SilverStone EPT20-20RA, EPT20-20RAS, EPT20-20RAE Operation Manual

Foreword
Thanks for your purchasing our pallet truck. This manual is about how to use, operation and maintenance EPT20-20RA/
EPT20-20RAS/EPT20-20RAE. Please operator and whom in charge of the truck must read the manual carefully before operate the truck.
We have the right to improve the truck, maybe there are some difference between
your product and the description in this manual.
Whedealerknow.
WARNING!
TO PREVENT SETIOUS RISK OF INJURY TO
YOUORSELF AND OTHERS OBSERVE THE
FOLLOWING SAFETY INSTRUCTIONS.
These truck may become hazardous if adequate maintenance is neglected. Therefore, adequate maintenance facilities, trained personnel and procedures should be provided.
Maintenance and inspection shall be performed in conformance with the following practices:
1. A scheduled planned maintenance,lubrication and inspection system should be followed.
2. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust, and inspect truck.
3. Before leaving the truck: – Do not park the truck on an incline. – Fully lower the load forks. – Set the key switch to the "OFF" position and remove the key.
4. Before starting to operate truck: – Be in operating position – Place directional control in neutral – Before operating truck, check functions of lift systems, directional control,speed control,steering, warning devices and brakes.
5. Avoid fire hazards and have fire protection equipment present. Do not use open flame to check lever, or for leakage of electrolyte and fluids or oil. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.
6. Brakes,steering mechanisms, control mechanisms,guards and safety devices shall be inspected regularly and maintained in legible condition.
7. Capacity, operation and maintenance instruction plates or decals shall be maintained in legible condition.
8. All parts of lift mechanisms shall be inspected to maintain them in safe operating condition.
9. All hydraulic systems shall be regularly inspected and maintained in conformance
with good practice. Cylinders, valves and other similar parts shall be checked to assure that "drift" has not developed to the extent that it would create a hazard.
10. Truck shall be kept in a clean condition to minimize fire hazards facilitate detection of loose or detective parts.
11. Modifications and additions which affect capacity and safe truck operation shall not be performed by the customer or user without manufacturers prior written approval. Capacity, operation and maintenance plates or decals shall be changed accordingly.
Catalog
Correct use and application
1. Truck Description
..............................................................................................................
3
1.1Application
...................................................................................................................
3
1.2 Assemblies
.................................................................................................................
4
1.2.1Control Handle
.................................................................................................
5
1.2.2Key switch
.........................................................................................................
5
1.2.3Battery discharge indicator
............................................................................
6
1.2.4Emergency brake switch
................................................................................
6
1.3 Identification points and data plates
.......................................................................
7
1.3.1Truck data plate
...............................................................................................
8
1.4.Standard Version Specifications
.............................................................................
9
1.4.1Performance data for standard trucks
..........................................................
9
1.4.2Dimensions
.....................................................................................................
10
2.Transport and Commissioning
.....................................................................................
14
2.1Transport
...................................................................................................................
14
2.2Using the Truck for the First Time
..........................................................................
14
2.3During brake-in
.........................................................................................................
15
3.Operation
...........................................................................................................................
16
3.1Safety Regulations for the Operation of pallet Trucks
........................................
16
3.2 Operate and run the truck
......................................................................................
17
3.2.1 Preparing
.......................................................................................................
17
3.2.2 Travel
.............................................................................................................
17
3.2.3Lifting, transporting and depositing loads
..................................................
20
3.2.4Parking the truck securely
............................................................................
21
4.Battery Maintenance & Charging
.................................................................................
22
4.1 Safety regulations for handling acid batteries
.....................................................
22
4.2 Battery type & dimension
.......................................................................................
22
4.3Charging the battery
................................................................................................
23
4.3.1Exposing the battery
.....................................................................................
23
4.3.2 Charging
........................................................................................................
23
4.4Battery removal and installation
.............................................................................
24
4.5Battery maintenance
................................................................................................
24
4.6Battery Disposal
.......................................................................................................
25
5.pallet Truck Maintenance
...............................................................................................
26
5.1Operational safety and environmental protection
................................................
26
5.2Maintenance
Safety
Regulations
...........................................................................
26
5.3Servicing and inspection
.........................................................................................
