DOWNLOAD PDF Jungheinrich Forklift ERC/ERC-Z 12/14/16 Operating Manual 50126632

ERC/ERC-Z 12/14/16 Operating instructions

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50126632 06.02

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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.

Safety instructions and important explanations are indicated by the following graphics: before safety instructions which must be observed to avoid danger to personf Used nel.

m

Used before notices which must be observed to avoid material damage.

A Used before notices and explanations. t Used to indicate standard equipment. o 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 assumed from the present operating instructions.

Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG

Jungheinrich Aktiengesellschaft Am Stadtrand 35 D-22047 Hamburg - Germany Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

Table of contents A

Correct use and application of the truck

B

Truck description

1 2 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 4.4

Application ........................................................................................... B 1 Assemblies ......................................................................................... B 2 Technical data - standard version ....................................................... B 3 Performance data ................................................................................ B 3 Dimensions ......................................................................................... B 4 EN standards ...................................................................................... B 5 Conditions for application .................................................................... B 5 Location of instruction labels and identification labels ........................ B 6 Truck identification plate ..................................................................... B 7 Load capacity ...................................................................................... B 7 Load capacity, wheel-arm lifting device .............................................. B 8 Label/Order/Inventory/Service No. ..................................................... B 8

C

Transportation and commissioning

1 2 3

Transportation by crane ...................................................................... C 1 First commissioning ............................................................................ C 1 Moving the truck with the drive unit inoperative .................................. C 2

D

Battery - Servicing, recharging, replacement

1 2 3 4 4.1 4.2 5 5.1

Safety regulations governing the handling of lead-acid batteries ........ D 1 Battery type ......................................................................................... D 2 Exposing the battery ........................................................................... D 2 Charging the battery ............................................................................ D 3 Charging the battery with stationary battery charger .......................... D 3 Recharging the battery with integrated battery charger (o) ................ D 4 Removing and installing the battery .................................................... D 7 Remove battery by lifting it upwards (truck without wheel-arm lifting device) ..................................................................... D 7 Remove battery by lifting it upwards (truck with wheel-arm lifting device) ....................................................................................... D 8 Lateral battery change (o) .................................................................. D 9

5.2 5.3

I1

I2

E

Operation

1 2 3 4 4.1 4.2 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 7.2 7.3 8

Safety regulations governing the operation of the fork lift truck .......... E 1 Description of controls and indicating instruments .............................. E 2 Starting up the truck ............................................................................ E 6 Operation of the fork lift truck .............................................................. E 8 Safety regulations applicable when operating the truck ...................... E 8 Driving, steering, braking .................................................................... E 9 Picking up and setting down loads ...................................................... E 12 Safe parking of the truck ..................................................................... E 16 Keyboard (CANCODE) (o) ................................................................. E 17 Functions ............................................................................................. E 17 Commissioning .................................................................................... E 18 Indicators ............................................................................................. E 19 Keys .................................................................................................... E 20 Master mode ....................................................................................... E 20 Parameter ........................................................................................... E 22 Display instrument (CANDIS) (o) ....................................................... E 26 Discharge monitor function ................................................................. E 27 Operating hours display ...................................................................... E 27 Switch-on test ...................................................................................... E 27 Fault location ....................................................................................... E 28

F

Maintenance of the fork lift truck

1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 7 7.1 7.2 7.3 8

Operational safety and environmental protection ................................ F 1 Safety regulations applicable to truck maintenance ............................ F 1 Servicing and inspection ..................................................................... F 3 Maintenance checklist ....................................................................... F 4 Lubrication schedule .......................................................................... F 6 Fuels, coolants and lubricants ............................................................. F 7 Notes on maintenance ........................................................................ F 8 Preparation of the truck for servicing and maintenance operation ...... F 8 Opening the front cover ....................................................................... F 8 Check hydraulic oil level ...................................................................... F 9 Check the transmission oil level .......................................................... F 9 Checking the electric fuses ................................................................. F 10 Recommissioning the truck ................................................................. F 11 Decommissioning the fork lift truck ..................................................... F 11 Operations to be performed prior to decommissioning ....................... F 11 Measures to be taken during decommissioning .................................. F 11 Recommissioning the truck ................................................................. F 12 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to VBG 36) .......................................................................... F 12

A Correct use and application of the truck A included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.

The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads.

It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.

Duties of the user: fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the operating duties.

The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.

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If these operating instructions are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.

Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained.

Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.

A1

B Truck description 1

Application The truck is an electric pedestrian stacker in four-wheel construction with foldable driver platform.

It is designed for transporting and lifting goods on level ground. The wheel arm lift (only for ERC-Z trucks) increases the ground clearance for transport over unevenground.

Depending on the design, the hoist frame permits loads to be stacked and retrieved up to a max. height of 5.35 m and to be transported over longer distances. The truck capacity is indicated on the identification label or the capacity label Qmax.

Due to its high travelling speed, the ERC 14/16 is equipped with safety extensions.

Truck types, capacities and motor output Typ

Capacity

Motor output

ERC / ERC-Z 12

1,200kg

2.0kW

ERC / ERC-Z 14

1,400kg

2.0kW

ERC / ERC-Z 16

1,600kg

2.0kW

B1

2

Assemblies

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Item

Designation

Item

1

o Keyboard (CANCODE)

8

t Wheel arms

2

o Display instrument (CANDIS)

9

o Lifting linkage (Only for wheel-armlifting)

3

t Key switch

10

o Charger

4

t Control shaft

11

t Supporting wheel

5

t Controller

12

t Hinged driver standing platform

6

t Free-view hoist frame

13

t Driven wheel

7

t Master switch

14

o Safety extension*)

t = Standard equipment

Designation

o = Optional equipment

*) not with vehicles with load bearing capacity of 1200kg B2

3

Technical data - standard version

of technical data according to VDI 2198, A Indication subject to modification and supplementing.

