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Table of contents

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1 Foreword

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
EC declaration of conformity in accordance with Machinery Directive . . . . . . . . . . . . . . . 3
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Standard design and optional equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Truck identification, Factory nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product support documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessories accompanying the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Safe-keeping and passing on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Copyright and proprietary rights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operator, form of address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 Safety

General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Non-ionising radiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Vibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Special safety advices for engaging loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safe handling of operating media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Risk assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Regular testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Residual risks when using order pickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Application area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Narrow aisle vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Original parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Directives and guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Driver's licence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Alterations to industrial trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

5212 804 3001 EN - 02/2017

I

Summary of Contents for EK-X10

Page 1: ...Original instructions High level order picker EK X10 2101 5212 804 3001 EN 02 2017 ...

Page 2: ......

Page 3: ...hts 7 Operator form of address 7 2 Safety General safety information 10 General safety information 10 Non ionising radiation 11 Vibrations 11 Special safety advices for engaging loads 13 Safe handling of operating media 14 Risk assessment 16 Regular testing 16 Residual risks 16 Residual risks when using order pickers 17 Application area 17 Intended use 20 Narrow aisle vehicles 21 Original parts 21...

Page 4: ...l commissioning 42 Commissioning 42 Transporting and loading 42 Drive battery 45 Replacing the battery 47 Daily commissioning 49 Checklist before starting work 49 Access to the driver s compartment 51 Access to the driver s compartment 51 Operating devices 52 Brake system 52 Steering system 53 Switching on the control system 55 Driving 56 Types of guidance 56 Driving without automatic guidance 58 ...

Page 5: ...with automatic guidance 68 Parking decommissioning 69 Parking and leaving the truck 69 Decommissioning 69 Emergency operation 70 Emergency operation 70 Emergency lowering valve 73 Emergency abseil system 75 5212 804 3001 EN 02 2017 III ...

Page 6: ... 90 6 Technical data Technical data 92 Driving speeds 93 7 Special equipment Inductive guidance IZF 96 Personal protection system MPSE 98 Pedestrian operation 99 Two person cab 101 Electronic access control 102 Working platforms 103 Trucks for use in cold storage 103 Load side operating panel 104 Battery on roller tracks 106 Acoustic warning signal 108 Leaning cushion 108 Tilt barrier 109 IV 5212 ...

Page 7: ...1 Foreword ...

Page 8: ... inform you about how to safely handle your industrial truck and how to keep it operational It is therefore essential that operators operating personnel and maintenance personnel familiarise themselves with understand and adhere to the contents of this manual The operability performance and service life of the vehicle are dependent on Proper use A daily inspection by the operator and Regular appro...

Page 9: ...GmbH Berzeliusstraße 10 D 22113 Hamburg Germany We declare that the Industrial truck according to these operating instructions Model according to these operating instructions conforms to the latest version of the Machinery Directive 2006 42 EC Personnel authorised to compile the technical documents See EC compliance declaration STILL GmbH 5212 804 3001 EN 02 2017 3 ...

Page 10: ... The procedures indicated should be complied with in full in order to avoid this danger NOTE Special attention is drawn to procedures and technical requirements that must particularly be observed Standard design and optional equipment These instructions describe the intended use and the prescribed maintenance and servicing for industrial trucks in the standard design and for the optional equipment...

Page 11: ... that the EU machine guidelines and all the relevant guidelines which are valid for this product have been met 2 Truck type 3 Truck serial number This serial number must be given in the event of any queries 4 Year of manufacture 5 Nominal loading capacity 6 Unladen weight 7 Battery voltage 8 Maximum battery weight 9 Minimum battery weight 10 Rated drive power 11 Ballast weight 12 Name of manufactu...

Page 12: ...truck is supplied with a box of acces sories upon delivery from the factory The contents differ depending on the truck type and the order This includes among other items an adhesive label that shows how to disable the magnetic brake on the traction motor using mechanical means This adhesive label can be affixed in a suitable position in the control compartment near the magnetic brake This box also ...

Page 13: ...s hereinafter operator to simplify the text The dimensions of the operator s compart ment on our industrial trucks are designed in accordance with standard DIN EN ISO 3411 and are accordingly constructed for both fe male and male operators This standard also stipulates ranges within which the operator s body weight and dimensions should lie If these industrial trucks are operated by per sons male ...

Page 14: ...1 Foreword Operator form of address 8 5212 804 3001 EN 02 2017 ...

Page 15: ...2 Safety ...

