EJE 116/118/120. Operating instructions Set

Transcription

1 Set 0 EJE 116/118/ Operating instructions G

2 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. F M t o Safety instructions and important explanations are indicated by the following graphics: Used before safety instructions which must be observed to avoid danger to personnel. Used before notices which must be observed to avoid material damage. Used before notices and explanations. Used to indicate standard equipment. 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 Hamburg - GERMANY Telephone: +49 (0) 40/ GB

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4 Table of contents A B Correct use and application of the truck Truck description 1 Description of use... B 1 2 Description of assemblies and functions... B 2 3 Technical data - Standard version... B Performance data for standard trucks... B Dimensions... B EN standards... B Conditions for application... B 5 4 Labels and plates... B Truck identification plate... B 7 C Transportation and commissioning 1 Transportation by crane... C 1 2 Commissioning... C 1 3 Moving an incapacitated truck... C Emergency operation with service key 741 (o)... C 3 D Battery - Servicing, recharging, replacement 1 Safety regulations governing the handling of lead-acid batteries... D 1 2 Battery type... D 2 3 Batteries and motor output:... D 2 4 Exposing the battery... D 3 5 Charging the battery... D Charging the battery with a stationary charging device... D Selecting the charging curves in the integrated charging device (o)... D 4 6 Removing and installing the battery... D 7 7 Battery discharge indicator (t)... D GB I 1

5 E Operation 1 Safety regulations governing the operation of the fork lift truck... E 1 2 Description of the operating controls and displays... E 2 3 Start-up of truck... E 4 4 Operation of the fork lift truck... E Safety regulations applicable when operating the truck... E Driving, steering, braking... E Picking up and setting down loads... E Rendering the vehicle safe when parking... E 9 5 Keyboard (CANCODE) (o)... E Code lock... E Travel programmes... E Parameters... E Parameter settings... E Travel parameters... E 17 6 Display instrument (CANDIS) (o)... E Discharge monitor function... E Operating hours display... E Switch-on test... E Fault location... E 22 F Maintenance of the fork lift truck 1 Operational safety and environmental protection... F 1 2 Safety regulations applicable to truck maintenance... F 1 3 Servicing and inspection... F 3 4 Maintenance Check - list EJE 116 / 118 / F 4 5 Lubrication Schedule EJE 116 / 118 / F Fuels, coolants and lubricants... F 7 6 Instructions for the servicing operations... F Preparing the truck for the performance of servicing and maintenance operations... F Removing the front cover... F Removing the drive cover... F Checking the electric fuses... F Recommissioning the truck... F 10 7 Decommissioning the fork lift truck... F Operations to be performed prior to decommissioning... F Measures to be taken during decommissioning... F Recommissioning the truck... F 11 8 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to BGV D27)... F 11 9 Final de-commissioning, disposal... F GB I 2

6 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions GB 1

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8 A Correct use and application of the truck 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 operating instructions and must always be heeded. National regulations are fully applicable. 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 operating 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. admissible 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 prevail. M Duties of the user: A user within the meaning of these operating instructions is defined 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 considered 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 operating duties. The user must ensure that the truck is not abused and only used within its design limits 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 maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions. If these Operating Instruction are not observed the warranty becomes void. The same applies if improper work is carried out on the device by the customer and/or third parties 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 written 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 GB A 1

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10 Set B Truck description 1 Description of use The truck is designed for transporting goods on a level surface. Palets with an open floor support or with lateral boards outside of the area of the load-bearing wheels or trolleys can be transported. The load capacity can be found on the load capacity label Qmax. Truck type, load capacity and motor output: Type Load capacity Motor output EJE 116 1,600 kg 1.0 kw EJE 118 1,800 kg 1.0 kw EJE 118 2,000 kg 1.0 kw 0803.GB B 1

