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5

Order picking and stacking

5.1

Adjusting the forks

WARNING!

Unsecured and incorrectly positioned loads can cause accidents

Before lifting a load unit the driver must ensure that it has been correctly palletised
and the truck’s capacity is not exceeded.

u

Instruct other people to move out of the hazardous area of the industrial truck.
Stop working with the truck if people do not leave the hazardous area.

u

Only carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.

u

Damaged loads must not be transported.

u

Never exceed the maximum loads specified on the capacity chart.

u

Never stand underneath a raised load handler / driver's cab.

u

Do not stand on the load handler.

u

Do not lift other people on the load handler.

u

Check the fork spread before lifting the load and adjust if necessary.

u

Insert the forks as far as possible underneath the load.

184

04.19 en-GB

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Содержание ETX 513

Страница 1: ...ETX 513 ETX 515 03 11 Operating instructions 51190312 04 19 en GB ETX 513 ETX 515...

Страница 2: ...2...

Страница 3: ...13 ETX 515 On behalf of Date EU DECLARATION OF CONFORMITY The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006 42 EG...

Страница 4: ...4 04 19 en GB...

Страница 5: ...lar features of the truck should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are indicated by the follo...

Страница 6: ...ht Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com 6 04 19...

Страница 7: ...trical requirements 45 5 Identification points and data plates 46 5 1 Data plate 48 5 2 Truck capacity plate 49 5 3 Attachment capacity plate 50 5 4 Jack contact points 50 6 Stability 51 C Transport a...

Страница 8: ...the Truck for Operation 124 3 1 Checks and operations to be performed before starting daily operation 124 3 2 Entry and exit 128 3 3 Setting up the operator position 128 4 Industrial Truck Operation 1...

Страница 9: ...7 Rack Height Select o 262 8 8 Horizontal positioning o 276 8 9 Weighing system o 292 8 10 Camera system 294 8 11 Rear view mirror o 295 8 12 Working platform o 296 8 13 Floor Spot o 308 8 14 Fire ex...

Страница 10: ...6 Safety tests to be performed at intervals and after unusual incidents 356 7 Final de commissioning disposal 357 8 Human vibration measurement 357 G Maintenance Inspection and Changing of Maintenance...

Страница 11: ...ngheinrich battery models If using another brand refer to the manufacturer s operating instructions 1 0506 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply o...

Страница 12: ...0506 GB 2 0506 GB 2...

Страница 13: ...um load and load distance are indicated on the load chart and must not be exceeded The load must rest on the load handler or be lifted by an attachment approved by the manufacturer The load must rest...

Страница 14: ...eatened by corrosion or excessive dust Furthermore the truck must not be operated in the vicinity of unprotected active components of electrical systems Operation in industrial and commercial environm...

Страница 15: ...etween the swivel traverse frame and the rack as well as the stored goods the load handler and the rack as well as the stored goods the raised load and the rack as well as the stored goods Z The safet...

Страница 16: ...rthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The proprietor must ensure that all users have read and understood these ope...

Страница 17: ...d pick goods on level surfaces in accordance with the VDMA guideline Open bottom pallets or pallets with diagonal boards can be lifted outside the range of the load wheels Loads can be stacked unstack...

Страница 18: ...be increased if special attachments are fitted WARNING An insufficient safety distance between the guided truck and the rack can result in accidents Failure to maintain the required and prescribed saf...

Страница 19: ...el direction definition The following determinations have been made for travel direction specification 1 4 2 3 1 4 2 3 Item Travel direction 1 Left 2 Drive direction 3 Load direction 4 Right 17 04 19...

Страница 20: ...p the load lowering speed in the event of a hydraulic system failure Deadman button After the truck is ready for operation see page 139 or see page 140 the deadman button in the footwell must be press...

Страница 21: ...nd maintenance free threephase motor with no wear parts The motor is directly attached to the single wheel driving gear ensuring rapid and trouble free maintenance Brake System The operator can brake...

Страница 22: ...idance mode is activated the steering is assumed by the truck controller when the guide wire is detected Manual steering is deactivated in this mode o Controls and displays Ergonomic controls ensure f...

Страница 23: ...ion damping lift cutout retardation and acceleration patterns cut outs etc rapidly and reliably To read off the error log to analyse fault causes To simulate and analyse program operations Simple func...

Страница 24: ...ect receipt of target position in narrow aisle by the truck computer Automatic vertical positioning Automatic horizontal positioning Automatic stacking Effective twin cycles Avoidance of wrong journey...

Страница 25: ...ll as for stacking and retrieving With rack height select the drive can select the required lift height via a keypad Lifting automatically ends when the required lift height is reached Rack Height Sel...

Страница 26: ...3 2 Assembly Overview 11 10 5 6 7 9 8 15 14 29 18 33 21 22 23 30 31 28 32 34 16 25 24 28 27 13 20 19 17 12 26 24 04 19 en GB...

Страница 27: ...pedal 21 o Front sensor for wire guidance system not shown 22 o Front scanner for personal protection system not shown 23 t Fork tine 24 t Load wheel 25 o Rail guidance wheel attachment behind the loa...

Страница 28: ...load free ranging 9 9 km h Travel speed without load RG 9 10 5 km h Travel speed with load RG 9 10 5 km h Travel speed without load WG 7 9 km h Travel speed without load WG 7 9 km h Lift speed withou...

Страница 29: ...hout load WG 7 9 km h Travel speed without load WG 7 9 km h Lift speed without load 0 46 0 46 m s Lift speed with load 0 45 0 45 m s Lower speed without load 0 48 0 48 m s Lower speed with load 0 48 0...

Страница 30: ...ions as per data plate 4 2 1 Dimensions of the ETX 513 ETX 515 with standard attachment W a b5 b3 b12 l1 l2 A st h 7 h 6 h 1 h 4 h 3 h 2 b 6 b 1 b 2 b 14 b 7 s m e D y x D z 1 m2 I6 I l8 l10 b8 r 28 0...

Страница 31: ...7 Seat height approx 1360 approx 1360 mm Ast Working aisle width for pallets 1200 x 1000 1600 1600 mm Wa Turning radius 2135 2460 mm s Fork dimensions 40 50 mm e 120 120 mm l 1200 1200 mm Lowest posit...

Страница 32: ...W a b5 b3 b12 l1 l2 A st h 7 h 6 h 1 h 4 h 3 h 2 b 6 b 1 b 2 b 14 b 7 s m e D y x D z 1 m2 I6 I l8 l10 b8 r 30 04 19 en GB...

Страница 33: ...distance 903 760 mm I8 x Fork pivot point toothed rack distance 735 567 mm I10 Outrigger width 170 170 mm m1 Ground clearance below mast 80 80 mm m2 Ground clearance centre wheelbase 85 85 mm r Fork...

Страница 34: ...4 2 2 Dimensions of ETX 513 T F ETX 513 T F with telescopic table z 32 04 19 en GB...

Страница 35: ...approx 1360 mm Ast Working aisle width for pallets 1200 x 1000 1400 1450 mm Wa Turning radius 2135 2460 mm s Fork dimensions 60 60 mm e 180 180 mm l 1200 1200 mm Lowest position of flat telescopic for...

Страница 36: ...z 34 04 19 en GB...

Страница 37: ...m2 Ground clearance centre wheelbase 85 85 mm m3 Load handler ground clearance 25 25 mm Clear internal operator position height distance from operator position floor to bottom of overhead guard 1518 1...

Страница 38: ...mast ZT Description ETX 513 ETX 515 h1 Mast height retracted 2570 5070 2670 5720 mm h3 Lift 3000 8000 3000 9000 mm h4 Mast height extended 4150 9150 4250 10250 mm h6 Overhead guard height 2461 2461 m...

Страница 39: ...ETX 515 h1 Mast height retracted 2900 4700 3200 5800 mm h2 Free lift 1750 3550 1950 4550 mm h3 Lift 5500 10000 6000 13000 mm h4 Mast height extended 6650 11150 7250 14250 mm h6 Overhead guard height 2...

Страница 40: ...ic truck mast weight including attachment 35 36 Basic truck weight excl battery Z The weight of the basic truck 36 is shown in the following table Truck Weight of basic truck ETX 513 2400 kg ETX 515 2...

Страница 41: ...data plate see page 48 A Net weight of the industrial truck without battery B Mast weight including attachment Formula for the ETX 513 B A 2400 kg Formula for the ETX 515 B A 2500 kg Example Required...

Страница 42: ...t load at front 38101 43502 Axle load without load at rear 27301 31802 Battery type used 3 PzS 465 5 PzS 775 Z The data listed in the table performance data dimensions and weights are based on a truck...

Страница 43: ...ed by a customer service organisation authorised by the manufacturer ETX 513 Description ETX 513 Tyres Vulkollan Wheels front load wheel 295 mm x 144 mm Wheels rear drive wheel 400 mm x 160 mm Wheels...

Страница 44: ...easuring chain for at 21 C at 0 02 m s Further deviations may occur in particular through the positioning of the sensor and different driver weights Z The vibration acceleration acting on the body in...