Page 16: ...e paid to the overall height and the centre of gravity which will be high as a result The condition of the floor surface influences the braking distance of the industrial truck The driver must take account of this in his driving and braking style General safety information Essentially all safety information located on the industrial truck must be observed Missing or illegible safety information is t...

Page 17: ...ruck operating com pany to explain these dangers to the employees in detail Maximum limit values for the electromagnetic emitted interference in accordance with EN 12895 at a distance of 10m Frequency MHz Electric field strength dBµV m 30 to 75 34 75 to 400 34 to 45 with increasing frequency 400 to 1000 45 Vibrations The vibrations of the machine must be deter mined on an identical machine in accor...

Page 18: ...ments The personal vibration load on the driver over a working day shall be determined in accordance with the Directive 2002 44 EC by the operating company at the actual place of use in order to consider all additional influences such as driving route intensity of use etc 12 5212 804 3001 EN 02 2017 ...

Page 19: ...s to be brought about by using appropriate containers or fastenings Before engaging any load ensure that it does not exceed the loading capacity of the truck diagram of permissible loads or the maximum permissible dimensions as specified by the data sheet Loads which are to be transported and placed in storage must be securely pack aged to ensure that the centre of gravity of the load does not shif...

Page 20: ...ven to death Even if such injuries do not feel particularly painful or serious a doctor must be consulted immediately The cause of the injury must be described exactly and the treatment started promptly ENVIRONMENT NOTE Oils pose a threat to the water supply and must accordingly always be transported and collected in regulation containers Do not spill oil Bind any spillages using suitable material...

Page 21: ...ted Battery acid is poisonous Always avoid breathing in vapours Battery acid is caustic Take all necessary precautions to prevent skin contact Rinse off battery acid immediately using plenty of clear water When handling battery acid wear personal protective gear such as gloves and clothing as well as facial protection Should skin contact still take place rinse immediately using plenty of clear wat...

Page 22: ...Regular testing This industrial truck must be checked at least once a year by a specialist expert according to our specifications Our test instructions summarise all activities that must be performed for the purposes of detecting damage or defects that have an effect on safety The requirements pursuant to FEM 4 004 are included in these test instructions A written report about the inspection has to...

Page 23: ...ng or racking parts The risk exists in trucks Without barriers and a cab rail Without rail guidance With feed in rollers on one or both sides With a one sided guide In versions specified the above mentioned risks may occur because second hand oper ation is not required for the truck type and the modes of operation In addition trucks without barriers or a cab rail may be driven with the driver s com...

Page 24: ...estrictions in the applicational area The trucks described here must notbe used in areas at risk from fire in areas at risk from explosions iin areas with atmospheres conducive to corro sion in atmospheres containing large amounts of dust in public traffic in refrigerated warehouses see special equip ment Cold storage on surfaces which are not horizontal The respective national regulations must be o...

Page 25: ...Safety 2 Application area 5212 804 3001 EN 02 2017 19 ...

Page 26: ...is risk must be countered by taking measures on site such as using approach rails for the load wheel arms It is the responsibility of the operating company to identify and eliminate any danger areas and or to prohibit any reasonably foreseeable misuse by issuing operating instructions The industrial truck is also suitable for raising lowering and transporting unit loads Use for other purposes is p...

Page 27: ...cles may only be operated in narrow aisles in accordance with the intended use if suitable precautions have been taken e g mobile or stationary protective equip ment to EN 2006 42 EG and EN ISO 13849 which prevent the possibility of collisions oc curring between persons and vehicles or which prevent persons and other vehicles also being present at that time In Europe it is the owner s responsibili...

Page 28: ...ensive training has been completed As the operating company you are responsible for ensuring that this requirement is fulfilled We recommend that you contact your branch or specialist representative They will be able to offer you the relevant training and tests required to obtain your driver s licence Alterations to industrial trucks Operating companies may only make alter ations or arrange for alt...

Page 29: ...on date and name and address of the organisation entrusted with this task Personal protective equipment For operation of our products no personal protective equipment is required under normal application conditions However it is possible that the use of personal protective equipment is required at the place of use due to the on site circumstances or local or internal regulations The national regul...

Page 30: ...2 Safety Personal protective equipment 24 5212 804 3001 EN 02 2017 ...

Page 31: ...3 Overview ...

Page 32: ...ers may be left open when the truck is being driven If the truck is driven at a lift height of greater than 1 2 m the barriers must be closed NOTE On the version with a simplex mast and auxiliary lift the changeover point for all of the affected functions is at approximately 0 4 m rather than at 1 2 m Horn The horn is an acoustic warning device that the driver can use at blind spots to signal that...