3.1

Performance data Designation Q Rated capacity c Load centre distance Travelling speed with / without rated load Lifting speed with / without rated load (controllable (ZT)) Lowering speed with / without rated load (controllable (ZT)) Max. climbing capacity (5 min.) with / without rated load

ERC 12 ERC 14 ERC 16 ERC-Z12 ERC-Z14 ERC-Z16 1,200 1,400 1,600 kg 600 600 600 mm 6.0 / 6.0 7.5 / 8.5 7.0 / 8.5 km/h 19/26

18/26

17/26

cm/s

43/43

43/43

43/43

cm/s

9/16

8/16

7/16

%

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3.2

Dimensions (all dimensions in mm) Designation l2 h13 h1 h2 h3 h4 h5 y B/b1 Wa Ast Ast

*) **)

Design length of front Height of fork when lowered Design height (depending on the mast) Free lift (ZZ and DZ) Lift (depending on the mast) Extended height of mast (depending on the mast) Initial lift Wheelbase Overall width Turning radius Width of aisle with pallets 800 × 1,200 lengthwise Width of aisle with pallets 1,000 × 1,200 crossways Dead weight

ERC 12/ ERC 14/ ERC-Z12 ERC-Z14 856*)/888*) 856*)/888*) 90 90 1,700 - 2,600 1,700 - 2,600

ERC 16/ ERC-Z16 856**)/888**) 90 1,700 - 2,600

1,219 - 2,119 1,219 - 2,119 2,500 - 5,350 2,500 - 5,350 2,981 - 5,831 2,981 - 5,831

1,169 - 2,069 2,400 - 5,250 2,931 - 5,781

122 1,357/1,599 800/836 1,565/1,804 2,414*)/ 2,483*) 2,441*)/ 2,565*)

122 1,357/1,599 800/836 1,565/1,804 2,414**)/ 2,483**) 2,441**)/ 2,565**)

122 1,357/1,599 800/836 1,565/1,804 2,414*)/ 2,483*) 2,441*)/ 2,565*)

Refer to truck identification label

at DZ+35 at DZ+43

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3.3

EN standards Continuous sound level:

68 dB(A) according to EN 12053 as stipulated in ISO 4871

continuous sound level is a value averaged according to standard regulations, A The taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.

Vibration:

0.96 m/s2 according to prEN 13059

swinging acceleration acting on the body in its operating position is, according to A The standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.

Electromagnetic compatibility (EMC) The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to prEN 12895 and the references to other standards contained therein. or electronic components and their arrangement may only be modified after A Electrical written approval by the manufacturer has been obtained.

3.4

Conditions for application Ambient temperature: - during operation: 5 C to 40 C

trucks must be specially equipped and approved for continuous use in enA Industrial vironments with temperatures below 5°C or in cold stores respectively with extreme temperatures or humidity changes.

B5

4

Location of instruction labels and identification labels

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Item

Designation

15

Capacity (only ERC-Z)

16

Truck identification plate

17

Attachment point of hooks for transportation by crane

20

UVV control label

21

Capacity

22

Battery identification plate (located in battery compartment)

capacity label (21) indicates the maximum capacity of the truck as Qmax. The A The rated capacity as shown must not be exceeded. the corresponding hood (refer to chapter F).

B6

4.1

Truck identification plate íê

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îç íð Item 24 25 26 27 28 29 30

Designation Type Serial No. Rated capacity in kg Battery: Voltage V Manufacturer Order no.

Load centre distance in mm

íï Item 31 32 33 34 35 36

Designation Drive power in kW Customer no.

Min./max. battery weight in kg Dead weight without battery in kg Year of manufacture Manufacturer logo

the event of queries relating to the truck or spare part orders, please state the serial A In No. (25) of the truck.

4.2

Load capacity

label (21) includes a table indicating f The the loading capacity (Q in kg) in relation

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to the load centre distance (D in mm) and the lifting height (H in mm).

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The arrow-shaped markings on the inner mast (37) and outer mast (38) show the driver when he has reached the lifting height limits that is defined on the load capacity label (21).

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B7

4.3

Load capacity, wheel-arm lifting device Trucks with a wheel-arm lifting device are provided with an extra label (15) indicating the permissible assignment to wheel-arm lifting device and main lifting device.

4.4

Label/Order/Inventory/Service No. íç ìð ìï Item 39 40 41

Description Order no.

Inventory No. Full Service No.

label contains the Full Service No. and is only handed out when a service conA This tract is being concluded.

B8

C Transportation and commissioning 1

Transportation by crane

use lifting equipment with sufficient bearing capacity (loading weight see identif Only fication label on truck).

If trucks are to be lifted that are provided with a wheel-arm lifting device, be careful not to protrude the lifting cylinders while the truck is being lifted. If the device is completely protruded, there is the risk that the cylinder protection is being released due to overloading.

hoisting point (2) is provided at the hoist frame for loading the truck with the help of A Ahoisting gear.

Trucks that are provided a with wheel-arm lifting device, have two more hoisting points (1) for loading. (refer to chapter E). on the hoisting mast. a wheel-arm lifting device, the hoisting gear can also be attached to the stops (1) on the vehicle chassis.

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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 lifted.

Trucks with wheel-arm lifting device must hang horizontally or slightly inclined in the direction of the lifting device.

2

First commissioning

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The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (towing cable) must be less than 6 meters in length.

is prohibited to hoist loads when the truck is operated via a towing cable with an f Itexternal battery.

In order to prepare the truck for work following delivery or transportation, the following operations must be performed:

(see chapter D).

C1

trucks with an optionally built-in battery charger, adjust the characteristics (loading A At cam) (see chapter D).

the battery (see chapter D).

the combined instrument correspond to

(see chapter E). the truck is parked for longer periods, the running surfaces of the wheels may be A Ifflattened.

