Electric Stacker PS15 Electric Stacker PS20 INSTRUCTION HANDBOOK Electric Stacker WARNING Do not use the electric truck before reading and understanding these operating instructions. NOTE: Please check the designation of your present type at the last page of this document as well as on the ID-plate. Keep for future reference. Version 03/2014 PS 15-SMS-002-EN 1 FOREWORD Before operating the electric stacker, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation could create danger. This handbook describes the usage of different electric stackers. When operating and servicing the truck, make sure, that it applies to your type. Chapter 11 describes specialized stipulations and regulations for the American market. Follow these instructions and stipulations if you operate the truck within the American market! Keep this handbook for future reference. If this or the warning/ caution labels are damaged or got lost, please contact your local dealer for replacement. This truck complies with the requirements according to EN 3691-1 (Industrial trucks- safety requirements and verification, part 1), EN 12895 (Industrial trucks- electromagnetic compatibility), EN 12053 (Safety of industrial trucks- test methods for measuring noise emissions), EN 1175 (Industrial truck safety – electrical requirements), assumed the truck is used according to the described purpose. The noise level for this machine is 70 dB(A) according to EN 12053. The vibration is 0,85 m/s2 (if equipped with a platform) according to EN 13059. ATTENTION: Environmentally hazardous waste, such as batteries, oil and electronics, will have a negative effect on the environment, or health, if handled incorrectly. The waste packages should be sorted and put into solid dustbins according to the materials and be collected disposal by local special environment protection bureau. To avoid pollution, it’s forbidden to throw away the wastes randomly. To avoid leaking during the use of the products, the user should prepare some absorbable materials (scraps of wooden or dry duster cloth) to absorb the leaking oil in time. To avoid second pollution to the environment, the used absorbable materials should be handed in to special departments in terms of local authorities. Our products are subject to ongoing developments. Because this handbook is only for the purpose of operating /servicing the stacker, therefore please have understanding, that there is no guarantee out of particular features out of this handbook. NOTE: On this manual, the left sign means warning and danger, which can lead to death or serious injury if not followed. Copyright The copyright remains with the company, mentioned on the CE- certificate at the end of this document or, if sold within the USA, with the company, mentioned on the company sticker. 2 3 TABLE OF CONTENTS 1. 2. CORRECT APPLICATION ............................................................................................5 DESCRIPTION OF THE STACKER ..............................................................................6 a. Overview of the main components.............................................................................6 b. Main technical data ....................................................................................................7 c. Description of the safety devices and warning labels (Europe and other, excepting USA) .................................................................................................................................8 d. Identification plate ......................................................................................................9 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS ..................................9 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING ....................................10 a. Commissioning ........................................................................................................10 b. Lifting/ transportation................................................................................................10 c. Decommissioning..................................................................................................... 11 5. DAILY INSPECTION ................................................................................................... 11 6. OPERATING INSTRUCTIONS ...................................................................................12 a. Parking.....................................................................................................................12 b. Residual lift diagram.................................................................................................12 c. Lifting .......................................................................................................................12 d. Lowering ..................................................................................................................13 e. Travelling .................................................................................................................13 