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5

Regular care and maintenance

Lubricants

Lubricants

CAUTION

Risk of damage to property
Trucks for cold store operation must be lubricated

using different lubricants. Refer to the operating

instructions for cold store trucks.

The following lubricants must be used:
Hydraulic system
• Hydraulic oil HLP DIN 51524/T2
• ID no. 8 036 912
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 marking and the max marking.
Gearbox
• Gearbox oil SAE 75W-90 API GL-5
• ID no. 732 600 0007
The standard gearbox holds 4.6 litres of

gearbox oil.
The heavy gearbox holds 7 litres of gearbox

oil.
Grease lubrication points
• ESSO Beacon 2 multi-purpose grease
• ID no. 8 010 107
Chain lubrication
• Chain spray Stabylan 2100
• ID no. 8 010 100
Lubricant for the joint between the shaft and

the hub
• Special grease Klüberplex BEM 34-132
• ID no. 8 052 709

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5231 804 2502 EN - 11/2017

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Summary of Contents for MX-X

Page 1: ...Original instructions Order picking truck MX X 2332 2334 5231 804 2502 EN 11 2017 ...

Page 2: ......

Page 3: ...f address 8 2 Safety Working safely 10 Non ionising radiation 11 Vibrations 11 Special safety information about load pick up 13 Safe handling of operating media 14 Risk assessment 16 Residual risks 16 Regular testing 16 Application area 17 Narrow aisle vehicles 17 Original parts 18 Directives and guidelines 18 Driver s licence 18 Alterations to industrial trucks 19 Personal protective equipment 19...

Page 4: ...tery commissioning 52 Replacing the battery 53 Function check 54 Daily commissioning 55 Checklist before starting work 55 Access to the driver s compartment 56 Access to the driver s compartment 56 Operating devices 57 Initial driving exercises 57 Adjusting the position of the operating panel 59 Adjusting the driver s seat 60 Driving 61 Braking driving and steering 61 Moving the load 64 Types of g...

Page 5: ...ble of contents g Securing the load support 74 Emergency operation 74 Emergency abseil system 79 Parking decommissioning 82 Parking and leaving the truck 82 Decommissioning 83 5231 804 2502 EN 11 2017 III ...

Page 6: ...hnical data 98 7 Special equipment Enabling options 100 Split operating panel 100 Inductive guidance IZF 102 Intermediate lift cut out 105 Mounting system for auxiliary components 105 Aisle entry assistant 105 Safe handling of the traction battery 107 Battery on a roller channel 109 Personal protection system MPSE 112 Telescopic table 113 Two person cab 114 Tilt barrier 117 Mirror and lighting mod...

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: ...ent version of EMC Directive 2014 30 EU for industrial trucks implemented in accordance with harmonised standard EN 12895 2015 Furthermore we declare that any radio equipment contained in this machine conforms with the most recent version of Radio Equipment Directive 2014 53 EU The manufacturer is solely responsible for exhibiting this declaration of conformity Notiﬁed body in accordance with Anne...

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 regular maintenance and prescribed maintenance for industrial trucks in the standard design and for the optional equipmen...

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: ...dustrial trucks In addition to these operating instructions a code of practice containing additional information for the operating companies of industrial trucks is also available This guide provides information for handling industrial trucks Information on how to select suitable industrial trucks for a particular area of application Prerequisites for the safe operation of industrial trucks Inform...

Page 13: ...s must be kept safely so that the opera tor always has access to them Documents can be ordered retrospectively Please give the ID or the order number If the truck is sold on the complete docu mentation should be passed on along with the truck Copyright and proprietary rights This manual and any excerpts thereof may not be reproduced translated or tansmitted in any form to third parties without the...

Page 14: ...which the op erator s body weight and dimensions should lie If these industrial trucks are operated by persons who do not meet these criteria the following effects must be expected The ergonomic conditions may be less favourable It may not possible for the operator to reach the pedals such as the accelerator pedal and brake pedal The useable height below the overhead guard may be too low The adjus...

Page 15: ...2 Safety ...

Page 16: ... also uncontrolled movements and are therefore prohibited The driver must secure the industrial truck against unauthorised use by removing and taking the switch key or by clearing the access information on the electronic access control system when leaving the industrial truck Safe working environment People must not encroach into the working area danger area of the industrial truck If a person doe...

Page 17: ... 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 accordance with the standard EN 13059 Vibration mea s...

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 5231 804 2502 EN 11 2017 ...

