EJB 14/16. Operating instructions

Transcription

1 EJB 14/ Operating instructions G

2 Foreword The present ORIGINL OPERTING INSTRUCTIONS are designed to provide suicient instruction or the sae operation o the industrial truck. The inormation is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identiication consists o a chapter letter and a page number. For example: Page B 2 is the second page in chapter B. The operating instructions detail dierent truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model. m Saety instructions and important explanations are indicated by the ollowing graphics: Used beore saety instructions which must be observed to avoid danger to personnel. Used beore notices which must be observed to avoid material damage. Used beore 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 eatures o the truck. No guarantee o particular eatures o the truck should thereore be inerred rom the present operating instructions. Copyright Copyright o these operating instructions remains with JUNGHEINRICH G. Jungheinrich ktiengesellschat m Stadtrand Hamburg - GERMNY Telephone: +49 (0) 40/ GB

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4 Table o contents Correct use and application o the truck... 1 B Truck description 1 Description o application... B 1 2 ssembly groups... B 2 3 Technical data... B Perormance data... B Dimensions... B Standard hoist rame versions EJB B Standard hoist rame versions EJB B EN standards... B Operation conditions... B 6 4 Location o instruction labels and identiication labels... B Truck identiication label... B Load capacity... B Label/Order/Inventory/Service No.... B 9 C Transportation and commissioning 1 Transportation by crane... C 1 2 First Commissioning... C 1 3 Wheel arm adjustment... C 2 4 Moving the truck without own drive... C 3 D Battery - servicing, recharging, replacing 1 Saety regulations governing the handling o lead-acid batteries... D 1 2 Battery types... D 2 3 Open battery hood... D 2 4 Charging the battery... D 3 5 Removing and installing the battery... D Remove battery by liting it upwards (truck without wheel-arm liting device)... D 4 6 Combined instrument... D GB I 1

5 E Operation 1 Saety regulations or the operation o the loor conveyor... E 1 2 Description o controls and indicating instruments... E 2 3 Putting vehicle in operation... E 4 4 Working with the truck... E Saety regulations or operating mode Drive... E Driving, steering, braking... E Picking up or lowering load units... E Sae parking o the truck... E Fault location... E 11 F Maintenance o the truck 1 Operational saety and protection o the environment...f 1 2 Saety regulations or repair...f 1 3 Maintenance and service...f 3 4 Maintenance check ist...f 4 5 Lubrication schedule...f Operating material...f 7 6 Notes on maintenance...f Preparation o the truck or servicing and maintenance operation...f Open the battery hood...f Open the ront hood...f Check hydraulic oil level...f Check the transmission oil level...f Exchanging the coarse sieve...f Checking the electric uses...f Recommissioning the truck...f 11 7 Taking the loor conveyor out o service...f Operations to be perormed prior to decommissioning...f Measures to be taken during decommissioning...f Recommissioning the truck...f 12 8 Saety checks to be perormed at regular intervals and ollowing any untoward incidents (D: UVV according to VBG 36)...F GB I 2

6 Correct use and application o the truck The Guidelines or the Correct Use and pplication o Industrial Trucks (VDM) are included in the scope o delivery or this truck. The guidelines are part o these operating instructions and must always be heeded. National regulations are ully applicable. The ork-lit truck described in these operating instructions is a truck that is suitable or liting and transporting loads. It must be used, operated and maintained according to the inormation in these operating instructions. ny other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. bove all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identiication plate or load diagram label shown on the truck. The ork-lit truck must not be operated in spaces subject to ire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail. m Duties o the user: user within the meaning o these operating instructions is deined as any natural or legal person who either uses the ork-lit truck himsel, or on whose behal 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 o the ork-lit truck, is charged with the observance o 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 lie and limb o the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other saety-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. I these Operating Instruction are not observed the warranty becomes void. The same applies i improper works are carried out at the device by the customer and/or third parties without permission o our Customer Service. Mounting o attachments: The mounting or installation o any attachments which will interere with, or supplement, the unctions o the truck is permitted only ater written approval by the manuacturer has been obtained. I necessary, the approval o local authorities has to be obtained. ny approval obtained rom local authorities does not, however, make the approval by the manuacturer unnecessary GB 1

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8 B Truck description 1 Description o application The truck is a our-wheel electric lit truck with control shat and controlled drive wheel. It is conceived or liting and transporting palleted goods on level ground. The nominal load capacity can be ound on the identiication label. The load capacity in relation to liting height and load centre distance is speciied on the load capacity label. B 1

9 2 ssembly groups Pos. EJB 14/16 Description 1 t Key switch 2 o Combined instrument (battery discharge monitor and operating hour meter) 3 t Control shat with control shat head 4 t "Shunt driving" button 5 t Driving regulator 6 t Collision-guard button 7 t Hoist rame 8 t Protective pane 9 t Battery hood 10 t Master switch (emergency stop) 11 o Load protection screen 12 t Liting device 13 t Wheel arm 14 t Front hood 15 t Supporting wheel 16 t Drive wheel 17 o Document case B 2