However, this flattening will disappear quickly when the truck is being driven.

3

Moving the truck with the drive unit inoperative

f This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a failure has rendered it immobile, proceed as follows:

and remove the key. o-key must be pressed.

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move. (refer to chapter F). screws (4).

The brake has now been released and the truck can be moved. arriving at the repair bay, ensure that f After the brake is put back to its initial state. The

truck must on no account be parked with the brake in the released condition.

The brake is now applied again.

C2

í

D Battery - Servicing, recharging, replacement 1

Safety regulations governing the handling of lead-acid batteries The truck must be parked and rendered safe before any operations on batteries are undertaken (refer to chapter E).

Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual, and the instructions of the manufacturer of the battery and of the battery recharging station, must be observed when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a nonskid insulating mat.

Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manu-

m

Before closing the battery hood, make sure that the battery cable cannot be damaged.

contain dissolved acid which is toxic and caustic. For this reason, protective f Batteries clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid.

If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.

m Only batteries with closed tray may be used. weight and dimensions have considerable influence on operational safety of f Battery the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.

D1

2

Battery type Depending on the use, the truck is equipped with different types of batteries.

The table below shows the capacity of the batteries and also the combinations used as standard equipment: 24V - 3PzSL - Battery

240Ah

24V - 3PzSL - Battery

270Ah

24V - 3PzSL - Battery

330Ah

For the battery weight, refer to the battery identification plate.

m

When changing / replacing the battery you must make sure that the battery is safely fastened in the battery compartment of the truck.

3

Exposing the battery

f Park the truck and render it safe (refer to chapter E).

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f Carefully open or close the battery hood. covers and connections must be restored to the normal operating condition before f All the truck is started up for work.

D2

4

Charging the battery As default, the truck is to be loaded with a stationary battery charger. The truck without wheel-arm lifting device can optionally be supplied with an integrated battery charger.

m

For recharging the battery, the truck has to parked in-doors in a sufficiently ventilated environment.

A Charging condition display (refer to chapter E).

4.1

Charging the battery with stationary battery charger

m

Connection / disconnecting battery connector and socket as well as pressing the master switch (2) may only be performed with truck and battery charger being switched off.

the recharging operation the tops of the battery cells must be exposed to enf During sure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage.

The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed.

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connector (3) and switch on the battery charger.

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Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.

D3

4.2

Recharging the battery with integrated battery charger (o)

f The battery charger must not be opened. If it is damaged, it has to be exchanged.

A Due to safety reasons, intermediate positions are available between the regulation If the truck is delivered without battery, an intermediate position is pre-selected as default. The red light-emitting diode (5) flashes - the battery cannot be recharged.

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Select charging curve in the integrated battery charger Use switch (7) at the battery charger to adjust the charging curves to the appropriate battery according to the following table.

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The power plug must be pulled before the corresponding charging curve is to be adjusted!

Provided that a battery is connected, a new setting can be acknowledged via the LEDs (cf., indicator) which will then be immediately effective.

Position of switch (7) 1 2 3 4 5 6

D4

selected charging curves (characteristics) Wet batteries: 100 - 330 Ah Maintenance-free: 100 - 140 Ah Maintenance-free: 150 - 200 Ah Maintenance-free: 210 - 300 Ah Free Free

Adjusting the charging curve The charging curve can be adjusted by performing the following steps: Connect the battery

This permits to use the battery charger as an adjustment aid Turn the adjustment switch to The red LED flashes fast no valid the right (i.e. clockwise) until it charging curve seltouches the limit stop. ected Turn the adjustment switch to After 3 seconds the green LED charging curve 1 the left (i.e. anticlockwise) until flashes only once selected it touches the limit stop.

Select the desired charging The red LED starts to flash in curve by turning the adjustthe intermediate positions. ment switch to the right If a valid charging curve is selected, the green LED starts to flash in the relevant switch position.

Starting the recharging process with integrated battery charger the recharging operation the tops of the battery cells must be exposed to enf During sure adequate ventilation. Metal objects must not be placed on the battery. Prior to

starting the recharging operation, check all cable connections and plugged connections for visible damage. The safety instructions provided by the battery supplier and battery charger supplier must be strictly observed.

Mains supply Line voltage: 230 V (+10/-15%) Line frequency: 50 Hz / 60 Hz The power plug (8) of the battery charger can be found in the battery compartment.

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D5

master switch (2) may only be operated with truck and battery charger being switA The ched off.

The flashing LED indicates the charging status and/or a fault (flashing codes see tathe power plug (8) is connected to the mains, all electric functions of the truck are A Ifinterrupted (electric driving lock). No operation of the truck is possible.

recharge procedure is automatically continued after a power failure.

A The The recharge procedure can be interrupted by pulling the power plug and can be continued in steps.

mains cable must not be damaged. f The Before commissioning the truck, the battery hood must be properly closed.

Charging times The time required for recharging depends on the capacity of the battery.

LED display Green LED (6) (charging status) is lit

Red LED (5) (fault)

Indication

---

Recharge procedure is finished; battery is full. (charging break, fill-up charge or equalization charge) flashes slowly --Charging process flashes fast --Indicates the start of a recharge procedure or that a new charging curve was adjusted. The number of the flashing pulses corresponds to the adjusted charging curve.

--is lit Excess temperature. Recharge process is interrupted.

--flashes slowly Safety charging interval exceeded. Recharge process is interrupted. Disconnection from the mains is required for restarting the charging process.

--flashes fast charging curve setting is invalid.

----Power failure and/or no battery connected.

Fill-up charge The fill-up charge begins automatically after the recharge procedure has ended.

Partial recharging The battery charger is designed in such a way that it automatically adapts to the charging status of partially recharged batteries. This permits to reduce wear and tear of the battery.

