ETM/V 214/216. Operating instructions

Transcription

1 ETM/V 214/ Operating instructions G

2 Important Information for Transport and Assembly of Hoist Frames for Reach Trucks Transport Depending on the height of the hoist frame and local conditions three different types of lifts may be undertaken: Standing with assembled hoist frame (for low heights) Standing with partially assembled hoist frame tilted against the overhead guard (for average height). Hydraulic hoses for lift function are disconnected Standing, with dismantled hoist frame (for large heights) all hydraulic hoses between the main unit and the hoist frame are disconnected. f Safety Instructions for Assembly and Commissioning On site assembly of the truck, commissioning and driver instruction shall only be carried out by staff trained and authorised by the manufacturer. Only after the lifting equipment has been correctly assembled may the hydraulic hoses be connected to the main unit / hoist frame interface and the truck put into operation

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4 Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B. The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model. F M t o Safety instructions and important explanations are indicated by the following graphics: Used before safety instructions which must be observed to avoid danger to personnel. Used before notices which must be observed to avoid material damage. Used before notices and explanations. Used to indicate standard equipment. Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions. Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand Hamburg - GERMANY Telephone: +49 (0) 40/ GB

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6 Table of Contents A B Regulatory Use of Machine Truck Description 1 Application... B 1 2 Description of Assemblies and their Function... B Truck... B Placing the Load... B 6 3 Technical Data Standard Design... B Performance Data... B Dimensions... B Standard Hoist Frames ETM/V 214/ B EN Standards... B Condition for Use... B 11 4 Identification Points and Data Plates... B Data plate, truck... B Capacity Plate, Capacity / Load Centre of Gravity / Lift Height... B Jack Securing Point... B Notice: Observe Operator Manual... B 14 C Transport und Commissioning 1 Transport... C 1 2 Lifting by Crane... C 2 3 Securing the Machine for Transport.... C 3 4 Transport Lock, Safety Brake... C 4 5 Commissioning... C 5 D Battery - Maintenance, Charging, Replacement 1 Safety Regulations when handling acid batteries... D 1 2 Battery Types... D 2 3 Exposing the Battery... D Battery troley - Emergency Unlocking... D 3 4 Battery Charging... D 4 5 Removing and Fitting the Battery.... D 5 6 Battery Discharge Display, Battery Discharge Monitor, Hourmeter... D Driver s Display (t)... D On Board Computer (o)... D 8 I 1

7 E Operation 1 Safety Regulations for the Operation of Fork Lift Trucks... E 1 2 Description of Operating and Display Elements... E 2 3 Starting the Truck... E How to use the safety belt (o)... E Preparation for Use... E Emergency Stop Device... E 11 4 Operating the Forklift Truck... E Safety Rules when Driving... E Driving, Steering, Braking... E Fork Adjustment... E Picking Up and Depositing a Load... E Emergency Lowering... E Operating Attachments... E Parking the truck safely... E 20 5 Mechanical Back Up Steering (Emergency Steering Operation)... E 21 6 Display Items... E Driver s Display (t)... E Driver display lights... E On Board Computer (o)... E Display Symbol for On Board Computer... E 30 7 Operator Keypad (CANCODE) (o)... E Code Key... E Parameters... E Parameter Settings... E 34 8 Changing Truck Parameters... E 37 9 Troubleshooting... E Auxiliary Electrical System... E Headlights... E Beacon... E Bridging Switch (ESA / electrical lift limit switch )... E Seat Heater... E 41 I 2

8 F Maintenance of Materials Handling Equipment 1 Operational Safety and Environmental Protection... F 1 2 Safety Regulations for Mantenance... F 1 3 Maintenance and Inspection... F 3 4 Maintenance Check List ETM/V 214/ F 4 5 Lubrication Schedule ETM/V 214/ F Operating Fluids... F Tank Capacity ETM/V 214/ F 7 6 Maintenance... F Prepare truck for maintenance and repairs... F Safety Belt Maintenance (o)... F Removing the seat hood... F Checking the hydraulic oil level... F Opening the fuse cover... F Removing the cover from the instrument panel... F Checking the electrical fuses.... F Starting the Truck Again... F 12 7 Putting the Truck Out of Service... F Measures to be taking before putting the truck out of service... F When the truck is de-commissioned... F Starting the truck again after de-commissioning... F 13 8 Safety test after periodic intervals and after special occurences. (D: UVV-Test BGV D27)... F 13 I 3