10 3 Technical data Speciication o technical data according to VDI Technical modiications and supplements reserved. 3.1 Perormance data Description EJB 14 EJB 16 Q Nominal load capacity kg C Load centre distance at standard ork length mm Driving speed with / without load 6.0 / / 6.0 km/h Liting speed with / without load 15 / / 23 cm/s Lowering speed with / without load 44 / / 40 cm/s Max. hill-climbing ability with / without load 8 / 16 7 / 16 % 3.2 Dimensions Description EJB 14 EJB 16 s lowered height o the load ork mm y Wheel base mm l 1 Truck length at ork length 1150 mm mm l 2 Length o ront section mm B Truck width (djustable min/max) 1120 / / 1570 mm b 4 Dimension between wheel arms (adjustable) mm b 5 Overall distance o ork (adjustable) mm m 2 Ground clearance mm st Working corridor width 1) 1000 x 1200 diagonal mm st Working corridor width 1) 800 x 1200 longitudinal mm Turning circle or shunt driving (raised Wa control shat) mm 1) with DZ hoist rame:+ 4 mm B 3

11 h 4 h 3 h 1 h5 l c h 2 h 8 Q m 2 s 20 y l 2 l 1 st b 4 b 5 B W a B 4

12 3.3 Standard hoist rame versions EJB 14 Description Telescopic mast (ZT) 3.4 Standard hoist rame versions EJB 16 Double dual reach lit (ZZ) 1) h 1 = +50 mm or ZT hoist rame at 100 mm ree lit (h 2 ) 2) only or ZT hoist rame 3) only or ZZ and DZ hoist rame 4) with LSG +410 mm 5) with LSG -410 mm Dual lit triplex mast (DZ) h 1 Overall height 1) mm h 2 Free liting capacity 2) mm h 3 Liting height mm h 4 Max. height 4) mm h 5 Free liting capacity 3) 5) mm Description Telescopic mast (ZT) Double dual reach lit (ZZ) Dual lit triplex mast (DZ) h 1 Overall height 1) mm h 2 Free liting capacity 2) mm h 3 Liting height mm h 4 Max. height 4) mm h 5 Free liting capacity 3) 5) mm B 5

13 3.5 EN Standards Permanent sound level: 65 db() 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, liting and in idle mode. The sound level is measured at the driver s ear. Electromagnetic compatibility (EC) Observance o the ollowing limit values according to pren "Floor Conveyors, Electromagnetic compatibility": -Intererence emission (EN ) -Resistance to disturbance (EN ) -Electrostatic discharge (EN ) lterations o the electric or electronic components and their arrangement must only by carried out with written approval o the manuacturer. 3.6 Operation conditions Environmental temperature Standard type during operation: +5 C to +40 C I the loor conveyor is to be permanently used in an environment with 5 C or less, in cold storage depots or in areas with extreme temperature or humidity changes, a special equipment and approval is required. B 6

14 V JUNGHEINRICH 4 Location o instruction labels and identiication labels Item Description 18 Load capacity 19 Prohibition sign Do not transport other persons 20 Truck identiication label 21 Limit-stop or crane loading 22 Prohibition sign Keep away rom under the load liting device 23 Prohibition sign "Do not put your hands through the hoist rame" 24 UVV control label 25 Identiication label, battery 26 Warning sign Caution: Low-voltage electronics B 7

15 4.1 Truck identiication 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 Item Description Item Description 27 Model 33 Load centre distance in mm 28 Serial no. 34 Min./max. battery weight in kg 29 Order no. 35 Net weight without battery in kg 30 Nominal load capacity in kg 36 Year o manuacture 31 Battery: Voltage V 37 Type no. mpere hours h 32 Maker 38 Maker s logotype In the event o queries relating to the truck or spare part orders, please state the serial no. (28) o the truck. 4.2 Load capacity The label (18) includes a table indicating the loading capacity (Q in kg) in relation to the load centre distance (D in mm) and the liting height (H in mm). 18 The arrow-shaped markings on the inner mast (39) and outer mast (40) show the driver when he has reached the liting height limits that is deined on the load capacity label (18) B 8

16 4.3 Label/Order/Inventory/Service No Item Description 41 Order no. 42 Inventory No. 43 Full Service No. This label contains the Full Service No. and is only handed out when a service contract is being concluded. B 9