Page 19: ...ad must not change during acceleration braking or during transport No parts must be allowed to fall If loads cannot be transported with the necessary level of safety an appropriate container or means of securing the load must be employed to ensure safety Loads must always be transported in suitable containers or secure packaging Loads comprising loose packages may not be stacked higher than the to...

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: ...iﬁc place of use Residual risks Despite observation of all pertinent safety regulations for the design and construction of our trucks and despite proper use by the operating company residual risks can occur during operation We refer to this speciﬁcally in the individual chapters Please heed all provided safety warnings Regular testing This industrial truck must be checked at least once a year by a...

Page 23: ...ﬂoor without signiﬁcant slopes below 3 normal work load 50 capacity utilization full load and half shift or half load and full shift and ambient temperatures according to EN 1175 1 WARNING Restrictions 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 conta...

Page 24: ... approved by us The incorporation and or use of such products can consequently adversely affect the structurally predeter mined properties of your vehicle and thus impair the active and or passive drivingsafety The manufacturers are in no way responsible for any damage caused by the use of non orig inal parts and accessories Directives and guidelines In most countries the national directives and g...

Page 25: ...st engineer for industrial trucks Have permanent records of the construc tion test s and execution of the alterations Make and approve corresponding alter ations to the signs stating the load capacity information signs and adhesive labels as well as in operating manuals and workshop manuals Mount a durable and easily visible label on the industrial truck providing details of the type of alteration...

Page 26: ...2 Safety Personal protective equipment 20 5231 804 2502 EN 11 2017 ...

Page 27: ...3 Overview ...

Page 28: ...s 5 Load wheel 6 Front guide rollers 7 Rear guide roller and support screws 8 Battery compartment or battery compart ment doors 9 Barrier or cab doors 10 Control compartment 11 Working spotlights 12 Rear view mirror 13 Lift mast 14 Lifting points for crane loading 15 Abseil system Option 22 5231 804 2502 EN 11 2017 ...

Page 29: ... 3 a Do not transport people on the load or on the load support b The driver s compartment is approved for use by one person only 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 Oil tank 5231 804 2502 EN 11 2017 23 ...

Page 30: ...et 10 Disconnect the battery male connector before removing the control compartment hood Only for the 80 V version A number of information signs are ﬁtted on every industrial truck depending on the family 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 provide...

Page 31: ...load support or to be carried as passengers 2 It is not permitted for people to sit or stand underneath a raised load or underneath a raised driver s compartment 3 Risk of crushing hands 4 Seat heater on off switch 5 Switch in switched off position 6 Switch in switched on position 7 Switch in automatic mode position 5231 804 2502 EN 11 2017 25 ...

Page 32: ...r 9 Truck with customised software Only the customer s special version and not the standard software may be installed in the truck control unit The pictograms shown here replace the pictograms for the standard version or are ﬁtted in addition to the standard pictograms 26 5231 804 2502 EN 11 2017 ...

Page 33: ...pair the driving behaviour and stability of the truck and are therefore not permitted without our agreement Add on parts and modiﬁcations e g the weld ing on of parts or the creation of openings could weaken the supporting structure and are therefore only permitted after acceptance by our design department Functional changes through modiﬁcations to the electrical system or the software also requir...

Page 34: ... no part of the load touches the ground Within the aisles the narrow aisle trucks are guided mechanically or inductively The steering of the truck is realized by a freely programmable controller CAN BUS All movements driving lifting lowering the cab lift lifting lowering the auxiliary lift swivelling the fork pushing the fork are inﬁnitely ad justable Operating errors can be prevented to a large e...

Page 35: ... or lowering the auxiliary lift or swivelling the fork 13 Reserved for special functions 14 Selection key for automatic functions e g fork cycle 15 Selection key for lifting or lowering the cab lift and auxiliary lift together in connection with pulling or pushing operating lever 1 or the selection key for swivelling the fork synchronously 180 to the left or right in connection with moving operati...

Page 36: ...on operation 1 6 PIN entry expected 7 2 Navigation destination is located on the left hand side 1 7 RFID entry expected 7 3 Navigation located on the right hand side 2 Not used 8 1 Remove from stock with a fork cycle 3 1 Creep speed active 8 2 Place into stock with a fork cycle 3 2 Turret head not in the end position 3 3 Telescopic fork not in the end position At points marked 1 8 the pictograms s...

Page 37: ...unction Operating statuses and information relevant for operation are shown on the display Using the display it may be possible to switch functions on and off or to switch between deﬁned statuses The display is presented in colour and is graphical The content is divided into four parts Left hand menu bar 1 Right hand menu bar 3 Top status bar 2 Central information area 4 5231 804 2502 EN 11 2017 3...