f. Steering....................................................................................................................14 g. Braking.....................................................................................................................14 h. Malfunctions.............................................................................................................15 i. Emergency...............................................................................................................15 7. BATTERY CHARGING AND REPLACEMENT ...........................................................15 a. Replacement............................................................................................................16 b. Battery Indicator.......................................................................................................16 c. Charging ..................................................................................................................16 8. REGULAR MAINTENANCE........................................................................................17 a. Maintenance checklist..............................................................................................17 b. Lubricating points .....................................................................................................19 c. Check and refill hydraulic oil ....................................................................................19 d. Checking electrical fuses .........................................................................................19 e. Removing, reattaching guarding ..............................................................................20 9. TROUBLE SHOOTING ...............................................................................................20 10. WIRING/ CIRCUIT DIAGRAM.....................................................................................22 a. Electrical circuit diagram ..........................................................................................22 b. Hydraulic circuit........................................................................................................23 11. SPECIALIZED STIPULATIONS FOR THE US- AMERICAN MARKET .......................24 a. Foreword/ Compliance .............................................................................................24 b. Description warning labels (only US- market) ..........................................................25 c. Technical data for US market ...................................................................................28 12. DECLARATION OF CONFORMITY (valid, if sold within the EU)................................30 4 1. CORRECT APPLICATION It is only allowed to use this electric stacker according to this instruction handbook. The trucks described in this handbook are self propelled pedestrian controlled electric power stacker, with electrically powered low height lifting function. The trucks are designed for stacking operations in dedicated racking by lifting and lowering the palletized load up to the desired lifting height. A wrong usage can cause human injuries or can damage equipment. The operator/ the operating company has to ensure the correct usage and has to ensure, that this truck is used only by staff, which is trained and authorized to use this truck. The truck has to be used on substantially firm, smooth, prepared, level and adequate surfaces. The truck is intended to be used for indoor applications with ambient temperatures between +5C and + 40C and for intensive operations without crossing permanent obstacles or potholes. Operating on ramps is not allowed. While operating, the load must be placed approximately on the longitudinal centre plane of the stacker. Lifting or transporting people is forbidden. If travelling the load must be lowered to the lifting point. It is not allowed to use this truck on tail lifts or loading ramps. The capacity is marked on the load diagram as well on the Identification plate. The operator has to consider the warnings and safety instructions. Operating lighting must be minimum 50 Lux. Modification No modifications or alterations to this truck which may affect, for example, capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof. This includes changes affecting, for example braking, steering, visibility and the addition of removable attachments. When the manufacturer or its successor approve a modification or alteration, they shall also make and approve appropriate changes to capacity plate, decals, tags and operation and maintenance handbooks. By not observing these instructions, the warranty becomes void. 5 2. DESCRIPTION OF THE STACKER a. Overview of the main components Fig. 1: Overview main components 1. Foldable platform 2. Main cover 3. Protective arm cover 4. Protective arms 5. Upper cover 6. Tiller 7. Safety (belly) button 8. Accelerator (butterfly button) 9. Middle cover 10. Battery cover 11. Emergency button 12. Discharge indicator and charging indicating LED 13. Key switch 14. Load wheels 15. Forks 16. Load backrest 17. Protective board 18. Protective board seat 