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Jungheinrich
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ERC-Z14

Jungheinrich ERC-Z12, ERC 14, ERC-12, ERC-Z14, ERC 16 Operating Instructions Manual

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Page 1
Operating instructions
50126632
ERC/ERC-Z 12/14/16
G
10.01-
06.02
Page 2
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
f
Used before safety instructions which must be observed to avoid danger to personnel.
m
Used before notices which must be observed to avoid material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment. o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
Page 3
0108.GB
Page 4
I 1
0602.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 4
3.3 EN standards ...................................................................................... B 5
3.4 Conditions for application .................................................................... B 5
4 Location of instruction labels and identification labels ........................ B 6
4.1 Truck identification plate ..................................................................... B 7
4.2 Load capacity ...................................................................................... B 7
4.3 Load capacity, wheel-arm lifting device .............................................. B 8
4.4 Label/Order/Inventory/Service No. ..................................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 First commissioning ............................................................................ C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery type ......................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with stationary battery charger .......................... D 3
4.2 Recharging the battery with integrated battery charger (o) ................ D 4
5 Removing and installing the battery .................................................... D 7
5.1 Remove battery by lifting it upwards (truck without
wheel-arm lifting device) ..................................................................... D 7
5.2 Remove battery by lifting it upwards (truck with wheel-arm
lifting device) ....................................................................................... D 8
5.3 Lateral battery change (o) .................................................................. D 9
Page 5
0602.GB
I 2
E Operation
1 Safety regulations governing the operation of the fork lift truck .......... E 1
2 Description of controls and indicating instruments .............................. E 2
3 Starting up the truck ............................................................................ E 6
4 Operation of the fork lift truck .............................................................. E 8
4.1 Safety regulations applicable when operating the truck ...................... E 8
4.2 Driving, steering, braking .................................................................... E 9
5 Picking up and setting down loads ...................................................... E 12
5.1 Safe parking of the truck ..................................................................... E 16
6 Keyboard (CANCODE) (o) ................................................................. E 17
6.1 Functions ............................................................................................. E 17
6.2 Commissioning .................................................................................... E 18
6.3 Indicators ............................................................................................. E 19
6.4 Keys .................................................................................................... E 20
6.5 Master mode ....................................................................................... E 20
6.6 Parameter ........................................................................................... E 22
7 Display instrument (CANDIS) (o) ....................................................... E 26
7.1 Discharge monitor function ................................................................. E 27
7.2 Operating hours display ...................................................................... E 27
7.3 Switch-on test ...................................................................................... E 27
8 Fault location ....................................................................................... E 28
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ....................................................................... F 4
5 Lubrication schedule .......................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Notes on maintenance ........................................................................ F 8
6.1 Preparation of the truck for servicing and maintenance operation ...... F 8
6.2 Opening the front cover ....................................................................... F 8
6.3 Check hydraulic oil level ...................................................................... F 9
6.4 Check the transmission oil level .......................................................... F 9
6.5 Checking the electric fuses ................................................................. F 10
6.6 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check
according to VBG 36) .......................................................................... F 12
Page 6
A 1
0600.GB
A Correct use and application of the truck
A
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these oper- ating instructions and must always be heeded. National regulations are fully applica- ble.
The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these oper- ating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A “user” within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid- ered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the op- erating duties. The user must ensure that the truck is not abused and only used within its design lim- its and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
Page 7
0600.GB
A 2
Page 8
B 1
1001.GB
B Truck description
1 Application
The truck is an electric pedestrian stacker in four-wheel construction with foldable driver platform. It is designed for transporting and lifting goods on level ground. The wheel arm lift (on- ly for ERC-Z trucks) increases the ground clearance for transport over unevenground. Depending on the design, the hoist frame permits loads to be stacked and retrieved up to a max. height of 5.35 m and to be transported over longer distances. The truck capacity is indicated on the identification label or the capacity label Qmax. Due to its high travelling speed, the ERC 14/16 is equipped with safety extensions.
Truck types, capacities and motor output
Typ Capacity Motor output
ERC / ERC-Z 12 1,200kg 2.0kW
ERC / ERC-Z 14 1,400kg 2.0kW
ERC / ERC-Z 16 1,600kg 2.0kW
Page 9
1001.GB
B 2
2 Assemblies
*
)
not with vehicles with load bearing capacity of 1200kg
Item Designation Item Designation
1 o Keyboard
(CANCODE)
8 t Wheel arms
2 o Display instrument
(CANDIS)
9 o Lifting linkage (Only for wheel-arm-
lifting)
3 t Key switch 10 o Charger 4 t Control shaft 11 t Supporting wheel 5 t Controller 12 t Hinged driver standing platform 6 t Free-view hoist frame 13 t Driven wheel 7 t Master switch 14 o Safety extension*
)
t = Standard equipment o = Optional equipment
6
8
9
10
11
7
5
1
13
14
12
2
3
4
Page 10
B 3
1001.GB
3 Technical data - standard version
A
Indication of technical data according to VDI 2198, subject to modification and supplementing.
3.1 Performance data
Designation
ERC 12
ERC-Z12
ERC 14
ERC-Z14
ERC 16
ERC-Z16
Q Rated capacity 1,200 1,400 1,600 kg
c Load centre distance 600 600 600 mm
Travelling speed with / without rated load
6.0 / 6.0 7.5 / 8.5 7.0 / 8.5 km/h
Lifting speed with / without rated load (controllable (ZT))
19/26 18/26 17/26 cm/s
Lowering speed with / without rated load (controllable (ZT))
43/43 43/43 43/43 cm/s
Max. climbing capacity (5 min.) with / without rated load
9/16 8/16 7/16 %
167
188 428
983
h
14 min
b
1
h
14 max
h
1
h
2
h
3
h
5
h
13
s
b
5
500
b
11
a
/2
R
e
h
4
l
x
c
Q
m
2
l
2
y
l
1
A
st
a
/2
W
a
Page 11
1001.GB
B 4
3.2 Dimensions
(all dimensions in mm)
*
)
at DZ+35
**
)
at DZ+43
Designation
ERC 12/
ERC-Z12
ERC 14/
ERC-Z14
ERC 16/
ERC-Z16
l
2
Design length of front 856*)/888*
)
856*)/888*
)
856**)/888**
)
h
13
Height of fork when lowered 90 90 90 h
1
Design height
(depending on the mast)
1,700 - 2,600 1,700 - 2,600 1,700 - 2,600
h
2
Free lift (ZZ and DZ) 1,219 - 2,119 1,219 - 2,119 1,169 - 2,069 h
3
Lift (depending on the mast) 2,500 - 5,350 2,500 - 5,350 2,400 - 5,250 h
4
Extended height of mast
(depending on the mast)
2,981 - 5,831 2,981 - 5,831 2,931 - 5,781
h
5
Initial lift 122 122 122 y Wheelbase 1,357/1,599 1,357/1,599 1,357/1,599 B/b
1
Overall width 800/836 800/836 800/836 W
a
Turning radius 1,565/1,804 1,565/1,804 1,565/1,804 Ast Width of aisle with pallets
800 × 1,200 lengthwise
2,414*
)
/
2,483*
)
2,414*)/
2,483*
)
2,414**)/
2,483**
)
Ast Width of aisle with pallets
1,000 × 1,200 crossways
2,441*)/
2,565*
)
2,441*)/
2,565*
)
2,441**)/
2,565**
)
Dead weight
Refer to truck identification label
167
188 428
983
h
14 min
b
1
h
14 max
h
1
h
2
h
3
h5h
13
s
b
5
500
b
11
a
/2
R
e
h
4
l
x
c
Q
m
2
l
2
y
l
1
A
st
a
/2
W
a
Page 12
B 5
1001.GB
3.3 EN standards
Continuous sound level: 68 dB(A)
according to EN 12053 as stipulated in ISO 4871
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0.96 m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical pla- ne. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit va- lues for electromagnetic emission and interference im- munity as well as testing of static electricity discharge ac- cording to prEN 12895 and the references to other standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation: 5°C to 40°C
A
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5°C or in cold stores respectively with extreme temperatures or humidity changes.