Page 38: ...This message informs you that the changed settings are being saved An acoustic signal accompanies the display of this message The message disappears after four seconds Menu structure The ten membrane switches can be freely conﬁgured to display your favourite functions on the main page As soon as the button 7 is actuated the menu bar 1 opens From this point the structure is always the same There is...

Page 39: ... Service Message list Top status bar The status bar at the top of the display is divided into three ﬁelds Left ﬁeld 1 Centre ﬁeld 2 Right ﬁeld 3 The status bar can display the following information Information Display format Graphical Battery charge level charge state Operating hours h Time hh mm Date dd mm yy Next maintenance interval h The status bar can be conﬁgured individually 5231 804 2502 E...

Page 40: ...e optional weight measurement is available the current weight of the load being lifted Lift height 2 Current height of the fork arms upper edge Type of guidance and steering angle 3 Driving speed 4 This part of the display cannot be parame terised Operation The display is operated using 15 membrane switches The function of buttons 2 to 4 is ﬁxed Button 5 has two functions Item number Function 2 Ch...

Page 41: ...vigation information is shown or hidden For this the key switch for the navigation must be set to AUTO Otherwise the symbol is greyed out and therefore cannot be selected 5 If the button is pressed and held when a drive order is active the drive order is deleted 6 The right hand menu bar with the available data regarding height preselection opens If the symbol is greyed out the industrial truck is...

Page 42: ...ation This combination is the same for all languages Procedure Push button 7 The menu in area 1 opens Press key sequence 6 3 and 4 Use buttons 2 to 6 to select the desired language in the list NOTE Only ﬁve languages are shown here The other 20 languages can be found by scrolling See Scrolling through the menu bar Exit the list by pressing button 8 Favourites The ten membrane switches can be freel...

Page 43: ...ge list Currently displayed error numbers can be hidden using push button 2 A warning symbol 1 remains in the status bar with the number of the current error The hidden errors can be displayed in the message list The errors are only displayed in the list until the cause is rectiﬁed All other errors can be read out using the diagnostic software Procedure Push button 7 The menu in area 1 opens Press...

Page 44: ...heir me chanical and stop The end positions are indicated by switches to the control system Only when the swivel shift fork is located in its left or right hand end position does the truck travel at the maximum speed permitted for the lift height If either the swivel or the side shift movement has not reached its end stop the vehicle travels at positioning speed only The symbol in the display for ...

Page 45: ...4 Operation ...

Page 46: ...essionally be our service personnel Be fore starting work work through the Checklist before starting work Weights of the units Industrial trucks are mainly transported in a disassembled state and must be assembled on site You must ascertain the weight of the individual units in order to assemble the truck safely and to select a suitable harness Our industrial trucks are constructed using a modular...

Page 47: ... the attachment A standard attachment europallet with a turret head weighs approximately 800 kg If another attachment is ﬁtted determine the weight of the additional attachment e g by weighing the attachment Weight of the driver s cab A standard driver s cab including carriage weighs approximately 660 kg Take into account the additional weight of attachments for example the weight of order picking...

Page 48: ...battery with the information on the nameplate on the truck If ballast weights are installed the weight of the ballast weights must be taken into account Weight of the chassis The weight of the chassis depends on its design and the ﬁtted equipment Transporting and loading General Depending on the overall height the industrial truck can be delivered as a complete unit or unassembled In each case det...

Page 49: ...this purpose at the top end of the lift mast 1 Harnesses suitable for this purpose must be used shackle or lifting device If necessary the individual lift mast parts must be lashed to each other during this process to prevent them from separating unintentionally and thus shifting the centre of gravity 5231 804 2502 EN 11 2017 43 ...

Page 50: ...issioning Hooking the lift mast on horizontally If the lift mast has to be crane loaded in a horizontal position 2 suitable shackles must be used in the indicated bores at the top end of the mast 3 44 5231 804 2502 EN 11 2017 ...

Page 51: ...ore mounting on a forklift truck fork or before ﬁtting a support perform a visual inspection to determine whether and where such elements should be mounted on the industrial truck in question Hooking the chassis on The cross beams above the battery compart ment serve as lifting points for the chassis To protect the paintwork of your industrial truck we recommend that you always use textile slings ...

Page 52: ...on and becoming damaged as a result Remove and dispose of the transportation safety device Option Mast bracing Mast bracing may be required depending on the conﬁguration of the order picking truck Once the mast bracing has been installed it must be adjusted according to factory speciﬁcations and tightened to the speciﬁed torques The mounting locations are marked with labels These labels specify th...