Page 33: ...position possible when travelling In the narrow aisle the order pickers are guided either mechanically or inductively please see chapter Optional equipment If the aisles are wide enough the industrial trucks can be driven freely with the load low ered All movements driving lifting lowering main lift cab lift lifting lowering auxiliary lift are infinitely adjustable Operating errors can be prevented...

Page 34: ... mast 1 Mast 2 Battery compartment 3 Driver s platform 4 Fork arms 5 Load rollers 6 Battery latch behind the cover 7 Detachable collision protection 8 Detachable hood of the control compart ment 9 Detachable battery compartment lid 10 Removable shelf Option 28 5212 804 3001 EN 02 2017 ...

Page 35: ...mast 4 Load side operating panel 5 Barrier 6 Fork arms 7 Battery compartment door followed by the battery and the battery lock 8 Load castor 9 Guide roller 10 Mast bracing 11 Removable hood to the battery compart ment 12 Direction indicator 13 Removable hood to the control compart ment 14 Removable collision protection Option 5212 804 3001 EN 02 2017 29 ...

Page 36: ...Driver s compartment only approved for use by a single person c It is not permitted for people to sit or stand on the load on the load support underneath a raised load or to be carried as passengers 4 Risk of crushing hands 5 Storage space for abseil system 6 Risk of crushing feet 7 Foot switch 8 Storage space for product documentation 30 5212 804 3001 EN 02 2017 ...

Page 37: ...A number of information signs are fitted on every truck depending on the series to draw attention to hazards technical data or requirements These signs must always be present in full and must always be legible NOTE The section entitled Labelling for special equipment provides details of further infor mation signs that may also be required based on the order 5212 804 3001 EN 02 2017 31 ...

Page 38: ...operated if a safety barrier closed on three sides is not present 5 Lubricants suitable for cold store applica tions must be used see lubricants for cold store trucks 6 Industrial truck with cold store equipment 7 This industrial truck must only be operated by operators with the appropriate training 8 Switch in switched off position 9 Switch in automatic mode position The pictograms shown here rep...

Page 39: ... surface for two hand operation 7 Special function preselection button 8 Override button e g to release the brake following automatic braking or to bridge intermediate lift cut out 9 Preselector button additional lift 10 Display field for truck operating status 11 Steering wheel and sensor surface for two hand operation 12 Operating rocker switch for cab lift or addi tional lift lower Option 5212 8...

Page 40: ...esidual charge When the truck is switched on the operating hours are displayed for 1 s and then the residual charge of the battery is displayed as a percentage 2 Not assigned 3 Not assigned 4 Not assigned 5 Not assigned 6 Steering angle actual value 7 Maintenance display 34 5212 804 3001 EN 02 2017 ...

Page 41: ...tching on the truck The display then changes to the battery residual charge The operating hours are counted according to the setting in the truck control unit and are displayed in 1 10 hours 6 minute cycle Battery residual charge The residual charge of the battery is shown as a percentage 5212 804 3001 EN 02 2017 35 ...

Page 42: ...or switchover to drive program 2 5 Entry of the number 5 or switch to operating hours display in hrs 6 Entry of number 6 or switchover to function 2 7 Entry of number 7 or switchover to drive program 3 8 Entry of the number 8 or switch to lift height display in mm 9 Entry of number 9 or switchover to function 3 10 LCD display see chapter LCD displays 11 Brightness sensor 12 Not assigned 13 Arrow b...

Page 43: ...y via the keypad required 11 Display for operating hours speed lift height load weight error messages 12 Barrier open 13 Operating status of the personal protection system 14 Error messages and information Option Displays information Info 1 Description Battery voltage too low Response Truck malfunctioning possible Cause Battery discharged Battery defective Remedy Charge battery Have battery checke...

Page 44: ...n on again Release the operating devices and select in correct sequence Info 15 Description Operation error for driving Response No driving function available Symbol in the display lights up Cause Incorrect sequence Foot switch signal missing 2 hand operation signal is missing Remedy Carry out the correct sequence In the event of all other errors contact the responsible service centre 38 5212 804 ...

Page 45: ...urrent fuse steering 4 Main current fuse drive and pump 5 Fuse holder not used 6 Combined drive and pump control 7 Steering motor 8 Drive motor 9 Steering gears and transmission 10 Detachable collision protection 11 Hydraulic oil tank 12 Filling opening hydraulic oil 13 Pump motor 14 Horn 15 Battery connector 5212 804 3001 EN 02 2017 39 ...

Page 46: ...3 Overview View into the control compartment 40 5212 804 3001 EN 02 2017 ...

Page 47: ...4 Operation ...