Page 13
1001.GB
B 6
4 Location of instruction labels and identification labels
A
The capacity label (21) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded. The “CAUTION: Low-voltage electronics” warning signs (23) are visible after opening the corresponding hood (refer to chapter F).
Item Designation
15 Capacity (only ERC-Z)
16 Truck identification plate
17 Attachment point of hooks for transportation by crane
18 Prohibitive sign “Keep away from under the load lifting device”
19 Prohibitive sign “Do not reach through the hoist frame”
20 UVV control label
21 Capacity
22 Battery identification plate (located in battery compartment)
23 Label “CAUTION: Low-voltage electronics”
16
18
23
17
17
17
15
19
kg
kg mm kg
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
20
21
22
Page 14
B 7
1001.GB
4.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial No. (25) of the truck.
4.2 Load capacity
f
The label (21) includes a table indicating the loading capacity (Q in kg) in relation to the load centre distance (D in mm) and the lifting height (H in mm).
The arrow-shaped markings on the inner mast (37) and outer mast (38) show the driver when he has reached the lifting height limits that is defined on the load capacity label (21).
Item Designation Item Designation
24 Type 31 Drive power in kW 25 Serial No. 32 Customer no. 26 Rated capacity in kg 33 Min./max. battery weight in kg 27 Battery: Voltage V 34 Dead weight without battery in kg 28 Manufacturer 35 Year of manufacture 29 Order no. 36 Manufacturer logo 30 Load centre distance in mm
kg
kg mm kg
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
VkW
Xxxxxxxxx Xxxxxxxxxx
xxxxxxxxxx
xxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
24 25
26 27 28
29
31
35
34
33 32
30
36
-Nr.
Serien-Nr.
Dmm
Hmm
Q
kg
21
37
38
Page 15
1001.GB
B 8
4.3 Load capacity, wheel-arm lifting device
Trucks with a wheel-arm lifting device are provided with an extra label (15) indicating the permissible assignment to wheel-arm lifting device and main lifting device.
4.4 Label/Order/Inventory/Service No.
A
This label contains the Full Service No. and is only handed out when a service con- tract is being concluded.
Item Description
39 Order no. 40 Inventory No. 41 Full Service No.
39
40
41
Page 16
C 1
1001.GB
C Transportation and commissioning
1 Transportation by crane
f
Only use lifting equipment with sufficient bearing capacity (loading weight see identi- fication label on truck). If trucks are to be lifted that are provided with a wheel-arm lifting device, be careful not to protrude the lifting cylinders while the truck is being lifted. If the device is com- pletely protruded, there is the risk that the cylinder protection is being released due to overloading.
A
A hoisting point (2) is provided at the hoist frame for loading the truck with the help of hoisting gear. Trucks that are provided a with wheel-arm lifting device, have two more hoisting points (1) for loading.
– Park the truck and render it safe
(refer to chapter E).
– Attach the hoisting gear to the stop (2)
on the hoisting mast.
– In case of trucks that are provided with
a wheel-arm lifting device, the hoisting gear can also be attached to the stops (1) on the vehicle chassis.
m
Secure the hoisting gear to the hoisting points ensuring that the hoisting gear will not slip! The hoisting gear must be atta- ched in such a way that it does touch any add-on parts while the truck is being lif- ted. Trucks with wheel-arm lifting device must hang horizontally or slightly incli- ned in the direction of the lifting device.
2 First commissioning
m
The truck must only be operated on battery current. Rectified alternate current will da- mage the electronics. Cables connected to the battery (towing cable) must be less than 6 meters in length.
f
It is prohibited to hoist loads when the truck is operated via a towing cable with an external battery.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check whether the equipment is complete and in perfect condition. – If required, mount the battery, make sure not to damage the battery cable
(see chapter D).
2
1
Page 17
1001.GB
C 2
A
At trucks with an optionally built-in battery charger, adjust the characteristics (loading cam) (see chapter D).
– Load the battery (see chapter D). – If required, check whether the settings of the combined instrument correspond to
the battery (see chapter D).
– Commission the truck as prescribed
(see chapter E).
A
If the truck is parked for longer periods, the running surfaces of the wheels may be flattened. However, this flattening will disappear quickly when the truck is being driven.
3 Moving the truck with the drive unit inoperative
f
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as fol- lows:
– Set the master switch to position “OFF”. – Set the key switch to position “OFF” (“0”)
and remove the key.
– If a code lock is installed, the
o-key must be pressed.
– Ensure that the truck cannot accidentally
move.
– Open the front cover and set it down
(refer to chapter F).
– Slacken the lock nuts (3) and tighten the
screws (4).
The brake has now been released and the truck can be moved.
f
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition.
– Loosen the screws (4) by approx. 5 mm and lock by tightening the lock nuts (3).
The brake is now applied again.
– Mount the front cover.
3
3
4
Page 18
D 1
1001.GB
D Battery - Servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by qualified personnel. The instructions contained in this operating manual, and the instructions of the manufacturer of the battery and of the battery recharging station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery re- charging. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- minals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a non- skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- tional environmental protection regulations or waste disposal provisions. The manu- facturer’s specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be dama- ged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into con- tact with battery acid. Spilled battery acid must be immediately neutralized.
m
Only batteries with closed tray may be used.
f
Battery weight and dimensions have considerable influence on operational safety of the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.
Page 19
1001.GB
D 2
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:
For the battery weight, refer to the battery identification plate.
m
When changing / replacing the battery you must make sure that the battery is safely fastened in the battery compartment of the truck.
3 Exposing the battery
f
Park the truck and render it safe (refer to chapter E).