D6

5

Removing and installing the battery

truck must stand horizontally. Batteries with exposed terminals or connectors f The 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.

replacing batteries, ensure that a battery of the same type is fitted. Supplemenf When tary weights may not be removed or changed in their position. reinstallation of the battery, visually check all leads and connectors for damage. f After Before commissioning the truck, the battery hood must be properly closed. changing the battery with the aid of a lifting gear, ensure that the lifting gear is A When of adequate capacity (the battery weight is indicated on the battery identification plate

at the battery trough). The battery must be lifted vertically to prevent crushing of the battery trough. The hooks are to be attached to the battery hoisting ears (9) that they cannot fall onto the battery cells when the hoisting gear is released.

5.1

Remove battery by lifting it upwards (truck without wheel-arm lifting device)

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The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.

D7

5.2

Remove battery by lifting it upwards (truck with wheel-arm lifting device)

battery cable of the truck must be laterally led outside. While removing the batf The tery, make sure that the cable is not squeezed.

ç

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The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.

D8

5.3

Lateral battery change (o)

the battery cover (13).

station. careful not to place your fingers between partition wall of the truck and the battery. f Be Heed the operating instructions of the battery change station.

Mounting the battery:

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The re-assembly can be performed by reversing the above actions; pay attention to the correct mounting position and battery connection.

D9

E Operation 1

Safety regulations governing the operation of the fork lift truck Driving permission: The fork lift truck must only be operated by persons who have been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.

Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him.

If the fork lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.

Prohibition of unauthorised use: The driver is responsible for the fork lift truck during working time. He must forbid unauthorised persons to drive or operate the fork lift truck. The transport or lifting of persons is forbidden.

Damage and defects: Damage or defects noted on the fork lift truck or on the attachments must immediately be brought to the notice of the person in charge. fork lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.

Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.

Danger area: endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling / lowering truck attachments.

persons must be asked to leave the danger area. The driver must give f Unauthorised a warning signal whenever a situation presenting danger to persons might develop.

The fork lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.

Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.

E1

2

Description of controls and indicating instruments Item Controls or indicating instrument respectively 1 Keyboard (CANCODE) 2 Display instrument (CANDIS)

ERC 12

ERC ERC-Z Function 14/16 12/14/16

o

o

o

o

o

o

3 Key switch

t

t

t

4 5

t t

t t

t t

-

-

t

-

-

t

8

Control shaft Button - warning signal (horn) Button - wheel arms lowering Button - wheel arms lifting Driving regulator

t

t

t

9

Bumper safety switch

t

t

t

6 7

Code settings Travel programme enable Operating hours meter Battery capacity display Shows the residual capacity of the battery as well as the accumulated operating hours of the truck.

Switches control voltage on and off.

Removing the key secures the truck against switching on by unauthorised personnel.

Steering and braking the truck.

Trigger warning signal.

Wheel arms are lowered with constant speed Wheel arms are lifted with constant speed Controls the driving direction driving speed.

Pedestrian-controlled operation: Safety function, which causes the vehicle to move for about 3 (Backward) and then switches off until the controller is briefly moved to the neutral position.

Ride-on mode: Non-functional.

E2

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E3

Pos. Controls or ERC ERC ERC-Z Function indicating instrument 12 14/16 12/14/16 respectively 10 Button t t t Lifting the lifting device.

Lifting the lifting device The lifting speed can be continuously adjusted with this key (adjustment range 8 mm).

11 Button t t t Lowering the lifting device.

Lowering the lifting deThe lowering speed can be vice continuously adjusted with this key (adjustment range 8 mm).

12 Terminal strip t t t Depositing of freight documents.

13 Master switch t t t The circuit is interrupted, all electric functions are switched (Emergency Stop) off. The truck is compulsory braked.

14 Control lamp at the o o Indicates the loading states battery charger (see chapter D).

15 Integrated battery char- o o Used for recharging the batteger ry.

16 Hinged driver standing t t t Pedestrian-controlled operatiplatform on: Driver standing platform in folded- up position: =>Truck travelling speed is limited to 6.0 km/h.

17 Hinged safety extensions

-

t = Standard equipment *)only at ERC-Z 14/16

E4

t

t*)

Stand-on operating mode: standing platform serves as deadman's switch function: Unweighted standing platform in folded-down position: =>travelling function blocked.

Standing platform in foldeddown position, driver standing on platform: =>travelling function rleased.

The travelling function is blokked if the safety extensions are not folded out when the standing platform is folded down. o = Optional equipment

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E5

3

Starting up the truck

starting or operating the truck, or before lifting any loads, the driver has to f Before make sure that nobody is within the danger area.

The electronic driving and steering systems automatically control their functions. If an error or fault occurs, the driving and steering functions are stopped. the truck is restarted, it is required to perform the relevant troubleshooting acf Before tions.

Checks and operations to be performed before starting daily work visible damage.

the wheels and the load lifting device) for

magnetic fastening.

f Do not operate the controller (8) when climbing on the truck. .

E6

Switching on the truck

position until reaching the stop. (refer to section 6.6).

A The combination instrument (CANDIS (o) (2)) shows the available battery capacity.

f

form (16) is folded up. (refer to section 4.2).

The truck is now ready for operation.

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E7

4

Operation of the fork lift truck

4.1

Safety regulations applicable when operating the truck Driving lanes and work areas: Only such lanes and routes that are specially allocated for truck traffic must be used. Unauthorized persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.

Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.

Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork lift truck to give suitable warnings.

Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.

Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft.

Persons riding in the lift together with the fork lift truck must only enter the lift after the fork lift truck has come safely to a standstill, and must leave the lift before the fork lift truck.

Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.

Towing trailers: The maximum trailer load given for the fork lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.

E8

4.2

Driving, steering, braking

extremely careful when driving and steering, especially when parts of the body f Be protrude from the truck contour.