11 Set 2 Description of assemblies and functions Item Designation Item Designation 1 t Discharge indicator 8 t Load lifting device o Display instrument (CANDIS) 2 o Keyboard (CANCODE) 9 o Integrated charging device 24V/30A (incl. safety circuit) 10 t Battery hood 3 t Key switch 11 t Controller o Key switch 12 t Collision safety device (with an additional second stage for brake release) 4 t Front cover 13 t Control shaft 5 t Drive cover (2 sections) 14 t Battery plug (emergency stop) 6 t Supporting wheels 15 t Inching speed pushbutton 7 t Drive wheel t = Standard equipment o = Optional equipment 0803.GB B 2

12 3 Technical data - Standard version Description of the technical data according to VDI Technical modifications and additions reserved. 3.1 Performance data for standard trucks Designation EJE 116 EJE 118 EJE 120 Q Load capacity 1,600 1,800 2,000 kg C Load centre distance for standard mm fork length *) Travelling speed with/without load 6.0 / / / 6.0 km/h Lifting speed with/without load 3.4 / / / 4.2 cm/s Lowering speed with/without load 5.3 / / / 3.6 cm/s Max. climbing capacity (5 min.) with/without load 10 / 20 9 / 20 8 / 20 % *) If the forks are longer, the load centre is in the middle of the fork. 3.2 Dimensions Designation EJE 116 / 118 / 120 Short version h 3 Lifting height 122 mm h 13 Load lifting device, lowered 85 mm Y* Wheel base (short, long) 1,240 / 1,310 mm l 1 Overall length (short, long) 1,630 / 1,700 mm l 2 Length including back of fork (short, long) 480 / 550 mm l Standard fork length 1,150 mm b 1 Truck width 700 mm Wa* Turning radius 1,450 / 1,520 mm Ast* Working aisle width 800 x 1200 pallets, lengthwise 1,915** / 1,985** mm Ast* Working aisle width 1000 x 1200 pallets, crosswise 1,865 / 1,935 mm a Safety distance 200 mm * Load section lifted / lowered +55 mm ** Diagonally as per VDI +204 mm 0803.GB B 3

13 1268 c l 803 Q 150 l GB 40 h 3 y h13 l b5 b 11 e a_ 2 W a a_ 2 A st B 4

14 3.3 EN standards Continuous sound level: 70 db(a) according to EN as stipulated in ISO 4871 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. Electromagnetic compatibility (EMC) The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN and the references to other standards contained therein. 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 Industrial trucks must be specially equipped and approved for continuous use in environments with temperatures below 5 C or in cold stores respectively with extreme temperatures or humidity changes GB B 5

15 Set 0 4 Labels and plates 16 Qmax 2000kg Item Designation 16 Truck identification plate 17 Load capacity Qmax 18 Prohibition sign Do not ride on truck 19 Lifting point for crane transportation 20 Plate confirming accident prevention checks (only D) 0803.GB B 6

16 4.1 Truck identification plate Item Designation Item Designation 21 Type 27 Manufacturer logo 22 Serial No. 28 Min./max. battery weight in kg 23 Rated capacity in kg 29 Drive power in kw 24 System voltage V 30 Load centre distance in mm 25 Dead weight without battery in kg 31 Year of manufacture 26 Manufacturer 32 Option The load lifting device must be lifted to read the identification plate. If you have questions concerning the truck or ordering spare parts, please indicate the serial number (22) GB B 7

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18 Set C Transportation and commissioning 1 Transportation by crane M M Only use lifting equipment with sufficient load capacity. Transportation weight = dead weight + battery weight; see truck identification plate.) Lifting points (1) are supplied on the chassis for transporting the truck using a crane. Safely park the truck (see Chapter E). Attach the crane equipment to the lifting points (1). Attach the crane equipment to the lift-ing points in such a manner that it absolutely cannot slip! Lifting equipment for the crane must be attached in such a manner that it does not come into contact with components during lifting. 2 Commissioning M Only drive the truck under battery power! A rectified alternating current damages the electronic components. Cable connections to the battery (towing cable) must be shorter than 6 m. In order to make the truck operationally ready after delivery or after transport, carry out the following: 1 Check the state and the completeness of the equipment. If necessary, install the battery; do not damage the battery cable. Charge the battery (see Chapter D). The battery discharge indicator must match the battery type (to be verified by manufacturer service personnel) if the customer uses a maintenance-free battery. Put the truck into operation as described (see Chapter E). After the truck is parked, the surfaces of the wheels may flatten. After a short driving time, this flattening disappears again. C 1