19. Mast 20. Pallet 21. Chassis 6 b. Main technical data Fig. 2: Technical data Dimensions Tires, chassis Weig ht Distinguishing mark Table1: Main technical data for standard version Type sheet for industrial truck acc. to VDI 2198 1.2 1.3 1.4 1.5 1.6 1.8 1.9 2.1 2.2 2.3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.2 4.3 4.4 4.5 4.9 4.15 4.19 4.20 4.21 4.22 Manufacturer`s type designation Power (battery ,diesel, petrol, gas, manual) Operator type Load Capacity / rated load Load centre distance Load distance ,centre of drive axle to fork Wheelbase Service weight Axle loading, laden front/rear Axle loading, unladen front/rear Tires Tire size, front Tire size, rear Additional wheels(dimensions) Wheels, number front/rear(x=driven wheels) Tread, front Tread, rear Lowered mast height Free lift height Lift Extended mast height Height of tiller in drive position min./ max. Height, lowered Overall length Length to face of forks Overall width Fork dimensions 7 Q (t) C (mm) X (mm) Y(mm) kg kg kg xw xw xw b10 (mm) b11 (mm) h1 (mm) h2 (mm) h3 (mm) h4 (mm) h14 (mm) h13 (mm) l1 (mm) l2 (mm) b1 (mm) s/e/l (mm) PS 15 Battery Pedestrian 1.5 600 765 1519 1596 1345/1663 955/553 Polyurethane (PU) 230×75 80× 70 124x60 1x+2/4 750 390/505 2220 1660 4915 5520 1370/945 85 2180 1030 1000 60/180/1150 Performa nce data Electricengine Additiona l data 4.25 4.32 4.33 4.34 4.35 5.1 5.2 5.3 5.8 5.10 6.1 6.2 6.3 6.4 6.5 6.6 8.1 8.4 Distance between fork- arms Ground clearance, centre of wheelbase Aisle width for pallets 1000X1200 lengthways Aisle width for pallets 800X1200 lengthways Turning radius Travel speed, laden/unladen Lift speed, laden/ unladen Lowering speed, laden/ unladen Max. gradeability performance, laden/ unladen Service brake Drive motor rating S2 60min Lift motor rating at S3 15% Battery acc. to DIN 43531/35/36 A, B, C, no Battery voltage, nominal capacity K5 Battery weight Energy consumption acc. to VDI cycle Type of drive control Sound level at driver’s ear according to EN 12053 b5 (mm) m2 (mm) Ast (mm) Ast (mm) Wa (mm) Km/h m/s m/s % kW kW V/Ah kg kWh/h dB(A) 570/685 25 2645 2592 1806 6.0/6.0 0.141/0.212 0.227/0.178 6/12 Electromagnetic 1.3 3.0 B,3PzS 24/ 350 288 2.1 AC- speed control 69 c. Description of the safety devices and warning labels (Europe and other, excepting USA) For the USA –market, the description of the safety and warning labels is mentioned in chapter 11. A B C E F G L Crane hook label Warning decal: Do not step under or on the forks Residual lift capacity sticker Never reach through Identification plate (ID-plate) Sticker to read and follow these instructions Sign of filling point The truck has an emergency button (11) which stops all lifting-, lowering-, driving- functions and engages the failsafe electromagnetic brake when it （only without platform） is pushed. By pulling this button, the truck can be （inside） operated after the controller checked the functions. Before operating, insert the key and turn the switch Fig.3: Safety and warning labels (13) clockwise. To prevent against unauthorized access, turn the key anti-clockwise and remove it, if you not operate this truck. The truck is equipped with a safety (belly) button (7) which switches the driving function away from the operator, if the truck travels towards the operator and the tiller is activated in the tillers operating zone. Follow also the instructions given on the decals. Replace the decals if they are damaged or missing. 8 d. Identification plate 1 2 3 4 5 6 Designation, type Serial number Rated capacity in kg Supply voltage in V Own mass (self weight) in kg without battery Name and address of manufacturer) 7 Battery weight minimum/ maximum 8 Nominal power in kW 9 Load center distance 10 Manufacturing data 11 Option 1 2 3 11 4 10 5 9 8 7 6 Fig. 4: Identification plate If sold to the EU, here the place of the CE marking 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS DO NOT Drive outside the stacking operation with a lifted load higher than the lifting point. Put foot or hand under or into the lifting mechanism. Allow other person than the operator to stand in front of or behind the truck when it is moving or lifting/lowering. Overload the truck. Put foot in front of the wheels, injury could result. Lift people. People could fall down and suffer severe injury. Push or pull loads. Use this truck on ramps. Use the truck without a removed protective screen (fig.1, pos. 17/ guarding). Side or end load. Load must be distributed evenly on the forks. Use the truck with unstable, unbalanced not stable load. Use truck without manufacturer’s written consent. Lifted loads could become unstable at wind forces. In the case of wind forces do not lift the load if there is any influence to the stability 9 Watch difference in floor levels when driving. Load could fall down or the truck could get uncontrollable. Keep watching the condition of load. Stop operating the truck if load becomes unstable. Brake the truck and activate the emergency button (11) by pushing when sliding load on or off the truck. If the truck has any malfunctions, follow chapter 8. Practice maintenance work according to regular inspection. This truck is not designed to be water resistant. Use the truck under dry condition. Prolonged continuous operation might cause damage of the power pack. Stop operation if temperature of hydraulic oil is too high. When operating the truck, the operator has to wear safety shoes. The truck is intended to be used for indoor applications with ambient temperatures between +5C and + 40C. The operating lighting must be minimum 50 Lux. It is not allowed to use the truck on ramps. To prevent unintended sudden movements when not operating the truck (i.e. from another person, etc.) switch off the truck and remove the key. 