converter U16 output 24 V 24 V 6.3 A 16 1F3 Drive controller 1 A
89
10
11
12
16 15 14 13
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6.8 Recommissioning the truck after cleaning or maintenance work
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 / EMERGENCY switch for proper functioning. – Check the brake for correct functioning. – Grease the truck in accordance with the lubrication schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than one month (e.g. due to internal reasons), 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 de- tailed below.
IMPORTANT During decommissioning, the industrial 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 industrial truck is to be decommissioned for more than 6 months, additional measures 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
(see section “Hydraulic oil“ in chapter G). – Apply a thin film of oil or grease to all parts not protected by a paint coating. – Lubricate the fork lift truck according to the lubrication chart
(see section “Lubrication schedule“ in chapter G). – Recharge the battery (see section “Charge the battery“ in chapter F). – Disconnect and clean the battery. Apply pole grease to the battery poles.
NOTICE In addition to this, all instructions given by the battery supplier must be
observed.
– Spray all exposed electrical contacts with a suitable contact spray.
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7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (see section “Charge the battery“ in chapter F).
IMPORTANT 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 sulphation, this will result in the destruction of the battery.
7.3 Recommissioning the truck after decommissioning
– Thoroughly clean the fork lift truck. – Lubricate the fork lift truck according to the lubrication chart
(see section “Lubrication schedule“ in chapter G). – Clean the battery. Grease the pole screws using pole grease and reconnect the
battery. – Recharge the battery (see section “Charge the battery“ in chapter F). – 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 (see section “Starting up the truck“ in chapter E).
IMPORTANT Battery-operated fork lift trucks:
If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
QwW Perform several brake tests immediately after recommissioning the truck.
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8 Safety inspections at regular intervals and after exceptional events
NOTICE Carry out a safety check in accordance with national regulations.
Jungheinrich recommends checks in accordance with FEM Guideline 4.004 Jungheinrich offers a special safety service for inspections with appropriately trained employees.
The industrial truck must be checked at least once a year (take note of the national requirements) or after unusual events (e.g. after an accident) by a person especially qualified to do so. The inspector must deliver an appraisal and evaluation only from the point of view of safety, uninfluenced by operational and financial circumstances. He must demonstrate adequate knowledge and experience to be able to assess the condition of an industrial truck and the effectiveness of the safety equipment in ac- cordance with engineering rules and the principles for the inspection of industrial trucks.
A complete inspection must be performed of the technical condition of the industrial truck in reference to accident safety. The industrial truck must also be thoroughly ex- amined for damage that could be caused by any improper use. An inspection record must be compiled. The results of the inspection must be retained at least until the next but one inspection.
The owner must ensure that all defects are rectified without delay.
If the industrial truck does not meet the normal operating and/or safety criteria and it is impossible to restore it to a condition meeting the relevant standards, guidelines and regulations for safety at work, it must be scrapped. The dismantled components and the operating materials removed from the vehicle must be disposed of profes- sionally in accordance with applicable environment protection regulations.
NOTICE The manufacturer has established a special safety service for this purpose,
with specially qualified employees. As visual confirmation that the industrial truck has passed the safety inspection, a label is attached to the truck. This label shows the month and year in which the inspection must be repeated.
9 Final de-commissioning, disposal
NOTICE Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
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10 Troubleshooting
This chapter enables the user to identify and correct basic faults and the results of incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Action
Truck does not drive.
– Battery plug not con-
nected.
– Check the battery plug and connect if
necessary. – Safety gates open – Close the safety gates – EMERGENCY DIS-
CONNECT switch pressed
– Unlatch EMERGENCY DISCON-
NECT switch
– Key switch in “0” posi-
tion
– Set key switch to “I”
– Battery charge too low. – Check battery charge, charge battery
if necessary – Foot switch not
pressed
– Press foot switch
– Faulty fuse. – Check fuses. – Travel cutout activated – Press travel cutout override switch
(charge battery) – Travel cutout activated
via aisle end safety de- vice
– Set foot switch or travel button to
neutral and press it again.
– Chains slack – See “Slack Chain Safety Device
Override” section in Chapter E
Load cannot be lifted
– Truck not operational – Carry out all measures listed under
“Truck does not start” – Battery charge too low,
lift cutout
– Check battery charge, charge battery
if necessary – Chains slack – See “Slack Chain Safety Device
Override” section in Chapter E – Faulty fuse. – Check fuses
Rapid travel disabled
– Main lift raised beyond
0,5 m/ 0.5 yard (1.6 ft)
– Lower Main Lift to below 0,5 m/ 0.5
yard (1.6 ft) m – WG search mode acti-
vated
– Align truck or turn off WG mode
– No test run performed – Perform lifting and lowering
Truck cannot be steered
– Truck not operational – Carry out all measures listed under
“Truck does not start” – Narrow aisle mode
switch pressed
– Switch off narrow aisle travel function
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