Page 48: ...oading ENVIRONMENT NOTE Separating hydraulic connections can result in the emergence of hydraulic oil Depending on the overall height the truck can be delivered assembled or dismantled In either case the weight of the components or the overall truck must be ascertained delivery papers and suitable hoisting equipment must be placed ready Hoisting NOTE We recommend using textile straps in order to p...

Page 49: ... supports in order to firmly tension the truck on the loading surface To do this remove the lid of the battery compartment In the case of trucks with high masts these must be additionally secured at the side with belts Mast bracing Mast bracings may be required depending on the configuration of the high level order picker Once the mast bracing has been installed it must be adjusted according to fact...

Page 50: ...4 Operation General commissioning Wheel nuts WARNING Wheel nuts can loosen after initial commissioning After the first eight operating hours tighten the wheel nuts to 195 Nm 44 5212 804 3001 EN 02 2017 ...

Page 51: ...metres of play This makes it impossible for the battery to slip or tip over while the truck is in motion The corresponding battery data tray number voltage capacity can be found on the order documentation Battery weight If a lighter battery is used temporarily the weight difference must be compensated for with a fixed ballast Size differences must be compensated for with shims The information on th...

Page 52: ...and functions correctly CAUTION Risk of short circuit Ensure that the battery cable is not crushed or trapped Before using the battery for the first time a proper commissioning procedure must be performed If the battery was obtained separately to the industrial truck the nominal voltage the required minimum weight and the attached battery male connector must be checked particularly carefully This i...

Page 53: ...phon Replacing the battery On this industrial truck the battery is replaced to the side Only suitable aids such as lifting gear and battery change frames may be used for this purpose In the standard design the battery rests in a recess 1 The battery should be replaced using a forklift truck The forklift truck used must be suitable for this purpose The fork must be of sufficient length for the exist...

Page 54: ...ding on the design of the industrial truck the battery compartment cover can either be removed manually or folded through a special hinge This makes the battery accessible from above so that you can access the battery male connector or perform battery maintenance There are two brackets on the inside of the battery compartment cover These can be used to hang the cover on the control compartment hoo...

Page 55: ...he checks before starting work any defects regarding operating or traffic safety are discovered then steps have to be taken immediately to properly and professionally repair theses defects It is prohibited to continue operating the industrial truck until the repairs have been completed Before starting work the driver must make sure that the industrial truck is in a safe operating condition General ...

Page 56: ...t not be bent or distored The load chains must be checked for condition wear tension and lubrication The load chain must not demonstrate any damage Further checks Check the overhead guard for deformation damage and cracks at welded seams Carry out a visual check of the overhead guard cover Carry out a visual check of the load back rest Check the wheels for foreign bodies Check the condition of the...

Page 57: ...ng If the barrier is touched at any point other than the points indicated while it is being opened there is a risk that hands may be crushed WARNING Risk of falling When climbing in and out it is important to note the difference in height between the driver s platform and the ground NOTE The barriers are monitored by electrical means If the driver s platform is raised higher than 1 2 m the industr...

Page 58: ...ss is complete the spring loaded brake also engages The foot switch serves equally as the service brake and the parking brake WARNING Danger of accidents The floor of the cab must be kept free of objects Otherwise there is a risk that the foot switch will be actuated Service brake In order to brake during normal operation it is also possible to release the operating lever This initiates an electron...

Page 59: ... finely metered by the deflection of the driving lever If the lever is released at the moment of direction switchover the truck comes to a standstill Emergency stop brake Pressing the emergency off switch 3 triggers the emergency braking An error message appears in the display Steering system The steering system works electrically The driver rotates the steering knob or steering wheel to determine t...

Page 60: ...y 135 to each side The steering thereby moves a maximum of around 95 to each side Steering wheel In trucks with a steering wheel the steering also moves a maximum of around 95 to each side You can use parameters to set whether 2 3 or 4 revolutions of the steering wheel are required The steering wheel has no end stops 54 5212 804 3001 EN 02 2017 ...

Page 61: ...ping points 2 NOTE Up to a cab lift height of 1 2 m the cab barriers may be left open when the truck is being driven If the truck is driven at a lift height of greater than 1 2 m the barriers must be closed On the version with a simplex mast and auxiliary lift the changeover point for all of the affected functions is not at 1 2 m but instead at approximately 0 4 m DANGER Danger of accidents Never ...

Page 62: ...tion Driving without guidance In standard trucks the operator s right hand selects the driving speed and drive direction The operator s left hand is used for steering and thus determines the course the truck takes Mechanical rail guidance MZF The industrial trucks can be guided mechani cally when travelling within aisles To achieve this a rail system is installed on the floor of the warehouse Two h...

