KMS 100. Operating instructions

Transcription

1 KMS 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 A 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. t o 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 Correct use and application of the truck...a 1 B Truck description 1 Description of application... B 1 2 Description of assemblies and functions... B Description of truck... B 3 3 Technical data of standard version... B General technical data... B Hoist frame construction... B EN Standards... B Operation conditions... B 8 4 Location of instruction labels and identification labels... B Truck identification label... B Load capacity... B 10 C Transportation and commissioning 1 Transport... C 1 2 Transportation by crane... C 1 3 First commissioning... C Commissioning without battery... C Commissioning with dismounted or tilted mast... C 2 4 Commissioning... C 3 D Battery - servicing, recharging, replacing 1 Safety regulations governing the handling of lead-acid batteries... D 1 2 Battery types... D 1 3 Charging the battery... D 2 4 Removing and installing the battery... D Removing and installing using a battery trolly... D 3 5 Checking battery condition, acid level, and acid density... D 4 6 Battery discharge indicator... D 4 I 1

5 E Operation 1 Safety regulations governing the operation of the truck... E 1 2 Operating panel arrangement variants... E 2 3 Description of controls and indicating instruments... E Operating controls and displays at the instrument panel... E Operating controls and indications at the Display... E Symbols indicating the truck s operating status... E 6 4 Putting vehicle in operation... E 7 5 Working with the truck... E Safety regulations for operating mode Drive... E Driving, steering, braking... E Lifting and lowering outside and inside the shelf aisles... E Combined driving (simultaneous driving and lifting).... E Commissioning and stacking... E Safe parking of the truck... E 17 6 Fault location... E Emergency-STOP... E Emergency lowering of driver s cabin... E Leaving the driver s cabin using the emergency rope-down facility... E Slack chain protection (acknowledge signal)... E Drive switch-off (o)... E Lift switch-off (o)... E End of aisle safety device (o)... E IG emergency operation... E Recovering the truck from a narrow aisle... E 24 I 2

6 F Truck maintenance 1 Operational safety and protection of the environment...f 1 2 Safety regulations for repair...f 1 3 Maintenance and service...f 3 4 Maintenance checklist KMS F Operating material...f 8 5 Description of servicing operations...f Prepare the truck for the performance of servicing and maintenance operations...f Securing the driver platform...f Cleaning the hoisting chains...f Inspecting the hoisting chains...f Repairing the chain...f Changing the transmission oil...f Cleaning the vent filter...f Changing of hydraulic oil filter...f Hydraulic oil...f Hydraulic hoses...f Checking the brake fluid...f Checking the electric fuses...f Recommissioning the truck...f 14 6 Taking the floor conveyor out of service...f Operations to be performed prior to decommissioning...f Measures to be taken during decommissioning...f Recommissioning the truck...f 15 7 Safety checks to be performed at regular intervals and following any untoward incidents (D: UVV according to UVB 36)...F 15 I 3

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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 instructions are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service. Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after 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. A 1

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10 B Truck description 1 Description of application The commissioner KMS 100 is an industrial truck with powered mechanism according to DIN It is operated from the vertically movable driver position and approved for one operating person. The load carrying area can always be moved to a convenient working height with the auxiliary fork lift. The commissioner is suitable for operation in narrow aisles with racks arranged at the side. It is especially designed for driving with lifted load. A perfect floor condition is a prerequisite: flat and horizontal floor according to the instructions of the manufacturer of the commissioner; the floor must be suitable for carrying the weight of the commissioner, the driver and the load during operation floor free of foreign matters and parts which might effect the operation or the stability of the commissioner The load capacity is stated on the identification plate. Model Load capacity Load centre KMS kg 600 mm B 1

11 2 Description of assemblies and functions Pos. Description 1 o Auxiliary lifter 2 t Vertically movable operator stand 3 t Lift mast 4 t Hoist frame 5 t Battery t = Standard equipment o = Optional equipment B 2