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18 C Transportation and commissioning 1 Transportation by crane Only use liting equipment with suicient bearing capacity (loading weight see identiication label on truck). hoisting point (1) is provided at the hoist rame or loading the truck with the help o hoisting gear. m Park the truck and render it sae (reer to chapter E). ttach the hoisting gear to the stop (1) on the hoisting mast. Secure the hoisting gear to the hoisting points ensuring that the hoisting gear will not slip! The hoisting gear must be attached in such a way that it does touch any add-on parts while the truck is being lited. 1 2 First commissioning m The truck must only be operated on battery current. Rectiied alternate current will damage the electronics. Cables connected to the battery (towing cable) must be less than 6 meters in length. It is prohibited to hoist loads when the truck is operated via a towing cable with an external battery. In order to prepare the truck or work ollowing delivery or transportation, the ollowing operations must be perormed: Check whether the equipment is complete and in perect condition. I required, mount the battery, make sure not to damage the battery cable (see chapter D). Load the battery (see chapter D). I required, check whether the settings o the combined instrument correspond to the battery (see chapter D). Commission the truck as prescribed (see chapter E). I the truck is parked or longer periods, the running suraces o the wheels may be lattened. However, this lattening will disappear quickly when the truck is being driven. C 1

19 3 Wheel arm adjustment The distance between the wheel arms is adjustable (reer to chapter B). djusting the wheel arms must only be carried out be trained service personnel. 4 Moving the truck without own drive This type o operation is prohibited on slopes and inclinations. I the truck must still be moved ater a ault has occurred, proceed as ollows: Set master switch to "OFF" position. Set key switch to "0" position and remove the key. Secure the truck against rolling away. Open and remove ront hood (see chapter F). Turn the screws (2) anticlockwise until you reach the limit stop. The solenoid brake is triggered. The truck can now no longer be moved. I you reached the target location, reset the brake system to its original condition! The truck must not be parked with released brake! 2 Return the screws (2) anticlockwise until they touch the limit stop. The original brake condition is restored. C 2

20 D Battery - servicing, recharging, replacing 1 Saety regulations governing the handling o lead-acid batteries Beore works are perormed on the batteries, the truck must be parked and suiciently secured (see chapter E). Servicing sta: Recharging, servicing and replacing o batteries must only be perormed by qualiied 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 perorming the above operations. Fire protection measures: Smoking and naked lames are not permitted when handling batteries. No inlammable substances or spark-generating materials must be present or stored within a distance o 2 meters o the truck parked or battery recharging. The location must be well ventilated. Fire ighting equipment must be kept ready. Servicing o 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 non-insulated poles must be covered with an antislip insulating jacket. m m Disposal o the battery: Batteries must only be disposed o as stipulated in the national environmental protection regulations or waste disposal provisions. The manuacturer s speciications or the disposal must be heeded. Beore 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. void physical contact with battery acid. I clothing, skin or eyes have accidentally come into contact with battery acid, liberally lush the aected 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. Only batteries with closed battery trough may be used. Battery weight and dimensions have considerable inluence on the saety o truck operation. change o battery equipment is only permitted with approval o the manuacturer GB D 1

21 2 Battery types Depending on the type, the truck can be equipped with dierent battery types. The battery weights are speciied on identiication label o the battery. m When changing / assembling the battery, make sure that it is properly ixed in the battery compartment the truck. The ollowing table shows the standard battery combinations and battery capacities: Truck type EJB 14 / 16 EJB 14 / 16 24V - Pz... - battery 3 PzS L 270 h 3 PzS L 330 h Depending on the battery type, also high-perormance or maintenance-ree batteries can be used. 3 Open battery hood Park the truck and render it sae (reer to chapter E). Set master switch (2) to "OFF" position. Open the battery hood (1). The battery hood (1) is held in place by its own weight GB D 2

22 4 Charging the battery m m s deault, the truck is to be loaded with a stationary battery charger. For recharging the battery, the truck has to parked in-doors in a suiciently ventilated environment. Park the truck and render it sae (see chapter E). Connection / disconnecting battery connector and socket as well as pressing the master switch (2) may only be perormed with truck and battery charger being switched o. Expose the battery (see section 3). During the recharging operation the tops o 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 or visible damage. The saety instructions provided by the battery supplier and battery charger supplier must be strictly observed. m Pull battery connector (3) rom the plug and socket connection o the truck. Remove insulation mat rom battery, i necessary. Connect the charging cable (4) o the battery recharging station with the battery connector (3) and switch on the battery charger. Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier GB D 3

23 5 Removing and installing the battery Expose the battery (see section 3). The truck must stand horizontally. Batteries with exposed terminals or connectors must be covered with a rubber mat to prevent short-circuits. Place battery connector and battery cable in such a way that they do not get caught within the truck interior when the battery is pulled out. When replacing batteries, ensure that a battery o the same type is itted. Supplementary weights may not be removed or changed in their position. ter reinstallation o the battery, visually check all leads and connectors or damage. Beore commissioning the truck, the battery hood must be properly closed. When changing the battery with the aid o a liting gear, ensure that the liting gear is o adequate capacity (the battery weight is indicated on the battery identiication plate at the battery trough). The battery must be lited vertically to prevent crushing o the battery trough. The hooks are to be attached to the battery hoisting ears (5) that they cannot all onto the battery cells when the hoisting gear is released. 5.1 Remove battery by liting it upwards (truck without wheel-arm liting device) Withdraw the battery connector. ttach hoisting gear to the hoisting ears (5). Lit out the battery. 5 The re-assembly can be perormed by reversing the above actions; pay attention to the correct mounting position and battery connection GB D 4