28
5.3.1Maintenance Checklist
.................................................................................
29
5.3.2 Lubrication Schedule
...................................................................................
31
5.3.3 Maintenance Instructions
............................................................................
32
5.4Decommissioning the industrial truck
...................................................................
35
5.4.1Prior to decommissioning
.............................................................................
35
5.4.2 Restoring the truck to operation after decommissioning
........................
35
5.5Safety checks to be performed at regular intervals and following any unusual incidents
..........................................................................................................................
36
5.6Final de-commissioning, disposal
..........................................................................
36
6.Troubleshooting
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37
2
Correct use and application
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full. The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.
Proprietor responsibilities
For the purposes of the present operator manual the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual. Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
Attaching accessories
The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer’s Approval.
3
1. Truck Description
1.1Application
The truck is a tiller operated electric pallet truck with a folding operator platform and side arms. The truck is designed for lifting and transporting goods on a level surface. The truck can pick up, outside the load wheel area, open bottom or diagonal board pallets as well as roll cages . The capacity of the truck is shown on the data plate or the data capacity plate Qmax.
4
1.2 Assemblies
Item Description Item Description
1 Travel switch 7 Caster wheel
2 Tiller 8 Drive wheel
3 Key switch 9 Folding operator platform
4 Battery discharge indicator 10 Ram protection
5 Emergency brake switch 11 Side arm
6 Side arm
5
1.2.1Control Handle
1.2.2Key switch
Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.
12
“Lower” button Lowers load forks.
13
“Lift” button Raises load forks.
14
Travel switch Controls the driving speed and direction
15
Warning signal button
Triggers a warning signal.
16
Collision safety switch
Safety function which, when activated, forces the truck to reverse until the switch restored to neutral.
6
1.2.3Battery discharge indicator
The LEDs (1) represent battery residual capacity, The LCD (2) displays the operating hours
Battery Discharge Indicator(1)
When the truck has been released vi
a
the key switch, the battery charg
e
status is displayed. The colours of the LEDs (1) represen
t
the following conditions:
LED colour value
Green Standard battery residual capacity 70-100%
Orange Standard battery residual capacity 50-60%
Flashing Red Standard battery residual capacity 0-20%
Battery Discharge for 70%, A flashing red show on storage battery charge warning. Battery Discharge for 80%, Two flashing reds show on battery charge used up warning, Lifting is now inhibited. The battery must be charged.
Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is a backlit display.
Power up test
On power up the display shows: – the operating hours – the charge status
1.2.4Emergency brake switch
The supply current is interrupted, all electrical functions are deactivated and the truck is automatically braked.
7
1.3 Identification points and data plates
Item
Description
1 Logo decal
2
Decal hook-up caution
3
Hook decal
4
Plate data
5
Decal operation warning
6
AC power decal
8
1.3.1Truck data plate
Item Description Item Description
1 Manufacturer 6 Fork length˄mm
˅
2 Model name 7 (Recommendation) Battery capacity˄Ah
˅
3 Type 8 Net weight w.o. battery˄kg
˅
4 Rated capacity˄kg
˅
9 Serial no.
5 Fork width(mm)
For queries regarding the truck or ordering spare parts always quote the truck serial number (9).
MODEL NUMBER EXAMPLE
EPT
20 – 20 R A
Electric pallet truck AC Power
Run
Capacity: 20=2000 kg
9
1.4.Standard Version Specifications
Technical specification details in accordance with JB/T3773.1-84. Technical modifications and additions reserved.
1.4.1Performance data for standard trucks
Item Description
EPT20-20RA EPT20-20RAS EPT20-20RAE
Unit
Q
Load capacity
2000 2000 2000 kg
C Load center 600 600 600 mm
Travel speed
laden 7.5 7.5 5.5 km/h
unladen 8.5 8.5 6.0 km/h
Lifting speed
laden 0.056 0.056 0.051 m/s
unladen 0.060 0.060 0.060 m/s
Lowering speed
laden 0.057 0.027 0.032 m/s
unladen 0.057 0.027 0.039 m/s
Maximum grade ability S
2
5 min.