– Fold up battery hood (1).
f
Carefully open or close the battery hood.
– Installation is in the reverse order.
f
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
24V - 3PzSL - Battery 240Ah
24V - 3PzSL - Battery 270Ah
24V - 3PzSL - Battery 330Ah
2
1
Page 20
D 3
1001.GB
4 Charging the battery
As default, the truck is to be loaded with a stationary battery charger. The truck wit- hout wheel-arm lifting device can optionally be supplied with an integrated battery charger.
m
For recharging the battery, the truck has to parked in-doors in a sufficiently ventilated environment.
A
Charging condition display (refer to chapter E).
4.1 Charging the battery with stationary battery charger
– Park the truck and render it safe (refer to chapter E).
m
Connection / disconnecting battery connector and socket as well as pressing the ma- ster switch (2) may only be performed with truck and battery charger being switched off.
– Expose the battery (refer to section 3).
f
During the recharging operation the tops of the battery cells must be exposed to en- sure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed.
– Pull battery connector (3) from the plug and socket connection of the truck. – Remove insulation mat from battery, if necessary. – Connect the charging cable (4) of the battery recharging station with the battery
connector (3) and switch on the battery charger.
m
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
3
4
Page 21
1001.GB
D 4
4.2 Recharging the battery with integrated battery charger (o)
f
The battery charger must not be opened. If it is damaged, it has to be exchanged.
A
Due to safety reasons, intermediate positions are available between the regulation
positions “1” to “6” of the switch (7).
If the truck is delivered without battery, an intermediate position is pre-selected as de- fault. The red light-emitting diode (5) flashes - the battery cannot be recharged.
Select charging curve in the integrated battery charger
Use switch (7) at the battery charger to adjust the charging curves to the appropriate battery according to the following table.
m
The power plug must be pulled before the corresponding charging curve is to be ad- justed!
Provided that a battery is connected, a new setting can be acknowledged via the LEDs (cf., indicator) which will then be immediately effective.
Position of switch (7) selected charging curves (characteristics)
1 Wet batteries: 100 - 330 Ah 2 Maintenance-free: 100 - 140 Ah 3 Maintenance-free: 150 - 200 Ah 4 Maintenance-free: 210 - 300 Ah 5F r e e 6F r e e
6
7
5
Page 22
D 5
1001.GB
Adjusting the charging curve
The charging curve can be adjusted by performing the following steps:
Starting the recharging process with integrated battery charger
– Park the truck and render it safe (refer to chapter E).
f
During the recharging operation the tops of the battery cells must be exposed to en- sure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed.
Mains supply
Line voltage: 230 V (+10/-15%) Line frequency: 50 Hz / 60 Hz
The power plug (8) of the battery charger can be found in the battery compartment.
– Expose the battery (refer to section 3). – Remove insulation mat from battery, if necessary. – Pull out master switch (2) (position “ON”). – Connect power plug (8) with a power socket.
Connect the battery This permits to use the battery
charger as an adjustment aid
Turn the adjustment switch to the right (i.e. clockwise) until it touches the limit stop.
The red LED flashes fast no valid
charging curve sel- ected
Turn the adjustment switch to the left (i.e. anticlockwise) until it touches the limit stop.
After 3 seconds the green LED flashes only once
charging curve 1 selected
Select the desired charging curve by turning the adjust- ment switch to the right
The red LED starts to flash in the intermediate positions. If a valid charging curve is sel- ected, the green LED starts to flash in the relevant switch po- sition.
8
Page 23
1001.GB
D 6
A
The master switch (2) may only be operated with truck and battery charger being swit- ched off.
The flashing LED indicates the charging status and/or a fault (flashing codes see ta- ble “LED display”).
A
If the power plug (8) is connected to the mains, all electric functions of the truck are interrupted (electric driving lock). No operation of the truck is possible.
– Pull plug (8) from the power socket and place it in the battery compartment.
A
The recharge procedure is automatically continued after a power failure. The recharge procedure can be interrupted by pulling the power plug and can be con- tinued in steps.
f
The mains cable must not be damaged. Before commissioning the truck, the battery hood must be properly closed.
Charging times
The time required for recharging depends on the capacity of the battery.
LED display
Fill-up charge
The fill-up charge begins automatically after the recharge procedure has ended.
Partial recharging
The battery charger is designed in such a way that it automatically adapts to the char- ging status of partially recharged batteries. This permits to reduce wear and tear of the battery.
Green LED (6)
(charging
status)
Red LED (5)
(fault)
Indication
is lit --- Recharge procedure is finished; battery is full.
(charging break, fill-up charge or equalization charge)
flashes slowly --- Charging process
flashes fast --- Indicates the start of a recharge procedure or that a
new charging curve was adjusted. The number of the flashing pulses corresponds to the adjusted charging curve.
--- is lit Excess temperature. Recharge process is interrup- ted.
--- flashes slowly Safety charging interval exceeded. Recharge pro- cess is interrupted. Disconnection from the mains is required for restarting the charging process.
--- flashes fast charging curve setting is invalid.
--- --- Power failure and/or no battery connected.
Page 24
D 7
1001.GB
5 Removing and installing the battery
– Expose the battery (refer to section 3).
f
The truck must stand horizontally. Batteries with exposed terminals or connectors must be covered with a rubber mat to prevent short-circuits. Place battery connector and battery cable in such a way that they do not get caught within the truck interior when the battery is pulled out.
f
When replacing batteries, ensure that a battery of the same type is fitted. Supplemen- tary weights may not be removed or changed in their position.
f
After reinstallation of the battery, visually check all leads and connectors for damage. Before commissioning the truck, the battery hood must be properly closed.
A
When changing the battery with the aid of a lifting gear, ensure that the lifting gear is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The battery must be lifted vertically to prevent crushing of the battery trough. The hooks are to be attached to the battery hoisting ears (9) that they cannot fall onto the battery cells when the hoisting gear is released.
5.1 Remove battery by lifting it upwards (truck without wheel-arm lifting device)
– Withdraw the battery connector. – Attach hoisting gear to the hoisting ears (9). – Lift out the battery.
The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.
9
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D 8
5.2 Remove battery by lifting it upwards (truck with wheel-arm lifting device)
– Withdraw the battery connector (3).
f
The battery cable of the truck must be laterally led outside. While removing the bat- tery, make sure that the cable is not squeezed.
– Attach hoisting gear to the hoisting ears (9). – Lift out the battery.
The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.
39
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1001.GB
5.3 Lateral battery change (o)
– Withdraw the battery connector. – Pull the locking mechanism (12) of the battery cover upwards while firmly holding
the battery cover (13). – Lift out the battery cover (13) and keep it in a safe location. – Position battery trolley next to the truck. – Push cautiously battery (11) from the truck onto the battery trolley / battery change
station.
f
Be careful not to place your fingers between partition wall of the truck and the battery. Heed the operating instructions of the battery change station.