19 Set 3 Moving an incapacitated truck In order to be able to move the truck in emergency operation, the electromagnetically operated brake must be released. Remove the front hood (2) (see Chapter F). Remove the right-hand drive cover (3) (see Chapter F). Screw on 2 off M4x20 bolts (4) to loosen the armature plate. F The truck can now be moved. Remove the bolts again when you have parked the truck. Braking is now restored.! C 2

20 3.1 Emergency operation with service key 741 (o) The EJE can be manually moved in case of faults in the electric system. A battery must be in the truck and connected. Set service key 741 (o) (701 is standard) to position 2 of the key switch. Key 701 for normal truck operation can be turned to key switch position 1 only. Press and hold the Inching speed pushbutton. The brake releases, i.e. the truck can be moved. The brake brakes the truck as soon as the inching speed pushbutton is released. C 3

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22 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 performed 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 recharging. 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. Terminals 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 nonskid insulating mat. M F M F Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer s specifications for the disposal must be heeded. Before closing the battery hood, make sure that the battery cable cannot be damaged. Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized. Only batteries with closed tray may be used. 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. D 1

23 2 Battery type For the battery weight, refer to the battery identification plate. M Depending on the use, the EJE is equipped with different types of batteries. (refer to chapter B). Batteries with non-insulated poles must be covered with an anti-slip insulating jacket. When changing / assembling the battery, make sure that it is properly fixed in the battery compartment the truck. 3 Batteries and motor output: M EJE Short version (K) EJE Long version (L) 24 V - PzS - battery 1 PzS 126 Ah 1 PzS 200 Ah 1 PzS 150 Ah Motor output 1.0 kw 0,8 kw The abbreviations K (short version) and L (long version) on the identification plate indicate the present model. Depending on the battery type, performance-enhanced and maintenance-free batteries can also be used. When replacing/installing the battery, pay attention that it is firmly seated in the battery compartment of the truck. D 2

24 Set 4 Exposing the battery M Safely park the truck (see Chapter E). Open the battery hood (2). To do so, open the hood at the recessed grip (1) and swing it up. If it is present, remove the isolation mat from the battery. The battery hood is held open only by its own weight. 5 Charging the battery M To charge the battery, park the truck in a closed, well-ventilated room. During charging, the surfaces of the battery cells must be exposed to provide sufficient aeration. No metallic objects must be laid on the battery. Before charging, check all cable and plug connections for visible damage. The safety regulations of the manufacturer of the battery and the charging station must be heeded. 5.1 Charging the battery with a stationary charging device Remove the battery plug (3). Expose the battery (see Section 4). Connect the battery plug (3) with the charging cable of the stationary charging device and switch on the charging device D 3

25 5.2 Selecting the charging curves in the integrated charging device (o) F The battery charger must not be opened. If it is damaged, it has to be exchanged. The switch (6) of trucks supplied without a battery is factory-set to the 0 position. The red light-emitting diode (4) flashes - the battery cannot be recharged Select charging curve in the integrated battery charger M M Use switch (5) at the battery charger to adjust the charging curves to the appropriate battery according to the following table. The power plug must be pulled before the corresponding charging curve is to be adjusted! Provided that a battery is connected, a new setting can be acknowledged via the LEDs (cf. indicator) which will then be immediately effective. Switch (5) Position Selected charge curves (characteristics) 1 Wet cell batteries: Ah 2 Maintenance-free: Ah 3 Maintenance-free: Ah 4 Maintenance-free: Ah 5 Wet cell batteries: Ah pulse characteristic 6 Wet cell batteries: Jungheinrich Ah All other switch (5) positions inhibit the charger, and the battery is not charged. D 4