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10 A Regulatory Use of Machine The document Guidelines for the Regulatory and Correct Use of Materials Handling Equipment (VDMA) is part of the delivery of this vehicle (VDMA). It forms part of the Operator Manual and its contents should be carefully observed. National regulations shall apply in their entirety. The vehicle described in this instruction is a materials handling vehicle suitable for lifting and transporting loads. It must be employed, operated and maintained in accordance with the information contained in this manual. Any other use is not in keeping with this directive and can lead to damage to persons, machine or property. Above all overloading the machine due to excessively heavy loads or incorrectly positioned loads must be avoided. The maximum permissible load to be lifted is displayed on a data plate attached to the vehicle or on the load diagram. The vehicle must not be operated in areas exposed to the risk of fire or explosion, nor in a very dusty environment. M Duties of the Operator: In keeping with the sense of this manual the operator is any natural or legal person who operates the vehicle or for whom it is operated by another person. In special cases (e.g. leasing, hire) the operator is the person who in accordance with the existing contractual agreement between the owner and the user of the vehicle undertakes to carry out such operating duties. The operator must ensure that the vehicle is only used in accordance with the regulations and danger to life and limb of the user or a third party is avoided. Furthermore, regulations concerning accident prevention and special safety rules as well as guidelines for driving, maintenance and commissioning shall be observed. The operator must ensure that all users of the vehicle have read and understood this instruction. Non compliance with this instruction will render our warranty invalid. This also applies if sub-standard work has been carried out on the vehicle by the client and /or a third person without the consent of the manufacturer s service department. Fitting Attachments: Fitting or installing additional equipment which affects the operation of the vehicle or enhances these functions may only be undertaken with the written permission of the manufacturer. Where necessary permission shall be obtained from the local authority. Local authority approval does not take precedence over manufacturer s approval GB A 1

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12 B Truck Description 1 Application The ETM/V 214/216 is a three wheel electric side seated, clear view reach truck. It is designed for use on level floors to lift and transport goods. Open bottom pallets or palets with transverse boards can be lifted inside or outside the area of the load wheels, and trolleys can be lifted. Loads can be stacked or unstacked and transported over longer distances. The capacity may be obtained from the data plate. Type Capacity Load Centre of Gravity ETM/V 214 1,400 kg 600 mm ETM/V 216 1,600 kg 600 mm B 1

13 2 Description of Assemblies and their Function Item. Description Item. Description 1 t Clear View Lift Mast 10 t Accelerator 2 t Overhead Guard 11 t Battery trolley unlocking 3 t Free Lift Cylinder 12 t Driver s display (not with T-Lifting Frame) 4 t Multi-Pilot o On board computer 5 t Load Wheels 13 t Two stage switch key with spare key (service). 6 t Outriggers o CANCODE 7 t Drive Wheel 14 t Emergency Stop Switch 8 t Dead man pedal 15 o Safety Belt 9 t Brake Pedal t Series Equipment o Auxiliary Equipment B 2

14 2.1 Truck Safety Instructions: An enclosed vehicle design with rounded edges facilitates safe handling of the ETM/V 214/216. The driver is protected by the driver s cab (2). The drive wheel (7) and the load wheels (5) are protected by a solid anti-crash mechanism. By activating the emergency switch all electrical power can be cut off in dangerous situations. The driver s display unit (12) shows the following conditions: Lift limit reached (o) Slow travel Service interval expired (service mode active) Overtemperature Battery latching unlocked Parking brake applied Forks horizontal (o) Sideshifter in central position (o) Dead man pedal (safety switch) not activated System warning / system fault Line break safety devices in the lift cylinders limit the lowering speed of the load in the event of a hydraulic system failure. Display Instruments: Driver display (12) with large surface display using TFT technology (t) or on board computer with LCD display (o), each with integrated residual time display, battery charge status, lift and drive profile settings and steering angle mode display. Traction Drive: The complete drive unit is enclosed in the vehicle chassis. A 6.9 kw fixed threephase motor operates the drive wheel (7) via a bevel spur gearbox. The electronic traction current control system ensures the smooth rotation of the drive motor and as a result smooth driving, powerful acceleration and electrically controlled braking with energy recovery. The degree of energy recovery can be adjusted via the driver s display unit. B 3

15 Brake Equipment: The electric braking unit consists of three independent braking systems. Operating the brake pedal introduces regenerative braking. Where required the load wheel brakes are activated via the vehicle s brake control system. The safety brake is electrically operated and works mechanically through a compression spring applied to a magnet brake mounted on the drive unit. This brake is used for emergency braking. A warning light appears when the brake is applied. Faults in the steering and braking systems (emergency stop trip) are shown on the driver s display or the on board computer. Emergency Stop Safety Concept: The emergency stop is controlled by the brake control system. The steering control system transmits a system status signal which is monitored by the brake control. If the signal fails to appear or a fault is identified the brakes will be applied immediately until the machine comes to rest. Control displays on the driver s display unit indicate an emergency stop. Each time the vehicle is switched on the system goes through a self diagnosis programme which only releases the parking brake (emergency stop) if a functionality check proves to be positive. Steering: Electrical steering is operated through a spur gear. Access to the service mode on the driver s display unit or the on board computer will afford a choice of three operating modes: 180 (o) 360 (continuous) (o) Switch between via key (t) The adjustable steering wheel serves as a steering transmitter. Drivers Cab: The driver s cab is designed ergonomically with ample foot room. To achieve the correct sitting position the driver s seat and the steering head can be adjusted by the driver. Accelerator and brake pedals are arranged as in a normal lorry. B 4

16 Item. Description Item. Description 1 t Clear View Lift Mast 10 t Accelerator 2 t Overhead Guard 11 t Battery trolley unlocking 3 t Free Lift Cylinder 12 t Driver s display (not with T-Lifting Frame) 4 t Multi-Pilot o On board computer 5 t Load wheels 13 t Two stage switch key with spare key (service). 6 t Outriggers o CANCODE 7 t Drive wheel 14 t Emergency Stop Switch 8 t Dead man pedal 15 o Safety Belt 9 t Brake Pedal t Series Equipment o Auxiliary Equipment B 5