Страница 45: ...be damaged by non ionised radiation Electrical equipment on the truck emitting non ionised radiation e g wireless data transmission can affect operators medical equipment pacemakers hearing aids etc...

Страница 46: ...o be constantly used in conditions of extreme temperature or air humidity fluctuations The truck is not authorised for use in cold stores The truck must only be used in an closed indoor environment Th...

Страница 47: ...turer certifies compliance with the requirements for the design and manufacture of electrical equipment according to EN 1175 Industrial Truck Safety Electrical Requirements provided the truck is used...

Страница 48: ...and data plates Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary 37 41 37 37 40 38 39 44 46 45 40 50 49 47 48 51 52 53 52...

Страница 49: ...azards in narrow aisle warning notice 43 Test plaque o 44 Read operating instructions notice 45 Capacity decal 46 Truck data plate 47 Add hydraulic oil decal t 48 Add bio hydraulic oil decal o 49 Caut...

Страница 50: ...kg 62 Output 57 Battery voltage V 63 Min max battery weight kg 58 Net weight w o battery kg 64 Manufacturer 59 Option 65 Manufacturer s logo Z For queries regarding the truck or ordering spare parts...

Страница 51: ...y plate 45 gives the capacity Q kg of the truck for an upright mast The maximum capacity is shown as a table with a given load centre of gravity D mm and the required lift height h3 mm The capacity pl...

Страница 52: ...hment as the specific capacity for each truck is indicated by the manufacturer It is shown in the same way as the truck s capacity and can be determined accordingly Z For loads with a centre of gravit...

Страница 53: ...en tested according to latest technological standards These take into account the dynamic and static tipover forces that can occur if used correctly Stability can also be affected by the following fac...

Страница 54: ...52 04 19 en GB...

Страница 55: ...or Assembly and Commissioning WARNING Incorrect assembly can result in accidents The assembly of the truck at the application site commissioning and driver training must only be performed by the manuf...

Страница 56: ...are trained in handling lifting slings and tools uWear personal protective equipment e g safety boots helmet hi vis jacket protective gloves etc when loading by crane uDo not stand under a swaying loa...

Страница 57: ...n lifting by crane refer to the truck data plate see page 48 WARNING Crane lifting gear can tear resulting in accidents Crane lifting gear can tear when routed over sharp edges causing the load to cra...

Страница 58: ...etc when loading by crane uDo not stand under a swaying load uDo not walk into or stand in a hazardous area uAlways use lifting gear with sufficient capacity for truck weight see truck data plate uAl...

Страница 59: ...ne lifting gear can tear resulting in accidents Crane lifting gear can tear when routed over sharp edges causing the load to crash uProtect the crane lifting gear with a suitable support 69 uDo not ro...

Страница 60: ...n handling lifting slings and tools uWear personal protective equipment e g safety boots helmet hi vis jacket protective gloves etc when loading by crane uDo not stand under a swaying load uDo not wal...

Страница 61: ...uding cab and load handler to be taken into account see page 38 Fit the transport retainer 71 WARNING Crane lifting gear can tear resulting in accidents Crane lifting gear can tear when routed over sh...

Страница 62: ...e crane slings only to the prescribed strap points and prevent them from slipping uUse the lifting gear only in the prescribed load direction uCrane slings should be fastened in such a way that they d...

Страница 63: ...ry data plate Lifting the battery with crane lifting gear Attach the lifting gear to the four eyes on the battery tray for weight refer to the battery rating plate The battery can now be raised and lo...

Страница 64: ...uck from moving uUse only fastening belts with sufficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats 77 78 24 79 80 31 81 82 69 73 74 75 69 76 Securing...

Страница 65: ...he tie down straps tensioning belts over sharp edges If this is not possible protect the tie down straps tensioning belts with a suitable material e g foam uProtect the tie down straps tensioning belt...

Страница 66: ...g uUse only fastening belts with sufficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats 85 85 84 77 86 11 82 87 84 71 83 69 Securing the mast for transpo...

Страница 67: ...outed over the lift chains with a suitable material e g foam Secure the mast 11 to the pallets 85 with tie down straps 84 Stow any supplied parts fork tines guide wheels etc on a pallet 88 so that the...

Страница 68: ...ges to prevent the truck from moving uUse only fastening belts with sufficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats 76 70 73 69 89 83 77 78 24 69...

Страница 69: ...n straps tensioning belts can tear when routed over sharp edges uProtect the tie down straps tensioning belts with a suitable support 69 uDo not route the tie down straps tensioning belts over sharp e...

Страница 70: ...ssembled uThe truck can then be started uIf several trucks have been delivered make sure that always the serial numbers of the load handlers masts and basic trucks match each other CAUTION Only operat...

Страница 71: ...ation authorised by the manufacturer WARNING Trapping hazard in the swivel and traverse area of the attachment There is a trapping hazard in the attachment area while the attachment is traversing and...

Страница 72: ...ainers ETX 515 only Z The transport retainers release the load wheel brakes when they are de energised Disassemble the load wheel guards by removing the three Allen screws from the load wheels Remove...

Страница 73: ...oil level and top up if necessary see page 346 Check that all safety mechanisms are present and test them e g tilt safety devices etc Start up the industrial truck as indicated see page 124 and see p...

Страница 74: ...assis When a tilt safety device 28 is used under the right side panel 16 an X is engraved in the chassis 34 after the serial number see page 46 CAUTION Before commissioning check industrial trucks to...

Страница 75: ...be no inflammable material or lubricants capable of creating sparks within 2 m around the truck The room must be ventilated Fire protection equipment must be on hand Battery maintenance The battery c...

Страница 76: ...with battery acid uNeutralise any spilled battery acid immediately with plenty of water uOnly batteries with a sealed battery container may be used uFollow national guidelines and legislation WARNING...

Страница 77: ...ion Z The battery weights can be taken from the battery data plate WARNING Loss of stability can cause accidents The weight and dimensions of the battery have a considerable effect on the operational...

Страница 78: ...ry compartment H B L H B L Truck model Length L Width W Height H ETX 513 ETX 513 T F 1072 mm 583 mm 923 5 mm Maximum battery height 880 mm ETX 515 ETX 515 T F 1072 mm 870 mm 923 5 mm Maximum battery h...

Страница 79: ...with those of the previously used battery Failure to comply with the prescribed battery weight range can render the truck unstable uUse only batteries whose weight is within the minimum and maximum r...

Страница 80: ...s strictly prohibited uAlways park the truck on a level surface In special cases the truck may need to be secured with wedges uAlways fully lower the mast and forks uSelect a place to park where no ot...

Страница 81: ...cedure Turn the industrial truck off with the key switch 8 and remove the key Press the Emergency Disconnect switch 9 down Unlatch the battery cover 15 To do this loosen the hook 97 on the mast 11 Clo...

Страница 82: ...ces must be exposed during charging to ensure adequate ventilation uDo not smoke and avoid naked flames when handling batteries uWherever an industrial truck is parked for charging there shall be no i...

Страница 83: ...e exposed to provide sufficient ventilation Do not place any metal objects on the battery Before charging check all cables and plug connections for visible signs of damage NOTICE Risk of fire and mate...

Страница 84: ...highly explosive and must not be ignited uSwitch the charging station and truck off first before connecting disconnecting the charging cable of the battery charging station to from the battery connect...

Страница 85: ...uDo not return the industrial truck to service until you have identified and rectified the fault Attach the battery connector 14 to the industrial truck CAUTION Open covers can cause injury and accid...

Страница 86: ...he same position uPark the truck on a level surface to prevent the battery from sliding out uMake sure the crane lifting gear has sufficient capacity to replace the battery uUse only approved battery...

Страница 87: ...i clockwise see arrow direction B Lift up the battery retainer 100 see arrow direction C Lift up the battery retainer 101 see arrow direction D Position the battery roller stand in front of the batter...

Страница 88: ...sition the battery roller stand with the battery 98 in front of the battery compartment in such a way that the battery 98 can be safely pushed into the truck s battery compartment Z The battery retain...

Страница 89: ...the chassis see arrow direction A Check all cables and plug connections for visible signs of damage CAUTION There is a risk of short circuits with damaged cables uReport any defects immediately to you...

Страница 90: ...ed Fork lift truck with a minimum fork length of 880 mm and a capacity in excess of 1 5 t Attention Note the maximum capacity with respect to the load centre distance Procedure Remove the battery conn...

Страница 91: ...ing the batteries during removal assembly Set the mast of the truck upright thereby bringing the load handler into a horizontal position Insert the forks of the truck into the fork shoes 102 of the ba...

Страница 92: ...the battery cover 14 98 102 16 101 15 101 102 Battery installation Requirements Park the truck on a level surface Expose the battery see page 78 Tools and Material Required Fork lift truck with a mini...

Страница 93: ...101 can swap positions This means that they can both be fitted in either the left or right side of the truck s chassis Insert the battery retainers 101 on either side into the truck chassis see arrow...

Страница 94: ...ave been applied If the battery retainers have not been inserted and latched correctly in the chassis the truck will not move The driver s display shows the Battery lock not applied symbol 103 Operati...