26 Adjusting the charging curve The charging curve can be adjusted by performing the following steps: Connect the battery Turn the setting switch to the right to select the desired characteristic curve This allows you to adjust via the charger If the characteristic curve is valid, the green LED flashes according to the set position. If invalid, the red LED flashes. Starting the recharging process with integrated battery charger F Park the truck and render it safe (refer to chapter E). During the recharging operation the tops of the battery cells must be exposed to ensure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed. Mains supply Mains voltage: 230 V (±6%) Mains frequency: 50/60 Hz (±1%) The charger power cable (6) is laterally accessible from the outside. Expose the battery (refer to section 4). Remove insulation mat from battery, if necessary. Battery plug must not be unplugged. Connect power plug (6) with a power socket. 7 F The flashing LED indicates the charging status and/or a fault (flashing codes see table LED display ). If the power plug (6) 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 (6) from the power socket and place it in the battery compartment. The recharge procedure is automatically continued after a power failure. The recharge procedure can be interrupted by pulling the power plug and can be continued in steps. The mains cable must not be damaged. Before commissioning the truck, the battery hood must be properly closed. D 5

27 Charging times The time required for recharging depends on the capacity of the battery. LED display Green LED (charging status) Fill-up charge The fill-up charge begins automatically after the recharge procedure has ended. Partial recharging Red LED (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 interrupted. --- flashes slowly Safety charging interval exceeded. Recharge process 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. The battery charger is designed in such a way that it automatically adapts to the charging status of partially recharged batteries. This permits to reduce wear and tear of the battery. D 6

28 Set 0 6 Removing and installing the battery F The truck must stand horizontally. To prevent short circuits, batteries with open poles or connectors must be covered with a rubber mat. Lay down the battery plug and cable in such a manner that they do not snag on the truck when the battery is pulled out. When transporting the battery with crane equipment, pay attention that the load capacity is sufficient (see battery weight on the battery identification plate on the battery trough). The crane equipment must pull vertically. The hooks of the crane equipment must never fall onto the battery cells. Expose the battery (see Section 4). Remove the battery plug (3). Connect the crane equipment to the eyelets (7). Pull the battery upwards and out of the battery trough. 8 3 M F Installation occurs in the reverse sequence; pay attention that the battery is installed in the correct position and is connected properly. After reinstallation, check all the cable and plug connections for visible damage. Close the battery hood slowly and carefully. Keep your fingers away from the area between the battery hood and the chassis. D 7

29 7 Battery discharge indicator (t) The battery discharge state is indicated as soon as the truck is switched on with the key switch or the CANCODE. 9 The colors of the LED (8) indicate the following: LED color Rating green Residual capacity, standard battery % Residual capacity, maintenance-free battery % orange Residual capacity, standard battery 30-40% Residual capacity, maintenance-free battery 50-60% green/orange Residual capacity, standard battery 20-30% flashing, 1Hz Residual capacity, maintenance-free battery 40-50% red Residual capacity, standard battery 0-20% Residual capacity, maintenance-free battery 0-40% Lifting of load units is no longer possible if the LED is lit in red. The lifting function is re-enabled at a battery capacity of at least 70 % only. The display is reset to 100% if the battery capacity determined when the truck is switched on is at least 70% of a fully charged battery. Depending on the residual capacity, the display is reduced in steps of 10%. The displayed residual capacity changes by no more than 10% within 3 minutes. The residual capacity displayed cannot rise while the truck is in operation. The residual capacity display is reset to 100% when the battery type is defined. Call the manufacturer service when LED flashes red and the truck cannot be operated any longer. The LED flashing red signals a truck controller malfunction. The flash sequence indicates the malfunction type. D 8

30 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 representative 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 during 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 attachments 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. F 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 includes the area within reach of falling loads or falling / lowering truck attachments. Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area. Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded. E 1