Page 53: ...operating hours tighten the wheel nuts to 195 Nm Support screws The setting of the support screws must be checked during initial commissioning and each time maintenance is performed The setting dimension 1 is dependent on the application of the truck and can be taken from the load capacity diagram 5231 804 2502 EN 11 2017 47 ...

Page 54: ...gs must not be covered or be closed Do not create any openings in the battery compartment that allow the explosive gas mixture to enter the driver s compartment Ensure that the room or area in which the battery is being charged is well ventilated Smoking ﬁre and open ﬂames are forbid den in an area of 2 m around the charged battery Battery acid is toxic Do not inhale vapours Battery acid is corros...

Page 55: ...ed To avoid this operate lifting gears and changeover frames with the utmost care Prevent heavy weights from bumping against the machine or equipment Be aware of pinch points and shear points when inserting the battery into or removing the battery from the battery compartment Ensure that you keep your ﬁngers hands and feet out of any areas where they could be at risk from one of the abovementioned...

Page 56: ... the weight difference using a ﬁxed ballast and the size difference must be equalised using shims In this case the speciﬁcations on the nameplate of the industrial truck must be changed or updated These narrow aisle trucks are equipped with an integrated battery discharge indicator that is set for normal wet lead batteries PzS as standard If a different battery type or different battery capacity i...

Page 57: ...of damage to property Incorrect battery chargers can cause total battery failure Start up If your industrial truck is equipped with a Euro battery plug make sure that the voltage index pin is in the correct position The set voltage can be read through a display window 1 WARNING Risk of accident Risk of injury from crushing and shearing points WARNING Risk of short circuit Do not clamp or crush bat...

Page 58: ... the industrial trucks Battery commissioning Proper commissioning must be performed if the industrial truck was ordered without a battery or if it was supplied with a dry pre charged battery because it had to be transported over a long distance e g from overseas Observe the information and guidelines from the battery manufacturer If the battery was obtained separately to the industrial truck the n...

Page 59: ...the battery is removed The battery is not provided with a latch WARNING Risk of accident risk of crushing Observe the information in the section entitled Safe handling of the traction battery Make sure that all four corners of the battery are within the recess Battery replacement with change frame The industrial truck can be optionally equipped with roller channels so that the battery can be repla...

Page 60: ...ough function check should ﬁrst be carried out For this see the Checklist before starting work If after having done the 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 using the truck until it is repaired If your truck is equipped wit...

Page 61: ...working order Check that all operating levers and push buttons return automatically to the neutral position Check that all the operating devices are in good condition Check that all the operating devices are operating correctly Checking the access control Check that the switch key can be pulled out when it is in the 0 position Check that the industrial truck cannot be operated when the switch key ...

Page 62: ...ey are in perfect condition and operate correctly Option Access to the driver s compartment Access to the driver s compartment Barriers DANGER Risk of crushing Only the area of the handle indicated must be used for opening and closing the barriers WARNING Risk of falling When climbing in and out it is important to note the difference in height between the ﬂoor of the driver s compartment and the g...

Page 63: ... WARNING Risk of falling When climbing in and out it is important to note the difference in height between the ﬂoor of the driver s compartment and the ground NOTE The glass doors are monitored by electrical means The industrial truck is only ready for operation when the doors have been correctly closed Operating devices Initial driving exercises WARNING Before starting work the Checklist before s...

Page 64: ... on to a moving truck Unlock the emergency off switch by turning it clockwise Switch on the key switch or activate the electronic access control NOTE Optionally these trucks can also be equipped with an electronic access control PIN code RFID chip magnetic card system See also the section entitled Special equipment If the truck is in an error free state the working spotlights will now light up and...

Page 65: ...osition of the clamp lever can be changed by means of an integrated latching mechanism To do this pull out the handle of the clamp lever 1 on its axle turn it to the required position and allow it to engage again Adjustment Release the clamp lever 1 by turning it to the left Keep hold of the operating panel with the other hand while doing this If the clamping device comes loose move the operating ...

Page 66: ...he driver s seat to the horizontal position Pull the handle 2 and move the seat into the required position The mechanism must noticeably engage Tilting the seat surface Pull handle 3 and move the seat surface into the required tilt position The mechanism must noticeably engage Folding the driver s seat away If the driver s seat is disruptive when operating the truck in a standing position it can b...