Mounting the battery:
– Insert battery up to battery stop (10). – Press in the battery stop and keep it in that position. – Pull battery into the truck.
The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.
13
12
11
10
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D 10
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E 1
0602.GB
E Operation
1 Safety regulations governing the operation of the fork lift truck
Driving permission: The fork lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his re- presentative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork lift truck du- ring working time. He must forbid unauthorised persons to drive or operate the fork lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork lift truck or on the attach- ments must immediately be brought to the notice of the person in charge. fork lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also inclu- des the area within reach of falling loads or falling / lowering truck attachments.
f
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork lift truck must immediately be brought to a standstill if persons, although as- ked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
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E 2
2 Description of controls and indicating instruments
Item Controls or
indicating instrument respectively
ERC12ERC
14/16
ERC-Z
12/14/16
Function
1 Keyboard
(CANCODE)
oo oCode settings
Travel programme enable
2 Display instrument
(CANDIS)
oo oOperating hours meter
Battery capacity display Shows the residual capacity of
the battery as well as the accumulated operating hours of the truck.
3 Key switch tt tSwitches control voltage on
and off. Removing the key secures the truck against switching on by unauthorised personnel.
4 Control shaft tt tSteering and braking the truck.
5 Button - warning
signal (horn)
tt tTrigger warning signal.
6 Button - wheel arms
lowering
-- tWheel arms are lowered
with constant speed
7 Button - wheel arms
lifting
-- tWheel arms are lifted
with constant speed
8 Driving regulator tt tControls the driving direction
driving speed.
9 Bumper safety switch tt tPedestrian-controlled operati-
on: Safety function, which causes the vehicle to move for about 3 secs in drive direction “R”
(Backward) and then switches
off until the controller is briefly moved to the neutral position. Ride-on mode: Non-functional.
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8
67
5 5
9
1
17
4
14
13
12
15
16
2
3
Page 31
0602.GB
E 4
*
)
only at ERC-Z 14/16
Pos. Controls or
indicating instrument respectively
ERC12ERC
14/16
ERC-Z
12/14/16
Function
10 Button -
Lifting the lifting device
tt t Lifting the lifting device.
The lifting speed can be conti- nuously adjusted with this key (adjustment range 8 mm).
11 Button -
Lowering the lifting de- vice
tt t Lowering the lifting device.
The lowering speed can be continuously adjusted with this key (adjustment range 8 mm).
12 Terminal strip tt t Depositing of freight docu-
ments.
13 Master switch
(Emergency Stop)
tt t The circuit is interrupted, all
electric functions are switched off. The truck is compulsory braked.
14 Control lamp at the
battery charger
oo Indicates the loading states
(see chapter D).
15 Integrated battery char-
ger
oo Used for recharging the batte-
ry.
16 Hinged driver standing
platform
tt t Pedestrian-controlled operati-
on: Driver standing platform in fol-
ded- up position: =>Truck travelling speed is li-
mited to 6.0 km/h.
Stand-on operating mode: standing platform serves as deadman's switch function:
Unweighted standing platform in folded-down position: =>travelling function blocked.
Standing platform in folded- down position, driver stan- ding on platform: =>travelling function rleased.
17 Hinged safety extensi-
ons
-
tt*
)
The travelling function is blok- ked if the safety extensions are not folded out when the standing platform is folded down.
t = Standard equipment o = Optional equipment
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8
67
5 5
9
1
17
4
14
13
12
15
16
2
3
Page 33
0602.GB
E 6
3 Starting up the truck
f
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
The electronic driving and steering systems automatically control their functions. If an error or fault occurs, the driving and steering functions are stopped.
f
Before the truck is restarted, it is required to perform the relevant troubleshooting ac- tions.
Checks and operations to be performed before starting daily work
– Visually check the entire truck (especially the wheels and the load lifting device) for
visible damage. – Check the steering play. – Visual inspection of cable connection. – Switch for safety switching height (18), visually inspect its cable connections and
magnetic fastening.
f
Do not operate the controller (8) when climbing on the truck.
.
18
18
8
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0602.GB
Switching on the truck
– Pull up the master switch (13). – Insert the key in the key switch (3) and turn the key clockwise towards the “I”
position until reaching the stop. – When a code lock is installed, you must enter an operator code
(refer to section 6.6). – Check the horn (5) for correct functioning.
A
The combination instrument (CANDIS (o) (2)) shows the available battery capacity.
f
When swivelling the driver’s standing platform (16) upwards, do not reach between the driver’s standing platform and the truck’s side wall.
– To initialise the truck, actuate the controller (8) once while the driver’s standing plat-
form (16) is folded up. – Check the service and counter-current brake for correct functioning
(refer to section 4.2).
The truck is now ready for operation.
5
1
16
13
2 3
8
Page 35
0602.GB
E 8
4 Operation of the fork lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially alloca-
ted for truck traffic must be used. Unauthorized persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local con- ditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must al- ways observe an adequate braking distance between the fork lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permit- ted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork lift truck driver has to sa- tisfy himself accordingly before driving into lifts or on to loading platforms. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift together with the fork lift truck must only enter the lift after the fork lift truck has come safely to a standstill, and must leave the lift before the fork lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carria- ge, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
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4.2 Driving, steering, braking
f
Be extremely careful when driving and steering, especially when parts of the body protrude from the truck contour.
Emergency cut-out
– Depress the master switch (13).
This will switch off all electric functions. The truck is compulsory braked.
Emergency stop
When the control shaft (4) is released, the truck is automatically braked (emergency stop). The control shaft will automatically move into the upper braking range (B).
f
If the control shaft is sluggish in moving into the braking range, the cause must be established and eliminated. If necessary, the return spring must be replaced.
B
4
13
Page 37
0602.GB
E 10
Driving
f
When swivelling the driver’s standing platform (16) upwards, do not reach between the driver’s standing platform and the truck’s side wall.
There are three different travelling modes:
– Pedestrian-controlled operation:
Swivel the safety extensions (17)*
)
inwards and then fold up
driver platform (16). – Ride-on mode:
Fold down driver platform (16). – Ride-on mode with increased speed:
Swivel the safety extensions (17)*
)
outwards and then fold down
driver platform (16).
A
The travelling function is blocked if the driver is not standing on the platform and the safety extensions* are not folded out.
*
)
not with vehicles with load bearing capacity of 1200kg
f
Do not drive the truck unless the hoods are closed and locked in the stipulated man- ner. When passing through swing doors, or similar, take care that the anti-collision button (1) is not inadvertently operated.
– Start up the truck (refer to section 3). – Swivel the control shaft (4) into driving range “F”. – Turn the controller (8) in the desired travelling direction: forward (V) or reverse (R).
The truck will move in the selected direction.
A
The travelling speed is controlled by means of the controller (8).