17 Operating and Display Elements: Operating and display elements can be clearly identified in the driver s cab. The Multi-Pilot (4) enables single handed operation of functions governing direction of travel, lifting / lowering, mast forward / back, mast tilt, sideshift left or right in sideshift mode (auxiliary hydraulic system HF5) (o)) and horn. On the driver s display panel (12) the battery discharge indicator and hourmeter are grouped together. The discharge indicator is designed as a monitor which cuts out lifting if the battery is low in order to avoid excessive discharge. Hydraulic Equipment: Pump unit with an AC motor and a noiseless precision high pressure pump. The equipment is controlled by the Multi-Pilot (4). Electrical Equipment: 48 volt system in the form of a twin cable system. Series electronic drive, lift and steering control. The electronic drive control system governs the travel rate with infinite speed control and permits regenerative braking when changing direction. Drive and lift parameters can be set via the driver s display unit (12). Warning displays, operating errors and service functions can also be shown at the driver s display unit. (For possible battery types, see Chapter D.) 2.2 Placing the Load Mast holder: The mast holder is mounted on suppert rollers. A simple telescopic pushing cylinder moves the holder backwards and forwards. The running rails for the mast holder are bolted on to the outriggers (6. ) Lifting Frame: The trucks are equipped with telescopic free lift units situated in the mast holder and which can be tilted. Adjustable side rollers and slide pieces take up the pressure exerted on the fork carriage if the load is positioned on one side. The fork arms are fitted to the fork carriage and are adjustable. With the twin lift Triplex mast (D) the first lift of the load carriage (free lift) is produced by a short, externally fitted lift cylinder (3) without changing the construction height. With a telescopic mast (T) the free lift is limited to 80 mm due to the design. Attachments: Hydraulic and mechanical attachments are possible. B 6

18 3 Technical Data Standard Design Release of technical data in accordance with VDI Technical modifications and supplements reserved. 3.1 Performance Data Description ETM/V 214 ETM/V 216 Q Capacity (where C = 600 mm) kg c Load Centre of Gravity mm Travel Speed 14.0 / / 14.0 km/h Drive and Fork Direction Gradeability with / without load 9/13 8/12 % Max. gradeability (5 min rating) 10/15 10/15 % with / without load e) Lift height up to 6500 mm 0.15 m/s Lift height up to 8300 mm 0.10 m/s Lift height above 8300 mm 0.08 m/s 3.2 Dimensions Lift speed with / without load Lowering speed with / without load Reach speed with / without load 0.44 / / 0.70 m/s (±10%) 0.50 / / 0.50 m/s (±15%) 0.2 e) 0.2 e) m/s up to 5600 mm up to 5600 mm Description ETM/V 214 ETM/V 216 s Lowered fork height mm h 6 Height above overhead guard mm 1 1 Overall length 2418/2346 a) 2418 b) mm 4 1 Reach c), d) 550/ mm 7 1 Length over outrigger mm b 1 / b 2 Overall width 1120/ /1270 mm Wa Turning radius mm Ast Working aisle width e) 800 x 1200 length e)f) 2701/ / mm Ast Working aisle width e) 2757/ x 1200 length e)f) 2668/ Net weight see data plate, truck a)fork length 800 mm; 560 Ah battery: +90 mm; 700 Ah battery: +180 mm b)fork Length 1150 mm; 560 Ah battery: +90 mm; 700 Ah battery: +180 mm c)560 Ah battery: -72 mm; 700 Ah battery: -144 mm d) 420 Ah battery: -70 mm; 560 Ah battery: -158 mm; 700 Ah battery: -264 mm e)560 Ah battery: + 90 mm; 700 Ah battery: +180 mm f) with floor covering mm B 7

19 β α β h 4 α h 3 h 1 l 4 l h 6 h 2 c h 7 Q h 8 m 2 l y l 7 l 1 x s e b 2 b 5 b 3 b 4 b 11 b 1 a 2 W a A st a 2 B 8

20 3.3 Standard Hoist Frames ETM/V 214/216 Description Telescopic Mast (T) Twin Lift Triplex Mast (D) Twin Lift Triplex Mast (D) reinforced h 1 Build Height mm h 2 Free Lift mm h 3 Lift mm h 4 Max.Height mm B 9

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22 3.4 EN Standards Constant Noise Level: 68 db(a) In accordance with EN complies with ISO The constant noise level is calculated in accordance with standard guidelines and takes into account the noise levels when driving, lifting and idling. The noise level is measured at the driver s ears. Vibration: 0.66 m/s 2 In accordance with EN According to standard guidelines the vibration acceleration exerted on the driver s body when driving is the linear integrated weighted vertical acceleration. It is ascertained when driving over humps at constant speed. Electromagnetic Compatability (EMC) The manufacturer confirms that the truck does not exceed the limits for electromagnetic fault emission and jamming resistance. The truck has been tested for the discharge of static electricity in accordance with EN as well as the standard instructions contained therein. Changes to electrical and electronic components and their arrangement may only be made with the written persmission of the manufacturer. 3.5 Condition for Use Ambient Temperature. - during operation -25 C to +40 C Special equipment and authorisation is required for trucks designed to be used constantly below 0 C or in conditions subject to extreme changes in temperture or air humidity. B 11