laden 8 8 6 %
unladen 16 16 8 %
Service brake
Electromagnetic Electromagnetic Electromagnetic
Service weight
Incl. battery 670 670 545 kg
Axle loading, laden
operator/load side
1066/ 1604 1066/ 1604 üü
kg
Axle loading, unladen
operator/load side
546/ 124 546/ 124 üü
kg
Motor rating power
Drive 1.5 1.5 1.1 Kw
Lift 2.2 2.2 0.8 Kw
Tyre type PU/PU PU/PU PU/PU
Tyre size, operator side Ɏ230×75
Ɏ230×75 Ɏ230×75
Tyre size, load side Ɏ85×70
Ɏ85×70 Ɏ80×60
Balance wheels (dimensions) Ɏ130×60
Ɏ130×60 Ɏ85×48
Battery
Type Industry battery Industry battery Industry battery
voltage/rated capacity
24/210
24/210 2×12/150
V/Ah
weight 190
190 2×54
kg
Sound level at operator's ear
74
74 70
dB(A)
10
1.4.2Dimensions
Item Description
EPT20-20RA EPT20-20RAS EPT20-20RAE
Unit
X
Load distance (Raised/ Lowered)
916/ 982 937/ 1003 978 946 mm
Y
Wheelbase 1420 1440
1420 1374 mm
h3 Lift height 125 125 120 mm
b11
Tread
load side
370/ 515
370/ 515 390 mm
h13
Fork height
lowered 85 85 85 mm
h14
Height of tiller arm in operating position
min 1150 1150 1150 mm
max 1470 1470 1470 mm
l1 Overall length
1860 1930
1860 1828 mm
l2
Length to face of forks 710
710 586 mm
b1
Overall width 730
730 734 mm
s
Fork dimensions
Thickness 55 55 55 55 55 mm
e Width 170 170 170 170 150 mm
l Length 1150 1220 1150 1220 1150 mm
b5 Fork spread 540/ 685 540/ 685 540/ 685 mm
m2
Ground clearance
35 50 50 mm
Wa Outer turning radius
1700 1725 1700 1725
1553 mm
Ast Aisle width
1000×1200 pallet crossways
2034 1984 1807 mm
800×1200 pallet lengthways
2084 2184 2007 mm
11
EPT20-20RA
12
EPT20-20RAS
13
EPT20-20RAE
14
2.Transport and Commissioning
2.1Transport
Lifting the truck by crane
There are two way to pack the truck: on
e
is use a stock, the other is use a box. Th
e
way to pick up depend on transport.
1.Only use crane handling equipmen
t
gear with sufficient capacity.
2.Loading weight > net weight of truck (
+
battery weight for electric trucks).Loading weight not only net weight of truck bu
t
also the stock or the box.
3.Stock (box) should be big enough and strong enough to bear hole truck. – Park the truck securely.(see 3.2.4 Parking the truck securely on page 21).
Make sure forks are positioned properl
y
for the pallet. Move forward slowly t
o
insert forks into the pallet as far a
s
possible and then stop the truck.
2.2Using the Truck for the First Time
Only operate the truck with battery current. Rectified AC current will damage the electronic components. Cable connections to the battery (tow leads) must be less than 6 m . Preparing the truck for operation after delivery or transport Procedure
Check the equipment is complete.Check the hydraulic oil level.Install the battery if necessary (where required), (see "4.4 Battery removal and
installation" on page 24) do not damage battery cable.
Charge the battery, (see "4.3 Charging the battery" on page 23).
When the truck is parked the surface of the tyres will flatten. The flattening will disappear after a short period of operation.
Warning
To avoid break the fork be hurt when you move the truck to stock. In order to keep the truck out of be scraped,please move the truck void in
void and flat place. – when you lowering the stock advert status of the place to avoid collapse.
15
2.3During brake-in
We recommended operating the machine under light load conditions for the first stage of operation to get the most from it. Especially the requirements given below should be observed while the machine is in a stage of 100 hours of operation.
1. Must prevent the new battery from over discharging when early used.
Please
charging when remain power less than 20%.