Страница 95: ...tery retainer s is are inserted in the chassis The battery lock not applied symbol 103 fades out The truck can now travel again at the approved speed Z Hydraulic operations are not affected if the bat...

Страница 96: ...94 04 19 en GB...

Страница 97: ...perating instructions The driver shall be afforded all due rights Unauthorised use of truck The driver is responsible for the truck during the time it is in use The driver must prevent unauthorised pe...

Страница 98: ...mmediately Safety devices and warning labels Safety devices warning signs see page 46 and warning instructions in the present operating instructions must be strictly observed Z Warnings and notices su...

Страница 99: ...2 Displays and Controls 2 1 Controls and displays on the control panel 114 106 5 104 112 107 108 109 116 115 113 9 8 118 18 20 19 105 120 119 117 111 110 26 97 04 19 en GB...

Страница 100: ...114 106 5 104 112 107 108 109 116 115 113 9 8 118 18 20 19 105 120 119 117 111 110 26 98 04 19 en GB...

Страница 101: ...ot applied display is lit in the driver s display see page 103 Steering driver s display and horn are enabled Hydraulic functions fork carriage rotate attachment traverse are enabled Travel functions...

Страница 102: ...ns shown in the driver s display shown as symbols are activated or confirmed with the button underneath the symbol The symbol has a dark background 105 Travel direction switch t Selects the travel dir...

Страница 103: ...and settings for standard functions e g setting the time and additional functions e g rack height select 110 Indicators t Note For manufacturer s service department only 111 Function keys F1 F6 t Rack...

Страница 104: ...14 Option button o Button for optional functions 115 Grip t Handle with Hydraulic functions control lever and Horn button 116 Horn button t Activates the horn activates an audible warning 117 Armrest...

Страница 105: ...ready for operation Indicates the truck is stationary Parking brake drive wheel brake is applied R Drive wheel brake referencing indicator t Indicates the truck has come to a halt and the drive wheel...

Страница 106: ...with aisle detection o Symbol lights up as soon as the truck is automatically guided and has received an aisle signal Truck guided without aisle detection Symbol lights up as soon as the truck is auto...

Страница 107: ...ow aisle As soon as the industrial truck receives an aisle signal the Truck guided without aisle detection symbol is replaced by the Truck guided with aisle detection symbol Truck not guided Symbol is...

Страница 108: ...wer referencing t Requests Main Lift to lower 127 Battery Discharge Indicator t Shows the battery charge status bar display 75 o Displays the battery charge status residual capacity as a percentage 12...

Страница 109: ...the narrow aisle see page 241 The truck brakes to a halt Perform cycle test display o Indicates that the cycle test of the personal protection system must be performed every 24 hours see page 239 The...

Страница 110: ...Truck is ready for operation Emergency Disconnect switch pressed 135 Displays possible travel speeds t Rabbit Max travel speed t Turtle Inching speed 136 Service mode active indicator t Shows event a...

Страница 111: ...62 or see page 276 t Denotes standard equipment o Denotes optional equipment WG Wire guidance RG Rail Guidance 2 3 Hourmeter Z Prepare the truck for operation see page 139 or see page 140 Service hour...

Страница 112: ...at least every 2 months Z Charge the battery see page 80 Requirements Connect the battery to the truck Close the battery cover Enter the operator position see page 128 Procedure Turn the EMERGENCY DI...

Страница 113: ...harge indicator shows the greater the battery s residual capacity Flashing Battery charge recommended Depending on the battery type the battery discharge indicator symbol flashes when there are one or...

Страница 114: ...fully discharge Full discharge shortens the useful life of the battery uCharge the battery at least every 2 months Z Charge the battery see page 80 Requirements Connect the battery to the truck Close...

Страница 115: ...residual capacity Flashing 30 21 Battery charge recommended 20 0 Battery charge required charge is below residual capacity level Main Lift and Auxiliary Lift raising is inhibited Z Raising is only ena...

Страница 116: ...e right Fork manual synchronised left rotate button t Activates manual fork carriage synchronised left rotate and load handler right traverse The attachment traverse movement is controlled with the hy...

Страница 117: ...ork carriage 90 and traverse the load handler to the centre Fork manual synchronised rotate to centre position button o Activates manual fork carriage synchronised 90 rotate and load handler centre tr...

Страница 118: ...lescopic forks can be operated Telescopic forks button o Activates the telescopic forks This hydraulic function is controlled with the hydraulic functions control lever Telescopic forks synchronised m...

Страница 119: ...ates asynchronous movement of the bottom telescopic forks This hydraulic function is controlled with the hydraulic functions control lever see page 249 2nd stacking depth display o Indicates that the...

Страница 120: ...y o Indicates that the left fork can be adjusted Left fork positioning button o Activates left fork positioning This hydraulic function is controlled with the hydraulic functions control lever Right f...

Страница 121: ...ctivates fork tilt This hydraulic function is controlled with the hydraulic functions control lever Special attachment display o Indicates that a special attachment can be operated Special attachment...

Страница 122: ...241 Travel is controlled with the travel control knob Warning field infringement display o Indicates that there are people obstacles in the warning field of the personal protection system in the narro...

Страница 123: ...ton o Overrides the lower limit This hydraulic function is controlled with the hydraulic functions control lever Travel cutout display o Appears as soon as automatic height dependent travel cutout is...

Страница 124: ...ton the menu currently shown in the driver s display changes to the Truck functions menu Battery latch not applied display t Appears when the truck has been switched on but the battery latch has not b...

Страница 125: ...strobe on and off Spotlight positioning display o Indicates that the spotlight can be switched on off Spotlight positioning button o Switches the spotlight on and off Reverse lights display o Indicat...

Страница 126: ...vented from being used by unauthorised people if people do not leave the hazardous area despite the warning 3 1 Checks and operations to be performed before starting daily operation WARNING Damage and...

Страница 127: ...the operator mat and step boards are non slip and damage free Check the tilt safety devices are present o see page 72 Check the load handler forks etc for visible signs of damage such as cracks bent o...

Страница 128: ...replaced before the truck is started uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rec...

Страница 129: ...age Check the battery connectors are secure Check battery lock battery attachment is present and working Make sure battery is securely fixed in the battery compartment Check battery cover and side pan...

Страница 130: ...ore than one person may operate the truck at a time 3 3 Setting up the operator position CAUTION An unsecured driver s seat and control panel can result in falls and injury An unsecured driver s seat...

Страница 131: ...r s seat and control panel so that all the controls are within reach and can be applied without having to strain Adjust the visibility aid equipment mirrors camera systems etc so that the working envi...

Страница 132: ...starting to use the truck uHold the weight setting lever 142 only by the recess do not reach through underneath the lever Adjusting the driver s weight NOTICE To achieve optimal seat cushioning the d...

Страница 133: ...ry An unsecured driver s seat can slide out of its guide during travel resulting in accidents uThe driver s seat must be locked in position uDo not adjust the driver s seat while travelling Procedure...

Страница 134: ...place when the truck is in operation uDo not adjust the control panel during operation Procedure Hold onto the control panel 118 Turn the height adjusting lever 144 anti clockwise Set the control pan...

Страница 135: ...ce when the truck is in operation uDo not adjust the control panel during operation Procedure Hold onto the control panel 118 Pull the longitudinal adjusting lever 145 up Set the control panel 118 to...

Страница 136: ...issible surface and spot load limits on the travel routes At blind spots get a second person to assist NOTICE Loads must not be deposited on travel or escape routes in front of safety mechanisms or op...

Страница 137: ...st always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times Abrupt stopping except in emergencies rapid U turns...

Страница 138: ...on Stop the truck immediately if visual contact is lost between the lookout and the operator Use the mirror only to observe the traffic behind you Should you need visibility aids mirrors monitors etc...

Страница 139: ...ct with the walls of the lift shaft People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck Work platf...

Страница 140: ...out WARNING Accident risk when transporting liquid loads The following risks may be present when transporting liquid loads Liquids sloshing out A change in the load centre due to sudden lifting and d...

Страница 141: ...RGENCY DISCONNECT switch 9 to unlock it Z Press the Emergency Disconnect 9 immediately if the truck starts to move or lift as soon as it is switched on Brief steering movements caused by steering refe...

Страница 142: ...ion see page 124 Connect the battery to the truck Insert and lock the battery latch Insert and lock the side panels correctly Close the battery cover see page 78 Enter the operator position see page 1...

Страница 143: ...ey 146 one digit back Press the CE key 150 to cancel entering the 5 digit access code Press OK 149 and confirm the access code entry Z If no travel steer or hydraulic operations are performed within a...

Страница 144: ...lic system is defective or faulty If damage or other defects are discovered on the truck or attachment special equipment the truck must be taken out of service until it has been repaired uReport any d...

Страница 145: ...nd see page 172 Test the lift cutouts o see page 207 Test the travel functions see page 152 and see page 156 Test the end of aisle safety device and aisle detection functions o see page 211 Test the t...

Страница 146: ...e the truck for operation see page 139 or see page 140 Procedure Press the deadman button 18 Carry out a Raise main lift reference run Raise the Main Lift until the 151 symbol is no longer illuminated...

Страница 147: ...which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle Procedure Pressing the lift cutout override button 104 underneath to the li...