23 4 Identification Points and Data Plates , 20, mv 1,5 V Item. Description 16 Warning Sign "Caution Low Voltage Electronics " 17 UVV Test Notice (D only ) 18 Drive direction when turning steering wheel 19 Capacity plate, Capacity Sideshifter 20 Capacity plate, Capacity / Load Centre of Gravity / Fork arms 21 Capacity plate, Capacity / Load Centre of Gravity / Lift height 22 Sign "Put on Safety Belt" (o) 23 Notice "Do not stand under the load carriage" 24 Crane loading securing points 25 Notice "Do not reach through the hoist frame" 26 Jack securing points 27 Notice "Hydraulic oil filler neck" 28 Data plate, truck 29 Caution: Observe Operator Manual B 12

24 4.1 Data plate, truck Item. Description Item. Description 30 Type 36 Manufacturer 31 Serial no.. 37 Battery weight min/max in kg 32 Rated capacity in kg 38 Drive power 33 Battery Voltage V 39 Load centre of gravity distance in mm 34 Net weight without battery in kg. 40 Year of manufacture 35 Manufacturer s logo 41 Option For queries regarding the truck or ordering spare parts please quote the vehicle serial number (31). B 13

25 4.2 Capacity Plate, Capacity / Load Centre of Gravity / Lift Height The capacity plate (22) gives the capacity (Q) of the vehicle in kg with a vertical hoist frame. In tabular form the maximum capacity is shown with a standard load centre of gravity distance * C (in mm) and the desired lift height H (in mm). The arrows (42 and 43) on the inner and outer masts show the driver when he has reached the preset lift heights shown in the load diagram. *) The standard load centre of gravity distance not only takes into consideration the load height but also the load width X.XXXX.XX.XX Example to calculate the maximum capacity: With a load centre of gravity distance C of 600 mm and a maximum lift height H of 3600 mm. the max. capacity Q is 1105 kg. 4.3 Jack Securing Point The notice "Jack securing point" (27) shows the place where the vehicle may be lifted and chocked up (see Chapter F) Notice: Observe Operator Manual When commissioning (see Chapter C) and using the mechanical auxiliary steering system (see Chapter E) carefully following the instructions contained in the Operator Manual. B 14

26 C Transport und Commissioning 1 Transport Depending on the height of the hoist frame and local conditions three different types of lifts may be undertaken: Standing with assembled hoist frame (for low heights) Standing with partially assembled hoist frame tilted against the overhead guard (for average height). Hydraulic hoses for lifting are disconnected Standing, with dismantled hoist frame (for large heights) all hydraulic hoses between the main unit and the hoist frame are disconnected. F Safety Instructions for Assembly and Commissioning On site assembly of the vehicle, commissioning and driver instruction shall only be carried out by staff trained and authorised by the manufacturer Only when the hoist frame has been correctly assembled may the hydraulic hoses be connected to the main unit / lift frame interface and the truck put into operation C 1

27 2 Lifting by Crane M Only use lifting equipment with sufficient capacity. (Weight Lifted = Net Weight + Battery Weight; see data plate, truck). M In order to lift the truck with a harness wrap slings around the strut of the overhead guard. Two suspension points (2) are located on the outriggers. Withdraw battery plug (1). Secure the truck with wedges to prevent it from rolling away! Fasten the harness to the lifting points so that it cannot slip! Lifting slings should be fastened to the harness so that when lifting they do not come into contact with any attachments. 1 2 C 2

28 3 Securing the Machine for Transport. F When transported on a lorry or a trailer the vehicle must be securely fastened down. The lorry or trailer must have securing rings fitted to its body. M To secure the vehicle pass the tensioning strap (3) through the overhead guard strut (1) and attach it to the securing rings. The tensioning strap must be secured by a tensioner (4). Loading shall be carried out by staff especially trained for that purpose in accordance with recommendations contained in Guidelines VDI 2700 and VDI In each case correct measurements shall be determined and appropriate safety measures adopted C 3

29 4 Transport Lock, Safety Brake F If a vehicle is delivered with or without a flat battery before the vehicle is started the transport locking device must be removed (2xM5 bolts). This device locks the compression spring which operates the safety brake so that the vehicle has no brakes when there is no power. The device consists of two screws which are screwed into the brake magnet (on the drive motor). This ensures that the spring cannot activate the brake. Removing the Transport Lock Push driver s seat out of the guide towards the steering wheel. Remove fan plug from seat hood. Remove seat hood (see Chapter F). Remove two-pin plug from magnetic brake Remove the brake release screws from the magnetic brake and insert them into the holes in the drive plate. The brake can now be operated without current. The truck can no longer be pushed without the battery. Connect the two-pin plug to the magnet brake. Re-fit hood. Connect the fan plug to the seat hood. Position driver s seat in guide. Install and connect the battery Turn on the main switch and key switch The truck is now ready for use. C 4