24 6 Combined instrument m Battery discharge indicator: The discharging status o the battery is indicated by 10 beams on battery icon (6) representing 10 %-steps. s the discharge proceeds, the beams go out rom top to bottom. I maintenance-ree batteries are used, the instrument must be adjusted in such a way that the T icon (9) appears next to the operating hours indicator. I this setting is not selected, the battery may be damaged due to a complete discharge. For adjusting the instrument, it is recommended to consult the manuacturer service. 6 7 T h When a remaining battery capacity o - 30 % or standard batteries - 50 % or maintenance-ree batteries is reached, a "CUTION" icon (7) is indicated. Recharging the battery is recommended. T h When a remaining battery capacity o - 20 % or standard batteries - 40 % or maintenance-ree batteries is reached, the "CUTION" icon goes out and a lashing "STOP" icon (8) appears. ter 5 min., the "STOP" icon box lights up permanently. Recharging the battery is recommended. 8 9 T 10 STOP h Battery discharge monitor: When the "STOP" icon is permanently lit, the liting unction is switched o. The liting unction can only be re-activated, when the connected battery is at least recharged by 70%. Operating hour meter: The operating hour meter (10) is integrated in the battery discharge indicator and displays the overall operating time o all driving and liting movements. The digit to the right-hand side o the decimal point is lashing when the device is active GB D 5

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26 E Operation 1 Saety regulations or the operation o the loor conveyor Driving licence: The loor conveyor must only be operated by persons who 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 o the truck. Rights, obligations and behavioural rules or the driver: The driver must have been inormed about his rights and duties, must have been trained in the operation o the truck and must be amiliar with these operating instructions. ll necessary rights must be granted to him. I the loor 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 or his truck during working time. He must orbid unauthorised persons to drive or operate the truck. Persons may neither be transported nor lited. Damages and deects: Damages or deects noted on the truck or on the attachments must immediately be brought to the notice o the person in charge. Trucks that cannot be saely operated (e.g. due to worn tires or deective brakes) must not be used until they have been properly repaired. Repairs: Without speciic training and express authorisation the driver is not allowed to perorm any repairs or modiications on the truck. Under no circumstances must the driver change the setting o switches or saety installations, or render them ineective. Danger zone: The danger zone is that area in which persons are endangered by driving or liting movements o the loor conveyor, its load liting devices (e.g. ork tines or attachments) or the load. lso the area in which the load may all down or in which a operating device may be lowered or all 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, i persons, although asked, do not leave the danger area. Saety devices and warning labels: The saety devices, warning labels and warning notes described in the present operating instructions must always be heeded. E 1

27 2 Description o controls and indicating instruments Pos. Controls or indicating instrument respectively 1 Master switch (Emergency Stop) EJB 14/16 t Function The circuit is interrupted, all electric unctions are switched o. The truck is compulsory braked. 2 Key switch t Switches the control current on and o. When the key is removed rom the key switch, the truck cannot be operated by unauthorised persons. 3 Combined instrument o Indicates the remaining capacity o the battery and the hours o operation that truck has already perormed (see chapter D). 4 Control shat t Steering and braking the truck. 5 Button - Shunt driving t I the control shat is in the upper braking range, the braking unction can be by-passed by pressing this button. The truck can only be moved with reduced speed (shunt driving). 6 Driving regulator t Controls the driving direction driving speed. 7 Collision-guard button 8 Button - Liting the liting device 9 Button - Lowering the liting device 10 Button - warning signal (horn) t t t t Truck drives away rom the operator and stops. Liting the liting device. The liting speed can be continuously adjusted with this key (adjustment range 8 mm). Lowering the liting device. The lowering speed can be continuously adjusted with this key (adjustment range 8 mm). Trigger warning signal. 11 Terminal strip t Depositing o reight documents. 12 Document case o Used or depositing documents t = Standard equipment o = Optional equipment E 2

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29 3 Putting vehicle in operation Beore starting or operating the truck, or beore liting any loads, the driver has to make sure that nobody is within the danger area. Checks and actions beore routine start-up Visual inspection or damages o the whole truck (especially tyres and load carrying devices). Visual inspection o battery ixing and cable connections. Starting up the truck Pull out master switch (1). Put key into the key switch (2) and turn right until stop to position "I". The combined instrument (3) indicates the available battery capacity. Check unction o horn (10). Check control shat (4) or braking and driving unction (see section 4.2). The truck is now ready or operation. E 4