R
R
V
V
F
B
B
8
4
17
16
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0602.GB
Driving up an incline
m
The load must be transported facing the incline!
Safety measures against “rolling down” of the truck: With the controller (8) set to neutral, the service brake is automatically applied after a brief jolt (the controller detects the truck’s rolling down on an incline). The controller (8) is used to release the service brake; the speed and driving direction are set as desired.
m
When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.
Steering
f
In narrow bends, the driver will be positioned at the outer contours of the truck.
– Swivel the control shaft (4) to left or right.
The position of the control shaft corresponds to the position of the steered driven wheel.
Electrical steering
The electric steering system is self-monitoring.
The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switching the truck off and on again. This method pre- vents the cancellation of a fault without eliminating the fault.
Braking
f
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The truck may be braked in three ways:
– either by counter-current braking (controller (8))
– or by means of the service brake (control shaft (4)) – or by using the generator brake (coasting)
f
In case of emergencies, the truck must only be braked using the service brake
(control shaft (4)).
m
During normal operation, the generator brake and counter-current braking should be applied. These methods of braking reduce wear and require less energy (energy recovery).
Page 39
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E 12
Braking by means of the service brake:
– Swivel the control shaft (4) into one of the braking ranges “B” or release the control
shaft altogether.
The drive motor will then be braked by means of the motor brake.
A
When the control shaft is released, it will automatically swivel into the upper braking range “B”. When the truck is parked, the motor brake will act as a parking brake.
Counter-current braking
– Setting the controller (8) to the opposite drive direction while travelling.
The truck is braked by counter-current until it starts moving into the opposite direction.
A
The braking effect depends on the setting of the controller.
Braking by means of the generator brake (coasting)
– Release the controller (8) - controller in home position (“0”).
Depending on the setting, the truck is braked by the generator braked, coasting to a stop.
A
The degree of speed reduction can be set by the manufacturer service.
m
When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.
5 Picking up and setting down loads
f
Before picking up a load, the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded. Do not grab into the hoist frame during lifting and lowering.
– Pass the fork tines as far as possible under the load. Picking up long loads cross-
wise is not permitted.
m
Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm).
A
In the case of the double-lift dual mast (ZZ) and the double-lift triple mast (DZ), the initial lift of the load carriage (free lift), without any changes to the design height, is provided by a short, centrally arranged free-lift cylinder.
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0602.GB
Lifting and lowering
Lifting
– Press the “Lift the lifting device”
button (10) until the desired height
has been reached.
Lowering
– Press the “Lower the lifting de-
vice” button (11) until the desired
height has been reached.
A
The lifting/lowering speed can be continuously adjusted with this button (adjustment range 8 mm).
Small button adjustment range = slow lifting / lowering Large button adjustment range = fast lifting / lowering
– Avoid any abrupt lowering of the load unit.
Safety switching height
For lifting starting at approx. 1.8 m:
– Lifting stop depends on the safety frame setting
(refer to switching matrix / safety switching height). – “Locking” the support roller (the lifting hydraulics acts on the support roller cylinder
with a noticeable alignment of the truck). – Travel speed reduction above the safety switching height. – Lowering the wheel-arm lift above the safety switching height.
1110
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E 14
Switching matrix / safety switching height
ERC / ERC-Z 12
ERC / ERC-Z 14/16
*
)
Sh = Safety switching height approx.1,800 mm (depending on lifting mast version)
**
)
optionally travelling (4.3 km/h) and lifting with the safety frames folded out above 1,800 mm in conjunction with a load guard is possible.
Platform Lifting
height
Speed (km/h)
with load
Collision guard button
active
Lifting
functions
active
Folded up <Sh *
)
4.3 Yes Yes
Folded up >Sh *
)
4.3 Yes Yes
Folded out <Sh *
)
6.0 No Yes
Folded out >Sh *
)
4.3 No Yes
Platform Safety
frame
Lifting height
Speed (km/h)
with load
Collision guard button
active
Lifting
functions
active
Folded upFolded in<Sh *
)
4.3 Yes Yes
Folded upFolded in>Sh *
)
4.3 Yes Yes
Folded upFolded
out
<Sh *
)
0NoNo
Folded upFolded
out
>Sh *
)
0NoNo
Folded
out
Folded in<Sh *
)
6,0 No Yes
Folded
out
Folded in>Sh *
)
4,3 No Yes
Folded
out
Folded out
<Sh *
)
7.5 / 7.0 No Yes
Folded
out
Folded out
>Sh *
)
0 **
)
No No **
)
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0602.GB
Wheel-arm lifting device (only ERC-Z) (t)
A
The “Lift wheel arms” and “Lower wheel arms” can be used to perform the lifting or lowering movement with a fixed speed.
f
To ensure the stability of the truck, the wheel arms will be automatically lowered from a specific lifting height of the fork onwards, depending on the used hoist frame type. From this lifting height onwards, the wheel-arm lifting device can no longer be used. The lowering movement cannot be interrupted! (Danger of injuries)
Lifting the wheel arms
– Press the “Lift wheel arms” (7) button.
Keep the button pressed, until the desi-
red lifting height has been reached.
Lowering the wheel arms
– Press the “Lower wheel arms” (6) but-
ton. Keep the button pressed, until the
desired lowering height has been rea-
ched.
Emergency lowering
f
No other personnel is allowed in the danger zone when using emergency lowering.
If the lifting device cannot be lowered due to a failure of the lifting controller, the emergency lowering procedure must be performed.
– Set key switch (3) in position “0” and
push master switch (13) to position
“OFF”. – Unplug the battery plug
(refer to chapter D). – Open front hood (refer to chapter F). – Loosen the screw at the valve block
(19).
A
The hex socket wrench required (2.5 mm) is attached to the valve block.
The lifting device is lowered.
– After emergency lowering, fully screw
in screw (19) again.
Setting the truck to operation after removing the fault.
67
19
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E 16
5.1 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
f
Do not park the truck on slopes! The load lifting device must always be completely lowered.
– Park the truck on level ground. – Completely lower the fork. – Set the key switch (3) to position “0”
and remove the key from the
switch. – If a code lock is installed, the o-key
must be pressed. – Set the master switch (emergency
cut-out) (13) to position “OFF”. – Fold in hinged safety extensions
(only with vehicles with a load bearing capacity of 1400 kg and 1600 kg).
f
When swivelling the driver’s standing platform upwards, do not reach between the driver’s standing platform and the truck’s side wall.
17
13
16
3
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0602.GB
6 Keyboard (CANCODE) (o)
The keyboard is provided with a key switch function. It is equipped with a 10-key numeric keypad and two special keys. After entering the correct code the control circuit is switched on.
6.1 Functions
The keyboard can only administer one master code and 600 operator codes. It is possible to assign a unique code to each truck. Only operator who know this code can use the truck. Alternatively, you can assign a unique code to each driver. All operator codes that are to be enabled for this truck must be stored in the keyboard.