2. Perform specified preventive maintenance services carefully and c.ompletely.
3. Avoid sudden stop, starts or turns.
4. Oil changes and lubrication are recommended to do earlier than specified.
5. Limited load is 7080% of the rated load.
16
3.Operation
3.1Safety Regulations for the Operation of pallet Trucks
Driver authorisation: The pallet truck may only be used by suitably trained personnel,
who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities: The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual . The driver shall be afforded all due rights . Safety shoes must be worn with pedestrian operated trucks.
Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. He shall prevent unauthorised persons from driving or operating the truck. It is forbidden to carry passengers or lift personnel.
Damage and Faults: The supervisor must be immediately informed of any damage or faults to the pallet truck. Trucks not safe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the pallet truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches.
Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or owering operating equipment.
Unauthorised persons must be kept away from the hazardous area. Where there is anger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed.
17
3.2 Operate and run the truck
3.2.1 Preparing
Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.
Checks and operations to be performed before starting daily work
– Visually inspect the entire truck (in particular wheels and load handler) for obvious damage. – Visually inspect the battery attachment and cable connections.
Switching on the truck
– Make sure the switch is depressed. – Insert the key in the key switch and turn it to the right as far as it will go ( position “ON”) – Test the warning button .
The truck is now operational. The battery discharge indicator indicates the existing battery charge status. – Test the braking operation of the tiller.
3.2.2 Travel
We distinguish between two travel modes:
Truck with a folding operator platform and moving tiller.
Do not reach between the operator platform and the truck panel when you fold up the platform.
– Pedestrian mode:
Push the side arms in, fold up the operator platform (1). The truck can only be
operated at the reduced travel speed.
– Rider mode:
Push the side arms out, fold down the operator platform (1). The truck can be
operated at maximum speed.
18
General:
– Set the tiller (5) to the travel zone (F). – Turn the controller (4) to the required direction (fwd. or rev.).
If the side arms are not folded out,the truck can only be operated at reduced speed. Do not drive the truck unless the panels are closed and properly locked.When travelling through swing doors etc. make sure that the doors do not activate the collision safety button (3).
19
Steering
In narrow bends the driver extends beyond the geometry of the truck. – Move the tiller (5) to the left or right.
Braking
The brake pattern of the truck depends largely on the ground conditions. The driver must take this into account when operating the truck.
The truck can brake in three different ways: – by plugging – by using the operating brake – with the emergency brake switch (Emergency Disconnect)
Plugging:
– When travelling, set the controller (8) to the opposite direction. The truck brakes regeneratively until it starts to move in the opposite direction.
The rate of braking depends on the position of the controller.
Braking with the service brake:
– Set the tiller (5) to one of the brake zones (B). The drive motor brakes regeneratively ( motor brake ) . Only when this brake fails to achieve the necessary brake force is the mechanical brake ( magnetic brake) applied.
When the truck is idle the magnetic brake (magnetic brake) applies. When the tiller is released it reverts to the upper braking zone (B).
Braking with the Emergency brake switch:
– Pull Emergency brake switch (11) up. The circuit is interrupted , all electrical functions are cut out and the truck automatically brakes (magnetic brake).
Switching Speed Mode:
– Put side arm (2) down. Controller start the mode of half speed.
ES20-20RAE(E Series) does not have the function.
20
3.2.3Lifting, transporting and depositing loads
Unsecured and incorrectly positioned loads can cause accidents
g
Instruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave th
e
hazardous.
g
Only carry loads that have been
correctly secured and positioned. Us
e
suitable precautions to prevent parts o
f
the load from tipping or falling down.
g
Do not transport witch bad
handbarrow ( as truck and stock ) .
g
Never stand underneath a raised load handler.
g
Do not stand on the load handler.
g
Do not lift other people on the load handler.
g
Insert the forks as far as possible underneath the load.
Lift
Press “Lift” button(8) until the height you need.
Lower
Press “Lower” button˄7˅until the lowest position.
Warning!
Before lifting a load unit the driver must make sure that it has been correctly stowed and does not exceed the truck’s capacity. Do not lift long loads at an angle.
Warning!
Don't lift to tiptop, to avoid shorted life of oil cylinder.
21
3.2.4Parking 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.
– Do not park the truck on an incline. – Fully lower the load forks. – Set the key switch to the "OFF" position and remove the key. –Drawing back the emergency brake switch . – Fold in the folding side arm Do not reach between the operator platform and the truck panel when you fold up the folding platform.