Page 63: ...is live with current The magnetic field generated by this wire is detected by sensors in the industrial truck and used to guide the truck Two hand operation is required to make use of the guidance system The operator s right hand selects the driving speed and drive direction The operator s left hand is used to actuate a sensor or a function As a general rule the truck switches over to using the gui...

Page 64: ...ses can be performed in a flat obstacle free area of the warehouse If the following exercises are performed the operator will soon be familiar with this industrial truck Only by completing these can full advantage of the high performance potential be taken Foot switch Pressing the foot switch 1 sends the release signal for travel to the traction controller When a drive direction is selected the par...

Page 65: ... lever is released at the same time as the drive direction is reversed the industrial truck remains stationary As a rule reversing should be used as the service brake for regular tasks Depending on the technical version of the industrial truck the barriers of the drivers cab may be left open when the truck is being driven up to a cab lift height of 0 4 m for industrial trucks with simplex mast and...

Page 66: ...ring knob 3 has an angle of rotation of approx 135 on each side and stops mechanically Industrial trucks with this equipment are mainly intended for use in warehouses with automatic guidance for fast switchovers from one aisle to another Conversely the steering wheel 4 has no stops To achieve the maximum steering angle of approximately 95 on each side it is necessary to make two three or four turn...

Page 67: ...optional features A distinc tion is made between two types of guidance Mechanical guidance Inductive guidance Mechanical guidance The mechanical rail guidance consists of one or two rails on or between which the industrial truck is guided with a maximum permissible play of 5 mm Entering the rack aisle Before entering the rail guidance position the industrial truck as centrally as possible and flush...

Page 68: ... pressing the operating lever upwards causes the main lift to be raised and the truck to drive forward This method of operation is known as a diagonal movement Lifting lowering the cab lift Press the foot switch Use the control rocker to select the direction of movement and speed or see Diagonal movement Lifting lowering the auxiliary lift operation with the operating panel Press the foot switch P...

Page 69: ...al truck can now be turned 90 on the spot and driven to the target aisle If the truck is turned back 90 at the correct point the industrial truck is in front of the new aisle ready to move in The adjacent drawing illustrates how to drive when changing aisles Diagonal travel The combination of driving and lifting functions or driving and lowering the cab lift is referred to as diagonal movement Dia...

Page 70: ...nt touches the back of the fork CAUTION During this process the load may be moved or even knocked over Make sure not to jolt the fork Setting down loads Carefully approach the place at which the load will be set down Position the load as accurately as possible Lower the load carefully until it rests se curely on the supporting surface Lower the fork until there is sufficient free space between the ...

Page 71: ...e from load centre of gravity grows larger The data for the current situation can be taken from the load capacity diagram Example Simplex mast Example for a truck with a low simplex mast The lift height of the stand on platform is max 1900 mm Distance between the load centre of gravity and the fork back 400 mm Max load 1000 kg 500 mm Max load 900 kg 600 mm Max load 800 kg Example Telescopic mast E...

Page 72: ...setting dimensions for the support screws must be checked every six months by authorised service personnel and must be adjusted if necessary 1 Infinitely variable lowering 2 Infinitely variable lifting Load pick up without automatic guidance High level order pickers are mainly intended for collecting or distributing goods in a con tainer or on a pallet It is not possible to place loads into stock or...

Page 73: ... creep speed are permitted Position the steering straight ahead Option Actuate operating rocker switch to the right or left for infinitely variable lifting or lowering of the cab Additional lift Before actuating the control rocker at 1 or 2 press the auxiliary lift selection key 3 Additional lift load side operation 1 Raise the auxiliary lift 2 Lower the auxiliary lift 3 Second manual button for 1 ...

Page 74: ...ds from stock in very narrow aisles When transporting loads the auxiliary lift must always be fully lowered DANGER Danger of tilting forward During picking work goods for transport and therefore weight accumulates on the load support Because picking is a manual process the truck control unit cannot monitor it and therefore also cannot warn of overloading The operator must ensure that the load capa...

Page 75: ...e truck is equipped with an electronic access control it must be reset and or the device for controlling access must be removed Where possible the truck should be parked at the start of a racking aisle or in a loading bay If there are parking spaces the truck must be parked there The fork is to be lowered to the floor as far as possible and if there is one the tilt attachment must tilt towards the ...

Page 76: ...e brake WARNING Danger for acidents If the brake has been mechanically disabled as de scribed below a suitable tow bar must be used for towing or a second vehicle must be coupled to the industrial truck so that it can take over the braking If the brake was released mechanically the brake must be checked for correct assembly and function when the industrial truck is recommissioned The brake lining ...