A
When shipped to the customer one operator and one master code is factory-set (2580 and 7295).
m
Change the master and operator codes when setting the truck into operation for the first time!
All possible codes are preset to one length (4, 5, or 6 digits). The length of the operator code is predefined by the length of the master code. The code is automatically checked after the corresponding number of keys is pressed.
The travel parameters for the operating mode can only be adapted in master mode. Moreover, the master mode permits setting the battery type and the special functions.
Page 45
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E 18
6.2 Commissioning
After switching on the master switch and the key switch the LED (20) lights up steady red also during operation.
If the keyboard is used as code switch, the control circuit switches on after entering the correct operator code (factory-set to 2580). LED (20) now lights up steady green.
When an incorrect code has been entered, LED (20) light up red for two seconds. After that you can enter a new code.
The travel programme (travel speed, deceleration and acceleration intensity are set) is activated, which is indicated by the greed LEDs (22, 23,42) on key 1, 2, or 3.
Set key (21) has no function in operating mode.
The control circuit is switched off by actuating the o-key (25). To switch on again, re-enter the code.
Switching off by o-key, key switch, or automatically, if the truck is not used for a preset time (automatic switch-off after a period between 10 seconds and 30 minutes can be activated in master mode).
1 2 3
4 5 6
7 8 9
0
Set
22
21
20
25
2423
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0602.GB
6.3 Indicators
Status displays of the individual LEDs
– steady (red) – steady (green) – flashing red – flashing green –off
Keyboard error messages
The following errors are indicated by a red flashing LED:
– New master code is already operator code. – New operator code is already master code. – Operator code to be changed does not exist. – Tried to change the operator code to an existing code. – Operator code to be deleted does not exist. – Code memory full.
LED (20) steady (red) Truck off (not ready for operation)
steady (green) Truck on (operating mode)
flashing red Truck with error message
flashing green Truck on (master mode)
LED (22) steady (green) Travel programme
flashing green Code change: old code, input
LED (23) steady (green) Travel programme
flashing green Code change: new code, first input
LED (24) steady (green) Travel programme
flashing green Code change: new code,
confirmation
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E 20
6.4 Keys
o-key (25)
The o-key (25) is always active and has the highest priority. It is used to set the truck from any state to the basic state (truck switched off and not ready for operation) and vice versa. It is exclusively used for switching off or resetting the truck.
Set key (21)
No function for the operator. In master mode, the entered values are confirmed by the Set key.
Numeric keys
Keys 1, 2, 3, 4, 5, 6, 7, 8, 9, 0 are used for entering codes.
6.5 Master mode
Parameter changes must be made carefully and only by trained personnel. Changing the parameters results in changed travel behaviour of the truck. Changes are only saved when DIL switch no. 8 on the controller is set to “ON”. To enter the master mode, the following is required:
– o-key (if in operating mode), – enter master code.
Enter a parameter number and confirm with Set key (21).
If an invalid input is entered (LED (20) flashes red) you return to the basic state of the master mode by actuating Set key (21). Enter a new parameter number and confirm with Set key (21).
The following example show the setting of the acceleration parameter (parameter
101) in the travel programme.
Display instrument
(CANDIS)
LED (20) LED (22) LED (23) LED (24)
Operating hours are indicated
284.9
green
flashing
off off off
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0602.GB
Acceleration example
After entering parameter number 101 and pressing the Set key, the current value 6 is read out and displayed
Change the value to 8 and confirm with Set key (21).
Display instrument
(CANDIS)
LED (20) LED (22) LED (23) LED (24)
current setting is displayed
101 6
green
flashing
off off off
changed setting is displayed
101 8
green
flashing
off off off
Parameter
number
Parameter
setting
value
Page 49
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E 22
6.6 Parameter
Parameter groups
The parameter number is composed of three digits. The first digit designated the parameter group according to table 1. The second and third digits are sequentially numbered from 00 to 99.
No. Parameter group 0xx Code lock settings
(Codes, travel programme enable, automatic switch-off, etc.)
1xx Travel programme
(Acceleration, coasting brake, speed, etc.)
4xx Programme-independent parameters
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0602.GB
Truck parameter list
LED 22-24 are located in the key pad fields 1-3.
No. Function Range
Setting value
Default Setting
value
Comments
Code lock - internal
000 Change master code
The length of the master code determines the length of the operator code. As long as operator codes have been programmed, only new codes with the same length can be entered. If the code length is to be changed, all operator codes must be deleted first.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 22 flashes) Enter the current
code
confirm (Set)
(LED 23 flashes)
Enter a new code
Confirm (Set)
(LED 24 flashes)
Repeat new code
Confirm (Set)
001 Add operator code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 23 flashes)
Enter a code
Confirm (Set)
(LED 24 flashes)
Repeat the code
entry
Confim (Set)
002 Change operator code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 22 flashes) Enter the current
code
Confirm (Set)
(LED 23 flashes)
Enter a new code
Confirm (Set)
(LED 24 flashes)
Repeat the code
entry
Confirm
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E 24
No. Function Range
Setting value
Standard
Setting
value
Comments
Code lock - internal
003 Delete operator code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 23 flashes)
Enter a code
Confirm (Set)
(LED 24 flashes)
Repeat the code
entry
Confirm (Set)
004 Clear code memory
(deletes all operator codes)
3265 3265 = delete
other entry = do not
delete
010 automatic switch-off 00 - 31 00 00 = none
Switch-off
01 to 30 =
Switch-off time in
minutes
31 = Switch-off in 10
seconds
030 Display of assigned
operator codes
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0602.GB
No. Function Range
Setting value
Standard
Setting
value
Comments
Travel programme
101 Acceleration 0 - 9 6 102 Coasting brake with
enable
0 - 9 6
104 Drive direction:
Maximum speed
0 - 9 6
105 Drive direction:
Pedestrian controller speed
0 - 9 6
108 Fork direction:
Maximum speed
0 - 9 6
109 Fork direction: Pedestrian
controller speed
0 - 9 6
Programme-independent parameters
411 Battery type (normal/high-
power/dry)
0 - 2 0 0 = Normal (wet)
1 = High-power (wet)
2 = Dry (maintenance-free)
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E 26
7 Display instrument (CANDIS) (o)
The instrument indicates:
– Battery discharge condition
(LED bars (27)),
– Operating hours
(LC display (29)).
In addition, error messages of the electronic components and parameter changes are displayed.
Discharge status indication
Depending on the battery type set, switch-on limits for the additional “Warning” (26) and “Stop” (28) indicators may result.