22
4.Battery Maintenance & Charging
4.1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries.
Maintenance personnel :
Batteries may only be charged, serviced or replaced by trained personnel .The present operator manual and the manufacturer ’s instructions concerning batteries and charging stations must be observed when carrying out the work.
Fire protection :
– Smoking and naked flames must be avoided when working with batteries. – Wherever a truck is parked for charging there shall be no inflammable material or operating fluids capable of creating sparks within 2 metres around the truck. – The area must be well ventilated. – Fire protection equipment must b
e
provided.
Protection against electric shock:
– Battery has high voltage and energy. – Do not bring short circuit. – Do not approach tools to the two poles of the batteryˈwhich can cause the sparkle.
4.2 Battery type & dimension
Battery type & dimension as follow :
Truck type Battery type
voltage/ rated
capacity
Battery height
(mm)
Battery length
(mm)
Battery width
(mm)
ES20-20RA
ES20-20RAS
Industry battery 24/210
540 650 200
ES20-20RAE
Industry battery
2×12/150 241 483 170
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
23
4.3Charging the battery
4.3.1Exposing the battery
Park the truck securely .
Drawing back the emergency brak
e
switch (3). Lift up the battery panel (1) using th
e
grip mould (2) and fold it back.
4.3.2 Charging
Safety regulations for Charging the battery
– To charge the battery, the truck must be parked in a closed and properly ventilated room. 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. – Forbid add water to battery directly. – Before start and finish charging t
o
make sure power is turn OFF. – It is essential to follow the safet
y
regulations of the battery and charging station manufacturers.
Charging step
Check whether the condition i
s
according with "Safety regulations fo
r
Charging the battery". – Park the truck securely(See 3.2.4 Parking the truck securely Page21 ). – Remove the battery plug (4).
Connect the battery plug (4) with th
e
charging lead of the stationary charger (5
)
and turn on the charger.
Warning!
Before closing the battery cover make sure that the battery lead cannot be damaged.
24
4.4Battery removal and installation
When transporting batteries using a crane ensure that the crane is of adequat
e
capacity ( the battery weight i
s
indicated on the battery data plate on th
e
battery container) . The crane lifting gea
r
must exert a vertical pull. The hooks of th
e
lifting gear must never fall into the batter
y
cells.
– Expose the battery (see Section 3). – Remove the battery connector (3). – Strap the crane lifting gear to the eyes (8). –Drawing back the emergency brake switch.
Installation is the reverse order . When reinstalling the battery , note the proper installation position and make sure the battery is connected correctly.
– After installing the battery again , check all cables and plug connections for visible signs of damage.
Close the battery panel carefully and slowly. Do not reach between the battery panel and the chassis.
4.5Battery maintenance
Do not overuse battery:
– If you use up the energy of battery till the pallet immovability, you will shorten its working hours. – Shower for battery appears need for chargeˈplease charge it quickly.
Inspection for electrolyte:
– Do not using pallet which is absent electrolyte. – Inspection for electrolyte level every week. – When electrolyte level is lowˈyou must add distilled water to the level appointed.
Battery maintenance:
The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease.Batteries with non insulated terminals must be covered with a non slip insulation mat.
25
Warning!
1. Do not use dry cloth or fibre cloth to clean the batteryˈavoiding static to bring the explosion.
2. Unfixing battery plug.
3. Cleaning with wet cloth.
4. Wearin
g
g
lasses fo
r
p
rotectingeyes rubberovershoes and rubbe
r
g
love.
4.6 Battery Disposal
Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws.The manufacturer’s disposal instructions must be followed.
Batteries contain an acid solution which is poisonous and corrosive . Therefore , always wear protective clothing and eye protection when carrying out work on batteries . Above all avoid any contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected parts should be rinsed with plenty of clean water-where the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.
Only batteries with a sealed battery container may be used.
The weight and dimensions of the battery have considerable affect on the operational safety of the truck. Battery equipment may only be replaced with the agreement of the manufacturer.
26
5.pallet Truck Maintenance
5.1Operational safety and environmental protection
The servicing and inspection operations contained in this chapter must be
performed in accordance with the intervals indicated in the servicing checklists.