Emergency cut-out

This will switch off all electric functions. The truck is compulsory braked.

Emergency stop When the control shaft (4) is released, the truck is automatically braked (emergency stop). The control shaft will automatically move into the upper braking range (B). the control shaft is sluggish in moving into the braking range, the cause must be f Ifestablished and eliminated. If necessary, the return spring must be replaced.

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E9

Driving

f There are three different travelling modes: Swivel the safety extensions (17)*) inwards and then fold up driver platform (16).

Fold down driver platform (16).

Swivel the safety extensions (17)*) outwards and then fold down driver platform (16). travelling function is blocked if the driver is not standing on the platform and the A The safety extensions* are not folded out. *) not with vehicles with load bearing capacity of 1200kg not drive the truck unless the hoods are closed and locked in the stipulated manf Do ner. When passing through swing doors, or similar, take care that the anti-collision button (1) is not inadvertently operated.

The truck will move in the selected direction.

A The travelling speed is controlled by means of the controller (8). Þ

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E 10

Driving up an incline

m

The load must be transported facing the incline!

With the controller (8) set to neutral, the service brake is automatically applied after a (8) is used to release the service brake; the speed and driving direction are set as desired.

m

When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.

Steering

f In narrow bends, the driver will be positioned at the outer contours of the truck.

The position of the control shaft corresponds to the position of the steered driven wheel.

Electrical steering The electric steering system is self-monitoring.

The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switching the truck off and on again. This method prevents the cancellation of a fault without eliminating the fault.

Braking braking behaviour of the truck strongly depends on the state of the floor. This f The must be taken into account by the driver for his driving behaviour.

The truck may be braked in three ways:

case of emergencies, the truck must only be braked using the service brake f In(control shaft (4)).

m

During normal operation, the generator brake and counter-current braking should be applied. These methods of braking reduce wear and require less energy (energy recovery).

E 11

Braking by means of the service brake: shaft altogether.

The drive motor will then be braked by means of the motor brake.

A When the control shaft is released, it will automatically swivel into the upper braking Counter-current braking

The truck is braked by counter-current until it starts moving into the opposite direction.

A The braking effect depends on the setting of the controller.

Braking by means of the generator brake (coasting)

Depending on the setting, the truck is braked by the generator braked, coasting to a stop.

A The degree of speed reduction can be set by the manufacturer service.

m

When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.

5

Picking up and setting down loads

picking up a load, the driver has to make sure that it is correctly palletised and f Before that the capacity of the truck is not exceeded.

Do not grab into the hoist frame during lifting and lowering. wise is not permitted.

m

Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm).

the case of the double-lift dual mast (ZZ) and the double-lift triple mast (DZ), the A In initial lift of the load carriage (free lift), without any changes to the design height, is provided by a short, centrally arranged free-lift cylinder.

E 12

Lifting and lowering Lifting button (10) until the desired height has been reached.

Lowering

height has been reached.

A

The lifting/lowering speed can be continuously adjusted with this button (adjustment range 8 mm).

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Small button adjustment range = slow lifting / lowering Large button adjustment range = fast lifting / lowering

Safety switching height For lifting starting at approx. 1.8 m: (refer to switching matrix / safety switching height). with a noticeable alignment of the truck). e the safety switching height.

E 13

Switching matrix / safety switching height ERC / ERC-Z 12 Platform

Lifting height

Speed (km/h) with load

Collision guard button active

Lifting functions active

Folded up

<Sh *)

4.3

Yes

Yes

Folded up

)

>Sh *

4.3

Yes

Yes

Folded out

<Sh *)

6.0

No

Yes

Folded out

>Sh *)

4.3

No

Yes

ERC / ERC-Z 14/16 Platform Safety frame

Lifting height

Speed (km/h) with load

Collision guard button active

Lifting functions active

Folded Folded up in

<Sh *)

4.3

Yes

Yes

Folded Folded up in

>Sh *)

4.3

Yes

Yes

Folded Folded up out

<Sh *)

0

No

No

Folded Folded up out

>Sh *)

0

No

No

Folded Folded out in

<Sh *)

6,0

No

Yes

Folded Folded out in

>Sh *)

4,3

No

Yes

Folded Folded out out

<Sh *)

7.5 / 7.0

No

Yes

Folded Folded out out

>Sh *)

0 **)

No

No **)

*)

Sh = Safety switching height approx.1,800 mm (depending on lifting mast version)

**) optionally travelling (4.3 km/h) and lifting with the safety frames folded out above 1,800 mm in conjunction with a load guard is possible.

E 14

Wheel-arm lifting device (only ERC-Z) (t)

A lowering movement with a fixed speed. ensure the stability of the truck, the wheel arms will be automatically lowered from f To a specific lifting height of the fork onwards, depending on the used hoist frame type.

From this lifting height onwards, the wheel-arm lifting device can no longer be used.

The lowering movement cannot be interrupted! (Danger of injuries) Lifting the wheel arms Keep the button pressed, until the desired lifting height has been reached.

Lowering the wheel arms ton. Keep the button pressed, until the desired lowering height has been reached. ê

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Emergency lowering

f No other personnel is allowed in the danger zone when using emergency lowering.

If the lifting device cannot be lowered due to a failure of the lifting controller, the emergency lowering procedure must be performed. push master switch (13) to position (refer to chapter D).

(19). hex socket wrench required A The (2.5 mm) is attached to the valve block.

The lifting device is lowered.

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in screw (19) again.

Setting the truck to operation after removing the fault.

E 15

5.1

Safe parking of the truck If the truck is left unattended, even for only short periods of time, it must be rendered safe.

f

Do not park the truck on slopes! The load lifting device must always be completely lowered.

and remove the key from the switch. o-key must be pressed.