Page 77: ... Towing off with steering system out of action If the steering has failed the industrial truck can be towed using equipment such as steerable heavy duty rollers Depending on the design the heavy duty rollers must be placed underneath the drive wheel or underneath the chassis As the drive wheel does not come into contact with the ground when using this towing method the brakes can also no longer op...

Page 78: ... lever be placed on the 0 sensor 5 NOTE If the industrial truck is jacked up high enough on the drive side the steering can be turned with the help of an assembly lever The cab must also be raised sufficiently so that it is not supported on the ground Jack up the industrial truck The drive wheel must be free of the ground Obtain a suitable assembly lever The assembly lever must have a rounded smoot...

Page 79: ... all parts of the body are completely inside the driver s cab and that there is no risk of injury for the operator during the lowering procedure The operator of the emergency lowering valve must be certain that the moving components of the lift mast are immediately set in motion on opening the valve Special attention must be given to the cab the chains and the inner masts of the lift mast All of t...

Page 80: ...dustrial truck may be put back into operation only once the cause of the defect has been rectified by a specialist If as described above a mechanical jam of the lift mast is suspected the abseil system must not be used The resulting vibrations could cause the mechanical jam to be released which could create a further hazard should the cab subside 74 5212 804 3001 EN 02 2017 ...

Page 81: ...r than 3000 mm above the ground NOTE Two versions are available As standard a system is supplied that includes a safety harness designed for people up to a height of approximately 2 m For larger operators a variant is available as an option that includes a safety harness that can be adjusted up to size XXL The storage location for the emergency abseil system is marked with an adhesive label 1 5212...

Page 82: ...ling The carabiner which is also included in the scope of delivery is hooked into this bore The rope is then guided through this carabiner Carabiners must always be closed Abseiling exercises are only permitted under the supervision of an expert In Germany the abseiling procedure must be practised at least once a year We recommend these practice exercises for other countries even if they have not ...

Page 83: ...ourable position the rope can be redirected with an additional carabiner in most versions of the overhead guard This additional carabiner is attached to the safety harness chest eyelet area To redirect the rope the carabiner is detached from its original position and reattached in a bore provided in a strut on the overhead guard 2 Testing A technical expert must check the abseil system at least on...

Page 84: ...pension points approved by the manufac turer are used Different operators If an industrial truck is used by multiple persons e g in multi shift use it may be indicated that several preset abseil systems must be kept on hand This is particularly sensible if the different operators are of widely varying heights and or weights and the safety harness would therefore have to be adjusted to a significant...

Page 85: ...5 Maintenance ...

Page 86: ...ompartment the hood must be removed Remove the two plastic screws Turning anti clockwise loosens the screws Lift the hood up and out of the latch Place it to the side The hood is very light It can be removed manually without any aids Proceed in the reverse sequence to fit the hood Place the hood carefully in its guide and latch and tighten the plastic screws until they are hand tight only Fuses in ...

Page 87: ... 5 Fuses Fuses 1 F2 control current fuse 5 0 A 2 F3 control current fuse 7 5 A 3 3F1 main current fuse for steering 35 A 4 F1 main current fuse for driving and hydraulics 275 A or 355 A 5212 804 3001 EN 02 2017 81 ...

Page 88: ...o engage us to perform regular testing FEM Only regular maintenance and service work will enable you to make full use of the warranty Maintenance Maintenance work does not require special prior knowledge or training and can be per formed by the operator or the workshop staff at the operating company Servicing In contrast service work must be performed only by appropriately trained personnel Specia...

Page 89: ...xiliary lift chain must be replaced when the wear limit is reached or if impermissible damage is present The technical condition of the chains from a safety perspective must be assessed by a competent person using the manufacturer s documentation Observe the current applicable guidelines for the cold store version of industrial trucks 5212 804 3001 EN 02 2017 83 ...

Page 90: ...evel in the gearbox and top up if necessary Gearbox first oil change after 1000 operating hours and every 2000 operating hours thereafter Drive unit check the tightness of the screw connection to the chassis ensure the appropriate torque Check the traction motor bearings for operating noise Chassis bodywork and fittings Check and lubricate the bearing points and joints Check that all doors flaps and ...

Page 91: ... Steering system Perform a functional check of the steering outside the aisle Check the steering angle 90 on both sides Steering check straight line travel Lubricate the steering gears with all purpose grease MZF function check IZF check for central positioning and accuracy of the guidance in relation to the guide wire Steering angle measurement check the level of play and the condition Check the ...