12 2.1 Description of truck Integrated information display to display all important information to the driver, like steering wheel position, platform height, truck status signals (e.g. malfunctions, entrance doors open, etc.), operating hours, battery capacity, time as well as status of the inductive guidance, etc. Electric steering system with small handy steering handle - steering wheel for precise and easy steering of the compact truck. Two-hand operation via capacitive sensors at the handle element and master pilot for relieved hand rest; no uncomfortable operation of dead man's circuits with strain on the wrists. Master pilot for simultaneous driving and lifting even if the truck is not operated directly. Functions are operated by natural thumb and hand movements for fatigueless operation without wrist strain; sensitive adjustment of drive and hydraulic motion for saving the commissioning goods. Exact driving to the commissioning position as well as exact positioning of the goods in stacking operation. Load-side, clear operating panels with a small front part provide good accessibility of the pallets for a high commissioning capacity. The driver must never move around to operate the devices and carry out commissioning. Roadway, load or fork tines are always visible. Different operating panel arrangement variants (see extras) to adjust the device operation to the corresponding commissioning goods or the warehouse conditions Flexibility through variable mounting of the operating panels even if the operating conditions change. Arrangement of auxiliary functions (e.g. auxiliary lifter) beside the supporting strap for efficient and safe device operation without changing the position of the hands. Release and speed control of the auxiliary functions through the master pilot. Multiple brake system with at least two independently operating systems. Soft and safe reduction of the truck speed is guaranteed in every situation. Wear-free dynamic service brake with energy regeneration as well as spring-loaded brake on drive motor as parking brake during stacking and as emergency stop brake. In due course the vehicles are equipped with an additional hydraulic load wheel brake. B 3

13 3 Technical data of standard version A Technical data is stated according to VDI Subject to technical changes and supplements. B 4

14 3.1 General technical data Identification 1.2 Type index of the manufacturer KMS Drive electric, diesel, fuel, fuel gas, net electric Electric 1.4 Operation hand, walking, standing, seat, commissioner Commissioner 1.5 Capacity/load Q (t) 1,0 1.6 Load centre distance c (mm) Load spacing x (mm) Wheel base y (mm) 1490 Weights 2.1 Dead weight with battery kg Axle load with load front/back kg 3260 / Axle load without load front/back kg 1690 / 1740 Wheels, travelling gear 3.1 Tire equipment solid-rubber, superelastic, air, polyurethane Tractothane 3.2 Tire size, front d 1 (mm) 230 φ/ Tire size, back d 2 (mm) 310 φ/ Wheels, number front/back (x=driven) 2/1x 3.6 Wheel gauge, front b 10 (mm) Wheel gauge, back b 11 (mm) 0 Electric motor 6.1 Drive motor, capacity S2 60 min kw 4,5 6.2 Lifting motor, capacity at S3 25% kw 9,5 6.3 Battery according to DIN 43531/35/36 A, B, C, no (max.) 4 PzS 560 A (600) 6.4 Battery voltage, nominal capacity K 5 V/Ah Weight of battery kg 933 Others 8.1 Type of driving control Impuls/MOSFET 8.4 Sound level, driver's ear db(a) Steering system electrically B 5

15 Basic dimensions 4.2 Height with hoist frame retracted h 1 (mm) Free lift h 2 (mm) Length of lift h 3 (mm) Height with hoist frame extended h 4 (mm) Height above vehicle shed (cabin) h 6 (mm) Seating/standing height h 7 (mm) Auxiliary lifter h 9 (mm) Total length of lift h 10 (mm) Commissioning height h 15 (mm) Lowered height h 13 (mm) Total length without load l 1 (mm) Length incl. fork back l 2 (mm) 2070 Distance swivel reach fork pivot L 3 (mm) Total width b 1 /b 2 (mm) 1010 / Fork tine dimensions s/e/l (mm) 40 x 100 x Fork carrier DIN 15173, class/shape A, B Fork carrier width b 3 (mm) Overall distance of fork b 5 (mm) Width of guide rollers b 6 (mm) Reach, sidewards b 7 (mm) Reach, sidewards from the center of the vehicle b 8 (mm) Road clearance with load below hoist frame m 1 (mm) Ground clearance in wheel base center m 2 (mm) Working aisle width for pallet 1000 x 1200 sideways A st (mm) Working aisle width for pallet 800 x 1200 lengthways A st (mm) Turning circle W a (mm) Pallet width b 12 (mm) Pallet length l 6 (mm) Distance swivel fork pivot l 8 (mm) Cabin depth entrance (mm) Clear cabin height inside h 11 (mm) Driver's seat carrier width outside b 9 (mm) Width swivel push frame b 14 (mm) Width jib l 10 (mm) - B 6