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(only with vehicles with a load bearing capacity of 1400 kg and 1600 kg).

f

E 16

6

Keyboard (CANCODE) (o) The keyboard is provided with a key switch function. It is equipped with a 10-key numeric keypad and two special keys. After entering the correct code the control circuit is switched on.

6.1

Functions The keyboard can only administer one master code and 600 operator codes. It is possible to assign a unique code to each truck. Only operator who know this code can use the truck. Alternatively, you can assign a unique code to each driver. All operator codes that are to be enabled for this truck must be stored in the keyboard.

shipped to the customer one operator and one master code is factory-set A When (2580 and 7295).

m

Change the master and operator codes when setting the truck into operation for the first time!

All possible codes are preset to one length (4, 5, or 6 digits). The length of the operator code is predefined by the length of the master code. The code is automatically checked after the corresponding number of keys is pressed.

The travel parameters for the operating mode can only be adapted in master mode.

Moreover, the master mode permits setting the battery type and the special functions.

E 17

6.2

Commissioning After switching on the master switch and the key switch the LED (20) lights up steady red also during operation.

If the keyboard is used as code switch, the control circuit switches on after entering the correct operator code (factory-set to 2580). LED (20) now lights up steady green.

When an incorrect code has been entered, LED (20) light up red for two seconds.

After that you can enter a new code.

The travel programme (travel speed, deceleration and acceleration intensity are set) is activated, which is indicated by the greed LEDs (22, 23,42) on key 1, 2, or 3.

Set key (21) has no function in operating mode.

The control circuit is switched off by actuating the o-key (25). To switch on again, re-enter the code.

Switching off by o-key, key switch, or automatically, if the truck is not used for a preset time (automatic switch-off after a period between 10 seconds and 30 minutes can be activated in master mode).

E 18

6.3

Indicators Status displays of the individual LEDs

LED (20) steady (red) steady (green) flashing red flashing green

Truck off (not ready for operation) Truck on (operating mode) Truck with error message Truck on (master mode)

LED (22) steady (green) flashing green

Travel programme Code change: old code, input

LED (23) steady (green) flashing green

Travel programme Code change: new code, first input

LED (24) steady (green) flashing green

Travel programme Code change: new code, confirmation

Keyboard error messages The following errors are indicated by a red flashing LED:

E 19

6.4

Keys o-key (25) The o-key (25) is always active and has the highest priority. It is used to set the truck from any state to the basic state (truck switched off and not ready for operation) and vice versa. It is exclusively used for switching off or resetting the truck.

Set key (21) No function for the operator. In master mode, the entered values are confirmed by the Set key.

Numeric keys Keys 1, 2, 3, 4, 5, 6, 7, 8, 9, 0 are used for entering codes.

6.5

Master mode Parameter changes must be made carefully and only by trained personnel. Changing the parameters results in changed travel behaviour of the truck.

To enter the master mode, the following is required: o-key (if in operating mode), Display instrument (CANDIS) Operating hours are indicated

284.9

LED (20) LED (22) LED (23) LED (24) green flashing

off

off

off

Enter a parameter number and confirm with Set key (21).

If an invalid input is entered (LED (20) flashes red) you return to the basic state of the master mode by actuating Set key (21). Enter a new parameter number and confirm with Set key (21).

The following example show the setting of the acceleration parameter (parameter 101) in the travel programme.

E 20

Acceleration example Display instrument (CANDIS) current setting is displayed changed setting is displayed

LED (20) LED (22) LED (23) LED (24)

101 6

green flashing

off

off

off

101 8

green flashing

off

off

off

Parameter Parameter number setting value After entering parameter number 101 and pressing the Set key, the current value 6 is read out and displayed Change the value to 8 and confirm with Set key (21).

E 21

6.6

Parameter Parameter groups The parameter number is composed of three digits. The first digit designated the parameter group according to table 1. The second and third digits are sequentially numbered from 00 to 99.

No. Parameter group 0xx Code lock settings (Codes, travel programme enable, automatic switch-off, etc.)

1xx Travel programme (Acceleration, coasting brake, speed, etc.)

4xx Programme-independent parameters

E 22

Truck parameter list No.

Function

Range Setting value

Code lock - internal 000 Change master code 0000 - 9999 The length of the master or code determines the 00000 - 99999 length of the operator or code. As long as operator 000000 - 999999 codes have been programmed, only new codes with the same length can be entered. If the code length is to be changed, all operator codes must be deleted first.

001 Add operator code

002 Change operator code

0000 - 9999 or 00000 - 99999 or 000000 - 999999

0000 - 9999 or 00000 - 99999 or 000000 - 999999

Default Setting value

Comments

(LED 22 flashes) Enter the current code confirm (Set) (LED 23 flashes) Enter a new code Confirm (Set) (LED 24 flashes) Repeat new code Confirm (Set) (LED 23 flashes) Enter a code Confirm (Set) (LED 24 flashes) Repeat the code entry Confim (Set) (LED 22 flashes) Enter the current code Confirm (Set) (LED 23 flashes) Enter a new code Confirm (Set) (LED 24 flashes) Repeat the code entry Confirm

LED 22-24 are located in the key pad fields 1-3.

E 23

No.

Function

Code lock - internal 003 Delete operator code

Range Setting value

Standard Setting value

0000 - 9999 or 00000 - 99999 or 000000 - 999999

004 Clear code memory (deletes all operator codes)

3265

010 automatic switch-off

00 - 31

Comments

(LED 23 flashes) Enter a code Confirm (Set) (LED 24 flashes) Repeat the code entry Confirm (Set) 3265 = delete

00

other entry = do not delete 00 = none Switch-off 01 to 30 = Switch-off time in minutes 31 = Switch-off in 10 seconds

030 Display of assigned operator codes

E 24

No.