Page 67: ...he foot switch is not actuated Braking Releasing the foot switch while driving triggers the electrical reverse current braking The industrial truck is braked to a standstill The electromagnetic parking brake is activated after a few seconds Releasing the operating lever for driving or the left hand sensor surface while driving triggers the electrical reverse current braking The industrial truck is...

Page 68: ...g speed depend ing on the driving situation and any options installed It is always possible to have the speed restricted by the authorised service centre but not to increase it The operator can continuously control the speed within the permitted area The authorised service centre can conﬁgure the acceleration and braking characteristics Steering The operator s left hand is used to actuate the stee...

Page 69: ...ving and main lift simultaneously both operating levers must be moved accordingly Moving the left operating lever in the direction of the fork 6 activates lowering of the main lift Moving this operating lever in the direction of the lift mast 7 activates lifting The degree of activation is always inﬁnitely variable The drive direction and the driving speed are selected using the right hand operati...

Page 70: ... operating levers must be moved accordingly In addition press the button 11 to select the combination of main lift and auxiliary lift The degree of activation is always inﬁnitely variable Moving the load Main lift and auxiliary lift The main lift and the auxiliary lift can be lifted and lowered together The lift height display will be synchronised Pressing button 1 and moving the left hand operati...

Page 71: ... left hand operating lever in direction 11 or 12 triggers the lifting or lowering of the auxiliary lift Swivelling and sliding the swivel fork 180 synchronously Pressing selection key 13 and moving the left hand operating lever 14 to the right or left triggers the synchronous movement This movement can be interrupted at any time or continued in the opposite direction To do this release the operati...

Page 72: ...ier to pick up loads at the front of the truck Option See the chapter entitled Special equipment Fork cycle This function enables an increase in handling performance through automation of load pick up and load deposit The details of the fork cycle function depend on the design of the industrial truck Option See the chapter entitled Special equipment Hydraulic special functions Additional hydraulic...

Page 73: ...n the right hand side of the operating panel are primarily assigned on an order speciﬁc basis If the industrial truck is not equipped with options the buttons on the top and underside of the operating panel 19 do not have a function Types of guidance The industrial trucks can be designed for Driving without guidance Driving with mechanical rail guidance Driving with inductive guidance And combinat...

Page 74: ...s 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 guidance system automatically More detailed information can be found in the relevant dedicated chapter Option Mechanical guidance MZF Mechanical guidance consists of one or two rails on or between which the truck is guided with a maximum ...

Page 75: ...e steering Changing the aisle If the truck is to be driven out of one aisle and into another the following notes must be observed Drive the truck completely out of the aisle Drive out of the aisle slowly and beware of any people or other trucks in the transfer aisle Once the truck is outside the rail the steering is reactivated by the rail switch The truck can now be turned 90 on the spot and then...

Page 76: ... 1500 kg 500 mm Max load 1285 kg 600 mm Max load 1125 kg The load capacity of the truck decreases as the lift height increases and the load centre of gravity distance grows larger The data for the current situation must be taken from the load capacity diagram NOTE This industrial truck can also be equipped with the intelligent load capacity diagram as an option Descriptions of this option can be f...

Page 77: ...low the locking lever to engage again 1 NOTE If the locking lever is engaged it is no longer possible to move the fork arms laterally CAUTION Risk of accident The side fork arm locking device 2 must be pre sent and must be in perfect working order Other wise the fork arms can be pushed out of the carrier by lateral forces and fall Option Emergency operation Emergency lowering Emergency lowering fu...

Page 78: ...ontrol com partment hood Open the two screw plugs 1 Hold the hood at the ventilation openings 2 lift it off and then place it to one side The hood is very lightweight and can therefore be removed by hand without using any tools The emergency lowering valve 3 is located in the control compartment and can be accessed once the cowling has been opened 72 5231 804 2502 EN 11 2017 ...

Page 79: ...of the lift mast must be involved This third person must be able to communicate clearly with both the operator of the emergency lowering valve and the operator of the industrial truck If a movement like the one described cannot be detected immediately or if one of the chains has slackened a mechanical jam at the lift mast is suspected The emergency lowering procedure must then be stopped immediate...

Page 80: ...bly strong brace around the bridge pieces on parts of the lift mast or place a suitably strong jack stand underneath the driver s cab Lock all existing shut off valves There is a valve for each main lift cylinder 1 one for each free lift cylinder 2 and two additional valves for the hydraulic lines for the attachment 3 Option Emergency operation If the entire truck control unit or part of it fails ...