31 2 Description of the operating controls and displays Item Operating control or display EJE 116 / 118 / 120 Function 1 Control shaft t Steers and brakes truck. 2 Battery plug (emergency stop) t The power circuit is interrupted and all electrical functions are switched off. 3 Discharge indicator t Battery discharge state. Display instrument (CANDIS) 4 Keyboard (CANCODE) o o Operating hours meter. Battery discharge state. Display of service messages and, in conjunction with CANCODE, drive parameters. Code settings. Releasing and selecting the travel programmes. Entering travel parameters. 5 Key switch t Switches the control current on and off. Pulling out the key prevents unauthorised persons from switching on the truck. Key switch with second position 6 Integrated charging device (incl. safety circuit) o o Releases the brake to allow a nonoperable truck to be moved. Charges the battery; insert the power plug into a mains socket. 7 Inching speed pushbutton t Pressing the Inching speed push button reduces travel speed and acceleration. When the control shaft is in the upper brake area, the braking function can be bypassed by pressing this key and the truck can be moved at reduced speed. 8 Controller t Controls the travelling direction and speed. 9 Collision safety button t Truck drives away from operator. 10 Button for lifting load lifting t Lifts load lifting device. device 11 Button for lowering load lifting t Lowers load lifting device. device 12 Operating key Horn t Gives an audible warning signal. t = Standard equipment o = Optional equipment E 2

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33 Set 3 Start-up of truck F Before the truck can be started up or operated or a load can be lifted, the driver must make sure that no-one is in the danger zone. Tests and duties before the daily start-up Check the entire truck (especially the tyres and the load lifting device) for damage. Check the battery holder and the cable connections. Switching on the truck Check that the battery plug (2) is plugged in. Insert the key in the key switch (5) and turn it all the way to the right to position I or enter the CANCODE (o) release code (see section 5). Press the warning signal pushbutton (12) to test its function. The truck is now ready for operation. o The battery discharge indicator (3) indicates the remaining battery capacity. Check the braking function of the control shaft (1) (see Section 4.2) E 4

34 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 allocated 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 conditions. 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 always 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 permitted. 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 satisfy 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 loads to be carried: The operator must make sure that the load is in a satisfactory condition. Only carry loads that are positioned safely and carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or falling down. E 5

35 4.2 Driving, steering, braking F It is not admissible to stay on the vehicle during driving. Emergency stop Pull out the battery plug (6). All electrical functions are switched off. Forced braking F M M When the control shaft is released, forced braking occurs - the control shaft automatically moves into the upper braking area (B). If the control shaft moves slowly into the braking position, the cause must be eliminated. If necessary, the gas pressure spring is to be replaced. Driving Travelling with raised forks / raised load beyond 500 mm above the ground is prohibited. Drive only with closed and properly locked hoods. Start the truck up (see Section 3). The travelling speed is controlled with the controller (8). Lower the control shaft (1) into the travel direction (F) and set the drive controller (8) to the desired direction (V or R, forward or backward). F Inching The driver must be particularly careful when using the Inching pushbutton (7). The truck can be shunted with the control shaft (1) in the vertical position (e.g. in confined spaces / elevators): Press the Inching pushbutton (7). Set the travel direction switch (8) to the desired direction (V or R, forward or backward). M F Parking brake is released. The truck starts moving slowly. The brake is applied when the Inching pushbutton is released only; at inching speed, braking is possible with the counter-current brake only (travel direction switch (8)). To brake the truck in an emergency, release the Inching pushbutton (7) immediately. Pressing the Inching speed push button in the drive section (F) causes the truck to travel at reduced speed and acceleration. E 6

36 Set 0 R V 1 B R F V B Steering Swing the control shaft (1) to the left or right. E 7

37 F Braking The braking behaviour of the truck strongly depends on the road surface conditions. The driver must take this into account in his driving behaviour. M Braking with the service brake: Raise or lower the control shaft (1) to one of the brake positions (B). The service brake is the regenerative brake. The mechanical brake is applied only if this brake does not reach the required deceleration. Braking using the countercurrent brake: 7 While driving, the controller (8) can be used to switch to the opposite direction. The truck is braked by the countercurrent until driving in the opposite direction takes affect. Braking with the coasting brake F M The truck is braked with the regenerative brake when the drive controller is in the 0- position. Bring the control shaft into the braking position in an emergency. Driving at inclines Transport the load pointing uphill! Securing the truck against rolling down : The brake is automatically applied with a short jolt when the drive direction switch is set to 0 (the controller detects the truck rolling down). With the drive controller you release the service brake and control the speed and the travel direction as desired. E 8