Function

Range Setting value

Standard Setting value

0-9 0-9

6 6

0-9

6

0-9

6

0-9

6

0-9

6

Programme-independent parameters 411 Battery type (normal/high0-2 power/dry)

0

Travel programme 101 Acceleration 102 Coasting brake with enable 104 Drive direction: Maximum speed 105 Drive direction: Pedestrian controller speed 108 Fork direction: Maximum speed 109 Fork direction: Pedestrian controller speed

Comments

0 = Normal (wet) 1 = High-power (wet) 2 = Dry (maintenance-free)

E 25

7

Display instrument (CANDIS) (o) The instrument indicates: (LED bars (27)), (LC display (29)).

In addition, error messages of the electronic components and parameter changes are displayed.

Discharge status indication

Numb er Bars

Wet battery Maintenance-free battery LED (yellow) LED (red) LED (yellow) LED (red) Warning Stop Warning Stop 10 90.1- 100% Off Off Off Off 9 80.1 - 90% Off Off Off Off 8 70.1 - 80% Off Off Off Off 7 60.1 - 70% Off Off Off Off 6 50.1 - 60% Off Off Off Off 5 40.1 - 50% Off Off On Off 4 30.1 - 40% Off Off On On 3 20.1 - 30% On Off On On 2 10.1 - 20% On On On On Avoid falling below the 20% limit for wet batteries resp. 40% limit for maintenance-free batteries.

E 26

Charging condition

7.1

Discharge monitor function With the discharge monitor function enabled, the lifting function switches of when reaching the discharge limit (the Stop LED switches on). Travelling and lowering is still possible. For wet batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. At 30% resp. 50% the batteries should be recharged (the yellow LED lights up as warning indication).

7.2

Operating hours display Display range between 0.0 and 99,999.0 hours. Travel and lifting movements are logged. This is a backlit display.

A Error messages The operating hours display is also used for indicating errors. The display shows a If several errors occur they are displayed one after the other. Errors are displayed as long as they persist. The operating hours display is overwritten with an error message. Most errors cause the emergency stop to be triggered. The error display is maintained until the control circuit is switched off (key switch). service personnel has access to detailed component descriptions and error A The codes.

Display for parameter changes (travel programmes) The parameter numbers are shown in the display. This is done in conjunction with the keyboard (CANCODE).

After a few seconds the display is overwritten again by the operating hours display.

7.3

Switch-on test After switching on the display shows:

E 27

8

Fault location This chapter helps the operator to locate and fix simple malfunctions or the results of operating errors him- or herself. The order of the work stated in the table must be observed for fault location.

Fault Truck does not move

Possible cause

Remedy

not connected

and reconnect it, if necessary

STOP) pressed

GENCY STOP)

form, lifting and travel function not active the battery and recharge, if necessary driving range (F)

range (F)

nected

charger from the mains

Load cannot be lifted

measures that are mentioned switching height form, lifting and travel function not active

bearing capacity (see identification label) (STOP icon)

the battery and recharge, if necessary

A please contact the Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.

E 28

F Maintenance of the fork lift truck 1

Operational safety and environmental protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.

of fork lift truck assemblies, especially of the safety installations, are not f Modifications permitted. On no account must the operational speeds of the truck be changed.

m

Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.

Upon completion of any checking and servicing activities, the operations contained in

2

Safety regulations applicable to truck maintenance Servicing and maintenance personnel: The fork lift truck must only be serviced and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.

Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.

Cleaning operations: No inflammable liquids must be used when cleaning the fork lift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery-operated fork lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.

m

If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning.

Cleaning by means of a steam jet is not permitted.

F1

Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork lift trucks, the truck must also be depowered by removing the battery plug.

Welding operations: To prevent any damage to electric or electronic components, these have to be removed from the fork lift truck before any welding operations are undertaken.

Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.

Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. The factory-mounted tyres must only be replaced by original spare parts of the manufacturer, since otherwise the specification of the data sheet cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified.

The external application of grease does not provide sufficient lubrication.

Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.

F2

3

Servicing and inspection Thorough and expert servicing is one of the most important preconditions for safe operation of the fork lift truck. The neglect of regular servicing intervals can lead to fork lift truck failure and constitutes a potential hazard to personnel and equipment.

m

The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.

The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows: W1 = every 50 operating hours, but at least once per week M3 = every 500 operating hours, but at least every 3 months M6 = every 1000 operating hours, but at least every 6 months M12 = every 2000 operating hours, but at least every 12 months

A The W1 maintenance intervals must be carried out by the operator / customer.

In the running-in phase of the truck, the following additional operations have to be carried out: After the first 50 - 100 hours of operation, at least after 2 months:

F3

4

Maintenance checklist

Maintenance intervals Standard = t W M M M Cold-storage depot = k 1 3 6 12 Chassis/ 1.1 Check all load bearing elements for damage t Design: 1.2 Check all bolted connections t 1.3 Check platform for correct functioning and damage t Drive unit: 2.1 Check the transmission for noises and leakage t 2.2 Check the transmission oil level t 2.3 Change the transmission oil l t Wheels: 3.1 Check for wear and damage t 3.2 Check the wheel bearings for correct fasteninga) l t Steering: 4.1 Check the steering wheel play t 4.2 Check the steering chain and chain sprocket for wear, l t adjust and grease 4.3 Check mechanical parts of steering column and grease, t if required Brake 5.1 Performance and adjustment check t system: 5.2 Check the brake linings for wear t 5.3 Check the brake linkage; adjust and grease, if necessary l t 5.4 Gas pressure spring (tiller shaft) to reset function, t check for tightness and damages Hoist frame: 6.1 Visual inspection of rollers l t 6.2 Check fork tines and fork carrier for wear and damage l t 6.3 Check secure attachment of hoist frame t 6.4 Check lift chains and chain guide for wear, adjust and t grease them.