30 4 Working with the truck 4.1 Saety regulations or operating mode Drive Routes and working areas: Only such lanes and routes that are specially allocated or truck traic may be used. Unauthorised third parties must stay away rom the working area. Loads may only be stored at places specially provided or this purpose. Driving the vehicle: The driver must choose a driving speed suitable or 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 keep an adequate braking distance between his truck and the vehicle in ront and he must be in control o the loor conveyor at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. Leaning or gripping out o the working and operating range is prohibited. Visibility during driving: The driver must look into the driving direction and have a suicient overview o the driving route. I load units are transported which are obstructing the driver's view, the loor conveyor is to be driven with the load pointing to the back. I this is not possible, a second person must give suitable warnings. Driving on slopes: Driving on slopes or descents is only permitted, i they are deined as traic routes and i the surace is clean and suitable or driving. In addition, these routes must conorm to the regulations or sae driving as deined in the technical truck speciications. Loads must always be carried at that end o the truck acing uphill. U-turns, cutting obliquely over slopes or inclines and parking o the 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. Driving in lits or on loading platorms: Lits and loading platorms must only be used, i they are o adequate load bearing capacity, i suitable or driving on, and i authorised by the user o the truck or truck traic. The truck must enter lits with the load in ront and must take up a position which does not allow it to come into contact with the walls o the lit shat. Persons riding in the lit together with the truck must only enter the lit ater the truck has come saely to a standstill, and must leave the lit beore the truck. Requirements or the load to be transported: Only loads that have been securely astened according to the regulations may be transported. Never transport loads that have been stacked higher than the top o the ork carrier or the load backrest. E 5

31 4.2 Driving, steering, braking Increased attention has to be paid during driving and steering the truck, especially i movements outside o the truck contour are to be perormed. It is not admissible to stay on the vehicle during driving. Driving with load liting devices or loads lited higher than the ground clearance distance is only permitted when the load is to be picked up or to be lowered to the ground. Beginning with a construction-dependent liting height the driving speed is automatically reduced during liting and increased again when lowering. EMERGENCY STOP Push master switch (1) down. ll electric unctions are switched o. The truck is compulsory braked. Emergency stop When the control shat (4) is released, the truck is compulsory braked (emergency stop) - the control shat (4) automatically swivels into the upper braking range (B). I the control shat (4) swivels only slowly into the braking position, it is required to perorm troubleshooting measures. For example, the return spring must be exchanged! 7 4 R 6 B 0 V F B R V 1 Driving Do not drive the truck unless the hoods are closed and locked in the stipulated manner. When driving through swinging doors, etc., make sure that the doors do not trigger the collision-guard button (7). Commissioning the truck (see section 3). Push the control shat (4) into the driving range (F) and set the driving switch (6) to the desired driving direction (V or R). The truck starts to drive into the selected direction. The driving speed can be continuously regulated with the driving switch (6). E 6

32 m I the truck can only be moved with reduced driving speed, a deect has occurred which is inluencing the saety o operation o the truck. It may be that the service brake can only be used ater pressing the EMERGENCY-STOP switch (1). The truck needs to be taken out o service and must be repaired by expert personnel (see chapter F). Driving on slopes The load must be transported pointing towards the mountain! Securing the truck against "rolling downhill": I the driving switch is set to zero, the service brake is automatically triggered when the truck starts to roll downhill (the control system detects the unintended movement o the truck). The driving switch can be used to release the service brake and to select the desired driving speed and direction. I the roll-o brake was deactivated by the service, only service brake and counterlow brake are available. Steering Swivelling the control shat to the let-hand or right-hand side. m Shunt driving The driver must pay special attention i he uses the "Shunt driving" button (5). The truck can be moved with its control shat (4) in vertical position (e.g. in conined spaces / lits): Press "Shunt driving" button (5). Set the driving switch (6) to the desired driving direction (V or R). The service brake is triggered. The truck changes to the slow-driving mode. The service brake is only activated ater releasing the "Shunt driving" button; in the Shunt driving mode, braking is only possible using the counterlow brake (driving switch (6)). In case o danger, the truck can be immediately braked by releasing the "Shunt driving" button (5) E 7

33 Braking The braking eect o the truck is mainly depending on the road surace. This must be taken into account by the driver or his driving behavior. The truck may be braked in three ways: - Using the service brake (control shat (4)), - Using dynamic braking (roll-o brake can be adjusted by the service), - Using the counterlow brake (adjustable via driving switch (6)). For standard driving operations, only the dynamic brake and that counterlow brake are to be used, since these brake types are reduce wear and tear and help to save energy (energy return supply). Braking with the service brake: In case o danger, the truck must be braked with the service brake (control shat (4)). Swivel control shat (4) upwards or downwards into one o the braking ranges (B). The drive motor is mechanically braked. When the control shat (4) is released, it swivels into the upper braking range (B).I the truck is parked, the service brake is used as parking brake 7 4 R 6 B 0 V F B R V 1 Dynamic braking (roll-o brake): m ter releasing the driving switch - driving switch set to zero - the truck is braked with the help o the dynamic brake (roll-o brake), depending on the selected setting. I the roll-o brake was deactivated by the service, only service brake and counterlow brake are available. Braking with the counterlow brake: I the control system or driving mechanism breaks down, the counterlow brake becomes ineective. Turn driving switch (6) into the opposite driving direction until the truck comes to a standstill. The braking eect depends on the position o the driving switch. E 8