Page 92: ...k for secure attachment Battery cable visually check the insulation Battery measure the battery voltage under load Battery measure the tray for short circuits Battery check the electrolyte level Drive and pump controller check the driving acceleration braking and reversing functions Check that the plugs and connections are securely attached Visually check the insulation of openly routed cables Che...

Page 93: ...setting of the lift mast rollers Check lateral clearance of the guide elements Lubricate the guide elements with all purpose grease Check the condition of the fork arms and proper operation of the locking mechanism Visually check the load forks for bends measure if necessary If you suspect there are cracks on the load fork check using the colour penetration procedure Lubricate the sliding surfaces...

Page 94: ...tions for your country Check the condition lubrication and voltage of the auxiliary lift load chains and check for wear elongation and damage Determine the degree of wear of the main lift load chains maximum permissible wear is 2 Determine the degree of wear of the auxiliary lift load chains maximum permissible wear is 3 Final tasks Test drive check all functions and special functions according to...

Page 95: ...d lift mast Trucks with a simplex mast are equipped with a hydraulic tank with 8 l volume Trucks with a telescopic mast are equipped with a hydraulic tank with 15 l volume The tanks are labelled with a min max mark ing After the hydraulic oil has been topped up or changed the oil level must be between the min and max marking Gearbox Oil quality must conform to at least API GL5 ID no 8 034 186 The ...

Page 96: ...ea of the battery where gas may be released When handling battery acid the specified safety measures must be observed Gel batteries Gel batteries are a particular type of lead acid battery The usage instructions and handling instructions from the respective manufacturer must be observed Li ion batteries To ensure safe operation industrial trucks that are powered by Li ion batteries must be equipped...

Page 97: ...6 Technical data ...

Page 98: ...ata for this truck depends on the order You will therefore receive a datasheet specially prepared for your truck when it is delivered Please use this accompa nying datasheet to find all the technical data Sound level driver s ear 61dB A 92 5212 804 3001 EN 02 2017 ...

Page 99: ... km h 350 mm 2150 mm 10 2 5 km h 2150 mm 2 5 km h Driving speeds without automatic guidance truck without auxiliary lift Lifting height cabin floor h12 Steering angle maximum driving speed vmax 1200 mm 9 0 km h 1200 mm 3000 mm 10 4 0 km h 1200 mm 3000 mm 10 2 5 km h 3000 mm 2 5 km h Driving speeds with automatic guidance with speed optimization Lifting height cabin floor h12 Steering angle maximum d...

Page 100: ...6 Technical data Driving speeds 94 5212 804 3001 EN 02 2017 ...

Page 101: ...7 Special equipment ...

Page 102: ...ignals are analysed Extensive safety circuits and a diagnostic program simplify system servicing work The operating devices for inductive guidance are integrated into the operating panel The operating status display indicates the active operating status 4 of the system After switching on the control system a self test runs in the guidance system Entering the aisle Guidance procedure Drive the truc...

Page 103: ...cted the aisle the maximum permissi ble speed within the aisle is possible Automatic driving within the aisle If the steering knob is turned accidentally to its straight ahead position middle stop during automatic drive mode the truck is automatically braked to a standstill Switching from automatic to manual operation within the aisle If the truck is accidentally switched to manual steering within...

Page 104: ...ple who have entered the braking area of the truck unplanned One safety laser scanner for each drive direction scans the braking area and triggers braking in the truck as soon as a person or object is detected in this area protective field As a rule these personal protection systems are active only with the guidance function Optionally the functional range can also be expanded to include front end ...

Page 105: ...d to 2 5km h Operation with a bridging plug is therefore only permitted for the retrieval of a truck This bridging plug must be kept locked away by the warehouse manager responsible and is only to be used under his instruction Pedestrian operation The vehicle can as an option be equipped with the additional pedestrian operation function for which 2 extra buttons are fitted on each side of the mast ...

Page 106: ... 1 is pressed the vehicle is moved at a maximum speed of 2 5 km h for a maximum of 3 seconds The button must be held down After the 3 seconds equivalent to a distance of approx 2 metres the button must be pressed again The vehicle stops immediately when the button is released NOTE The auxiliary lift must not be operated during pedestrian operation 100 5212 804 3001 EN 02 2017 ...

Page 107: ...imension Where applicable additional covers facing the mast side to prevent leaning out to the side depending on the cab dimension DANGER The truck operator bears responsibility for the passenger Allowing the passenger to ride in the can without the operating mode switch having been moved to the correct position presents a potential risk of serious or fatal injury to the passenger The operator is ...