38 Set 4.3 Picking up and setting down loads m m Before a load can be picked up, the driver must make sure that it is properly paletted and does not exceed the permitted load capacity of the truck. Loading long goods transversely is not permitted. Drive the truck s fork tines completely under the load. The lifting and lowering speeds are preset. Lifting Press the Lift load lifting device pushbutton (10) (for left-handed operation o (13)) until the desired height is reached. Release the button immediately when the end stop of the load lifting device is reached. Lowering Press the Lower load lifting device pushbutton (11) (for left-handed operation o (14)) Rendering the vehicle safe when parking F Always render the truck safe when parking it. Do not park the truck on an incline. The load lifting device must always be entirely lowered. Lower the load lifting device. Set key switch (5) to position 0 and remove the key or press CANCODE Off. E 9

39 5 Keyboard (CANCODE) (o) The operator keyboard is composed of 10 numeric keys, a Set key and an o-key. Activation of the travel programs by means of switches 1,2,3 is indicated by green LEDs. The o-key indicates operating conditions by a red/green LED It has the following functions: Code lock function (setting the truck into operation). Selecting the travel program. Setting the travel and battery parameters, only in conjunction with the indicator instrument (CANDIS (o)). The o-key has top priority and reset the truck 7 Set from any condition to the basic condition without modifying any settings. 5.1 Code lock After entering the correct code, the truck is ready for operation. It is possible to assign an individual code to every truck, operator or even operator group. M When delivered from the factory, the operator code (factory setting ) is indicated on a removable sticker. Change the master and operator codes when setting the truck into operation for the first time! (refer to section 5.4). E 10

40 Commissioning The LED (15) lights up red after the battery plug has been plugged in and, if applicable, the key switch has been switched on. After entering the correct operator code (factory setting ) the LED (15) lights up red. When an incorrect code has been entered, LED (15) lights up red for two seconds. After that you can enter a new code. The Set key (16) has no function in operating mode. Switching off The truck is switched off by actuating the o -key (20). The truck can be switched off automatically after a preset time. For that purpose the corresponding code lock parameter must be set (refer to section 5.4) Set E 11

41 5.2 Travel programmes By actuating the numeric keys 1, 2, and 3 you can select three travel programmes. The activated programme is indicated by the green LEDs (17), (18), (19) in the corresponding key. The travel programmes differ with respect to travelling speed, acceleration, and deceleration. Factory settings: Programme 1: Soft running Programme 2: Normal operation Programme 3: Power operation (preset for commissioning) The travel programs can be adapted individually to the truck (refer to section 5.5). 5.3 Parameters In programming mode, the operator keyboard allows the setting of the code lock functions and the adaption of the travel programmes. Additionally, the battery parameters can be set. For trucks without indicator instrument (CANDIS (o)) only the code lock parameters can be set. 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. 0xx 1xx 2xx 3xx 4xx Parameter group Code lock settings (Codes, travel programme enable, automatic switch-off, etc.) Travel programme 1 parameters (Acceleration, coasting brake, speed, etc.) Travel programme 2 parameters (Acceleration, coasting brake, speed, etc.) Travel programme 3 parameters (Acceleration, coasting brake, speed, etc.) Programme-independent parameters E 12

42 5.4 Parameter settings M F To change the truck settings the master code must be entered. The master code is factory-set to Change the master code when setting the truck into operation for the first time (refer to section 5.1). Safety notes for trucks with indicator instrument (CANDIS (o)) Parameter settings must be made carefully and only by special trained personnel. If in doubt, consult the manufacturer's service. Every setting procedure must be monitored on the LC display of the indicator instrument (CANDIS (o)). If in doubt, the setting procedure must be cancelled by pressing the o-key (20). Since the truck's travel behaviour is changed, you must perform a trial in a specially assigned and suitable working area run after changing any of the parameters. Entering the master code: Press the o-key Enter master code Display instrument (CANDIS) Operating hours are indicated LED (15) o-key green flashing LED (17) Key 1 LED (18) Key 2 LED (19) Key 3 off off off Code lock parameters Setting procedure for trucks without indicator instrument (CANDIS (o)): Enter the three-digit parameter number and confirm with Set key (16). Enter or change the setting value according to the parameter list and confirm with Set key (16). When the input is incorrect, the LED (15) of the o-key (20) lights up red. After entering the parameter number again, the setting value can be entered or changed. Repeat the procedure to enter further parameters. To terminate the input, press the o-key (20). E 13