30 Moving the truck without a battery Withdraw battery plug. Push driver s seat out of the guide towards the steering wheel. Remove fan plug from seat hood. Remove seat hood (see Chapter F). Remove two-pin plug from magnetic brake Remove the brake release screws from the drive plate and insert them into the holes in the magnetic brake. M The brake is now ventilated without current. The vehicle can be pushed or pulled without the battery. After pushing operation is complete the brake release screws must be removed again. Remove the brake release screws from the magnet brake and insert them into the holes in the drive plate. Connect the two-pin plug to the magnet brake. Re-fit hood. Connect the fan plug to the seat hood. Position driver s seat in guide. Connect battery plug. Switch on the main switch and key switch The truck is now ready for use. 5 Commissioning F M Before commissining the machine ensure that the hydraulic hoses to the main unit/ hoist frame interface have been connected. Operate the truck only with battery power! The AC current of the rectifier will damage electrical components. Connecting cables to the battery (trailing cables) must be less than 6 metres. To prepare the machine after delivery or transport the following tasks must be carried out: Install battery (where required). Do not damage battery cable. Charge up the battery (see Chapter D). Where necessary remove the transport lock for the safety brake Operate the truck as described above. (see Chapter E). If delivered without a battery the truck can only be steered by means of the mechanical back-up system (see Chapter E). After commissioning it is possible that slight brake scrubbing noises will be heard. C 5

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32 D Battery - Maintenance, Charging, Replacement 1 Safety Regulations when handling acid batteries Before any work is carried out on the batteries the truck must be safely parked (see Chapter E). Maintenance Personnel: Batteries may only be charged, maintained or changed by staff particularly trained for that purpose. These operating instructions and manufacturer s regulations concerning batteries and charging stations shall be observed when work is being carried out. Fire Protection: Smoking and open fires shall be avoided when working with batteries. Where a truck is parked up for charging there shall be no inflammable material or operating fluids capable of sustaining a spark within a distance of 2 metres around the machine. The space must be ventilated and fire protection equipment must be on hand. Battery Maintenance: The cell cover of the battery must be kept dry and clean. Cable posts and terminals nust be kept clean, smeared with dielectric grease and be securely tightened. Batteries with non insulated posts must be covered with a non slip insulation mat. M F M F Battery Disposal: Batteries may only be disposed of in accordance with national Environmental Protection Laws or the Law governing Disposal of Hazardous Items. The manufacturer s instructions concerning disposal must be fulfilled.. Before closing the battery top ensure that the battery cable cannnot be damaged. Batteries contain dissolved acid which is poisonous and corrosive. Consequently when carrying out work on batteries protective clothing and eye protection must be worn. Above all avoid any contact with battery acid. Nevertheles should clothing, skin or eyes come in contact with acid then the effected parts should be rinsed with copious amounts of clean water - where the skin or eyes are affected a doctor must be summoned immediately. Disturbed battery acid should be immediately neutralised. Only batteries with an enclosed chamber may be used. The weight and dimensions of a battery have considerable influence on the operational safety of the truck. A change of battery equipment is only permitted on the agreement with the manufacturer. D 1

33 2 Battery Types Depending on truck application various types of batteries may be installed. The following table shows which combinations can be included as standard: F Capacitance Standard (L) High Performance HX) 48 V - 3PzS - Battery 420 Ah 420L 450H 48 V - 4PzS - Battery 560 Ah 560L 600H 48 V - 5PzS - Battery 700 Ah 700L 750H The battery weight is given on the battery data plate. When changing or installing a battery ensure that the battery is securely located in the space provided. 3 Exposing the Battery F Preparing for Operation (see Chapter E). Tilt the Multi-Pilot (1) in arrow direction (U). Move the mast holder up to the stop near the battery and let go of the Multi-Pilot (the mast is now in the end position). Again tilt the Multi-Pilot (1) in the direction of arrow (U) and move the mast holder further towards the stop position (preparation for latching battery). Keep the Multi-Pilot (1) in the direction of arrow (U) and pull the battery truck lock. The driver s display panel will show ( Battery Latched" (red graphic symbol) (t) or the control light will appear come on the board computer panel (o). Tilt Multi-Pilot (1) towards arrow (T) and push the mast holder with the coupled battery trolley until the battery is clear for maintenance. Switch off the main switch and the key switch The battery plug and socket may only withdrawn or connected when the main switch and the charging equipment are switched off. Withdraw battery plug (2) from the socket. Where necessary remove the insulation mat from the battery. The safety switch for the battery locking system permits travel in creep mode providing the battery trolley is uncoupled and the control display (4) is not deleted. Before the truck is started up again the battery trolley must be pushed to its leaving position in order to uncouple the battery trolley and the mast holder. The control display (4) must be out. D 2

34 F The truck must only be driven slowly inside the battery charging station with the battery leading! T 1 U Battery troley - Emergency Unlocking Preparation for Use (see Chapter E). Tilt Multi-Pilot (1) towards arrow (U), move the mast holder up to the stop position towards the battery. Release the Multi-Pilot (1). Tilt the Multi-Pilot (1) towards arrow (U) and move the mast holder further to the stop towards the battery Switch off the main switch and the key 6 switch Remove driver s seat and disconnect fan connection. Remove seat hood. (see Chapter F). Withdraw the lock (6) from ring (e.g. use screw driver).. Re-fit hood. Re-connect fan and install driver s seat Switch on the main switch and key switch Tilt Multi-Pilot (1) towards arrow (T) and push the mast holder with the coupled battery trolley until the battery is clear for maintenance. Control display (4) lights up Switch off the main switch and the key switch D 3