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. Commissioning Table 2: Commissioning data Type PS 15 / 5000 Commissioning weight [kg] 1626 Version/ Lift [mm] 5000 After receiving our new truck or for re-commissioning you have to do following before (firstly) operating the truck: Check if are all parts included and not damaged Eventually installation and charging the batteries (follow chapter 7) Do the work according to the daily inspections as well as functional checks. b. Lifting/ transportation For transporting, remove the load, lower the forks to the lowest position and fix the truck safe with dedicated lifting gear according to the following figures. Lifting Fig.5: Lifting with a crane USE DEDICATED CRANE AND LIFTING EQUIPMENT DO NOT STAND UNDER THE SWAYING LOAD DO NOT WALK INTO THE HAZARDOUS AREA DURING LIFTING 10 Lower the forks and park the truck securely. Fasten the truck according to fig.6 by fixing dedicated lashing belts to each side of the truck’s crane hook holes and fasten the other side at the transporting truck. Transportation DURING TRANSPORTATION ON A LORRY OR TRUCK ALWAYS FASTEN THE TRUCK SECURELY Lower the forks and park the truck on the iron plate securely. Fixe the forks by the iron sheet with two screws. Fasten the truck by fixing dedicated lashing belts according to fig. 6 and fasten the other side at the transporting truck. Fig. 6: Fixing points c. Decommissioning For storage, remove the load, lower the truck to the lowest position, grease all in this handbook mentioned greasing points (regular inspection), eventual protect the truck against corrosion and dust. Remove the batteries and jack the truck safely, so that there will be no flattening after storage. For final decommissioning hand the truck to a designated recycling company. Oil, batteries and electric components must be recycled due to legal regulations. 5. DAILY INSPECTION This chapter describes pre-shift checks before putting the truck into operation. Daily inspection is effective to find the malfunction or fault on this truck. Check the truck on the following points before operation. Remove load from truck and lower the forks. DO NOT USE THE TRUCK IF ANY MALFUNCTION IS FOUND. Check for scratches, deformation or cracks. Check if there is any oil leakage from the cylinder. Check the vertical creep of the truck. Check the chain and rollers for damages or corrosion. Check the smooth movement of the wheels. Check the function of the emergency brake by activating the emergency button. Check, the tiller arm- switch braking function Check the lifting and lowering functions by operating the buttons. Check if the protective screen has no damages and that is correctly assembled. Check the audio warning signal. Check if all bolts and nuts are tightened firmly. 11 Check the function of the key switch. Check the speed limitation switch. Visual check if there are any broken hoses or broken electric wires. If supplied with a backrest extension, check it for damages and correct assembling. 7 6. OPERATING INSTRUCTIONS 8 BEFORE OPERATING THIS TRUCK, PLEASE FOLLOW THE WARNINGS AND SAFETY INSTRUCTIONS (CHAPTER 3). BEFORE OPERATING THIS TRUCK, ENSURE THAT THE LOAD OR OTHER EQUIPMENT NOT CAUSES INSUFFICIENT VISIBILITY! 22 23 Make sure, that the load is palletized and stable and that Fig.7: Tiller operating controls the daily inspection is carried out. For starting, insert the key and turn it clockwise to the “ON”- position. Eventually before inserting the key switch (13), the emergency button (11) must be pulled carefully. Press the horn button (22) to activate the audible warning signal. a. Parking DO NOT PARK THE TRUCK ON INCLINED SURFACES Fig.8: Key switch The truck is equipped with an electromagnetic failsafe stopping and parking brake. Always lower the forks fully and drive the truck to a safe area. Turn the key anti- clockwise to the “Off” – position and remove the key. b. Residual lift diagram The residual lift diagram indicates the maximum capacity Q [kg] for a given load centre c [mm] and the corresponding lift height H [mm] for the truck with horizontal load. The white markings on the mast indicate if the specific lifting limits reached. For instance with a load centre of gravity distance c of 600 mm and a maximum lift height H of 5000 mm, the max. capacity Q is 750 kg. Fig. 9: Residual lift diagram c. Lifting DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 1500 kg. LIFT ONLY CAPACITIES ACCORDING TO THE RESIDUAL LIFT DIAGRAM. 