16 Performance data 5.1 Driving speed with / without load km/h 10,0 / 10,5 5.2 Lifting speed with/without load m/s 0,28/0, Lowering speed with / without load m/s 0,40/0, Traverse speed with/without load m/s Hill climbing ability with/without capacity % max. hill-climbing ability with/without load % Acceleration time with/without load s Service brake dynamic 5.11 Parking brake/dead man electr. spring-load accumulator 3.2 Hoist frame construction Double telescope (DT) and tripe telescope (TT) hoist frame with complete free lift Model Lift h 3 [mm] Overall height retracted (ZT) h 1 [mm] Overall height retracted (DZ) h 1 [mm] Free lift for DZ h 2 [mm] Overall height extended h 4 [mm] Model Height above vehicle shed h 6 [mm] Auxiliary lifter h 9 [mm] Total lifting height h 10 [mm] Commissioning height h 15 [mm] B 7

17 3.3 EN Standards Continuous sound level: A 65 db(a) according to pren as stipulated in ISO The permanent sound level is an average value determined according to the standard s guidelines and takes into consideration the sound level when driving, lifting and in idle mode. The sound level is measured at the driver s ear. Vibration: A Vibration acceleration in standing position: 1,11 m/s 2 according to document N47E of CEN/TC 150/WG8. The vibration acceleration applied to the operator s body is measured according the standard s guidelines as a linearly integrated, weighted acceleration in vertical direction. The acceleration is measured when driving across bumps at steady speed. A Electromagnetic compatibility (EMC) The following limit values are observed according to the product standards Electromagnetic Compatibility of Industrial Trucks (9/95) : - interference emission (EN ) - interference immunity (EN ) - electrostatic discharge (EN ). Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained. 3.4 Operation conditions Environmental temperature in operation 0 C bis + 40 C. B 8

18 4 Location of instruction labels and identification labels Pos. Description 1 Truck identification label 2 Sign Emergency lowering device 3 Warning sign Lifting of persons prohibited 4 Warning sign Keep away from under the load lifting device 5 Warning sign Danger of crushing 6 Warning sign Caution: Low-voltage electronics 7 Attachment point for jack 8 Fill in hydraulic oil 9 Capacity plate 10 Sign Read operating instructions 11 Prohibitive sign Do not travel on load lifting device 12 Emergency outlet 13 Sign for opening and closing the hood 14 Pick-up points for crane transportation B 9

19 4.1 Truck identification label Xxx Xxxx Xxxx Xxxx Xxxxxxx Xxxxxx Xxxxxxxx Xxxxxx Xxxxxx Xxxxxxxxx Xxxxxxxxxx Xxxxxxxxx Xxxxxxxxx Xxxxx Xxxxx Xxxxx Xxxxx Xxxxxxx Xxxxxxxxxx Xxxxxx Xxxxxxxxx Xxxxxx Xxxxxx Xxxxxxx Xxxxxx Xxxxxx Xxxxxxxxxxxxxx Xxxxxxxxxxxxxxx Xxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxxx xx Xxxxxxxxxxxxxxxxxxxxxxxxx xx Xxxxxxxxxxxxxxxxxxx xx Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx X Xx Xxxxxxxxxxxxxxxxxxxxxx xx xx Xxxxxxxxxxxxxxxxxx Pos. Description Pos. Description 18 Model 24 Load centre distance in mm 19 Serial no. 25 Min./max. battery weight in kg 20 Order no. 26 Net weight without battery in kg 21 Capacity in kg 27 Year of manufacture 22 Battery: voltage V 28 Type no. Ampere hours Ah 23 Maker 29 Maker s logotype In the event of queries relating to the truck or spare part orders, please state the serial no. (19) of the truck. 4.2 Load capacity The label (12) shows a table with the capacity Q of the truck in relation to the load center distance (D in mm) and the lifting height (H in mm). 12 -Nr. Serien-Nr. Hmm Qkg Dmm B 10

20 C Transportation and commissioning 1 Transport Depending on the overall height of the hoist frame and local conditions the on-site transport can be carried out in one of three different ways: m Standing, with hoist frame and load lifting device mounted (for low height versions) Standing, with tilted hoist frame and dismounted load lifting device, resting on transport frame Standing, with hoist frame and load lifting device dismounted (for tall versions) On-site assembly of the truck, commissioning, and instructing of operator must be carried out by trained personnel of the manufacturer. Transport regulations and erection instructions must be observed! 2 Transportation by crane m Ensure that only lifting gear of adequate capacity is used (for weight of the truck refer to the truck identification label. See chapter B). m Park the truck and render it safe (refer to chapter E). If the mast is mounted, the crane points are at the top of the mast crosshead. If the mast is tilted, the lifting gear must be mounted at the top of the mast crosshead and at the crosshead on the bottom of the mast. If the truck is to be lifted by crane with tilted mast, the transportation parts must be mounted. Secure the hoisting gear to the hoisting points (1) ensuring that the hoisting gear will not slip! 1 1 C 1