Page 81: ...wing or a second industrial truck must be coupled to the industrial truck so that it can take over the braking Before the truck is put back into service restore the brake system to perfect working order Traction motor brake 1 option Disassemble the brake blocks To do this remove three mounting screws Place the brake blocks to one side 2 option Tighten the brake anchor plate To do this screw two sc...

Page 82: ...functions may be selected If any hydraulic functions were to be selected an error message would appear in the display Option Towing with operational steering If the steering of the industrial truck is still operational once the brake has been released the industrial truck can be towed either with a rope or with the tow bar 76 5231 804 2502 EN 11 2017 ...

Page 83: ...r box end wrench Before the industrial truck is recommis sioned the pinion shaft must be ﬁxed back in its original position Activating the emergency steering device 48 V version Using a suitable tool e g a screwdriver remove the lock washer 1 When doing so make sure that the lock washer does not jump off Insert the pinion shaft into the same bore 2 from below Insert the lock washer from above into...

Page 84: ...4 Operation Emergency operation Attachment points 5 for towing with the drive unit leading 6 for towing with the fork leading 78 5231 804 2502 EN 11 2017 ...

Page 85: ...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 5231...

Page 86: ...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 87: ...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 88: ...nd or weights and the safety harness would therefore have to be adjusted to a signiﬁcant degree In such trucks it must be ensured that only the suspension points approved by the manufac turer are used Parking decommissioning Parking and leaving the truck NOTE It is the operator s duty to remove the ignition key when he leaves the truck thus securing the truck against unauthorised use If the truck ...

Page 89: ...TE If the industrial truck described here has to be taken out of operation make sure that all com ponents are disposed of in accordance with the valid guidelines The used consumables in particular are to be recycled or disposed of correctly 5231 804 2502 EN 11 2017 83 ...

Page 90: ...4 Operation Parking decommissioning 84 5231 804 2502 EN 11 2017 ...

Page 91: ...5 Regular care and maintenance ...

Page 92: ...e work except functional tests disconnect the battery male connector Only electricians from the respective service partner may perform work on the electrical system To ensure the safe operation of your industrial truck over a long period of time it is absolutely essential that the machine is maintained regularly The activities listed in the maintenance schedule must be performed thoroughly and cor...

Page 93: ...eduled at intervals of 1000 hours or 12 months You can use the maintenance schedule to determine what work is required The following maintenance schedules are based on 10 000 operating hours Once this number of operating hours is reached the cycle starts again from the beginning The intervals must be reduced for trucks exposed to high levels of dust and signiﬁcant temperature ﬂuctuations A check o...

Page 94: ...clean and dry If damage becomes apparent on the industrial truck have it repaired without delay Perform checks on the industrial truck after changes and damage Investigate any changes in the noise on the industrial truck Perform battery maintenance in accordance with the manufacturer s instructions Maintenance schedule At operating hours 1000 h 2000 h 3000 h 4000 h 5000 h Carried out 6000 h 7000 h...

Page 95: ...he function and condition Support screws in the chassis check the setting according to the speciﬁcations on the nameplate Adjust as necessary Battery compartment door and battery compartment hood check and adjust as necessary Battery compartment door and battery compartment hood check and adjust as necessary Battery compartment check that the battery is securely positioned and check side stops on ...

Page 96: ... the brake clearance by freewheeling Load wheels check the condition and thickness of the brake lining Replace if ne cessary Brake lining blow out abrasion with oil free air Brake retardation values check after each adjustment dynometer or retardation measuring device Automatic braking check the function as per the order Inductive transmitter photo cells check the function setting and condition Op...

Page 97: ...lics Hydraulic system check the oil level To do this fully lower the load support The oil level must be between the minimum and maximum marking The markings on the hydraulic oil tank become visible once the control compartment hood is removed Hydraulic system check for leak tightness Hydraulic oil ﬁlter of the hydraulic oil tank replace Air ﬁlter of the hydraulic oil tank replace Pump motor check ...

Page 98: ...ck the condition and function of the latches Load fork visually check for bends measure if necessary Load fork if you suspect there are cracks check with the colour penetration proce dure Adjustable fork lubricate sliding surfaces with all purpose grease Maintenance schedule At operating hours Carried out 2000 h 4000 h 6000 h 8000 h 10000 h Gearbox Gearbox perform an oil change every 4000 h Hydrau...

Page 99: ...n the area 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 ...

Page 100: ...ax mark ing After the hydraulic oil has been topped up or changed the oil level must be between the min marking and the max marking Gearbox Gearbox oil SAE 75W 90 API GL 5 ID no 732 600 0007 The standard gearbox holds 4 6 litres of gearbox oil The heavy gearbox holds 7 litres of gearbox oil Grease lubrication points ESSO Beacon 2 multi purpose grease ID no 8 010 107 Chain lubrication Chain spray S...