35 Before installing the battery lock rectify the fault on the battery unlocking system. The safety switch for the battery lock only enables creep mode providing the battery trolley is unlatched and the control light (4) is still lit. To start up the truck the battery trolley must be in its leaving position in order to uncouple the battery trolley and the mast. Control display (4) must be faded out. 4 Battery Charging F F Expose Battery (see Section 3). To carry out the charging procedure the top surface of the cells must be exposed in order to guarantee adequate ventilation. No metal objects must be left on top of the battery. Before commencing the charging process visibly check the cable and connections for damage. Where required remove the insulating mat from the battery. Connect the charging cable to the battery plug (2) Charge the battery up in accordance with the manufacturer s instructions for both the battery and the charging station. The safety regulations provided by the battery and charging station manufacturer shall be strictly observed. D 4

36 5 Removing and Fitting the Battery. F Expose Battery (see Section 3). In order to avoid a short circuit, exposed poles or connections must be covered with an rubber cover. When using a crane to change the battery ensure that there is sufficient lifting capacity (see battery weight on the battery data plate fitted to battery holder). The lifting harness must exert a vertical pull so that the battery holder is not crushed. Hooks shall be fitted so that when the sling chains are slackened off they do impinge on the battery cells. Removal and Installation using a Lifting Harness F F Loosen fixing bolts (9) in the red battery retaining bracket (8) Remove retaining bracket (8). Couple lifting harness to battery holder (7). Lift the battery clear and move out to the side. Dismantling and assembling with battery trolley (o) The truck must lie horizontally so that when removing the battery retaining bracket the battery itself does not roll out. Loosen fixing bolts (9) in the red battery retaining bracket (8) Remove retaining bracket (8). Lift the battery to the side on to the battery trolley Installation to be carried out in reverse order. When changing the battery it may only be replaced by one of similar design. Following installation the cable and connections must be visibly checked for damage and cover plates must be replaced securely D 5

37 6 Battery Discharge Display, Battery Discharge Monitor, Hourmeter 6.1 Driver s Display (t) M Battery Discharge Display: The charge status of the battery (10) is displayed in 10% increments on the driver s display unit. The serial setting for the battery discharge display / discharge monitor is applied to standard batteries The battery must be charged when there is a battery residual capacitance of 20% for standard batteries or 40% for maintenance free batteries. Battery Discharge Monitor: Lifting is cut out when the residual capacity falls below the required level. An appropriate message will be shown on the driver s display unit. Lifting will only be restored when the connected battery is charged up to 70% of maximum. Remaining Time Display: The remaining time is shown up to 20% residual capacity (for maintenance batteries 40%) To display the remaining time the 7 segment display above battery (11) can be switched over by activating the shift key (13) for 3 seconds. It switches between actual time and time remaining. D 6

38 Hourmeter: Pressing the shift key (13) briefly produces other display fields (12 and 14). If no lift height, maximum lift or load weight is available then the appropriate lines are by-passed. Display Field 1 (14) Display Field 2 (12) Operating Hours Load Weight Operating Hours Lift Height Operating Hours Max. Lift Height Lift Height Load Weight Lift Height Max. Lift Height Load Weight Lift Height Load Weight Max. Lift Height If there is no lift height, maximum lift height or load weight available then the display field 2 remains empty. "Energy Recovery" Display for Regenerative Lowering and Braking During "Energy Recovery" the discharge display switches over to driver s display so that the bars in the battery icon fill up from 0 to 100% (from bottom to top). This occurs in cycles irrespective of battery charge status (fully or partially charged). The display goes out when energy recovery is complete. D 7

39 6.2 On Board Computer (o) M Battery Discharge Display: The charge status of the battery (15) is shown in 10% increments on the display. The serial setting of the battery discharge display / discharge monitor is applied to standard batteries. When using maintenance free batteries the display must be set so that the symbol (T) appears after the percentage figure. If this setting is not carried out the battery may be damaged because of excessive depletion. When adjusting the instrument the manufacturer s service department must be called in ABC DEF 50 % T 4 GHI 5 JKL 6 MNO 0 km/h 7 PQRS CE 8 TUV 0 9 WXY OK 0009 h 08:45 17 The battery must be charged when there is a battery residual capacitance of 20% for standard batteries or 40% for maintenance free batteries. Battery Discharge Monitor: Lifting is cut out when the residual capacity falls below the required level. An appropriate message will be shown on the driver s display unit. Lfiting will only be restored when the connected battery is charged up to 70% of maximum. Remaining Time Display: The Battery Remaining Time Display is an option which can be activated via a parameter in the service mode. The remaining time is shown up to 20% residual capacity (for maintenance batteries 40%) Alternatively the Battery Remaining Time display is shown as a percentage figure (15) under the battery symbol (Format R 00:00). D 8

40 Hourmeter: The operating hours are displayed next to the clock time. The operating hours meter (17) shows the total time of travel and lifting movements. Display "Energy Recovery" when lowering and braking pay load During Energy Recovery" the discharge display on the computer switches over so that the bars in the battery icon fill up from 0 to 100% (from bottom to top). This occurs in cycles irrespective of battery charge condition (fully or partially charged). The display goes out when energy recovery is complete. D 9