21 3 First commissioning 3.1 Commissioning without battery m A This operating mode is not permitted when negotiating inclines and gradients (no brake!). If the truck is operated without battery, the load bearing wheel brake must be released before commissioning. f Screw off the protective cover (5) of the vent valve. Push tube (4) onto vent connection and insert the other end of the tube into the brake fluid reservoir (3) located above. Brake fluid is under pressure. Danger of causticization A m Open vent valve (6) and allow emerging brake fluid to drain into the brake fluid reservoir. Close vent valve and brake fluid reservoir. The operatability of the brake system is restored after inserting the battery and after operating the foot switch several times. Test the brake deceleration. These measures may only be performed by service engineers of the manufacturer. 3.2 Commissioning with dismounted or tilted mast If the truck has been delivered with dismounted or tilted mast due to tall height, the mast has to be mounted by a trained mechanic. If mast is tilted, loosen lift mast pedestal (7) (do not remove screws). Set hoist frame with suitable hoisting equipment to a vertical position. Add compensating sheets, if available, and screw down mast and lifting mast bearing. C 2

22 4 Commissioning m The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (towing cable) must be less than 6 meters in length. In order to prepare the truck for work following delivery or transportation, the following operations must be performed: m If necessary, install and charge the battery (see chapter D, sections 4 and 5). Commission the truck as detailed in chapter E, section 3. Please check if the tilting protection (1) is existing before commissioning the trucks. All safety devices must be checked on their availability and function. 1 1 C 3

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24 D Battery - servicing, recharging, replacing 1 Safety regulations governing the handling of lead-acid batteries The truck must be parked and rendered safe before any operations on batteries are to be 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 as prepared by the battery supplier and as available at 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. 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. 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 have accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor, when skin or eyes have come into contact with battery acid. Spilled battery acid must be immediately neutralised. 2 Battery types Depending on their application, the WK truck is equipped different with battery types. All battery types are approved according to DIN A. The following table shows the standard battery combinations and battery capacities: Battery type Truck type 48V 560 AH KMS V 600 AH KMS 100 f The battery weights can be seen from the battery identification plates. Battery weight and dimensions have a considerable influence on the stability of the truck. Therefore, a change of the battery type is only permitted with the prior consent of the truck manufacturer. D 1

25 3 Charging the battery f f Park the truck and render it safe (see chapter E). Turn the key switch to 0 (Zero) and push the Emergency stop switch. Lift the battery hood to its full extent. The battery connector and socket must only be connected or disconnected with both the truck and the battery charger switched off. f f Withdraw the battery connector. Remove any insulating matting from the batteries. 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. Connect the charging cable of the battery charger to the battery connector. Switch on the battery charger. Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed. D 2

26 4 Removing and installing the battery f f Batteries with exposed terminals or connectors must be covered with a rubber mat to prevent short-circuits. When replacing batteries, ensure that a battery of the same type is fitted. Additional weights must not be removed and their position must not be changed. f Turn the key switch to 0 (Zero) and push the emergency stop switch. Lift the battery hood to its full extent. The battery connector and socket must only be connected or disconnected with both the truck and the battery charger switched off. Withdraw the battery connector. Lift out the chassis lateral part. 4.1 Removing and installing using a battery trolly f The vehicle must be on level ground, to prevent accidental movement of the battery after loosening the battery safety device. f Release the battery safety device. Pull the battery laterally onto a battery trolley. Installation is in the reverse order. Following reinstallation of the battery, visually check all leads and connectors for damage and prior to the recommissioning of the truck check that the battery safety device is tightened again, that the battery hood is safely locked. D 3

27 5 Checking battery condition, acid level, and acid density The service instructions of the battery supplier apply. Check the battery casing for cracks and acid leaks. Remove oxidation residues from the battery terminals and lightly grease with acidfree pole grease. Screw out the screw caps and check the acid level. The acid level must be a minimum of 10-15mm above the plate top. Check the acid density according to the suppliers specifications with an acid pipette and subsequently remount the screw caps. If necessary, recharge the battery. 6 Battery discharge indicator After turning the key in the key-operated switch to the right and pulling the emergency stop switch, the battery discharge indicator steplessly displays the remaining capacity. The indicator is flashing at a remaining capacity of 30 %. If the capacity indication falls below 20 %, the lifting unit is switched off % D 4