12 Travel with the lowered forks fully underneath the pallet and press the lifting button (fig. 7, 22) until you reached the desired lifting height. d. Lowering If the forks are in the racking, firstly travel out of the racking carefully with or without the pallet. By travelling out of the racking, take care that the forks are not touching the racking. Press the lowering button (fig. 7, 23) carefully. Lower the load until the forks are clear of the pallet, then drive the truck carefully out of the load unit. e. Travelling TRAVEL ON INCLINES ONLY WITH THE LOAD FACING UPHILL. DO NOT TRAVEL ON INCLINES MORE THAN SPECIFIED WITH THE TECHNICAL DATA. TRAVELLING IS ONLY ALLOWED IF THE FORKS ARE LOWERED DOWN TO THE LIFTING POINT (<300MM). Fig.11: Operating direction After starting the truck by turning the inserted key to the “ON”- position (fig. 8),; and eventually by pulling the emergency button carefully, move the tiller to the operating zone (‘F’, fig.11). Turn the accelerator button to the desired direction forward ‘Fw.’ Or backwards ‘Bw.’(fig. 11). Control the travelling speed by moving the accelerator button (8) carefully until you reached the desired speed. If you move the accelerator button back to the neutral position, the controller decelerates the truck until the truck stops. If the truck stopped, the parking brake will be engaged. 13 Drive carefully the truck to the destination. Watch the route conditions and adjust the travelling speed with the accelerator- button. THE TRUCK CAN BE EQUIPPED OPTIONAL WITH A FOLDABLE PLATFORM AND SIDEWAYS PROTECTIVE ARMS. PAY ATTENTION, THE BEHAVIOR FOR THE RIDE ON MODE IS DIFFERENT TO THE PEDESTRIAN MODE. Besides the pedestrian mode, following travelling modes can be used: Travelling with platform (1) folded downside and sideways arms (4) in protective position Travelling with maximum speed. Travelling with platform (1) folded downside and sideways arms (4) folded downside Depending on the Controllers parameter setting, the speed might be lower, but not higher than 6km/h. Travelling with platform (1) folded upright and sideways arms (4) folded downside Depending on the Controllers parameter setting, the speed might be lower, but not higher than 6km/h. f. Steering OPTIONAL THE TRUCK CAN BE EQUIPPED WITH AN ELECTRIC STEERING SYSTEM. TAKE CARE BY OPERATING A TRUCK WITH THIS KIND OF SYSTEM; THE BEHAVIOR OF THE TRUCK MIGHT BE DIFFERENT THAN TO A TRUCK WITHOUT ELECTRIC STEERING SYSTEM. You steer the truck by moving the tiller to the left or right side. g. Braking THE BRAKING PERFORMANCE DEPENDS ON THE TRACK CONDITONS AND THE LOAD CONDITONS OF THE TRUCK The braking function can be activated on several ways: By moving the accelerator button (8) back to the initial ‘0’ position or by releasing the button, the regenerative braking is activated. The truck brakes until it stops. By moving the accelerator button (8) from one driving direction directly to the opposite direction, the truck brakes regenerative until it starts travelling into the opposite direction. The truck brakes, if the tiller is moved up or down to the braking zones (‘B’). If the tiller is released, the tiller moves automatically up to the upper baking zone (‘B’). The truck brakes until it stops. The safety (belly) button (7) prevents the operator from being crushed. If this button is activated, the truck decelerates and/ or starts travelling into the backwards direction (‘Bw.’) for a short distance and stops. Please consider, that this button also operates, if the truck is not travelling and the tiller is 14 in the operating zone. h. Malfunctions If there are any malfunctions or the truck is inoperative, please stop using the truck and activate the emergency button (6) by pushing it. If possible, park the truck on a safe area, turn the key switch (4) anticlockwise and remove the key. Inform immediately the manager and, or call your service. If necessary, tow the truck out of the operating area by using dedicated towing/ lifting equipment. i. Emergency In emergencies or in the event of tip over (or off dock), keep safe distance immediately. If possible push the emergency button (6). All electrical functions will be stopped. 7. BATTERY CHARGING AND REPLACEMENT Only qualified personnel are allowed to service or charge the batteries. The instructions of this handbook and from the battery- manufacturer must be observed. The batteries are liquid acid traction batteries. Optional maintenance free batteries are available; for these batteries re- filling is prohibited. Recycling of batteries undergoes national regulations. Please follow these regulations. By handling batteries, open fire is prohibited, gases could cause explosion! In the area of battery charging neither burning materials nor burning liquids are allowed. Smoking is prohibited and the area must be ventilated. Park the truck securely before starting charging or installing/changing the batteries Before finishing the maintenance work, make sure, that all cables are connected correctly and that there are no disturbing towards other components