Page 101: ...f electric shock Before the control compartment hood is removed the battery male connector must be disconnected The fuses are installed in the control compart ment To gain access to the control compartment the hood must be removed Open the two screw plugs 1 Hold the hood at the ventilation openings 2 lift it off and then place it to one side The hood is very lightweight and can therefore be remove...

Page 102: ...5 Regular care and maintenance Removing the control compartment hood 96 5231 804 2502 EN 11 2017 ...

Page 103: ...6 Technical data ...

Page 104: ...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 66dB A 98 5231 804 2502 EN 11 2017 ...

Page 105: ...7 Special equipment ...

Page 106: ... for the intermediate lift cut out and to acknowledge errors that can be acknowledged Flashes red when it needs to be pressed 4 Manual automatic two way switch for inductive guidance 5 Selection keys for favourites 6 7 8 Selection keys for additional hydraulic functions 9 Emergency off switch 10 Operating lever for driving 11 Sensor surface for two hand operation of the main lift or for shifting i...

Page 107: ...erating lever 1 to the left or right 16 Selection of a menu display 17 Selection within a menu 18 Go back one step in the menu or conﬁrm a selection 19 Back to the main menu 20 Light sensor for automatically illuminating the display lighting 21 Steering knob or steering wheel 22 Sensor surface for two hand driving within the aisle Option 5231 804 2502 EN 11 2017 101 ...

Page 108: ...agnostic program simplify service work on the system The operating devices for inductive steering control are integrated into the operating panel The display indicates the current operating status of the system After the controller is switched on a self test runs in the steering control system Switch 1 on the operating panel is used to switch from manual driving mode to automatic driving mode Ente...

Page 109: ...e When both antennas detect the induction track the wire search is complete and the Aisle symbol 5 is displayed The truck can now be driven at the permis sible speed within the racking NOTE Themore precisely the driver drives the middle of the industrial truck onto the wire groove the faster the guidance procedure will be completed This means that several of the above steps can be skipped Entering...

Page 110: ...ly braked to a standstill It is then only possible to continue at creep speed Driving speed adaptation The automatic speed adaptation feature adjusts the maximum possible driving speed according to the current situation If an unsafe situation arises for example an error occurs the driving speed is limited or the driving function is switched off completely Leaving the induction track Drive the enti...

Page 111: ...nts The driver s cab can be equipped with a sys tem consisting of rods and support mountings in order to mount additional components Additional components may include Writing surface with paper clip 1 Storage area for barcode scanner gun 2 Support mounting for data terminal Support mounting for printer NOTE The support mountings and clamping devices must always be in perfect condition so that the ...

Page 112: ... chapter entitled Inductive guidance IZF This means that the truck is aligned precisely so that it can be driven into the guide rails Electrical aisle detection only occurs when the truck is completely within the guide rails Once aisle detection has been successful inductive guidance is automatically turned off NOTE If the man auto button is not switched to auto matic the truck behaves like a mech...

Page 113: ...these openings must not be covered or be closed Do not create any openings in the battery compartment that allow the explosive gas mixture to enter the driver s compartment Ensure that the room or area in which the battery is being charged is well ventilated Smoking ﬁre and open ﬂames are forbid den in an area of 2 m around the charged battery Battery acid is toxic Do not inhale vapours Battery ac...

Page 114: ...ped or crushed To avoid this operate lifting gears and changeover frames with the utmost care Prevent heavy weights from bumping against the machine or equipment Be aware of pinch points and shear points when inserting the battery into or removing the battery from the battery compartment Ensure that you keep your ﬁngers hands and feet out of any areas where they could be at risk from one of the ab...

Page 115: ...sing a battery change frame The battery is secured with clamping devices on both sides and held in position in this way Monitoring The battery locks are electrically monitored If one of the locks is not correctly locked in place an error message appears in the display and the truck will stop WARNING Every time before starting work the battery locks 2 must be checked for perfect condition and funct...

Page 116: ...is possible that the actions described below may need to be repeated in several steps If the rubber buffer thread spring element is not able to move smoothly this must be rectiﬁed before setting 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 truck Rotate the knurled head screw 1 and the rubber buffer 3 all...

Page 117: ...he battery lock is clamped securely if the rubber buffer is clearly deformed If sufﬁcient clamping is not achieved via these steps it is possible that a battery with incorrect dimensions has been inserted The truck must not be used if the battery is not securely locked Doing so would result in the risk of accidents and damage When the clamping has been carried out a thread must still be visible at...