Numb
er
Bars
Charging
condition
Wet battery Maintenance-free battery
LED (yellow)
Warning
LED (red)
Stop
LED (yellow)
Warning
LED (red)
Stop
10 90.1- 100% Off Off Off Off
9 80.1 - 90% Off Off Off Off
8 70.1 - 80% Off Off Off Off
7 60.1 - 70% Off Off Off Off
6 50.1 - 60% Off Off Off Off
5 40.1 - 50% Off Off On Off
4 30.1 - 40% Off Off On On
3 20.1 - 30% On Off On On
2 10.1 - 20% On On On On Avoid falling below the 20% limit for wet batteries resp. 40% limit for maintenance-free batteries.
26
27
28
29
Page 54
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7.1 Discharge monitor function
With the discharge monitor function enabled, the lifting function switches of when reaching the discharge limit (the Stop LED switches on). Travelling and lowering is still possible. For wet batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. At 30% resp. 50% the batteries should be recharged (the yellow LED lights up as warning indication).
7.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting movements are logged. This is a backlit display.
A
For maintenance-free batteries a “T” symbol is shown in the display.
Error messages
The operating hours display is also used for indicating errors. The display shows a “C” for a component and then a three-digit component number. When an error occurs, an “E” is shown with a three-digit error number. If several errors occur they are displayed one after the other. Errors are displayed as long as they persist. The operating hours display is overwritten with an error message. Most errors cause the emergency stop to be triggered. The error display is maintained until the control circuit is switched off (key switch).
A
The service personnel has access to detailed component descriptions and error codes.
Display for parameter changes (travel programmes)
The parameter numbers are shown in the display. This is done in conjunction with the keyboard (CANCODE). The display has the format “PPPVVV”. “P” is the parameter number, “V” is a value. After a few seconds the display is overwritten again by the operating hours display.
7.3 Switch-on test
After switching on the display shows:
– the software version – the operating hours – the charging condition
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8 Fault location
This chapter helps the operator to locate and fix simple malfunctions or the results of operating errors him- or herself. The order of the work stated in the table must be ob- served for fault location.
A
If it is not possible to rectify the fault by performing the indicated “remedial actions”, please contact the Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
Fault Possible cause Remedy
Truck does not move
– Battery connector
not connected
– Check the battery connector
and reconnect it, if necessary – Master switch (EMERGENCY
STOP) pressed
– Release master switch (EMER-
GENCY STOP) – Key switch in position “0”. – Set the key switch to position
“I”. – No driver on folded-out plat-
form, lifting and travel function not active
– Stand on folded-out platform
– Battery voltage too low – Check the charging status of
the battery and recharge, if ne-
cessary – Control shaft not swivelled into
driving range (F)
– Swivel control shaft into driving
range (F) – Faulty fuse – Check fuses F1 and 1F1 – Truck battery charger is con-
nected
– Disconnect the truck battery
charger from the mains
Load cannot be lifted
– Truck not operative. – Perform all troubleshooting
measures that are mentioned
under “truck does not drive”
– refer to switching matrix / safety
switching height – No driver on folded-out plat-
form, lifting and travel function not active
– Stand on folded-out platform
– Hydraulic oil level too low – Check hydraulic oil level – Faulty fuse – Check fuse 2F1 – load too high – Pay attention to the maximum
bearing capacity (see identifi-
cation label) – Discharge monitor is triggered
(STOP icon)
– Check the charging status of
the battery and recharge, if
necessary
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F Maintenance of the fork lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To en- sure safe and reliable operation of the fork lift truck, only spare parts of the manufac- turer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tip- ping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork lift truck. Prior to commencing cleaning operations, all safety measures that are re- quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope- rated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com- pressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
m
If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis- sioning” must be performed.
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F 2
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork lift trucks, the truck must also be depowe- red by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components, these have to be removed from the fork lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. The factory-mounted tyres must only be replaced by original spa- re parts of the manufacturer, since otherwise the specification of the data sheet cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubri- cation is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy- draulic components, also renew the hoses in this hydraulic system.
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1001.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork lift truck. The neglect of regular servicing intervals can lead to fork lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large tem- perature fluctuations or multiple-shift operation, the servicing intervals must be shor- tened accordingly.
The following servicing checklist indicates the operations to be performed and the re- spective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week M3 = every 500 operating hours, but at least every 3 months M6 = every 1000 operating hours, but at least every 6 months M12 = every 2000 operating hours, but at least every 12 months
A
The W1 maintenance intervals must be carried out by the operator / customer.
In the running-in phase of the truck, the following additional operations have to be car- ried out:
After the first 50 - 100 hours of operation, at least after 2 months:
– Tighten pole screws of battery and check condition of the cell connectors. – Perform visual inspection of the electronic and mechanic components. – Check lift chains for equal tension. – Check arresting and limitation of the fork tines. – Check transmission for leakages. – Check screw connections and mechanical safety retentions for tight fit. – Check the wheel nuts for security and retighten, if required. – Change all hydraulic oil filters. – Check the hydraulic connections for leakages and retighten, if required. – Check glide pieces at mast and adjust, if necessary.
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F 4
4 Maintenance checklist
Maintenance intervals
Standard = t WMMM Cold-storage depot = k 13612
Chassis/ Design:
1.1 Check all load bearing elements for damage t
1.2 Check all bolted connections t
1.3 Check platform for correct functioning and damage t
Drive unit: 2.1 Check the transmission for noises and leakage t
2.2 Check the transmission oil level t
2.3 Change the transmission oil lt
Wheels: 3.1 Check for wear and damage t
3.2 Check the wheel bearings for correct fasteninga) lt
Steering: 4.1 Check the steering wheel play t
4.2 Check the steering chain and chain sprocket for wear, adjust and grease
lt
4.3 Check mechanical parts of steering column and grease, if required
t
Brake system:
5.1 Performance and adjustment check t
5.2 Check the brake linings for wear t
5.3 Check the brake linkage; adjust and grease, if necessary lt
5.4 Gas pressure spring (tiller shaft) to reset function, check for tightness and damages
t
Hoist frame: 6.1 Visual inspection of rollers lt
6.2 Check fork tines and fork carrier for wear and damage lt
6.3 Check secure attachment of hoist frame t
6.4 Check lift chains and chain guide for wear, adjust and grease them.
t
6.5 Check the lateral clearance of the mast profiles and whether they are parallel to each other
t
6.6 Check safety devices for proper attachment and damages
lt
Lifting de- vice:
7.1 Check function, wear and tear and adjustment t
7.2 Visual check of rollers, slide pieces and stops lt
7.3 Check fork tines and fork carrier for wear and damage lt
Hydr. system: 8.1 Check function kt
8.2 Check all connections for leakage and damage b) kt
8.3 Check hydraulic cylinders for leakage, damage and secure attachment
kt
8.4 Check the oil level kt
8.5 Change hydraulic oil c) kt
8.6 Change filter t
8.7 Check the pressure relief valves for correct functioning kt
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a) First check of the wheel nuts after approx. 100 operating hours for tight fit. Re-tighten if
necessary. For starting torque, see maintenance plan.
b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours;
tighten, if necessary.
c) 1. exchange after 500 hours of operation / if required, change coarse sieve.