Any modification to the pallet truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the pallet truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturerÿs specialist department.
Upon completion of inspection and servicing, carry out the activities listed in the
Ā
Recommissioning (on page 34)āsection.
5.2Maintenance Safety Regulations
Maintenance personnel
Industrial trucks must only be serviced and maintained by the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
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 jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath a raised load handler if it is supported by a sufficiently strong chain.
Cleaning
Do not use flammable liquids to clean the industrial truck. Prior to cleaning, all safety measures required to prevent sparking (e.g. through short circuits) must be taken. For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies. If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
27
and electronic components must be carefully covered beforehand as moisture can cause malfunctions. Do not clean with pressurised water. After cleaning the truck, carry out the activities detailed in the “Recommissioning (on page 34)” section.
Electrical System
Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid
electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.
Welding
To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.
Settings
When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.
Tyres
The quality of tyres affects the stability and performance of the truck. When replacing factory fitted tyres only used original manufacturer’s spare parts, as otherwise the data plate specifications will not be kept. When changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing wheels always left and right simultaneously).
Lift chains
Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.
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5.3Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts. The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as: W = Every 50 service hours, at least weekly A = Every 500 operating hours B = Every 1000 operating hours, or at least annually C = Every 2000 operating hours, or at least annually W service intervals are to be performed by the customer. In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.
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5.3.1Maintenance Checklist
ֱݏ䯈䱨
Standard
˙ ƾ
Cold Store
˙ ƿ
W A B C
Brake 1.1 Check magnetic brake air gap.
ƾ
Electrics 2.1 Test instruments, displays and control
switches.
ƾ
2.2 Test warning and safety device.
ƿ ƾ
2.3 Check fuse ratings.
ƾ
2.4 Make sure wire connections are secure and check for damage.
ƾ
2.5 Test micro switch setting.
ƾ
2.6 Check contactors
ƾ
2.7 Frame leakage test ƾ
2.8 Test cable and motor attachments.
ƾ
2.9 Check carbon brush wear, replace if
necessary.
ƾ
Power
supply
3.1 Visually inspect battery ƿ ƾ
3.2 Check battery cable connections are secure,
grease terminals if necessary.
ƿ ƾ
3.3 Check acid density, acid level and battery
voltage.
ƿ ƾ
Travel 4.1 Check motor suspension.
ƾ
4.2 Check the transmission for noise and
leakage.
ƾ
4.3 Replace gear oil if service life exceeded
(10,000 hours).
4.4 Check travel mechanism, adjust and
lubricate if necessary.
Check tiller recuperating function.
ƿ ƾ
4.5 Check wheels for wear and damage.
ƿ ƾ
4.6 Check wheel bearings and attachments. ƾ
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Truck
design
5.1 Test the operator’s platform and check for
damage.
ƾ
5.2 Check chassis for damage and screw
connections.
ƾ
5.3 Check labels.
ƾ
Hydraulic operation
6.1 Check operation, wear and setting.
ƾ
6.2 Check forks for wear and damage. ƾ
6.3 Test hydraulic system.
ƿ ƾ
6.4 Check that hose and pipe lines and their
connections are secure, check for leaks and
damage.
ƿ ƾ
6.5 Check cylinders and piston rods for damage
and leaks, and make sure they are secure.
ƿ ƾ
6.6 Check hydraulic oil level.
ƿ ƾ
6.7 Replace hydraulic oil filter.
ƿ ƾ
6.8 Replace hydraulic oil.
ƿ ƾ
6.9 Check wheels for wear and damage. ƾ
Agreed
performan
ce
levels
7.1 Lubricate truck in accordance with
Lubrication Schedule.
ƿ ƾ
7.2 Test run ƾ
7.3 Demonstration after servicing
ƾ
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5.3.2 Lubrication Schedule
32
Fuels, coolants and lubricants
Handling consumables: Consumables must always be handled correctly. Follow the
manufacturer’s instructions.
Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Instructions.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent/consumable mixture must be disposed of in accordance with regulations.