Страница 148: ...cedure Do not press the deadman button 18 Press and hold down on the Attachment traverse button 120 Traverse the attachment through the centre of the swivel traverse frame Turn the Hydraulic functions...

Страница 149: ...carriage right rotation Turn the Hydraulic functions control lever 113 anti clockwise Fork carriage left rotation Rotate fork carriage back to home position see page 182 Rotate referencing is success...

Страница 150: ...te Time Standard setting dd mm yyyy hh mm ss US setting mm dd yyyy hh mm ss am pm Selecting the Set Date Time menu Requirements Prepare the truck for operation see page 139 or see page 140 Procedure P...

Страница 151: ...n also be entered directly with the number field on the numerical keypad 112 Use the cursor keys 146 148 to select the next or previous field Cursor key 146 previous field Cursor key 148 one field for...

Страница 152: ...4 7 Emergency Disconnect 9 150 04 19 en GB...

Страница 153: ...the Emergency Disconnect 9 as a service brake Press the Emergency Disconnect 9 All electrical functions are deactivated The truck brakes to a halt Releasing the Emergency Disconnect Procedure Turn th...

Страница 154: ...ation see page 139 or see page 140 Procedure Press and hold down on the deadman button 18 Fully lower the Main Lift Turn the Hydraulic functions control lever 113 anti clockwise Carry out a test run o...

Страница 155: ...travel speed is infinitely controlled by the accelerator pedal 20 The further the accelerator pedal 20 is pressed the greater the travel speed Use the steering wheel 5 to steer the truck in the requir...

Страница 156: ...side narrow aisles The truck is automatically guided and steering wheel 5 operation is deactivated 4 10 Brakes WARNING Accident risk while braking The truck s brake pattern depends largely on the grou...

Страница 157: ...brake pedal 19 Braking with the reversing brake t Procedure During travel set the travel direction switch 105 to the opposite direction The truck brakes regeneratively via the traction controller unt...

Страница 158: ...e must not be rendered ineffective misused adjusted or removed uReport any defects to your supervisor immediately uTag out and decommission a faulty lift truck uOnly return the truck to service when y...

Страница 159: ...e g pallets load units etc A collision between the truck and the protruding objects could also cause material damage to the truck and the rack construction uCheck the length and height of the narrow...

Страница 160: ...only in narrow aisles with undamaged secure guide rails Press the deadman button Approach the aisle at reduced speed so that the truck 162 is aligned with the narrow aisle and is within the demarcati...

Страница 161: ...avel speed is governed by the accelerator pedal 20 Z The travel speed is infinitely controlled by the accelerator pedal 20 The further the accelerator pedal 20 is pressed the greater the travel speed...

Страница 162: ...Switch automatic guidance on off button 106 Z The Truck guided display 163 changes to the steer angle indicator 124 The truck is now free to move again The steer angle indicator 124 shows the current...

Страница 163: ...endered ineffective misused adjusted or removed uReport any defects to your supervisor immediately uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identif...

Страница 164: ...driver of the truck in a narrow aisle can be injured by objects protruding from the racks e g pallets load units etc A collision between the truck and the protruding objects could also cause material...

Страница 165: ...e has been deactivated note the position of the drive wheel as manual steering is now activated again uRe activate the wire guidance and re align the truck During alignment the rear section of the tru...

Страница 166: ...itch automatic guidance on off button 106 The wire acquisition signal sounds Move the truck 162 slowly in the direction of the guide wire 164 Z The truck is automatically guided when it reaches the gu...

Страница 167: ...avel speed is governed by the accelerator pedal 20 Z The travel speed is infinitely controlled by the accelerator pedal 20 The further the accelerator pedal 20 is pressed the greater the travel speed...

Страница 168: ...Switch automatic guidance on off button 106 Z The Truck guided display 163 changes to the steer angle indicator 124 The truck is now free to move again The steer angle indicator 124 shows the current...

Страница 169: ...dal 20 simultaneously Main Lift lower Turn the Hydraulic functions control lever 113 anti clockwise Main lift raise Turn the Hydraulic functions control lever 113 clockwise Travel in load direction Pu...

Страница 170: ...uck Stop working with the truck if people do not leave the hazardous area uIf people do not leave the hazardous area despite the warning prevent the truck from being used by unauthorised people uOnly...

Страница 171: ...there no leakage in the hydraulic system raise the Main Lift slightly and then lower it again slowly uReport any defects immediately to your supervisor uMark defective truck and take out of service uD...

Страница 172: ...ulic hoses may become damaged uWhen lowering the load handler ensure that the lift chains are not resting on anything and are slack uRaise the load handler carefully until the lift chains are tensione...

Страница 173: ...re in proportion to how far the Hydraulic functions control lever 113 is moved The maximum lift speed is achieved when the attachment is in the home position or the telescopic table is in the centre p...

Страница 174: ...ing out swivel traverse synchronised rotate or lift lower movements with the load handler Stop working with the truck if people do not leave the hazardous area uThe truck must be prevented from being...

Страница 175: ...xternal signs of damage or defects Faulty attachments can cause the load to fall uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck...

Страница 176: ...urn the Hydraulic functions control lever 113 clockwise Traverse attachment to the left Turn the Hydraulic functions control lever 113 anti clockwise Z The traverse speed is in proportion to how far t...

Страница 177: ...rn the Hydraulic functions control lever 113 clockwise Rotate fork carriage left Turn the Hydraulic functions control lever 113 anti clockwise Z The rotary speed is in proportion to how far the Hydrau...

Страница 178: ...ions control lever 113 The attachment must then be moved manually to the home position Synchonised fork carriage right rotation and load handler left traverse Press and hold down on the 104 button und...

Страница 179: ...e cancelled by releasing the 104 button The attachment must then be moved manually to the home position Synchonised fork carriage right rotation and load handler left traverse Press and hold down on t...

Страница 180: ...on 18 Press 104 under the synchronised rotate menu change symbol 166 The display changes from the menu item Synchronised rotation menu change 166 to Synchronised rotation until forks in centre positio...

Страница 181: ...matic synchronised rotation until forks are in centre position the fork carriage is rotated 90 from the home position and the attachment is positioned in the centre of the traverse pivot frame Require...

Страница 182: ...or with a raised load load handler is dangerous and is strictly prohibited uAlways park the truck on a level surface In special cases the truck may need to be secured with wedges uAlways fully lower t...

Страница 183: ...wn Set the attachment to the home position t see page 182 Traverse the telescopic table to the centre position o see page 183 Switch off the truck to do this Turn the key in the key switch 8 left as f...

Страница 184: ...on see page 139 or see page 140 Procedure Do not press the deadman button 18 Traverse the attachment to the right or left limit position of the sideshift frame 113 see page 174 Rotate the forks 23 par...

Страница 185: ...Requirements Prepare the truck for operation see page 139 or see page 140 Procedure Do not press the deadman button 18 Traverse the telescopic table to the centre position 113 The driver s display sho...

Страница 186: ...o not leave the hazardous area uOnly carry loads that have been correctly secured and positioned Use suitable protection measure to prevent parts of the load from tipping or falling down uDamaged load...

Страница 187: ...e extension safety mechanisms 172 The truck must not be operated without an extension safety mechanism 172 uCheck the extension safety mechanisms 172 are present uEnsure the extension safety mechanism...

Страница 188: ...CAUTION Injury risk when replacing forks The forks can slide off the fork carriage when being replaced As a result you could injure your legs uWear personal protective equipment e g safety boots etc...

Страница 189: ...y forks with lifting slings and a crane before pushing them down from the fork carriage uKeep all parts of your body away from the forks and fork carriage WARNING Using two different forks can cause a...

Страница 190: ...nd forks not touching the ground Procedure Disassemble the extension safety mechanism 172 Lift up the locking lever 170 Carefully push the fork tines 23 off the fork carriage 171 The fork tines 23 are...

Страница 191: ...70 down and move the fork tines 23 until the locking pin engages in a slot WARNING Unsecured forks can cause accidents The forks must be prevented from falling with the extension safety mechanisms 172...

Страница 192: ...e transported uIf the stacked load obscures forward visibility then you must reverse the truck uMake sure you have enough visibility when reversing uNever exceed the maximum loads specified in the cap...

Страница 193: ...ad handler so that the load can be lifted Do not press the deadman button Slowly insert the forks into the pallet until the fork shank touches the load or the pallet Z The load unit must not extend by...

Страница 194: ...gles 90 to the truck see page 175 Press the deadman button Lower raise the load handler so that the load can be lifted Slowly insert the forks into the pallet until the fork shank touches the load or...

Страница 195: ...ions Procedure Z Always transport loads with both forks When transporting heavy loads always ensure that both forks carry the same weight Press the deadman button Raise the load slightly Z Always tran...

Страница 196: ...become damaged uWhen lowering the load handler ensure that the lift chains are not resting on anything and are slack uRaise the load handler carefully until the lift chains are tensioned and not resti...

Страница 197: ...y set the load into its storage location Press the deadman button Carefully lower the load handler so that the forks are clear of the load Z Avoid depositing the load suddenly to avoid damaging the lo...