28 E Operation 1 Safety regulations governing the operation of the truck Driving licence: The truck must only be operated by personnel that have been adequately trained and have proved to the persons in charge or their representatives their ability to handle the truck correctly and who have been explicitly entrusted with the operation of the truck. Rights, obligations and behavioural rules for the driver: The driver must have been informed about his rights and duties, must have been trained in the operation of the truck and must be familiar with these operating instructions. All necessary rights must be granted to him. If the floor conveyor is to be accompanied by a second person, it is required to wear protective shoes. Operation through unauthorised persons is prohibited: The driver is responsible for his truck during working time. He must forbid unauthorised persons to drive or operate the truck. The transport or lifting of persons is forbidden. Damages and defects: Damage or defects noted on the truck or on the attachments must immediately be brought to the notice of the person in charge. Trucks that cannot be safely operated (e.g. due to worn tires 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 truck. Under no circumstances must the driver change the setting of switches or safety installations, or render them ineffective. f Danger zone: The danger zone is that area in which persons are endangered by driving or lifting movements of the floor conveyor, its load lifting devices (e.g. fork or attachments) or the load. Also the area in which the load may fall down or in which a operating device may be lowered or fall down belongs to this area. Unauthorised persons must be told to leave the danger area. The driver must give a warning signal, whenever a situation presenting danger to persons might develop. The 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

29 2 Operating panel arrangement variants Variant I In case of standard equipment the operating panels are arranged at the front, i.e. in front of the auxiliary lifter. Accordingly the information display under the driver's overhead guard is also arranged in load direction. Variant II The operating panel and the information display are arranged at the mast side. The information display is arranged under the driver's overhead guard. Variant III The operating controls are arranged diagonally. The driver is looking to the left in load direction. The operating panel module "stearing" is arranged at the mast side and the "master pilot" is arranged at the load side. The information display is located at the load side under the overhead guard of the driver. The auxiliary lifter is operated at the load side. E 2

30 Variant IV The operating controls are arranged at the load side and diagonally. The driver is directly or diagonally looking to the left in load direction. The operating panel module "stearing" is additionally available at the mast side. The information display is located at the load side under the overhead guard of the driver. The auxiliary lifter is operated at the load side. Variant V The operating controls are arranged at the mast side and diagonally. The driver is directly or diagonally looking to the left in mast direction. The operating panel module "stearing" is additionally available at the load side. The information display is located at the mast side under the overhead guard of the driver. The auxiliary lifter is operated at the load side. Variant VI Double arrangement of operating controls in load and mast direction. The information display is arranged at the load or at the mast side. The auxiliary lifter is operated at the load and at the mast side. E 3

31 3 Description of controls and indicating instruments 3.1 Operating controls and displays at the instrument panel 10 Pos. Function 1 Emergency stop master switch 2 Steering 3 Supporting strap (two-hand operation) 4 "Pushbutton lift switch-off 5 "Pushbutton track guidance = drive wheel in straight forward position induction guide = induction guide on 6 Drive control knob 7 Horn 8 Hydraulic control knob (two-hand operation) 9 Key switch 10 Optional function keys E 4

32 3.2 Operating controls and indications at the Display Pos. Operating control Function resp. display 12 Display Crawling pace t Drive is switched to crawling pace 13 Steering position indicator t RG IG Indicates the current position of the drive wheel referring to neutral position Aisle recognition track-in possible, track-in in progress, vehicle on track 14 Indication "main lift t Indicates the height of the cabin 15 Display Operating hours t Indicates the operating hours since commissioning 16 Display Time t Indicates the time of day 17 Battery discharge indicator 18 Display Parking brake on 19 Display Emergency- STOP 20 Display Service required/ malfunction 21 Slack-chain safety device display 24 Display Induction guide on IG 26 Display o Lift switch-off inactive 28 Display Synchronous t turning right t = Standard equipment RG = rail guide t Indicates the charging condition of the battery t Illuminates, when the parking brake is engaged t Illuminates, when the Emergency-STOP has been activated t Illuminates, when a service action is required or a malfunction has occurred t Indicates that the slack-chain safety device has responded RG Indicates the straight forward position of the drive wheel Indicates that the induction guide is active Indicates that the automatic lift switch-off has been deactivated Indicates that the function Synchronous turning right has been activated o = Optional equipment IG = induction guide E 5