A
The maintenance intervals refer to normal service conditions. If you are working un- der difficult conditions, reduce the intervals, if required.
Maintenance intervals
Standard = t WMMM Cold-storage depot = k 13612
Electr. system:
9.1 Check function t
9.2 Check all cables for secure connection and damage t
9.3 Check the fuses for correct amperage t
9.4 Check switches and trip cams for proper functioning and seating
t
9.5 Check contactors and relays, replace wearing parts, if necessary
t
9.6 Check functioning of warning devices and safety circuits kt
Electric motors:
10.1 Check wear of carbon brushes t
10.2 Check the motor for secure attachment t
10.3 Suck out engine block, check wear of collector kt
Battery: 11.1 Check acid density, acid level and cell voltage lt
11.2 Check the terminals for secure attachment and apply pole grease
lt
11.3 Clean battery connections, check for tight fit lt
11.4 Check the battery cables for damage and replace, if necessary
t
11.5 Check the battery lock for proper functioning t
Lubrication service:
12.1 Grease truck according to lubrication schedule lt
General mea- surements:
13.1 Check electrical system for short to ground t
13.2 Check driving speed and braking distance t
13.3 Check lifting and lowering speed t
13.4 Check safety facilities and switch-off devices t
Demonstrati- on:
14.1 Perform a trial run under a nominal load t
14.2 Demonstrate the truck to a person charged with inspec- tion upon completion of the maintenance of the truck
lt
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F 6
5 Lubrication schedule
g Slide faces s Grease nipple
Filler neck for hydraulic oil
b Filler neck Gear oil a Drain plug Gear oil
Cold store usage 1.25l - 1.3l;
1)
Mixing proportion for application in cold-storage depots 1:1
2)
only ERC-Z
3)
Filling level see “Check hydraulic oil level”
4)
1.25l - 1.3l; depending on the drive type (always up to the lower edge of the filler neck).
a
b
B
1,25 - 1,3 l
MA = 105 Nm
B+C
1)
3)
4)
G
G
A A+C
1)
2)
Eg F
g
EF
s
E
ERC/Z
F
s
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1001.GB
5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type ma- terials must be stored in adequate containers. They might be inflammable and, the- refore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualitiies resp., except if mi- xing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be dis- posed of according to the regulations.
Grease Data
Code Order-no. Supply Qty Designation Used for:
A 29 200 670 5,0 l H-LP 46, DIN 51524 Hydraulic system B 29 200 680 5,0 l CLP 100, DIN 51517 Transmission
C 29 200 810 5,0 l H-LP 10, DIN 51524 Transmission,
hydraulic system E 29 201 430 1,0 kg Grease, DIN 51825 Lubrication F 29 200 100 1,0 kg Grease, TTF52 Lubrication
G 29 201 280 0,4 l Chain spray Chains
Code Saponification Dropp.
point °C
Worked penetr.
at 25° C
NLG1 class Service tempe-
rat. °C
E Lithium 185 265-295 2 -35/+120
F -- -- 310-340 1 -52/+100
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6 Notes on maintenance
6.1 Preparation of the truck for servicing and maintenance operation
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
– Park the truck and render it safe (refer to chapter E). – Disconnect the battery connector to prevent accidental or unauthorised truck ope-
ration.
f
When working under raised forks or the raised vehicle, they should be secured so that the possibility of them dropping, tipping or slipping is excluded. When the vehicle is raised, the instructions in the Chapter ”Transport and commissioning” must also be observed. The vehicle should be secured against rolling away before doing any work on the ser- vice / parking brakes.
6.2 Opening the front cover
Truck equipped with hinged driver standing platform:
– Fold down the stand-on platform (1) and fold out safety frame (2).
General:
– Unscrew screws (3) with a hex. socket wrench (socket width 8) (Key (4) in battery
compartment).
– Lift front hood (3), remove it from the truck and keep it in a safe place. – Installation is in the reverse sequence of operations.
f
Drive only with closed and properly locked hoods!
1
2
3
4
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6.3 Check hydraulic oil level
– Prepare the truck for servicing and maintenance operations (refer to chapter F, sec-
tion 6.1). – Open the front hood (see section 6.2). – Check the hydraulic oil level of the hydraulic tank (see section 5).
A
There are markings on the hydraulic tank (see section 5). The oil level must be chek- ked with the lifting device being lowered.
– If required, top up with hydraulic oil with the required characteristics
(see section 6.3; see table).
A
Mounting is performed in reverse order.
6.4 Check the transmission oil level
– Prepare the truck for servicing and maintenance operations (see section 6.1). – Open the front hood (see section 6.2). – Loosen 2 x screws (3) using the key (4). – Check gear-oil level - oil level must reach the filler neck
(see section 5). – If required, top up with gear oil with the required characteristics (see section 5.1). – Mounting is performed in reverse order.
Marking Litre Lifting heights (h
3
)
ZT ZZ DZ
4 ca. 8,3 --> 5300 3 ca. 8,0 - > 4100 < 5300 2 ca. 6,8 > 3100 > 2800 - 1 ca. 5,1 < 3100 < 2800 -
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6.5 Checking the electric fuses
– Prepare the truck for the performance of servicing and maintenance operations
(refer to section 6.1). – Open the front cover (refer to section 6.2). – Check all fuses for correct ratings and possible damage according to the table and
exchange them, if required. – Mount the front cover (refer to section 6.2).
Item Description Protection of: Value
5 F1 Total control fuse 10 A 6 1F1 Drive motor (in parallel to 1F10) 150 A 7 2F1 Pump motor 150 A 8 1F10 Drive motor (in parallel to 1F1) 40 A 9 6F1 Discharge indicator/operating hour meter 10 A
9
8
7 6
5
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6.6 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
– Check the horn for proper functioning. – Check the master switch for correct functioning. – Check the brake for correct functioning. – Lubricate truck according to lubrication schedule. – Refer to chapter “Starting up the truck”.
7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be par- ked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
m
During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional mea- sures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck. – Check the brakes for correct function. – Check the hydraulic oil level and top up if required (refer to chapter F). – Apply a thin film of oil or grease to all parts not protected by a paint coating. – Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F). – Recharge the battery (refer to chapter D). – Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
m
Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
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7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck. – Lubricate the fork lift truck according to the lubrication chart (refer to chapter F). – Clean the battery. Grease the pole screws using pole grease and reconnect the
battery. – Recharge the battery (refer to chapter D). – Check if the gear oil contains condensed water and change if required. – Check if the hydraulic oil contains condensed water and change if required. – Start up the fork lift truck (refer to chapter E).
A
Battery-operated fork lift trucks: If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork lift truck has to be chek- ked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experi- enced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the in- spection of fork lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects. Apart from this, the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with specially qualified staff. As visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to it. This plaque indicates in which month of which year the next test will be due.
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