Страница 198: ...become damaged uWhen lowering the load handler ensure that the lift chains are not resting on anything and are slack uRaise the load handler carefully until the lift chains are tensioned and not resti...

Страница 199: ...thout striking any objects Carefully bring the load to its storage location Carefully lower the load handler so that the forks are clear of the load Z Avoid depositing the load suddenly to avoid damag...

Страница 200: ...system is displayed with a corresponding error code contact the manufacturer s service department Additional troubleshooting must only be performed by the manufacturer s specialist service engineers...

Страница 201: ...e 205 Travel cutout activated via end of aisle safety device Set the accelerator pedal to neutral and apply it again Load cannot be lifted Truck not operational Carry out all remedial measures listed...

Страница 202: ...age 213 4916 During the power up test a Functions button under the driver s display and or a key on the numerical keypad has been pressed Do not press the Functions button switch truck off and on agai...

Страница 203: ...NG Risk of accidents material damage through automatic lowering of load handler If the load handler is in the rack emergency lowering cannot be performed Due to leakage from the hydraulic system there...

Страница 204: ...ing uNever stand underneath a raised load handler uIf the load handler is lowered with the emergency lowering device below it the driver must be in a safe area to avoid any danger uDo not perform emer...

Страница 205: ...to do this Turn the key in the key switch as far to the left as it will go 8 Press the red button on the ISM access module o Press the Emergency Disconnect 9 Open the drive compartment cover 95 see pa...

Страница 206: ...The load handler is lowered WARNING Only return the truck to service when you have identified and rectified the fault 204 04 19 en GB...

Страница 207: ...ver the position of the truck needs to be adjusted with respect to the rack in order to stack or retrieve a load proceed as follows WARNING The truck can cause accidents Travel cutout is an additional...

Страница 208: ...direction Push the travel direction switch 105 left Travel in drive direction Press the deadman button 18 Apply the accelerator pedal 20 The truck can now travel at slow speed 175 104 20 18 105 NOTICE...

Страница 209: ...liary function designed to support the operator which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle Z Lift cutout only becomes...

Страница 210: ...ift is raised Lift cutout is deactivated Z Lift cutout is re activated every time the mast falls below the lift limit height 153 104 18 113 NOTICE Pressing the 104 button under the corresponding overr...

Страница 211: ...auxiliary function designed to support the operator which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle Z Lower cutout only be...

Страница 212: ...ift is lowered The lower cutout is deactivated Z Lift cutout is re activated every time the mast rises above the lower limit height 176 104 18 113 NOTICE Pressing the 104 button under the correspondin...

Страница 213: ...nets in the direction of the end of the aisle it comes to a halt WARNING The stopping distance depends on the travel speed To continue travelling Briefly release the deadman button and accelerator ped...

Страница 214: ...of the narrow aisle at this speed WARNING The stopping distance depends on the travel speed WARNING Accident risk due to truck without braking system End of aisle safety braking is an additional func...

Страница 215: ...If during operation one of the monitors for steering control steering system wire guidance the safety cutout for the traction electronic system or the power electronic system applies the truck safety...

Страница 216: ...a narrow aisle Moving the truck without a battery WARNING Disabling the brakes can be dangerous Recovering the truck from a narrow aisle or moving the truck without a battery must only be performed by...

Страница 217: ...s Fully lower the mast see page 168 or see page 201 Traverse the attachment to the home position t see page 182 Traverse the telescopic table to the centre position o see page 183 Disconnect the batte...

Страница 218: ...setscrews 177 are used to tension unlock the compression springs which activate the parking brake so that the truck does not brake when de energised Release the load wheel brake ETX 515 only see page...

Страница 219: ...ruck on a level surface In special cases the truck may need to be secured with wedges uAlways fully lower the mast and forks uSelect a place to park where no other people are at risk of injury from lo...

Страница 220: ...y the load wheel brake ETX 515 only see page 219 CAUTION Open covers can cause injury and accidents uThe covers battery cover side panels drive compartment cover etc must be closed during operation Cl...

Страница 221: ...81 182 Releasing the load wheel brake Requirements Fully lower the mast see page 168 or see page 201 Traverse the attachment to the home position t see page 182 Traverse the telescopic table to the ce...

Страница 222: ...o undo the load wheel brake from the drive compartment Z The setscrews are used to tension unlock the compression springs which activate the load wheel brakes so that the truck does not brake when de...

Страница 223: ...are at risk of injury from lowering forks WARNING If the brakes are not working place wedges underneath the wheels of the truck to prevent it from moving 95 8 9 183 24 181 181 182 Activating the load...

Страница 224: ...ompartment cover etc must be closed during operation Close the drive compartment cover 95 see page 330 Fit the panels 183 of the load wheels 24 on both sides Place the panels 183 onto the load wheels...

Страница 225: ...truck if the steering system is damaged The truck can only be steered without its own drive system when it is stationary uDo not adjust the truck s steering angle during a recovery operation uWhen se...

Страница 226: ...eft as far as the stop and remove the key Press the red button on the ISM access module o Press the Emergency Disconnect 9 Open the drive compartment cover 95 see page 330 Set the drive wheel 31 to th...

Страница 227: ...ing angle has to be changed during a recovery operation this can only be performed when the truck is stationary see page 223 uOnly return the truck to service when you have identified and rectified th...

Страница 228: ...nd the recovered truck during a recovery operation Recover the truck carefully and slowly If the steering angle has to be changed during a recovery operation brake until the truck comes to a halt CAUT...

Страница 229: ...n on the ISM access module o Press the Emergency Disconnect 9 NOTICE Risk of damage from the tow rope During recovery route the tow ropes to the front in such a way as to avoid damaging the hydraulic...

Страница 230: ...eered without its own drive system when it is stationary see page 223 After recovery secure the truck to prevent it from moving see page 215 and see page 219 WARNING If the brakes are not working plac...

Страница 231: ...the red button on the ISM access module o Press the Emergency Disconnect 9 NOTICE Risk of damage from the tow rope During recovery route the tow ropes to the front in such a way as to avoid damaging t...

Страница 232: ...eered without its own drive system when it is stationary see page 223 After recovery secure the truck to prevent it from moving see page 215 and see page 219 WARNING If the brakes are not working plac...

Страница 233: ...ergency Disconnect 9 Open the drive compartment cover see page 330 NOTICE Risk of damage from the tow rope Do not route the tow rope 187 over the tailgate 188 as the tailgate 188 is not designed for r...

Страница 234: ...eered without its own drive system when it is stationary see page 223 After recovery secure the truck to prevent it from moving see page 215 and see page 219 WARNING If the brakes are not working plac...

Страница 235: ...m are required eye protection The laser scanner meets the requirements of standards CDRH 21 CFR 1030 10 and DIN EN 60825 2001 WARNING Caution exposure to hazardous radiation can result if the operatin...

Страница 236: ...er covered load handler lowered Crawl speed released when approaching the last pallet location at a closed narrow aisle end Automatic reduction of maximum speed to 2 5 km h before exiting the aisle Ad...

Страница 237: ...h lower cutout on detection of persons 7 3 Environmental awareness The safety laser scanner is designed to keep environmental damage to a minimum It uses minimal energy and resources Always act with r...

Страница 238: ...hing the front screen In addition damp clean the connecting lug at the bottom of the front screen Wipe the screen dry with a clean soft woollen cloth micro fibre cloth or a new soft paper towel CAUTIO...

Страница 239: ...ement object in protection field The truck stops Off Warning field clear no object in warning field The truck can move at the maximum speed setting Lit Warning field infringement object in warning fie...

Страница 240: ...pecialist service engineers The manufacturer has a service department specially trained for these tasks In order for customer services to react quickly and specifically to the fault the following info...

Страница 241: ...you to perform the cycle test During this time the travel speed is restricted to slow travel 2 5 km h uThe speed restriction is only removed when the cycle test has been performed Cycle test Procedure...

Страница 242: ...uck for operation see page 139 or see page 140 Drive the truck into the narrow aisle and establish automatic guidance see page 156 190 104 20 18 Obstacles and or persons in the PPS warning field The d...

Страница 243: ...stacle or person are no longer in the protection field Requirements Prepare the truck for operation see page 139 or see page 140 Drive the truck into the narrow aisle and establish automatic guidance...

Страница 244: ...ion field infringement However it does not release the operator from his responsibility to bring the truck to a halt in good time before it reaches any obstacles and or persons The personal protection...

Страница 245: ...retina if it comes into direct eye contact uDo not look into the laser beam 192 192 The laser beam rack compartment display indicates the correct position of the truck with respect to the rack compart...

Страница 246: ...working with the truck if people do not leave the hazardous area uThe truck must be prevented from being used by unauthorised people if people do not leave the hazardous area despite the warning uOnl...

Страница 247: ...ut traverse or lift lower movements with the load handler Stop working with the truck if people do not leave the hazardous area uThe truck must be prevented from being used by unauthorised people if p...

Страница 248: ...rn the truck to service when you have identified and rectified the fault Z Maintenance intervals are specified in the section Maintenance Inspection and Changing of Maintenance Parts Requiring Replace...