Page 108: ...on all functions must come to an immediate stop Electronic access control The operating panel controller is switched on by pressing the button 1 The symbol 2 appears in the display and asks for the 5 digit PIN code programmed in the controller to be entered using the keypad If the PIN code is entered correctly the truck control unit is switched on and the industrial truck is ready for operation If...

Page 109: ...he forks to be raised or transported Trucks for use in cold storage Trucks for use in cold storage are provided with extensive extra equipment in order to guarantee full functioning at low temperatures 30 C Special instructions for the operation of these trucks must be observed which are not contained in this operating manual Trucks designed for operation in refrigerated environments are marked wi...

Page 110: ...e truck is switched on NOTE For switching on follow the notes in the operating instructions in the chapter entitled Switching on the controller Changing the active operating panel CAUTION During the operating panel switchover the steering in addition to all other functions can be switched to the other operating panel As a result the switcho ver can cause a major change in the steering angle Move t...

Page 111: ...eral movement of the industrial truck Carefully set off Operating panel load side only An industrial truck can be equipped with an operating panel on the load side 1 only as special equipment A switchover is not required here The key switch 4 and the display 5 remain on the mast side There is no steering knob or operating console on this side For industrial trucks with IZF the inductive guidance c...

Page 112: ...means If one of the latches does not lock correctly an error message appears in the display and the industrial truck does not work WARNING Before starting each shift check that the battery locks are in good working order and that they are functioning correctly Option Removing the battery lock Loosen both knurled head screws 1 Grasp the latch 2 by the handle Press towards the battery slightly Then ...

Page 113: ... first time it is possible that the actions described below may need to be repeated in several steps If the thread of the rubber buffer spring element does not move smoothly it must be loosened before the setting is defined Insert the battery approximately in the centre of the battery compartment In doing so one of the battery locks will remain as a stop in the industrial truck Rotate the knurled he...

Page 114: ...k of accident and damage When the clamping has been carried out part of the thread must still be visible at 5 and 6 Acoustic warning signal Optionally these trucks can be equipped with an acoustic warning signal transmitter as an additional safety system The signal is generated depending on the drive direction or the speed The signal can be limited to specific areas Leaning cushion When driving in ...

Page 115: ...ety reasons the tilt barrier is unlocked only under certain conditions Function The barrier can only be opened if The barriers are closed The sensors for the second hand are not actuated The operating levers for driving hydraulics are in the neutral position The foot switch is not actuated The driving speed v is 0 1 km h The barrier will be locked if One of the barriers is opened The foot switch a...

Page 116: ...7 Special equipment Tilt barrier 110 5212 804 3001 EN 02 2017 ...

Page 117: ...rake system 52 Braking characteristics 10 braking distance 17 Bridging plug X99 98 C Cab lift 27 Changing aisles 61 Changing the PIN code 102 Checking all operating devices 49 Checking the access control 49 Checking the barriers 49 Checking the connecting elements 49 Checking the lifting accessory 49 Checklist before starting work 42 49 Clearance 70 Climbing in 51 Climbing out 51 Closing the barri...

Page 118: ... 16 Feminine form of address 7 Filling opening for hydraulic oil 39 Floor height 10 floor load 17 Floor structure 10 floor surface 17 Folding battery compartment cover 47 Foot switch 58 Fork arms 28 29 Form of address 7 Frequency 11 Front end monitoring 98 Function 36 Function checking 49 Function checking the brake assemblies 49 Function checking the steering 49 Fuses 80 81 G Gear oil 14 Gearbox 39...

Page 119: ...rating company 11 Oil containing wastes 14 Opening the barriers 51 Opening the control compartment cover 70 Operating and maintenance manual 6 Operating company 16 Operating devices 33 Operating error 27 Operating hours 35 Operating instruction document 16 Operating lever for driving 58 Operating media 14 Operating panel on the lift mast side 104 Operating panel on the load side 104 Operating pane...

Page 120: ...helf height 27 Side guide rollers 17 Simplex mast 65 Sound level 92 Spare parts list 6 Special safety advices for engaging loads 13 Special tool 84 Specialist 16 Speed indicator 36 Spring loaded brake 52 Standard design 4 Steering 58 Steering angle 34 53 Steering knob 53 Steering motor 39 Steering wheel 53 Support screws 66 Suspended loads 13 Switching on the control system 55 T Technical data 92 ...

Page 121: ...Index g W Warranty 82 Wear limit for lifting chains 82 Weight indicator 36 Wet lead battery 45 Wheel screws 42 Working platforms 103 5212 804 3001 EN 02 2017 115 ...

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