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42 E Operation 1 Safety Regulations for the Operation of Fork Lift Trucks Driver Authorisation: The forklift truck may only be used by auitable persons who have been trained to drive the truck, who have proved to the owner or his representative that they can drive and handle loads and have been authorised to operate the truck by such owner or his representative. Driver s Rights, Responsibilities and Regulations. The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be made familiar with the contents of the present Operator Manual. He must be afforded all his due rights. Safety shoes must be worn when operating pedestrian lift trucks. Unauthorised Use of Truck: The driver is responsible for the forklift during the time it is in use. He shall prevent unauthorised persons from driving or operating the truck. It is forbidden to carry or hoist persons. Damage and Complaints : Damage or any complaints regarding the forklift truck or its attachments shall immediately be reported to a supervisor. Machines not safe for operation shall not be used until they are deemed fit for use following authorised repair and commissioning. Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authoristion to do so. On no account shall he adjust or render unusable safety equipment or switches. F Danger Areas: A danger area is defined as the area in which a person is at risk due to truck movement, lifting operations, load lifting parts (e.g. forks or anciliary equipment) or the load itself. This also includes areas which can be reached by falling loads or lowering mechanical devices. Unauthorised persons must be kept away from the danger area. Where there is danger to persons a warning shall be given in good time. If unauthorised persons are still within the danger area then the truck shall be brought to rest immediately. Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed. E 1

43 2 Description of Operating and Display Elements Item. Operating or Function Display Element 1 key switch t Switches current on and off. By removing the switch the truck cannot be switched on by unauthorised persons. Keypad (CANCODE) o Sets the code and switches on the truck 2 Main Switch (Emergency disconnect) t The supply current is interrupted, all electrical functions are switched off and the truck brakes are applied automatically. 3 Multi-Pilot t Function operation: Travel forward / reverse Lift/lower load pickup Extend / retract mast holder Tilt hoist fram forward or backward, fork tilt Sideshift left / right Horn button Auxiliary hydraulics (HF5) (o) 4 Steering switch t Change steering range from 180 or Sideshift centring switch o Sideshift positioned in centre 6 Forks horizontal switch o Forks set to horizontal position (fork tilter only) 7 Lock for arm rest t Longitudinal displacement of arm rest 8 Driver s seat lock t The driver s seat can be adjusted horizontally 9 Driver s seat weight adjustment t Adjusting driver s weight for optimal seat cushioning 10 Backrest adjustment t The driver s seat backrest can be adjusted 11 Accelerator t The traction speed is infinitely variable 12 Brake Pedal t Brake applied to truck 13 Dead man pedal t Not Activated: Travel inhibited, truck brought to rest. Activated : Travel released t = Series Equipment o = Auxliary Equipment E 2

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45 Item. Operating or Function Display Element 14 Battery trolley unlocking t Unlocks the battery trolley 15 Bridging switch o Avoids damage to forks or the load in the outrigger area. 16 Steering column t Adjust steering column height and distance adjustment 17 Driver display t Displays important drive and lifting parameters; selecs and displays types of steering operations, warning signs, provides information regarding incorrect operation and service displays (see Section 5) On board computer o Replaces the key switch. Control voltage switch on off Release of truck functions via PIN-Code. t = Series Equipment o = Auxliary Equipment E 4

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47 3 Starting the Truck F Before the truck is started, operated or a load unit raised, the driver must ensure that there is no one standing in the danger area. Daily tests and procedures before commencing work The entire truck (particularly wheels and lifting devices) to be inspected for damage. Check whether the load chains are evenly tensioned Visibly check battery and cable connections Adjusting the driver s seat To achieve optimal seat cushioning the driver s seat must be adjusted according to the driver s weight. The driver s seat must not be occupied when being adjusted driver s weight. To adjust the driver's weight : Pull the lever (9) in the direction of the arrow and return. The previous weight setting is reset to the minimum value Setting range of seat suspension from 50 kg to 130 kg 19 F Move lever (9) again in the direction of the arrow until the corresponding weight mark on scale (18) is reached. Then finally return lever. Sit on the driver s seat From the driver s seat do not reach out to the side wall / roof of cab Adjust ing the backrest Lift up locking lever (10) and adjust the tilt of the backrest (19). Release locking lever, the backrest is set Adjusting the sitting position: F Pull up the locking lever to locate the driver s seat (8) in the direction of the arrow and push the seat forwards or backwards to the desired position. Re-engage locking lever (8). The driver s seat must be securely located in the desired position. The position of the driver s seat must not be altered when driving. The seat adjustment refers to series standard design. For other designs refer to the manufacturer s adjustment instructions. When adjusting ensure that all controls are within reach E 6

48 Adjusting the steering column Slacken the steering column stop (16) and set the steering head (20) to the required position horizontally and vertically. Re-tighten the steering column stop Adjusting the arm rest Lift the arm rest (7) lock and set the arm rest (21) to the desired position (longitudinally). Release the arm rest lock (7) 7 21 E 7