33 3.3 Symbols indicating the truck s operating status After switching on the truck s operating status is indicated in the display. Barriers open Foot-operated switch not activated If the following symbols are displayed, a reference run must be carried out according to the indication, i.e. the main lift must be lifted by approx. 30 cm and lowered again. Then the control gives a release to carry out all movements of the truck with full speed. Reference run: Lift main lifter Reference run: Lower main lifter E 6

34 4 Putting vehicle in operation f Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area. f f f Checks and actions before routine start-up Perform a visual check of the entire truck for obvious damages or leakages. Check the battery attachment and the cable connections for damages and tight seat. Check the battery connector for tight seat. Check the overhead guard for damages. Check the load lifting device for obvious damages such as cracks, bent or heavily abrased fork. Check the load bearing wheels for damages. Check whether the load chains are tightened evenly. Check whether all safety measures are in good condition and working properly. In case of a rail guide, check idler pulleys on true running and damages. Check brakes for correct function. Only one person is allowed in the driver s cabin! Provide operatability When closing or opening the cabin lock between barrier and frame, take care not to pinch your fingers. Fully close the safety barriers on both sides. Insert key into the key switch (3) and turn clockwise. Turn the Emergency-OFF switch (2) to unlock it. Check the warning signal (horn) for correct function. Check the service brake and parking brake for correct function. Carry out reference run of the lifting mast to adjust height indication and maximum movements. If during start-up procedure any unwanted driving or lifting movements are observed, immediately operate the Emergency-OFF switch. 3 E 7

35 5 Working with the truck 5.4 Safety regulations for operating mode Drive Routes and working areas: Only such lanes and routes that are specially allocated for truck traffic may be used. Unauthorised third parties must stay away from the working area. Loads may only be stored at places specially provided for this purpose. Driving the vehicle: The driver must choose a driving speed suitable for the 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 his 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. Visibility during driving: The driver must look into the driving direction and have a sufficient overview of the driving route. When loads that obstruct the clear view are transported, the truck must travel with the load at the rear. If this is not possible, a second person must give suitable warnings. Driving on slopes: It is not allowed to drive on ascending and decending gradients! Driving in lifts or 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 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 truck must only enter the lift after the truck has come safely to a standstill, and must leave the lift before the truck. Requirements for the load to be transported: Only loads that have been securely fastened according to the regulations may be transported. Never transport any loads that have been stacked higher than the top of the fork carrier or the load backrest. E 8

36 5.5 Driving, steering, braking Emergency stop Push master switch (2) down. All electrical functions are switched off. Do not impair the operation of the main switch by laying objects onto the instrument panel! Driving m Two different operating modes are available for driving: freely travelling or restricted guidance. The restricted guidance is either carried out by rail or induction guide. The operating mode used is dependent on the guidance system of the shelf system where the truck is operated. Do not drive the truck unless the hoods are closed and locked in the stipulated manner. The foot switch must always be pressed during all movements of the truck. Driving outside aisles Close safety barriers (1). Insert key into key switch and switch on. Loosen main switch (emergency- OFF) by turning. Step on the foot-operated button (4). Lower auxiliary lifter completely, carry out reference run of the main lift as indicated on the display and lift main lift by turning the hydraulic control knob (13) to the right until the fork tine is lifted from the ground. Slowly turn drive control knob (5) with your right hand. Turning direction is the driving direction Adjust the driving speed by turning the drive control knob further clockwise or counterclockwise. Steer the truck in the desired direction with the steering wheel (7). E 9

37 Steering Outside narrow aisles the truck is steered using the steering wheel. The angle of the drive wheel is indicated in the display (13). Braking A The braking behavior of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behavior. Braking by means of the service brake While driving, turn the drive direction switch to its zero position or into the opposite travelling direction, the truck is now braked by counter-current. Braking by means of foot-operated switch A m If the foot switch is released, the truck is decelerated dynamically until standstill. Then the holding brake is activated. Do not use this method of braking as service brake! Braking by means of Emergency-STOP switch By activating the Emergency-STOP switch the truck is abruptly braked to standstill. Only activate the Emergency-STOP switch in emergency situations! E 10