34 4.3 Picking up or lowering load units Beore a load unit is picked up, the driver has to make sure that it is properly palletised and does not exceed the permitted bearing capacity o the truck. Do not grab into the hoist rame during liting and lowering. Drive the truck with the ork tines as ar as possible below the load unit. It is not permitted to pick up long goods with the truck driving transversally below the good. The double-two liting hoist rame (ZZ) and the triple-two hoist rame (DZ) the irst liting movement o the load carriage (ree liting capacity) is realised without changing the overall height with the help o a short ree-liting cylinder which is centrally arranged. Liting Press the "Lit the liting device" button (8) until the desired height has been reached. Lowering Press the "Lower the liting device" button (9) until the desired height has been reached. m The liting/lowering speed can be continuously adjusted with this button (adjustment range 8 mm). Small button adjustment range= slow liting/lowering Large button adjustment range= ast liting/lowering void any abrupt lowering o the load unit. 8 9 E 9

35 Emergency lowering system The emergency lowering system may only be used i there are no persons within the danger zone. I the liting device can no longer be lowered due to a deect in the liting control system, the emergency lowering system has to be activated. Set key switch (2) to its "0" position and set the master switch (1) to its "OFF" position. Pull the battery connector (see chapter D). Open the ront hood (see chapter F). Loosen the screw on the valve group (13). The required llen key (2.5 mm) can be ound at the valve group. The liting device is lowered. Retighten the screw (13) ater the emergency lowering procedure has been perormed. The truck may only be retaken into service ater the required troubleshooting measures were successully perormed Sae parking o the truck I the truck is let unattended, even or only short periods o time, it must be rendered sae. Do not park the truck on slopes! The liting device must always be completely lowered. Bring control shat (4) into brake position (B). Lowering the liting device. Set key switch (2) to "0" position and remove the key. Set master switch (1) to "OFF" position. E 10

36 4.5 Fault location This chapter helps the operator to locate and ix simple malunctions or the results o operating errors him- or hersel. The order o the work stated in the table must be observed or ault location. Fault Possible cause Remedy Truck does not move Load cannot be lited Battery connector not connected Master switch (EMERGENCY STOP) pressed Check the battery connector and reconnect it, i necessary Release master switch (EMERGENCY STOP) Key switch set to 0 position Set the key switch to position "I" Battery voltage too low Check the charging status o the battery and recharge, i necessary Control shat not swivelled into driving range (F) Faulty use Swivel control shat into driving range (F) Check uses F1 and 1F1 Truck not ready or operation Perorm all troubleshooting measures that are mentioned under "truck does not drive" Hydraulic oil level too low Check hydraulic oil level Faulty use Check use 2F1 load too high Pay attention to the maximum bearing capacity (see identiication label) I it is not possible to rectiy the ault by perorming the indicated "remedial actions", please contact the Customer Service, as more intricate aults can only be rectiied by specially trained and qualiied service personnel. E 11

37 E 12

38 F Maintenance o the truck 1 Operational saety and protection o the environment m The checks and maintenance work listed in this chapter have to be perormed according to the intervals o the maintenance checklists. Modiications o truck assemblies, especially o the saety installations, are not permitted. On no account must the operational speeds o the truck be changed. Only original spare parts have been passed by our quality assurance service. In order to ensure sae and reliable operation only original spare parts o the manuacturer must be used. Old parts and changed consumption type materials must be disposed o in accordance with the applicable environmental protection regulations. The Oil Change Service o the manuacturer is available or oil changes. Upon completion o any checks and servicing activities, the operations contained in the section "Recommissioning" must be perormed (see section 6.8). 2 Saety regulations or repair Servicing and maintenance personnel: Maintenance and repair o the loor conveyors may only be perormed by expert personnel o the manuacturer. The Service Organisation o the manuacturer has service engineers available that have been speciically trained or these tasks. We thereore advise to conclude a maintenance contract with the manuacturer s Service Base responsible or the area. Liting and jacking up: When a ork-lit truck is to be lited, the liting gear must only be secured to the points specially provided or this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck rom slipping or tipping over (use o chocks, wooden blocks). Work underneath raised orks must only be carried out, when the ork is immobilised and supported by a chain o adequate strength. m Cleaning operations: No inlammable liquids must be used when cleaning the industrial truck. Prior to perorming cleaning operations all appropriate saety measures must be taken to avoid sparking (e.g. due to short circuits). The battery connector must be disconnected. Electric and electronic components must be cleaned with lowpressure air or suction air and a non-conducting, antistatic brush. I the truck is to be cleaned using water or a steam jet, all electric and electronic assemblies have to be careully covered beorehand, as humidity will cause malunctions. Steam-cleaning is not permitted. Upon the completion o cleaning work the operations detailed in section Recommissioning have to be perormed. F 1