of the truck. Depending on the version, the truck is equipped with following liquid acid traction battery- type: 1 pc (LxWxH)] 3PzS 24V/ 350 Ah (C5) [624x284x627 IT IS ONLY ALLOWED TO USE LIQUID ACID TRACTION BATTERIES. THE WEIGHT OF THE BATTERIES HAS AN INFLUENCE TO THE TRUCKS OPERATING BEHAVIOR. PLEASE CONSIDER THE MAXIMUM OPERATING TEMPERATURE OF THE BATTERIES. Fig. 12: battery replacement 15 a. Replacement Park the truck securely and switch off the stacker with the key (13) and activate the emergency button (11). Open the battery cover and pull out the hinge. Then remove the battery cover, unscrew and remove the battery fixing plate, pull out the battery plug (Fig.14), and take the batteries out with a crane. The installation is in the reverse order of the removal. Please connect the positive terminals firstly. Otherwise the tuck could be damaged. b. Battery Indicator The discharge status is indicated by ten red LED segments. Battery discharged Battery charged Fig.13: Battery discharge indicator Only when the battery is properly charged, the most right LED lit. As the battery’s state-of-charge decreases, successive LEDs light up, only one on at a time. The 2nd from left LED flashes, indicating “energy reserve” (70% depth of discharge). The 2 most left LEDs alternately flash, indicating “empty” (80% depth of discharge). c. Charging Before charging ensure that you are using an appropriate charger for charging the installed battery! Before using the charger, please fully understand the instructions of the charger instructions. Always follow these instructions! The room, where you are charging must be ventilated. Battery The exactly charge status can be only checked plug from the dischrge indicator. To control the status, the charging must be interrupted and the truck must be started. Park the truck at a dedicated secured area with a deidcated power supply. Lower the forks and remove the load. Open the battery cover and let it stay upright. Switch the truck off and connect the battery plug to the charging 16 Fig.14: Battery charging plug of the charger. The charger starts charging the battery if the charger is connected to the main power supply. Disconnect the battery plugs after the charger finished charging. Connect the battery plug with the plug at the truck. Close the battery cover. 8. REGULAR MAINTENANCE Only qualified and trained personnel are allowed to do maintenance on this truck. Before maintaining, remove the load and lower the forks to the lowest position. If you need to lift the truck, follow chapter 4 b by using designated lashing or jacking equipment. Before working, put safety devices (for instance designated lift jacks, wedges or wooden blocks) under the truck to protect against accidental lowering, movement or slipping. Please pay attention by maintain the tiller arm. The gas pressure spring is pre-loaded by compression. Carelessness can cause injury. Use approved and from your dealer released original spare parts. Please consider that oil leakage of hydraulic fluid can cause failures and accidents. It is allowed to adjust the pressure valve only from trained service technicians. If you need to change the wheels, please follow the instructions above. The castors must be round and they should have no abnormal abrasion. Check the items emphasized maintenance checklist. a. Maintenance checklist Table 3: Maintenance checklist Interval (Month) 1 3 6 12 Hydraulic 1 Check the hydraulic cylinder, piston for damage noise and leakage 2 Check the hydraulic joints and hose for damage and leakage 3 Inspect the hydraulic oil level, refill if necessary 4 Refill the hydraulic oil ( 12 month or 1500 working hours) 5 Check and adjust the function of the pressure valve (1500 kg +0/ +10%) Mechanical system 6 Inspect the forks for deformation and cracks 7 Check the chassis for deformation and cracks 8 Check if all screws are fixed 9 Check mast and chain for corrosion, deformation or damages, replace if necessary 10 Check the gearbox for noise and leakage 11 Check the wheels for deformation and damages, replace if necessary 12 Lubricate the steering bearing 13 Inspect and lubricate the pivot points 14 Lubricate the grease nipples 15 Replace the guarding and/or protective screen if it is damaged Electric system 17 16 Inspect the electric wiring for damage 17 Check the electric connections and terminals 18 Test the Emergency switch function 19 Check the electric drive motor for noise and damages 20 Test the display 21 Check if correct fuses are used, if necessary replace. 