38 m A A Driving in narrow aisles Unauthorized persons must stay away from narrow aisles (travelling routes of trucks in shelf systems without safety measures for persons walking in opposite direction); through-traffic is prohibited for persons. These work areas must be marked accordingly. Existing safety equipment at the trucks or the shelf system to avoid risks and protect persons must be inspected daily. This equipment must not be rendered unusable nor must it be misused, obstructed or removed. Any defect of the safety equipment must be immediately reported and corrected. Before entering a narrow aisle the driver must make sure that there are no persons or other vehicles in the aisle. You must only drive into free narrow aisles. If there are persons in the narrow aisle, any operation must be stopped immediately. You must only drive into narrow aisles with trucks intended for use in narrow aisles. If a narrow aisle is equipped with a non-mechanical way striping guidance, the truck must only be driven out of the narrow aisle with crawling speed if the way striping guidance is faulty or switched off. Trucks with rail guide Rail-guided trucks are equipped with sensors activating the aisle recognition when driving into the self aisles. A Drive the truck with reduced speed towards the narrow aisle so that it is in line with the aisle and its markings. Observe all markings on the travel path. Slowly drive the truck into the narrow aisle. Make sure that the guide rollers of the truck thread into the guide rails of the narrow aisle. E 11

39 Press push-button Induction guide on (23). The drive wheel is automatically adjusted in straight direction and the indicator light Induction guide on (24) illuminates. The manual steering is now inoperative. To prepare starting, grasp the handle of the handrest with the left hand (twohand operation). Continue driving the truck with the desired speed in the narrow aisle. Carry on driving the truck in the narrow aisle with the desired speed. Trucks with induction guide Drive the truck with reduced speed at an angle towards the guiding wire. For tracking-in the truck must not be standing in parallel to the guiding wire. The tracking-in angle must be smaller than 35. The tracking procedure should be started in forward direction, since the least time and distance are required in this direction. When close to the guiding wires, switch on the induction guidance with the push-button (23). Indicating light "induction guide active (24) is illuminated. The driving speed is reduced. When reaching the guiding wire, the automatic guidance of the truck is started. The indicator Tracking-in in progress (35) illuminates. The audible tracking signal sounds. E 12

40 The forced induction control takes over the truck steering and slues the truck to the guiding wire. A After the truck has been exactly trackedin to the guiding wire, the tracking-in process is terminated. The indicator (36) changes to Induction guided and the audible signal is turned off. The truck is now guided by forced induction control. In narrow aisles operating mode, the drive and hydraulic function can only be initiated by two-hand control. For two-hand operation the supporting strap (1) of the operating panel module "stearing" and the hydraulic control knob (2) must be grasped. Simultaneous operation of both control knobs (2 and 3) enables combined driving (simultaneous driving and lifting /lowering). f To leave the guiding wire the ON/OFFswitch for the forced induction control switch must switched off. Switching from forced to manual control must not be performed before the entire truck has left the shelf aisle. E 13

41 5.6 Lifting and lowering outside and inside the shelf aisles A In elevated position the operator is not permitted to leave the operator's seat - it is prohibited to climb onto building structures or other vehicles. Lifting - lowering (main lifter) A Step on the foot-operated button. Turn hydraulic control knob (2) simultaneously Clockwise turn = lifting Anti-clockwise turn = lowering The lifting and lowering speeds are proportional to the rotary motion of the hydraulic control knob. If the line break safety device is activated, it can be unlocked by lifting it again. Lifting - lowering (auxiliary lifter) Step on the foot-operated button. Press pushbutton (4) for auxiliary lifter. Turn hydraulic control knob (2) simultaneously Clockwise turn = lifting Anti-clockwise turn = lowering The lifting and lowering speeds are proportional to the excursion of the hydraulic control knob. E 14

42 5.7 Combined driving (simultaneous driving and lifting). A Step on the foot-operated button (1). Trun driving control knob (3) according to the desired driving direction and speed (see chapter "Driving, stearing, decelerating"). Swing hydraulic control knob (2) simultaneously to lift or lower the main lift. Clockwise turn = lifting Anti-clockwise turn = lowering The hydraulics control knob can be used to control the movements of the load lifting device sensitively. To avoid unnecessary mechanical and hydraulic strain, the corresponding hydraulics control knob must be set to its zero position when a hydraulic pressure limiting valve has been activated. The warning lights are automatically switched on when lowering or driving. E 15