39 Working on the electrical installation: ll work on the electrical installation must be carried out only by electrotechnically skilled personnel. Beore commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated loor conveyors, the truck must also be depowered by removing the battery connector. Welding operations: To prevent any damage to electric or electronic components, these have to be removed rom the ork-lit truck beore any welding operations are undertaken. Settings: The vehicle settings must be observed when carrying out repairs and changing hydraulic / electric / electronic components. Tire equipment: The quality o the tires greatly aects the stability and the driving behaviour o the ork-lit truck. Modiications must only be carried out ater discussion with the manuacturer. When replacing wheels or tires, it must be ensured that the truck remains level (tires and wheels must always be replaced in pairs, i.e. let and right together). Lit chains: The lit chains wear rapidly i not lubricated. The intervals stated in the service checklist apply or use in normal environment. For applications in aggravated conditions (dust, temperature), requent re-lubrication must be perormed. Use the correct chain spray oil as prescribed. I grease is only externally applied, no suicient lubrication can be realised. Hydraulic hoses: The hoses must be replaced ater a service lie o six years. When replacing hydraulic components the hoses in this hydraulic system should be replaced. F 2

40 3 Maintenance and service m Thorough and expert servicing is one o the most important preconditions or sae operation o the ork-lit truck. The neglect o regular servicing intervals can lead to ork-lit ailure and constitutes a potential hazard to personnel and operation. The indicated servicing intervals are based on single-shit operation under normal operating conditions. For applications in dusty environments, or involving large temperature luctuations or multiple-shit operation, the servicing intervals must be shortened accordingly. The ollowing servicing checklist indicates the operations to be perormed and the respective intervals to be observed. The ollowing maintenance intervals are deined: W1 = Every 50 operating hours, at least, however, once a week M3 = Every 500 operating hours, at least, however, every 3 months M6 = Every 1000 operating hours, at least, however, every 6 months M12 = Every 2000 operating hours, at least, however, every 12 months In the running-in phase o the truck, the ollowing additional operations have to be carried out: ter the irst 100 operating hours: Check the wheel nuts or security and retighten, i required. Check the hydraulic connections or leaks and retighten, i required. ter the irst 500 operating hours: Changing hydraulic oil and ilter cartridge Flush the the coarse sieve, i required exchange it (see section 6.6). F 3

41 4 Maintenance checklist Maintenance intervals Standard = t W M M M Cold-storage depot = k Chassis/ 1.1 Check all load bearing elements or damage t Design: 1.2 Check all bolted connections d) t Drive unit: 2.1 Check the transmission or noises and leakage t 2.2 Check the transmission oil level t 2.3 Change the gear oil k t Wheels: 3.1 Check or wear and damage t 3.2 Check seating and attachment a) k t Steering: 4.1 Check the steering clearance t Brake 5.1 Check or correct unction and adjustment k t system: 5.2 Check the return spring or repositioning unction and t damage 5.3 Check the brake linings or wear t 5.4 Check the brake linkage; adjust and grease, k t i necessary Hoist rame: 6.1 Visual check o rollers, slide pieces and stops k t 6.2 Check ork tines and ork carrier or wear and damage k t 6.3 Check secure attachment o hoist rame t 6.4 Check lit chains and chain guide or wear, adjust and grease them. t 6.5 Check the lateral clearance o the mast proiles and whether they are parallel to each other t 6.6 Check saety devices or proper attachment k t and damages Liting device: 7.1 Check unction, wear and tear and adjustment t 7.2 Visual check o rollers, slide pieces and stops k t 7.3 Check ork tines and ork carrier or wear and damage k t Hydr. system: 8.1 Check unction k t 8.2 Check all connections or leakage and damage b) k t 8.3 Check hydraulic cylinders or leakage, damage and k t secure attachment 8.4 Check the oil level k t 8.5 Change hydraulic oil c) k t 8.6 Change ilter t 8.7 Check the pressure relie valves or correct unctioning k t a) First check o the wheel nuts ater approx. 100 operating hours or tight it. Re-tighten i necessary. For starting torque, see maintenance plan. b) Hydraulic connections to be irst checked or leakage ater approx. 100 operating hours; tighten, i necessary. c) 1. exchange ater 500 hours o operation / i required, change coarse sieve. d) Check the wheel arm astening screws or the irst time ater approx. 100 operating hours and re-tighten, i necessary. For starting torque, see maintenance plan. The maintenance intervals reer to normal service conditions. I you are working under diicult conditions, reduce the intervals, i required. F 4