22 Test the audio warning signal 23 Check the contactors 24 Check the frame leakage (insulation test) 25 Check function and wear of the accelerator 26 Check the electrical system of the drive motor Braking system 27 Check brake performance, if necessary replace the brake disc or adjust the air gap Battery 28 Check the battery voltage 29 Clean and grease the terminals and check for corrosion and damage 30 Check the battery housing for damages Charger 31 Check the main power cable for damages 32 Check the start-up protection during charging Function 33 Test the audio warning signal 34 Check the air gap of the electromagnetic brake 35 Test the emergency braking 36 Test the reverse and regenerative braking 37 Test the safety (belly) button function 38 Check the steering function 39 Check the lifting and lowering function 40 Check the tiller arm switch function 41 Test the key switch of damages and function 42 Test the speed limitation switch (lifting height >~300mm) General 43 Check if all decals are legible and complete 44 Check if the protective screen and or guarding is not damaged 45 Inspect the castor, adjust the height or replace it, if worn out 46 Carry out a test run 18 b. Lubricating points Lubricate the marked points according to the maintenance checklist. The required grease specification is: DIN 51825, standard grease. 1 2 3 4 5 6 Bearings in wheels Main frame post Chain Hydraulic system Steering bearing Gear box c. Check and refill hydraulic oil Fig. 15: Lubricating points The required hydraulic fluid- type is H-LP 46, DIN 51524 Viscosity is 41.4 - 47 Depending on the type the amount Is 9.4L Waste material like oil, used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company. The oil level height shall be in the not lifted position min.9.3L to 9.5L. If necessary add oil at the filling point. d. Checking electrical fuses Remove the main cover. The fuses are located according to fig. 16; the size is according to table 4. Table 4: Size of the fuses FU1 FU2 FU3 FU01 FU02 Fig. 16: Location fuses 19 Rate 10A 0.5A 15A 150A 200A e. Removing, reattaching guarding DO NOT USE THIS TRUCK, IF THE GUARDING IS DAMAGED OR NOT CORRECTLY ASSEMBLED! If the guarding needs to be removed, unbolt the fixing screws and remove the screen carefully. The screws will remain with the screen. For reattaching place the screen to the right position and fix each screw correctly. If you need to replace parts, please call your next service partner. Move the clips for the protective screen sideways and remove the screen. Assembling is in the opposite direction. Please make sure that the the screen is fixed correctly and that the fixing elements are not damaged. 9. TROUBLE SHOOTING If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 5: Trouble shooting TROUBLE CAUSE Load weight too high Battery discharged Lifting fuse faulty Hydraulic oil level too low Load can’t be lifted Oil leakage Lifting stops at 1800mm Lifting stops at 1800mm Oil leakage from air breathing Height sensor for 1800mm height defect Excessive quantity of oil. Battery is charging REPAIR Lift only the max. capacity, mentioned on the ID-plate Charge the battery Check and eventually replace the lifting fuse Check and eventually refill hydraulic oil Repair the hoses and/or the sealing of the cylinder Move the protective arms into the downside position Check the sensor for the protective arm Check the height sensor on the mast Reduce oil quantity. Charge the battery completely and then remove the main power plug form the electrical socket. Connect the battery correctly Check and eventually replace fuses Charge the battery Stacker not starts operating Battery not connected The fuse is faulty Battery discharged Combined emergency switch is activated 20 De-activate the combined emergency switch by insert and pull the knob. Tiller in the operating zone Only travelling in one direction Protective arms in the upright position, platform folded upright Foldable platform or protective arms in one of the allowed positions Foldable platform or protective arms not in one of the allowed positions The accelerator and the connections are damaged. The battery is discharged. The electromagnetic brake is engaged. The relating tiller cables are disconnected or damaged The stacker only travels very slowly Defective height sensor for reduced speed at 300mm height Electric system overheated Defective heat sensor The stacker starts up suddenly The controller is damaged. The accelerator not moves back to its neutral position. Move the tiller firstly to the braking zone. Move the protective arms into the downside position Check the proximate sensors for the arms and platform Check the correct function of the arms and/or platform Check the accelerator and the connections. Check the battery status at the discharge indicator Check the electromagnetic brake Check the tiller cables and connections. Check the sensor Stop using and cool down the truck Check and if necessary replace the heat sensor Replace the controller. Repair or replace the accelerator. If the truck has malfunctions and can’t be operated out of the working zone, jack the truck up and go with a load handler under the truck and safe the truck securely. Then move the truck out of the aisle. 