Code Description Used for
A HM46# Hydraulic system
B Grease, Polylube GA352P Lubrication
C GL-85W-90 Gear case
5.3.3 Maintenance Instructions
Prepare the truck for maintenance an
d
repairs
All necessary safety measures must b
e
taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: – Park the truck securely (See 3.2.4 Parking the truck securely Page 21 ). – Draw back the emergency brake swich to prevent the truck from accidentall
y
starting. – When working under a raised lift truck, secure it to prevent it from tipping or slidin
g
away.
33
Removing the front panel
Trucks with folding operator platform: – Fold down the operator platform (1). – Remove the four screws (2). – Lift off the panel (3) and place it next to the truck. When the work is finished, closed the panel (3).
Replacing the drive wheel
The drive wheel must only be replaced by authorised service personnel.
Checking the hydraulic oil level
– Prepare the truck for maintenance and repairs (see section 6.1). – Opening the front panel (see Section 6.3). – Check hydraulic oil level in hydraulic reservoir .
If necessary, add hydraulic oil of the correct grade up . (for hydraulic oil specification, see Section 5).
Check transmission oil level
– Prepare the truck for maintenance and repairs (See 5.3.3 Maintenance Instructions Page32). – Remove the front panel . – Turn the control handle to the right limited pisition. – Check the transmission oil level, it should be at the control plug level (See 5.3.2 Lubrication Schedule Page31). – If necessary add transmission oil of th
e
correct grade . Installation is the reverse order.
Warning!
Forbid adding transmission oil within impurity.
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Checking electrical fuses
– Prepare the truck for maintenance and repairs (See 5.3.3 Maintenance Instructions Page32 ). – Dismantle the front panel. – Check rating of all fuses in accordance with table, replace if necessary.
Item To protect: Rating
1
Traction / Lift motor
Fuse
200A
2 Controller Fuse 10A
Recommissioning
The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed. – Test horn. – Test Emergency brake switch. – Test brake. – Lubricate the truck in accordance with the maintenance schedule.
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5.4Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months , e.g. foroperational reasons,it must be parked in a frost-free and dry location and allnecessary measures must be taken before, during and after decommissioning as described. On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged. If the truck is to be out of service for more than 6 months , further measures must be taken in consultation with the manufacturer’s service department.
5.4.1Prior to decommissioning
– Thoroughly clean the truck. – Check the brakes. – Check the hydraulic oil level and replenish as necessary (See 5.3.3 Maintenance Instructions Page32 ). – Apply a thin layer of oil or grease to an
y
non-painted mechanical components. –Lubricate the truck in accordance with th
e
maintenance schedule (See 5.3.2 Lubrication Schedule P31). – Charge the battery (See 4.3Charging th
e
battery P23). – Disconnect the battery, clean it and apply grease to the terminals. In addition, follow the batter
y
manufacturer’s instructions. – Spay all exposed electrical contacts with a suitable contact spray.
5.4.2 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck. – Lubricate the truck in accordance with the maintenance schedule (See 5.3.2 Lubrication Schedule P31 ). – Clean the battery, grease the terminals and connect the battery. – Charge the battery (See 4.3Charging the battery P23). – Check transmission oil for condensed water and replace if necessary. – Check hydraulic oil for condensed water and replace if necessary. – Start up the truck (see 3.2.2Operate and run the truck P17).
If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly. Perform several brake tests immediately after re-commissioning the truck.
Warning
ʽ
Charge every months: – Charge the battery. Battery powered trucks: The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the batter
y
.
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5.5 Safety checks to be performed at regular intervals and following any
unusual incidents
Carry out a safety check in accordance with national regulations. EP has a special safety department with trained personnel to carry out such checks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of pallet trucks.
A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified. A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.
5.6Final de-commissioning, disposal
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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6.Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Action
Truck does not start.
– Battery connector not connected
ˉ Key switch in “0” position ˉBattery charge too low
ˉFaulty fuse ˉ
Truck in charge mode
– Check the battery connector and connect if necessary. – Set key switch to “I” – Check battery charge, charge battery if Necessary – Test fuses – Interrupt charging
Load can not be lifted
Charge capacity below 20%
/ 40% – Hydraulic oil level too low – Excessive load
Charging the battery
Check the hydraulic oil level – Note maximum capacity (see data plate)
If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer ’ s service department ,as any further troubleshooting can only be performed by specially trained and qualified service personnel.
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