49 3.1 How to use the safety belt (o) F Before starting the forklift read these instructions carefully. F Put on the belt before starting the truck. Change the belt height setting according to body size. The belt will protect against serious injury. 24 M F A frozen belt lock or reel must be allowed to thaw out and dry. The hot air temperature must not exceed +60 C. Do not alter the belt setting. Safety belt and seat hood to be checked for damage following an accident and replaced if necessary. Damaged or unusable belts to be replaced only by contracted dealers or branches. Only original spare parts to be used for retrofits or repairs E 8

50 M How to proceed in unusual situations (o) If there is a danger of a tipover, proceed as follows: Press the upper body against the back of seat. Grip the steering wheel with both hands and fix your feet firmly on the floor. Lean your body out against the direction of fall. Safety belt user instructions (o) F Before starting the forklift pull the belt from the reel, pull tightly across the body and engage in the lock (22). The belt must not be twisted when fastened. When operating the forklift (driving, lifting, lowering etc.) always sit with your back against the backrest. The automatic lock on the belt reel allows for sufficient movement in the seat. F If you sit on the front edge of the seat too long, the extended belt offers less protection. Belt only to be used to secure one person. After use press the red switch and manually feed the lock tongue (23) back to the reel. Procedure for starting the forklift on an incline (o) The automatic lock prevents the belt from coming loose when the truck is on a strong incline. The belt can no longer be pulled from the reel. Carefully drive the truck out from the inclined position and apply the belt. E 9

51 1 2 DEF 3 4 GHI 7 PQRS CE ABC 5 JKL 8 TUV 0 6 MNO 9 WXY OK Set Preparation for Use Pull out the main switch (2) Insert the key in the key switch and turn to the right to position "I" or: for trucks without a key switch enter the free switch code via CANCODE (1a), or. via the on board computer. With CANCODE (o), the start PIN 2580 is inserted via the control panel (1a) and confirmed by the set key a 2 For the on board computer (17a) (o), enter the start PIN and confirm with OK. 17a 1 2 BITTE PINCODE EINGEBEN Check the horn operation. The truck is now ready for use. The battery charge monitor shows the battery capacity available. Check the brake and handbrake operation (see Section 4.2). On starting the dead man pedal must be activated. E 10

52 3.3 Emergency Stop Device The truck is equipped with an emergency stop device. After switching on the main switch (2) and the ignition switch (1) or entering the Pin code there is an automatic safety prompt. Emergency Stop Display If a fault is detected on the steering or brake systems, a display will appear on the driver display panel (t) (17) or on the board computer (o) (17a) (see Section 6.2). Emergency Stop Activation If a fault occurs in the steering system during travel which impairs the safety of the operator there will be a controlled braking of the truck until it comes to rest. Emergency Stop Re-Set. M Turn the main switch and key switch off and on again. If the emergency stop display appears on the driver display (t) or on the on-board computer (o) even after repeatedly pressing the emergency stop reset button, contact the manufacturer s service department to have the fault rectified. If, after the emergency stop has been triggered, the truck is in a dangerous area or aisle it can be operated via the emergency mechanical steering system (see Section 5). E 11

53 4 Operating the Forklift Truck 4.1 Safety Rules when Driving Routes and Work Areas: The truck may only be driven on routes specifically designated for traffic. Unauthorised persons must not enter the working area. Loads must only be deposited at the designated places Travel Procedure: The driver must adjust the speed of the truck to suit local conditions. He must drive slowly into curves and also when approaching and driving in narrow gangways, when traveling through swing doors and approaching blind areas. He must always keep a safe braking distance to the truck ahead and keep the truck under control. Sudden stopping (except in case of danger) fast turning, overtaking at dangerous or blind spots is not permitted. It is not permitted to lean or reach out of the working and operating area. Visibility when Driving: The driver must look in the direction in which he is travelling and shall always maintain a clear view of the road ahead. If a load is being transported which impairs his view then the load must be carried on the trailing end of the truck. If this is not possible, a guard shall be posted who shall walk ahead of the truck. Negotiating Inclines or Dips: Negotiating inclines or dips is only permitted if such roads are clean and have a non-slip surface and providing such journeys are safely undertaken in accordance with the technical specifications for that truck. During such operations the load shall always be carried on the incline side of the truck. Turning, traversing and parking of the forklift is not allowed on inclines or dips. Driving downhill may only be permitted with reduced speed and where the brake can be applied instantly. Elevators and Docks: Elevators or docks may only be entered if they are sufficiently robust to carry the load, are suitable for traffic and are authorised by the owner for operation. This must be checked before traffic is allowed onto them. The forklift must be driven into the elevator with the load leading and be positioned such that the truck does not come into contact with the shaft sidings. Persons riding in the elevator may only enter when the truck is secure and must vacate the lift before the truck. Composition of the transported load: Loads may only be transported whose safety has been ensured in accordance with safety regulations. Never transport loads which have been stacked higher than top of the fork carriage or the load guard. Towing Trailers: The maximum trailing load for a forklift truck towing unbraked or braked trailers shall not be exceeded. The trailer load must be secured in accordance with regulations and must not exceed the dimensions permitted for that roadway. After coupling and before starting the driver shall ensure that the trailer coupling cannot become detached. Forklift trucks towing a load must be driven so that the trailing truck is safe and can be stopped under any conditions. E 12