6.5 Check the lateral clearance of the mast profiles and t whether they are parallel to each other 6.6 Check safety devices for proper attachment l t and damages Lifting de7.1 Check function, wear and tear and adjustment t vice: 7.2 Visual check of rollers, slide pieces and stops l t 7.3 Check fork tines and fork carrier for wear and damage l t Hydr. system: 8.1 Check function k t 8.2 Check all connections for leakage and damage b) k t 8.3 Check hydraulic cylinders for 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 filter t 8.7 Check the pressure relief valves for correct functioning k t

F4

Electr. system:

Electric motors: Battery:

Maintenance intervals Standard = t W M M M Cold-storage depot = k 1 3 6 12 9.1 Check function t 9.2 Check all cables for secure connection and damage t 9.3 Check the fuses for correct amperage t 9.4 Check switches and trip cams for proper functioning and t seating 9.5 Check contactors and relays, replace wearing parts, if t necessary 9.6 Check functioning of warning devices and safety circuits k t 10.1 Check wear of carbon brushes t 10.2 Check the motor for secure attachment t 10.3 Suck out engine block, check wear of collector k t 11.1 Check acid density, acid level and cell voltage l t 11.2 Check the terminals for secure attachment and apply l t pole grease 11.3 Clean battery connections, check for tight fit l t 11.4 Check the battery cables for damage and replace, if t necessary 11.5 Check the battery lock for proper functioning t 12.1 Grease truck according to lubrication schedule l t

Lubrication service: General mea- 13.1 Check electrical system for short to ground surements: 13.2 Check driving speed and braking distance 13.3 Check lifting and lowering speed 13.4 Check safety facilities and switch-off devices t Demonstrati- 14.1 Perform a trial run under a nominal load t on: 14.2 Demonstrate the truck to a person charged with inspec- l t tion upon completion of the maintenance of the truck

t t t

a) First check of the wheel nuts after approx. 100 operating hours for tight fit. Re-tighten if necessary. For starting torque, see maintenance plan. b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours; tighten, if necessary. c) 1. exchange after 500 hours of operation / if required, change coarse sieve. maintenance intervals refer to normal service conditions. If you are working unA The der difficult conditions, reduce the intervals, if required.

F5

5

Lubrication schedule g

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a

Slide faces Grease nipple Filler neck for hydraulic oil Filler neck Gear oil Drain plug Gear oil Cold store usage 1.25l - 1.3l;

1) Mixing proportion for application in cold-storage depots 1:1 2) only ERC-Z 3) 4)

1.25l - 1.3l; depending on the drive type (always up to the lower edge of the filler neck).

F6

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5.1

Fuels, coolants and lubricants Handling consumption type material: Consumption type material must always be handled properly. Manufacturer's instructions to be observed.

handling is injurious to health, life, and environment. Consumption type maf Improper terials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.

When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualitiies resp., except if mixing is expressively prescribed in these operating instructions.

Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.

Code Order-no.

A 29 200 670 B 29 200 680 C 29 200 810 E F G

29 201 430 29 200 100 29 201 280

Supply Qty 5,0 l 5,0 l 5,0 l

Designation H-LP 46, DIN 51524 CLP 100, DIN 51517 H-LP 10, DIN 51524

1,0 kg 1,0 kg 0,4 l

Grease, DIN 51825 Grease, TTF52 Chain spray

Dropp. point C 185 --

Worked penetr. at 25 C 265-295 310-340

Used for: Hydraulic system Transmission Transmission, hydraulic system Lubrication Lubrication Chains

Grease Data Code Saponification E F

Lithium --

NLG1 class 2 1

Service temperat. C -35/+120 -52/+100

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6

Notes on maintenance

6.1

Preparation of the truck for servicing and maintenance operation All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:

ration. working under raised forks or the raised vehicle, they should be secured so that f When the possibility of them dropping, tipping or slipping is excluded. When the vehicle is observed.

The vehicle should be secured against rolling away before doing any work on the service / parking brakes.

6.2

Opening the front cover Truck equipped with hinged driver standing platform:

General: compartment).

f Drive only with closed and properly locked hoods!

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6.3

Check hydraulic oil level tion 6.1).

are markings on the hydraulic tank (see section 5). The oil level must be chekA There ked with the lifting device being lowered. (see section 6.3; see table).

Marking

Litre

Lifting heights (h3) ZT

ZZ

DZ

4

ca. 8,3

-

-

> 5300

3

ca. 8,0

-

> 4100

< 5300

2

ca. 6,8

> 3100

> 2800

-

1

ca. 5,1

< 3100

< 2800

-

A Mounting is performed in reverse order.

6.4

Check the transmission oil level

(see section 5).

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6.5

Checking the electric fuses (refer to section 6.1).

exchange them, if required.

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Item 5 6 7 8 9

F 10

Description F1 1F1 2F1 1F10 6F1

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Protection of: Total control fuse Drive motor (in parallel to 1F10) Pump motor Drive motor (in parallel to 1F1) Discharge indicator/operating hour meter

Value 10 A 150 A 150 A 40 A 10 A

6.6

Recommissioning the truck Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:

7

Decommissioning the fork lift truck If the fork lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.

m

During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.

If the fork lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.

7.1

Operations to be performed prior to decommissioning

A In addition to this, all instructions given by the battery supplier must be observed.

7.2

Measures to be taken during decommissioning Every 2 months:

m

Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.

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7.3

Recommissioning the truck

battery.

fork lift trucks: A Battery-operated If switching troubles are experienced in the electric system, spray the exposed con-

tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.

f Perform several brake tests immediately after recommissioning the truck.

8

Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to VBG 36) At least once yearly, or after any untoward incident, the fork lift truck has to be chekked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork lift trucks.

The inspection must comprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects. Apart from this, the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.

The user has to ensure that all defects are eliminated without delay.

manufacturer has set up a special safety service with specially qualified staff. As A The visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to it. This plaque indicates in which month of which year the next test will be due.

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