Страница 249: ...pic forks of the telescopic table to the left Turn the Hydraulic functions control lever 113 anti clockwise Z The traverse speed is in proportion to how far the Hydraulics function control lever 113 i...

Страница 250: ...aterial damage to the telescopic forks The telescopic forks must not be used to push or press loads Requirements Prepare the truck for operation see page 139 or see page 140 Procedure Do not press the...

Страница 251: ...elescopic table when choosing the telescopic forks An individual telescopic fork tine must not be chosen when the load on the two telescopic forks is overlapping i e when laden with a wire box uAlways...

Страница 252: ...escopic table to the right Turn the Hydraulic functions control lever 113 clockwise To traverse the selected telescopic fork of the telescopic table to the left Turn the Hydraulic functions control le...

Страница 253: ...Changing of Maintenance Parts Requiring Replacement see page 359 8 3 1 Fork sideshift o Requirements Prepare the truck for operation see page 139 or see page 140 Procedure Do not press the deadman bu...

Страница 254: ...on the button 104 under the Fork adjustment symbol 198 To reduce the fork spread Turn the Hydraulic functions control lever 113 clockwise To increase the fork spread Turn the Hydraulic functions contr...

Страница 255: ...for operation see page 139 or see page 140 Procedure Press 104 under the Fork adjustment sideshift menu change symbol 199 The display changes from the menu item Fork adjustment sideshift menu change 1...

Страница 256: ...nder the Fork adjustment symbol 198 To reduce the fork spread Turn the Hydraulic functions control lever 113 clockwise To increase the fork spread Turn the Hydraulic functions control lever 113 anti c...

Страница 257: ...chment daily for external signs of damage or defects Faulty attachments can cause the load to fall uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnl...

Страница 258: ...load greater than the weights specified on the capacity plate for completely extended telescopic forks is lifted extension of telescopic forks is disabled The Telescopic fork sideshift 201 symbol ligh...

Страница 259: ...n the weights specified on the capacity plate for completely extended telescopic forks is lifted extension of telescopic forks is disabled Retract the attachment left or right until the automatic stop...

Страница 260: ...Warnings sub menu item 203 appears in the driver s display Z Truck operations are inhibited in this menu Press the button 104 under the Warnings sub menu symbol 203 The Operator specific settings men...

Страница 261: ...he Select button 147 in the cursor field The Travel acceleration symbol appears in the driver s display see table below The operator can toggle between functions using the cursor keys 146 148 Cursor k...

Страница 262: ...in lift lower speed V Sideshift speed V Steering wheel transmission v CAUTION Altering travel parameters can cause accidents Increasing the settings for acceleration steering travel lifting and loweri...

Страница 263: ...n a pre defined area in the program Cursor key 156 strengthen the setting Cursor key 157 weaken the setting Press OK on the numerical keypad 112to save the settings 112 156 148 157 146 147 108 Leaving...

Страница 264: ...ttachment in home position without load Attachment in centre position without load Attachment in home position with load Attachment in centre position with load Lowering and lifting an attachment with...

Страница 265: ...or operation see page 139 or see page 140 Drive the truck into the narrow aisle and establish automatic guidance see page 156 Procedure Press the Select button 147 in the cursor field Using the numeri...

Страница 266: ...the first number entered is used as a multiple of ten the second as a unit position If an incorrect entry is made it can be deleted by pressing the CE button on the numerical keypad 112 Press OK on th...

Страница 267: ...dure Using the numerical keypad 112 enter the area 205 see page 263 Using the numerical keypad 112 enter the rack number 206 see page 264 Z Depending on the current lift height an arrow is shown on th...

Страница 268: ...ions control lever 113 anti clockwise Z If another rack is selected during the positioning process this is displayed for approx 1 second and stored in an intermediate log On reaching the current wareh...

Страница 269: ...cancelled by pressing the CE button on the numerical keypad or by pressing the EMERGENCY DISCONNECT switch To approach the Pre limit required height manually o The Hydraulic functions control lever 1...

Страница 270: ...ENCY DISCONNECT switch To approach the required height automatically o Select the travel direction with the direction switch Depress accelerator The nominal height is then approached automatically in...

Страница 271: ...load handler see page 168 Retract the load handler see page 174 The following stacking options are available for stacking operations Stacking procedure not active Press the deadman button 18 When the...

Страница 272: ...rminal is only issued when the attachment has abandoned and then returned to the home position During the positioning procedure another compartment can be entered This entry is shown for approx 1 sec...

Страница 273: ...if the Hydraulic functions control lever 113 is in neutral Z The hydraulic speeds are in proportion to the movement of the Hydraulic functions control lever 113 During the positioning procedure anothe...

Страница 274: ...er 113 clockwise and hold it down until the operation is complete Z The hydraulic speeds are fixed and cannot be influenced The hydraulic functions stop when the Hydraulics function control lever 113...

Страница 275: ...ons stop when the Hydraulics function control lever 113 is released The stacking operation continues when the Hydraulic functions control lever 113 is applied again Pressing one of the Attachment trav...

Страница 276: ...The following symbols appear in the driver s display for left stacking operations 112 113 120 18 119 274 04 19 en GB...

Страница 277: ...press the deadman button Hydraulic functions control lever 113 Clockwise turn Lift retrieve Anti clockwise turn Lower stack Do not press the deadman button Traverse attachment right to the home posit...

Страница 278: ...grammable warehouse conditions The setting is made by the manufacturer s customer service department To achieve constant insertion widths over the entire lift height ten height dependent traverse adju...

Страница 279: ...rtical position of the warehouse location entered is the height of the forks This ensures that the required pallet is stacked or retrieved The horizontal position of the warehouse location entered is...

Страница 280: ...218 219 223 222 224 225 221 220 211 212 213 214 Item Symbol Function Description 207 Truck in narrow aisle transponder recognised 208 The travel in drive direction symbol indicates that a horizontal...

Страница 281: ...ed 217 Rack row display only single digit entry allowed 218 Position mark display horizontal position in narrow aisle single double or three digit entries allowed 219 Rack height Rack display lift hei...

Страница 282: ...iage left warning symbols flash until the correct position is reached 212 213 217 Incorrect rack row entered with order Check entry The question mark and rack row symbols flash alternately 221 218 Inc...

Страница 283: ...Carry out the existing order Faulty data transmission The order is not accepted The error number is issued Data transmission not repeated despite error recognition NAK The order is not accepted The er...

Страница 284: ...a load on the forks Symbols in storage mode with attachment Symbol Function Attachment in home position without load with load Without load lower lift to reach the warehouse location With load lower l...

Страница 285: ...to reach the warehouse location With load lower lift to reach the warehouse location Without load traverse the telescopic forks to the left right With load traverse the telescopic forks to the left ri...

Страница 286: ...input via radio The destination is transmitted to the truck via radio Warehouse destination manual entry default setting Z The position of the symbols can be adapted to customer requirements The setti...

Страница 287: ...12 The entry in the location marker field 218 can be one two or three digits Press the cursor key 148 The background of the Rack height field 219 goes dark Enter the required rack height with the nume...

Страница 288: ...ored in the truck s memory In this case the order in memory symbol 215 is shown in the driver s display When the current order has been processed it is deleted from the driver s display and any order...

Страница 289: ...maximum of two orders can be stored in the truck s memory The destination scanned in first is shown on the driver s display as the current order The second destination scanned in is stored in the truc...

Страница 290: ...put via the radio terminal is now complete The destination can now be approached When the current order has been processed it is deleted from the driver s display Feedback is sent from the industrial...

Страница 291: ...in the drive direction when the Travel in drive direction symbol 208 is displayed Push the travel direction switch 105 left Travel in drive direction Slowly apply the accelerator pedal 20 Travel in th...

Страница 292: ...anti clockwise Z Continue to apply the Hydraulic functions control lever 113 until you reach the required height The vertical position of the warehouse location has now been reached The operator can...

Страница 293: ...vel direction switch 105 right Travel in load direction Slowly apply the accelerator pedal 20 The industrial truck begins automatic horizontal and vertical destination approach Z Truck movement can be...

Страница 294: ...ptionally with a weighing system When the load has been raised slightly with the Main Lift the weight is shown on the driver s display in kg 131 see page 168 NOTICE The weighing system is not a substi...

Страница 295: ...Hydraulic function control lever 113 for approx 10 cm Press the Quit sub menu button 108 Z Truck movement is inhibited in this truck menu The driver s display shows the Weigher display zero setting s...

Страница 296: ...irection 230 231 232 234 233 Using the camera system Press the button 234 on the monitor to switch the camera system on or off Press the button 233 to lighten or darken the screen day night settings P...

Страница 297: ...r her individual needs CAUTION Incorrect adjustment of the rear view mirror can cause accidents An incorrectly adjusted rear view mirror can collide with the rack or goods when operating in narrow ais...

Страница 298: ...travelling or lifting lowering Z Operate the work platform only at reduced travel hydraulic speeds WARNING The use of working platforms is governed by national law In some states the use of working p...

Страница 299: ...en the gate in emergencies 237 Grab handles two hand compulsion 238 Connecting cable between work platform and truck 239 Gate 240 Operator platform 241 Fork shoes 242 Work platform for the standard at...