43 5.8 Commissioning and stacking m Picking up, transporting and setting down of loads Before picking up a load, the driver has to make sure that it is correctly palletized and that the capacity of the truck is not exceeded. Observe the capacity diagram! Check the fork tine distance for the pallet and adjust, if necessary. Load fork tines symmetrically. Picking up a load from the front m Drive truck in crawling pace. Slowly insert the fork tines into the pallet until the fork back touches the load resp. the pallet. Slightly lift the load off the ground and drive the truck slowly (at crawling pace) backwards. Prerequisite for problem-free working is a perfect ground structure. Transporting a load Outside the shelf aisle, transport the load as low as possible above the floor observing the minimum ground clearance. Only transport loads on both fork tines. When transporting heavy loads, make absolutely sure that the load is evenly distributed across both fork tines. Accelerate the truck sensitively. Travel at a steady speed. Be prepared to brake at any time. Sufficiently lower the travelling speed in tight bends. It is not allowed to drive on ramps as well as ascending and decending gradients. The use is only permitted in closed halls and on flat floors according to DIN Part 1. E 16

44 Setting down a load m m Carefully approach the storage location. Before setting down a load the driver must see for himself that the storage location is suited for the load (measurements and adequate load bearing capacity). Lift the load lifting device to a height sufficient to drive to the storage location without bumping. Carefully stack the load into the storage bay. Lower the load lifting device sensitively until the fork tines are being released. Avoid pancaking the load, in order to prevent damaging the load and the load lifting device. Carefully move the load lifting device out of the load. Fully lower the load lifting device. 5.9 Safe parking of the truck f A If the truck is left unattended, even for only short periods of time, it must be rendered safe. Parking the truck on slopes or inclines is not permitted. In some cases it may be required to secure the truck with chocks, for example. Choose a parking location considering that persons cannot get caught by the lowered fork tines. Lower cabin completely. Lower the fork tines to ground level. Remove safety key in neutral position. E 17

45 6 Fault location This chapter enables the user to locate and to remedy simple faults or the consequences of operating errors. The disturbances are shown on the display. The order of the work stated in the table must be observed for fault location. Fault Possible cause Remedy Truck does not move Battery connector not connected Check the battery connector and reconnect it, if necessary Safety barriers open Close safety barriers Emergency stop pressed Unlock emergency stop Key switch in position "0 Set the key switch to position "I" Battery voltage too low Check the charging condition of the battery and recharge if necessary Foot-operated switch not Step on foot-operated switch activated Drive switch-off activated Press override drive switch-off key and leave danger area Drive switch-off by aisle protection Switch off automatic drive control and re-align truck to guiding wire Slack chain protection Override slack chain protection and Load cannot be lifted Fast travel not possible Vehicle cannot be steered activated See "Truck does not drive remedy the cause Perform all troubleshooting measures that are mentioned under "truck does not drive" Battery voltage too low, lift switch-off Check the charging condition of the battery and recharge if necessary Level of hydraulic oil too Check hydraulic oil level and refill, if low necessary Main lifter lifted more Lower main lifter below 1,2 m than 1,2 m IG search mode activated Track-in truck or deactivate IG mode IG track-in process not Repeat track-in process completed Floor system release is run in again missing See "Truck does not Perform all troubleshooting measures drive that are mentioned under "truck does not drive" Push-button for narrow Switch off narrow aisle operating aisle operating mode has mode been pressed If it was not possible to eliminate the fault by performing the remedial actions indicated above, or if a fault or malfunction is indicated by a corresponding error code, please inform the customer service. More intricate faults can only be rectified by specially trained and qualified service staff. E 18

46 6.1 Emergency-STOP When the automatic emergency stop facility has been activated (if, for example, the guidance is lost, the electrical steering fails or the safety device is activated) the truck is decelerated until standstill. Before putting it into operation again you must determine cause for the malfunction and eliminate the fault. Setting into operation has to be performed according to these operating instruction of the manufacturer. 6.2 Emergency lowering of driver s cabin f When using the emergency lowering facility make sure that all personnel stands clear of the danger zone. The load lifting device is lowered by a person with the emergency lowering facility located at the lower part. Driver and the helping person must communicate during this process. Both persons must stand in an area considered as safe, so that they are not endangered by the actions. The truck may only be put into operation again when the fault has been located and eliminated. If necessary, the cabin can be lowered by a second person at the ground. Slowly open drain valve (37) through the bore hole with Allan key. Do not unscrew screw completely. The cabin is lowered. Fasten Allan key to the truck again after opening the drain valve. 37 E 19