43 Setting procedure for trucks with and without indicator instrument (CANDIS (o)): Enter the three-digit parameter number and confirm with Set key (16). The indicator instrument (CANDIS (o)) continues to display the operating hours. If the display changes, cancel the setting procedure with the o-key (20) and restart from the beginning. Enter or change the setting value according to the parameter list and confirm with Set key (16). When the input is incorrect, the LED (15) of the o-key (20) lights up red. After entering the parameter number again, the setting value can be entered or changed. Repeat the procedure to enter further parameters. To terminate the input, press the o-key (20). The following parameters can be entered: Code lock parameter list No. Function Range Setting value Code lock 000 Change master code The length of the master code (4 to 6 digits) also determines the length (4 to 6 digits) 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. 001 Add operator code (max. 600) or or or or Default Setting value Comments Work flow 7295 (LED 17 flashes) Enter the current code confirm (Set) (LED 18 flashes) Enter a new code confirm (Set) (LED 19 flashes) Repeat new code Confirm (Set) 2580 (LED 18 flashes) Enter a code confirm (Set) (LED 19 flashes) Repeat the code entry Confim (Set) E 14

44 No. Function Range Setting value Code lock 002 Change operator code or or Default Setting value Comments Work flow (LED 17 flashes) Enter the current code Confirm (Set) (LED 18 flashes) Enter a new code Confirm (Set) (LED 19 flashes) Repeat the code entry 003 Delete operator code or or Confirm (LED 18 flashes) Enter a code Confirm (Set) (LED 19 flashes) Repeat the code entry 004 Clear code memory (deletes all operator codes) Confirm (Set) = delete LED are located in the key pad fields 1-3 (refer to section 5.2). other entry = do not delete 010 automatic switch-off = none Switch-off 01 to 30 = Switch-off time in minutes 31 = switch-off after 10 seconds E 15

45 No. Function Range Setting value Code lock 021 Travel programme 1* ) Enable Default Setting value Comments Work flow 0 or = Travel programme not enabled 022 Travel programme 2* ) Enable 023 Travel programme 3* ) Enable 030 Display of the number of used operator codes* ) 1 = Travel programme enabled 0 or = Travel programme not enabled 1 = Travel programme enabled 0 or = Travel programme not enabled 1 = Travel programme enabled * ) only in conjunction with indicator instrument (CANDIS (o)) Keyboard error messages The following errors are indicated by a red flashing LED (15): 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. E 16

46 5.5 Travel parameters For trucks without indicator instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service. The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101). Acceleration example Display instrument (CANDIS) current setting is displayed changed setting is displayed Parameter number Parameter setting value LED (15) o-key green flashing green flashing LED (17) Key 1 LED (18) Key 2 LED (19) Key 3 off off off off off off F Enter the three-digit parameter number (101) and confirm with the Set key (16). Check the LC display of the indicator instrument (CANDIS (o)) (parameter number and current parameter value are displayed). If there is no input for approx. 5 seconds, the display switches back to operating hours indication. If another parameter number than the one displayed is desired, you must wait until the operating hours are displayed again. Enter or change the parameter value according to the parameter list. Check the LC display of the indicator instrument (CANDIS (o))(confirm with the Set key (16)). The LED (15) of the o-key (20) switches briefly to steady light and start flashing again after approx. 2 seconds. When the input is incorrect, the LED (15) of the o-key (20) lights up red. After entering the parameter number again, the setting value can be entered or changed. Repeat the procedure to enter further parameters as soon as the LED (15) of the o- key (20) flashes. To terminate the input, press the o-key (20). During the parameter input the travel function is switched off. If the setting value is to be checked in travel operation, follow this sequence: Select the modified travel programme after entering the parameter value, confirm with the Set key (16). The truck is now in travel operation and can be checked. To continue the setting operation, confirm with the Set key (16) again. E 17