Page 118: ...on systems are active only with the guidance function Optionally the functional range can also be expanded to include front end monitoring CAUTION Risk of accident Even if a personal protection system is used we do not permit people and very narrow aisle trucks to be in the same aisle at the same time We have therefore allowed for a maximum of safety category 2 NOTE The makes of mobile personal pr...

Page 119: ...ing speed of the truck is restricted 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 Telescopic table Description NOTE To ensure proper use the information in the enclosed manufacturer s documents must be observed The table...

Page 120: ...ces e g shifting of the load with the fork proﬁle extended in a longitudinal and lateral direction Maintenance of the telescopic table NOTE The information in the enclosed manufactu rer s documents must be observed to ensure proper maintenance of the telescopic table Two person cab If a driver s cab is equipped appropriately two people may be inside at the same time during normal operation The add...

Page 121: ...sponsibility of the truck operator to make sure that this key is actually switched to the appro priate position when operating with two people The equipment described below only becomes active if the switch has been activated The truck operator must instruct the passenger as to the correct ope ration of the additional equipment and as to safe conduct when travelling If the passenger does not compl...

Page 122: ...nds at all times and thus keep his body in a safe position To monitor this the passenger must always actuate both buttons 4 Only then are the truck functions also enabled If the passenger releases one of the buttons whilst travelling or during a hydraulic movement this function will stop immediately 116 5231 804 2502 EN 11 2017 ...

Page 123: ... a reclined position the tilt barrier opens out to the side towards the racking This means that the distance to the racking is reduced which facilitates order picking If the operator releases the tilt barrier it is automatically returned to the initial position by spring force The tilt barrier consists essentially of a mobile upper part a ﬁxed bottom part and a hinge connecting the upper and botto...

Page 124: ...ons describe in detail how to assemble and conﬁgure the module This module can be supplied in various versions and combinations As LED workplace lighting for illuminating the racking next to the industrial truck With an integrated fan motor for circulating air in the driver s compartment With an integrated parabolic mirror as a rear view mirror CAUTION Risk of accident The curvature of the mirror ...

Page 125: ...rage 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 with the adjacent symbol CAUTION Icy ﬂoors Icy ﬂoors have a very negative effect on steering and...

Page 126: ...erface Additional components in the driver s cab require galvanically isolated power supplies Each power supply has a separate fuse The customer s printer or terminals can therefore be supplied with voltage The mounting position and number as well as the voltage supplied are order speciﬁc 120 5231 804 2502 EN 11 2017 ...

Page 127: ...raking characteristics 10 61 64 braking distance 17 Bridging plug X99 112 C Cab doors 61 64 Care 86 Chain lubricant 94 Changing the aisle 68 Checking all operating devices 55 Checking the access control 55 Checking the cab doors 55 Checking the emergency off switch 55 Checking the lifting accessory 55 Checking the overhead guard 55 Checking the wheels 55 Checklist before starting work 40 55 Climbi...

Page 128: ...Gel batteries 93 Gel battery 50 General safety information 10 Glass doors 56 Guidance 67 H Hand and arm vibrations 11 Hooking on the lift mast 42 Hooking the chassis on 42 Hooking the lift mast on horizontally 42 Horn 10 Hydraulic oil 14 94 Hydraulically adjustable fork arms 71 I Inductive guidance 67 102 Initial driving exercises 57 Installing the battery 50 Instruction 79 Intended use 4 6 27 Int...

Page 129: ...7 Order related documentation 6 Original parts 18 Other checks 55 P Parking brake 61 64 Pedestrian mode 10 Permitted batteries 52 Personal protection 14 Personal protection system 112 Personal protective equipment 19 Personal protective gear 14 PIN code 57 Product documentation 6 Programming display 31 Protection against contact 114 PzS 50 R Recycling 83 Regular maintenance 4 86 88 Regular testing...

Page 130: ...or wheel nuts 42 Towing 74 Towing with non operational steering 74 Towing with operational steering 74 Traction battery 48 107 Traction motor brake 74 Trafﬁc supervisor 10 Training 18 Transport travel 27 Transportation safety device on glass doors 42 Transporting and loading 42 Truck identiﬁcation 5 Two hand operation 61 64 100 Two person cab 79 114 Types of guidance 67 U Unauthorised use 10 Under...

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Page 132: ...STILL GmbH 5231 804 2502 EN 11 2017 ...

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