42 Electr. system: Electric motors: Maintenance intervals Standard = t W M M M Cold-storage depot = k Check unction t 9.2 Check all cables or secure connection and damage t 9.3 Check the uses or correct amperage t 9.4 Check switches and trip cams or proper unctioning and t seating 9.5 Check contactors and relays, replace wearing parts, t i necessary 9.6 Check unctioning o warning devices and saety circuits k t 10.1 Check wear o carbon brushes t 10.2 Check the motor or secure attachment t 10.3 Suck out engine block, check wear o collector k t Battery: 11.1 Check acid density, acid level and cell voltage k t 11.2 Check the terminals or secure attachment and apply k t pole grease 11.3 Clean battery connections, check or tight it k t 11.4 Check the battery cables or damage and replace, t i necessary Lubrication service: 12.1 Grease truck according to lubrication schedule k t General measurements: 13.1 Check electrical system or short to ground t 13.2 Check driving speed and braking distance t 13.3 Check liting and lowering speed t 13.4 Check saety acilities and switch-o devices t Demonstration: 14.1 Perorm a trial run under a nominal load t 14.2 Demonstrate the truck to a person charged with inspection upon completion o the maintenance o the k t truck F 5

43 5 Lubrication schedule G B b B+C 1) 1,4l +C 1) M = 105 Nm 2) a g Slide aces s Grease nipple Filler neck or hydraulic oil b Filler neck Gear oil a Drain plug Gear oil 1) Mixing proportion or application in cold-storage depots 1:1 2) Filling level see "Check hydraulic oil level" F 6

44 5.1 Operating material Handling operating material: Consumption type material must always be handled properly. Manuacturer's instructions to be observed. Improper handling endangers health, lie and environment. Operating material must only be stored in containers conorming to speciication. They might be inlammable and must not come into contact with hot components or open ire. When illing in consumption type materials, use clean containers only. It is prohibited to mix consumption type materials o dierent grades or qualities, except i mixing is expressively prescribed in these operating instructions. -This instruction may only be ignored, i another mixing ratio is explicitly prescribed in this manual. void any spilling. Spilled liquid must be removed immediately using a suitable binding agent, and the mixture o consumption type material and binding agent is to be disposed o according to the regulations. Code Order-no. Supplied Description Used or: quantity l H-LP 46, DIN Hydraulic system B l CLP 100, DIN Transmission C l H-LP 10, DIN Transmission hydraulic system E kg Grease, DIN Lubrication service F kg Grease, TTF52 Lubrication service Grease standard values Code Type o Saponiication Dropping point C Worked penetration at 25 C NLG1 Class Service temperature C E Lithium /+120 F /+100 F 7

45 6 Notes on maintenance 6.1 Preparation o the truck or servicing and maintenance operation ll required saety measures must be taken to prevent any accidents in the course o the servicing and maintenance operations. The ollowing preparatory operations must be perormed: Park the truck and render it sae (reer to chapter E). Disconnect the battery connector to prevent accidental or unauthorised truck operation. When work has to be perormed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping o the truck. When liting the truck, the instructions included in chapter Transportation and Commissioning have to be observed. 6.2 Open the battery hood See chapter D. 6.3 Open the ront hood Turn the control shat to the truck outer edge or incline it slightly. Release the hood locking mechanism (1); the key (2) can be ound in the battery compartment. Raise the hood (3) and place it next to the truck. Mounting is perormed in reverse order F 8

46 6.4 Check hydraulic oil level Prepare the truck or servicing and maintenance operations (see section 6.1). Open the ront hood (see section 6.3). Check the hydraulic oil level o the hydraulic tank (see section 5). There are markings on the hydraulic tank (see section 5). The oil level must be chekked with the liting device being lowered. I required, top up with hydraulic oil with the required characteristics (see section 5.1; see table) Mounting is perormed in reverse order. 6.5 Check the transmission oil level Marking Litre Liting heights (h 3 ) E ZT ZZ DZ Upper edge approx up to approx approx up to 4300 up to approx up to 4300 up to approx. 5.1 all up to 3200 up to Prepare the truck or servicing and maintenance operations (see section 6.1). Open the ront hood (see section 6.3). Loosen 2 x screws (5) using the key (2). Remove careully the wheel cover (4). Check gear-oil level - oil level must reach the iller neck (see section 5). I required, top up with gear oil with the required characteristics (see section 5.1). Mounting is perormed in reverse order. 6.6 Exchanging the coarse sieve m m Preparation o the truck or servicing and maintenance operations (reer section 6.1). Open the ront hood (see chapter F, section 6.3). Loosen the screwed connection (6). Pull o the connection (7) and remove the coarse sieve. Insert a new coarse sieve. Mounting is perormed in reverse order. Tighten screwed connection (6) with max Nm. 6 7 F 9