Страница 300: ...k by the owner Procedure Check the work platform for damage before using it Check the lock 243 on the work platform is present and check for damage Close the gate 239 Z The work platform must be lifte...

Страница 301: ...Work platform raised securely symbol appears in the driver s display The raised and locked work platform is monitored by non contact sensors Slowly retract the forks and work platform back to the hom...

Страница 302: ...mage before using it Check the lock 243 on the work platform is present and check for damage Close the gate 239 Z The work platform must be lifted in such a way that at all times during travel lifting...

Страница 303: ...stop on the load handler 244 The work platform is prevented from falling The Work platform raised securely symbol appears in the driver s display The raised and locked work platform is monitored by n...

Страница 304: ...ely to your supervisor uTag out and decommission a faulty lift truck uOnly return the work platform to service when you have identified and rectified the fault WARNING Work platforms can be hazardous...

Страница 305: ...m to fall and injure people inside the work platform Objects falling out of the work platform can injure the operator of the truck or damage the truck uBefore operating the work platform make sure the...

Страница 306: ...ork platform gate 239 Step on the work platform Close the work platform gate 239 Z While the truck is in operation the work platform attachment and the closed gate 239 are permanently monitored Openin...

Страница 307: ...ile in a raised position uThe driver must never leave the truck while the work platform is in operation Destination reached The person in the work platform can start to work Leaving the work platform...

Страница 308: ...is clear of the ground Disconnect the work platform electrically from the truck Remove the connecting cable 238 and suspend it in the work platform Fully extend the attachment and work platform Lower...

Страница 309: ...clear of the ground Disconnect the work platform electrically from the truck Remove the connecting cable 238 and suspend it in the work platform Remove the physical lock 243 of the work platform from...

Страница 310: ...are forewarned of the approaching truck This avoids accidents when exiting the narrow aisle at interchanges and other warehouse areas with restricted visibility CAUTION Risk of accident due to restri...

Страница 311: ...e warning notice Caution Potentially dangerous optical radiation is present and legible and replace if necessary uDo not look directly into the light beam of the Floor Spot uWhen performing maintenanc...

Страница 312: ...8 13 2 List of assemblies for Floor Spot 247 248 Item Description 247 o Floor Spot in the load direction 248 o Floor Spot in the drive direction 310 04 19 en GB...

Страница 313: ...lling stationary Floor Spot 247 and Floor Spot 248 are switched off Truck travels in drive or load direction Truck travel function Function of the Floor Spot Truck travels in drive direction Floor Spo...

Страница 314: ...r Spot 248 is switched on Floor Spot 247 is switched off Truck travels in load direction Floor Spot 247 is switched on Floor Spot 248 is switched off Travel within narrow aisle narrow aisle with end o...

Страница 315: ...passes over the end of aisle safety device in the drive direction Floor Spot 248 is switched on Floor Spot 247 is switched off Guided truck passes over the end of aisle safety device in the load direc...

Страница 316: ...The use of inappropriate extinguishing agents can cause fire to spread and hence injure the operator uThe proprietor is responsible for choosing suitable extinguishing agents and fire extinguishers uT...

Страница 317: ...perating speeds of the truck must not be increased under any circumstances Exception Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer...

Страница 318: ...ufacturer for this truck may be installed near the computer controllers and wire guidance sensors antennae These components computers controllers wire guidance sensors antennae must therefore not be r...

Страница 319: ...the following target groups Operating company The maintenance personal of the operating company has the technical expertise and experience to perform the activities in the maintenance check list for...

Страница 320: ...uck only on a level surface and prevent it from moving accidentally uOnly use a jack with sufficient capacity When jacking up the truck take appropriate measures to prevent it from slipping or tipping...

Страница 321: ...er uDo not clean the electrical system with water uClean the electrical system with weak suction or compressed air use a compressor with a water trap and not a conductive anti static brush CAUTION Ris...

Страница 322: ...Electric currents can cause accidents Make sure the electrical system is voltage free before starting work on it The capacitors built into the controller must be completely discharged The capacitors...

Страница 323: ...environmental protection regulations To change the oil contact the manufacturer s customer service department who have been specially trained for this task uNote the safety regulations when handling...

Страница 324: ...ight at the same time Z When replacing wheels fitted at the factory only use the manufacturer s original spare parts Otherwise the truck s rated performance cannot be ensured Attachment Repairs and In...

Страница 325: ...rescribed containers uAlways fill consumables in clean containers uDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the operating instr...

Страница 326: ...ntact and digestion If you swallow oil do not induce vomiting but call for a doctor immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has come into contact with your skin rin...

Страница 327: ...Lubrication Schedule Z Details of the correct lubricant to be used are given in the lubricant chart see page 327 Outer mast Grease nipple Centre mast Load handler Inner mast Load handler 325 04 19 en...

Страница 328: ...F F C E E A C D D E C B C C C g Contact surfaces c Hydraulic oil drain plug s Grease nipple b Transmission oil filler neck Hydraulic oil filler neck a Transmission oil drain plug 326 04 19 en GB...

Страница 329: ...s E 50 002 004 400 ml Contact spray grease Running surfaces F 51 085 365 500 ml All purpose cleaner Laser scanner of personal protection system PPS 51 085 537 1 unit Cleaning cloth Add a 2 content of...

Страница 330: ...Preparing the truck for maintenance and repairs 9 8 18 20 19 15 14 16 All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs The following preparation...

Страница 331: ...tched on accidentally When working under a raised lift truck secure it to prevent it from lowering tipping or sliding away WARNING Risk of accidents when working under the load handler driver s cab an...

Страница 332: ...er Requirements Prepare the truck for maintenance and repairs see page 328 Tools and Material Required Allen key key width 5 to undo the screws 94 Procedure Remove both screws 94 using the Allen key k...

Страница 333: ...ver and the truck when you close the cover Carefully close the drive compartment cover 95 CAUTION Open covers can cause injury and accidents uThe covers battery cover side panels drive compartment cov...

Страница 334: ...ruck securely see page 180 uPress the Emergency Disconnect uDisconnect the battery uRemove any rings or metal bracelets etc before working on electrical components CAUTION The use of incorrect fuses c...

Страница 335: ...ntroller 259 Pull the fuses 252 258 and their brackets out of the controller 259 Check the fuses 252 258 in accordance with the following table and replace as required Insert the fuses 252 258 and the...

Страница 336: ...dio terminal etc 10 A 254 F1 2 Control panel and horn control fuse 10 A 255 5F1 Overhead guard control fuse e g work lights operator position lighting fan etc 10 A 256 F2 1 Internal DC DC converter co...

Страница 337: ...Load circuit Controller active Display status when truck is switched on When the truck is switched on the displays indicated grey are lit green If one of the displays A1 A3 A4 A5 B2 B3 B4 is not lit r...

Страница 338: ...68 Tools and Material Required Allen key key width 22 to undo or tighten the screw 264 of the fastening bolt 263 Procedure Raise the load handler until the inner mast 261 is above the bracket 262 see...

Страница 339: ...the lowering valve see page 201 Turn the lowering valve clockwise as far as it will go Close the drive compartment cover see page 330 The load handler is now protected against accidental lowering Mai...

Страница 340: ...ed load handler driver s cab Raise the load handler until the inner mast 261 is no longer resting on the bracket 262 see page 168 Z If the Lift cutout symbol 153 appears as the load handler is being r...

Страница 341: ...nothing between the battery cover and the truck when you close the battery cover Close the battery cover see page 78 Turn the EMERGENCY DISCONNECT switch 9 to unlock it Switch on the truck to do this...

Страница 342: ...for a doctor uWear personal protective equipment e g safety boots hi vis jacket goggles work gloves etc when working with solvents Z The intervals stated in the service checklist apply to normal duty...

Страница 343: ...ial truck uNever reach or climb into moving truck parts uNever stand underneath a raised load handler Position the working platform lifting stage or safety ladder directly next to the industrial truck...

Страница 344: ...t chains Replace a chain immediately if it shows external signs of damage Damage will result in permanent breakage and hence tearing of the lift chain uReport any defects immediately to your superviso...

Страница 345: ...wo chains uWhen replacing chains the connecting bolts between the chain anchor and the chain must be replaced uAlways use new original parts uLift chains must only be replaced by the manufacturer s cu...

Страница 346: ...ure must be disposed of in accordance with regulations WARNING Faulty hydraulic hoses can result in injury and infection Pressurised hydraulic oil can escape from fine holes or hairline cracks in the...

Страница 347: ...eplace if necessary uIf the operating conditions become more arduous the inspection intervals must be reduced accordingly uIn normal operating conditions a precautionary replacement of the hydraulic h...

Страница 348: ...t be disposed of in accordance with regulations uObserve national regulations when handling hydraulic oil uWear safety gloves when handling hydraulic oil uPrevent hydraulic oil from coming into contac...

Страница 349: ...spilled hydraulic immediately with an appropriate bonding agent uThe bonding agent consumable mixture must be disposed of in accordance with regulations CAUTION Consumables and used parts are an envi...