47 The following parameters can be entered: Travel programmes No. Function Range Setting value Travel Programme Acceleration 0-9 (0,2-2,0 m/s 2 ) 102 Coasting brake 0-9 (0,2-1,1 m/s 2 ) 104 Maximum speed in drive direction via controller 108 Maximum speed in fork direction via controller 0-9 (2,8-6,2 km/h) 0-9 (2,8-6,2 km/h) Standard Setting value 3 (0,8 m/s 2 ) 3 (0,5 m/s 2 ) 3 (4,8 km/h) 3 (4,8 km/h) Comments depending on controller depending on controller No. Function Range Setting value Travel Programme Acceleration 0-9 (0,2-2,0 m/s) 202 Coasting brake 0-9 (0,2-2,0 m/s) 204 Maximum speed in drive direction via controller 208 Maximum speed in fork direction via controller 0-9 (2,8-6,2 km/h) 0-9 (2,8-6,2 km/h) Standard Setting value 6 (1,4 m/s) 6 (0,8 m/s) 8 (6,0 km/h) 8 (6,0 km/h) Comments depending on controller depending on controller E 18

48 No. Function Range Setting value Travel Programme Acceleration 0-9 (0,2-2,0 m/s 2 ) 302 Coasting brake 0-9 (0,2-2,0 m/s 2 ) 304 Maximum speed in drive direction via controller 308 Maximum speed in fork direction via controller 0-9 (2,8-6,2 km/h) 0-9 (2,8-6,2 km/h) Standard Setting value 9 (2,0 m/s 2 ) 9 (1,1 m/s 2 ) 8 (6,0 km/h) 8 (6,0 km/h) Comments depending on controller depending on controller Battery parameters For trucks without indicator instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service. The parameters are set in the same way as for the travel parameters. The following parameters can be entered: No. Function Range Setting value Battery parameters 411 Battery type (normal/high-power/dry) Standard Setting value Comments = Normal (wet) 1 = High-power (wet) 412 Discharge monitor function 0 / = Dry (maintenance-free) Setting value 0 / 1 is to be interpreted as: 0 = off 1 = on E 19

49 6 Display instrument (CANDIS) (o) The instrument indicates: Remaining battery charge (LED bars (22)) Operating hours (LC display (24)). In addition, service messages from the electronic components and parameter changes are indicated. Discharge status indication Depending on the battery type set, switch-on limits for the additional Warning (21) and Stop (23) indicators may result. Number Bars Charging condition LED (yellow) Warning Wet battery LED (red) Stop Maintenance-free battery LED (yellow) Warning LED (red) Stop % Off Off Off Off % Off Off Off Off % Off Off Off Off % Off Off Off Off % Off Off Off Off % Off Off On Off % Off Off On On % On Off On On % On On On On Avoid falling below the 20% limit for wet batteries resp. 40% limit for maintenance-free batteries. E 20

50 6.1 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% for wet batteries resp. 50% for maintenance-free batteries the batteries should be recharged (the yellow LED lights up as warning indication). 6.2 Operating hours display Display range between 0.0 and 99,999.0 hours. Travel and lifting movements are logged. This is a backlit display. For maintenance-free batteries a T symbol is shown in the operating hours display (24). Error messages The operating hours display is also used for indicating errors. The error is displayed in two parts and starts with a C for component and a three-digit component number, then an E for error with alternating three-digit error number. If several errors occur they are displayed one after the other. The errors are displayed as long as they are present (always in combination Cxxx / Exxx). 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 (Code lock). When CANDIS is not available, the error code is signaled by the flashing discharge indicator LED. Detailed component descriptions including error codes are available at the manufacturers service. Display for parameter changes (travel programmes) The LC display (24) is used in conjunction with the operator keyboard (CANCODE (o)) to display the setting parameters. The first three digits of the display show the parameter numbers, the last three digits indicate the parameter value. Setting values of parameter group 0XX (code lock) are not displayed. 6.3 Switch-on test After switching on the display shows: the software version of the display instrument (short-term), the operating hours the charging condition E 21