Страница 350: ...267 WARNING Overfilling the hydraulic reservoir can result in accidents and damage the environment The hydraulic oil should not be above the MAX marking on the dipstick as any escaping oil can damage...

Страница 351: ...ing notice on the hydraulic reservoir Add hydraulic oil In this case you may only use hydraulic oil HLP D22 including 2 share of Additiv 68 ID to fill the hydraulic reservoir WARNING You cannot change...

Страница 352: ...access module and depending on the setting press the green button on the ISM access module o WARNING After cleaning or maintenance work test all the safety mechanisms to ensure they are working corre...

Страница 353: ...rt any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault Test the service and park...

Страница 354: ...lows uJack up the truck only on a level surface and prevent it from moving accidentally uOnly use a jack with sufficient capacity When jacking up the truck take appropriate measures to prevent it from...

Страница 355: ...you have identified and rectified the fault Test the brakes Check the hydraulic oil level and replenish if necessary see page 346 Apply a thin layer of oil or grease to any non painted mechanical com...

Страница 356: ...discharge can damage the battery Self discharge can cause the battery to fully discharge Full discharge shortens the useful life of the battery uCharge the battery at least every 2 months Z Charge th...

Страница 357: ...and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault Start up the truck see page 124 Z If there are switching problems in the electri...

Страница 358: ...inspector The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose A complete test must be carried out on the technical condition of t...

Страница 359: ...rained personnel in accordance with the procedures as specified by the manufacturer 8 Human vibration measurement Z Vibrations that affect the operator over the course of the day are known as human vi...

Страница 360: ...358 04 19 en GB...

Страница 361: ...uck have a considerable impact on component wear The following service inspection and replacement intervals are based on single shift operation under normal operating conditions The intervals must be...

Страница 362: ...ce a week 1 1 1 Maintenance contents 1 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains Clean the running faces in the mast sections and a...

Страница 363: ...aisle recognition Load sensing Hydraulic operations Clean the sensors Telescopic table Hydraulic operations Clean and lubricate the attachment Swivel traverse frame Hydraulic operations Clean and lub...

Страница 364: ...ery components for damage The function and secure seating of the battery connector and for damage Travel Wheels for wear and damage Chassis structure Industrial truck for damage and leaks Labels are l...

Страница 365: ...tructure Supports tilt safety devices are present and for damage Restraint system Chassis structure The function of the driver s seat restraint system and for damage Optional equipment Chassis structu...

Страница 366: ...acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead acid battery Power supply Battery cable connections are secure 364 04 19 en...

Страница 367: ...Electrical system Note All safety components encoder laser scanner Flexisoft safety PLC and relays must be replaced after 240 months Test the contactors and or relays Carry out a chassis insulation re...

Страница 368: ...ecessary traversing rotating speeds for the correct value Agreed services Carry out a test run with the rated load or a customer specific load Clean the motor housing of the travel and lift motor Demo...

Страница 369: ...nents Test the Personal Protection System Clean the front screens of the PPS laser scanner Test the warning and protective field areas of the Personal Protection System Rail guidance Electrical system...

Страница 370: ...and or light switch for aisle recognition Load sensing Hydraulic operations Clean the sensors Test the sensors 2nd stacking depth System components Test function and settings W S lowering cut off Trav...

Страница 371: ...upport columns Tilt safety devices Chassis structure Measure the height related and capacity related settings Swivel traverse frame Hydraulic operations Adjust eccentric bolts on the swivel traverse f...

Страница 372: ...ion System e g to ensure it is cut off by the activation frequency Lead acid battery international Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and ba...

Страница 373: ...the combined control unit and for damage Electrostatic discharge strap or chain is present and for damage Power supply The function of the battery latch and battery attachment and for damage The funct...

Страница 374: ...leaks and damage Lateral play of the mast sections and fork carriage The presence of the stops and for wear and damage Load chain mounting elements and chain pins for wear and damage Mast rollers and...

Страница 375: ...uidance Travel The fastening of the rail guidance The rail guidance and their bearings for wear and damage Battery refill system Power supply The function of the battery refill system and for leaks Fo...

Страница 376: ...of the attachment to the truck and the load bearing components for secure fit and damage Aisle recognition System components The function of the aisle recognition magnetic switch and or light button a...

Страница 377: ...le Electrical system Access module is secure and functions correctly and for damage Telescopic table Hydraulic operations Attachment bearings guides and stops for wear and damage Proper securing of th...

Страница 378: ...Electrical optional equipment Electrical system The function of the optional electrical equipment and for damage Restraint system Chassis structure The function of the driver s seat restraint system a...

Страница 379: ...and for damage The mains plug and mains cable for damage The current collectors and bus bar feed for damage The secure seating of the cables and electrical connections and for damage Lead acid batter...

Страница 380: ...arts at the specified intervals 1 2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic oil additive 2000 12 Hydraulic system breather filter 2000 12 Hydraulic...

Страница 381: ...cts of the equipment No guarantee of particular features of the traction battery should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instruction...

Страница 382: ...EN 4 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinric...

Страница 383: ...ed cells 17 5 1 Description 17 5 2 Operation 18 5 3 Servicing PzV and PzV BS lead acid batteries with sealed armour plated cells 21 6 Aquamatik water replenishment system 22 6 1 Water replenishment sy...

Страница 384: ...02 16 EN 6...

Страница 385: ...g with the battery or using electrolyte additives will invalidate the warranty Observe the instructions for maintaining the safety rating during operation for batteries in accordance with Ex I and Ex...

Страница 386: ...02 16 EN 8 14 Safety instructions and warning information...

Страница 387: ...ng Keep away from naked flames and strong heat sources Always wear protective clothing e g safety goggles and safety gloves when working on cells and batteries Always wash your hands after completing...

Страница 388: ...crease the electrolyte density The corresponding adjustment factor is 0 0007 kg l per K e g electrolyte density 1 28 kg l at 45 C corresponds to a density of 1 29 kg l at 30 C The electrolyte must com...

Страница 389: ...e current C5 5h 5 Nominal electrolyte density1 1 Reached within the first 10 cycles 1 29 kg l 6 Nominal temperature2 2 Higher temperatures shorten the useful life lower temperatures reduce the availab...

Страница 390: ...ive to negative and check that contacts on the battery terminal conducting system are secure Check the M10 terminal screws of the conductors and connectors are secure and if necessary torque to 23 1 N...

Страница 391: ...ed to the battery in terms of voltage charge capacity and battery technology Before charging check all cables and plug connections for visible signs of damage Ventilate the room in which the truck is...

Страница 392: ...charger ensuring the terminals are connect positive to positive and negative to negative Switch on the charger The battery is charged Z Charging is considered to be complete when the electrolyte densi...

Страница 393: ...suitable for the production of electrolyte 4 3 2 Daily Charge the battery after each discharge After charging check the electrolyte level of each battery cell and replenish as required Open the plug 1...

Страница 394: ...electrolyte density and the electrolyte temperature in all the cells Compare the results with the previous ones Z If you find significant differences compared with the previous measurements or differ...

Страница 395: ...lectrolyte is sulphuric acid which is fixed in gel The density of the electrolyte cannot be measured 5 1 1 Battery nominal data Name Explanation PzV Lead acid battery with Standard closed armour plate...

Страница 396: ...ging can cause explosions The battery gives off a mixture of oxygen and hydrogen electrolytic gas during charging Gassing is a chemical process This gas mixture is highly explosive and must not be ign...

Страница 397: ...tery cell Always charge the battery with DC current All DIN 41773 charging procedures are permitted in the format approved by the manufacturer Always connect the battery to a charger that is appropria...

Страница 398: ...with 0 004 V C per C The battery is charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compen...

Страница 399: ...ous ones Z Carry out the measurements after full charging and subsequent resting for at least 5 hours Z If you find significant differences compared with the previous measurements or differences betwe...

Страница 400: ...k water replenishment system 6 1 Water replenishment system design 18 Water container 19 Tap connection with ball cock 20 Flow indicator 21 Shut off cock 22 Locking coupling 23 Battery lock connector...

Страница 401: ...securely The plug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port 6 3 Adding water Water should be added to the batter...

Страница 402: ...ubing of the individual plugs is in accordance with the existing electric circuit No changes should be made 6 8 Operating temperature Batteries with automatic water replenishment systems should only b...

Страница 403: ...be checked and replaced if necessary Battery connection A hose is attached to the pump module which together with the charge leads is routed from the charger to the charging connector The air is pass...

Страница 404: ...ed to severe temperature fluctuations the electrolyte may flow back into the hose system Attach a separate coupling system to the air inlet line such as locking coupling to the battery side and throug...

Страница 405: ...lose to a drainage system for processing the electrolytic rinsing water All health and safety as well as water and waste disposal regulations are observed when disposing of used electrolyte or rinsing...

Страница 406: ...t the temperature does not exceed 60 C at a distance of 30cm behind the outlet nozzle Observe the maximum operating pressure of 50 bar Observe a minimum distance of 30 cm from the top of the battery T...

Страница 407: ...cells for PzV batteries If the battery is to be taken out of service for a long period 3 months it should as far as possible be charged to 50 of its charge level and stored in a dry room protected fr...

Страница 408: ......

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