21 10. WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram Fuses CS 15 FU1 : 10 A FU2 : 0,5 A FU3 : 15 A FU01 : 150 A FU02 : 200 A Fig. 17: Electric diagram 22 b. Hydraulic circuit Fig. 18: Hydraulic circuit 23 11. SPECIALIZED STIPULATIONS FOR THE US- AMERICAN MARKET The content in this chapter is specialized for the US-American market. a. Foreword/ Compliance Operating this truck requires knowledge which can be acquired from this instruction handbook. This handbook must be kept available throughout the entire period of use of the industrial truck. IT IS LAW; YOU MUST BE TRAINED AND CERTIFIED TO OPERATE THIS TRUCK! READ AND OBEY ALL WARNINGS AND INSTRUCTIONS IN THIS MANUAL AND ON THE TRUCK! Only properly trained operators are allowed to operate a powered industrial truck. Your employer must train you and certify, that you are qualified to operate this truck (required by OSHA § 1910.178). The training must satisfy OSHA requirements and as minimum the topics mentioned in this handbook. Depending on the context in this operating manual, the user can refer to several people, including the owner of the truck, anyone who leases or borrows this truck, and the operator as defined in ASME B56.1. Please pay attention to the section in ASME B56.1 concerning the operator. In this standard, it is defined that the safe operation is the responsibility of the operator (ASME B56.1-2003, Part II, section 5.1.1). You and others can be seriously injured or even killed if you don’t use this truck correctly. Before operating your truck, inspect your truck and ensure that it is in correct working order. This truck was designed and built to current industry and government standards. For more information see following: - ASME B56.1 (American Society of Mechanical Engineers) - OSHA §1910.178 (Occupational Safety and Health Act) - UL 583 (Underwriters Laboratory) - ANSI Z535.4 (American National Standards Institute) This sign indicates hazard situations, if not avoided, will result in serious injury or death. The instructions or precautions to this message must be observed to avoid the potential risk of injury or death. If not followed, warning indicates hazard situations which may lead to moderate injury. The instructions or precautions to this message must be observed to avoid the potential risk of injury or death. If not followed, caution indicated situations which may lead to minor injury. Instructions or precautions must be observed to avoid minor injury. 24 b. Description warning labels (only US- market) （ only without platform ） （inside） Fig. 19: Warning labels and safety devices (only USA) A C F G H I Crane hook label Residual lift capacity sticker Identification plate (ID-plate) Sticker to read and follow these instructions Sign warning electrical devices Sign danger not riding J Sign danger being crushed K Sign not under, on forks L Sign oil filling point M Sign warning stay clear stop truck N Sign danger battery The truck is equipped with an emergency button (11) which stops all lifting-, lowering-, driving- functions and engages the failsafe electromagnetic brake when it is pushed. The function is described in chapter 2c. Follow the instructions given on the decals. Replace the decals if they are damaged or missing. 25 Sign read and follow this instruction (G) Sign not under, on forks (K) Sign warning electrical devices (H) Sign danger not riding (I) (only if not equipped with a foldable platform) Sign oil filling point (L) Sign warning stay clear stop truck (M) Sign danger being crushed (J) 26 Sign danger battery (N) 27 c. Technical data for US market Fig. 20: Technical data Table 6: Main technical data for standard version(USmarket) Dimensions Tires, chassis Weight Distinguishing mark Type sheet for industrial truck acc. to VDI 2198 1.2 Manufacturer`s type designation PS 15SL two-stage-mast PS 15SL three-stage-mast 2900FFL 4600 FFL 3600FFL 6000 FFL 1.4 Power (battery ,diesel, petrol, gas, manual) Operator type 1.5 Load Capacity / rated load Q(lbs) 3306.9 1.6 C(in) 23.6 x(in) 28.4 1.9 Load centre distance Load distance ,centre of drive axle to fork Wheelbase 2.1 Service weight lbs 2844.0 2910.1 3712.6 3897.8 2.2 Axle loading, laden front/rear lbs 2778/3373 2811/3406 3062./3763 3155/3856 lbs 1841/1003 1874/1036 2202/1316 2295/1409 1.3 1.8 Pedestrian 54.6 y(in) 59.8 3.1 Axle loading, front/rear Tires 3.2 Tire size, front xW (in) 9.1×3.0 3.3 xW (in) 3.1×2.8 xW (in) 4.9x2.4 3.6 Tire size, rear Additional wheels(dimensions) Wheels,number front/rear(x=driven wheels) Track, front 3.7 Track, rear b11(in) 4.2 Lowered mast height h1 (in) 4.3 Free Lift height h2 (in) 58.3 72.0 59.8 84.9 4.4 Lift height h3 (in) 112.8 140.4 179.7 234.8 4.5 Extended mast height Height of tiller in position min./ max. h4 (in) 132.7 160.2 201.4 259.8 2.3 3.4 3.5 4.9 unladen Battery Polyurethane (PU) drive 1x+2/4 22.4 b10(in) 29.5 42.9-54.9 76.8 h14 (in) 90.6 81.9 53.9/37.2 28 107.9 h13 (in) 4.19 Overall length l1 (in) 82.7 77.3 4.20 Length to face of forks l2 (in) 36.0 40.55 4.21 Overall width b1 (in) 31.3 39.4 4.22 Fork dimensions s/e/l(in) 1.2/3.9/45.3 4.25 b5 (in) 7.9-28.3 m2 (in) 0.98 4.35 Distance between fork-arms Ground clearance, centre of wheelbase Aisle width for pallets 1000X1200 crossways Aisle width for pallets 800X1200 lengthways Turning radius 5.1 Travel speed, laden/ unladen mph 5.2 fpm 16.1/29.9 19.1/32.3 fpm 18.7/21.3 25.2/23.6 5.10 Lift speed, laden/ unladen Lowering speed, laden/ unladen Max. gradeability, laden/ unladen Service brake 6.1 Drive motor rating S2 60min HP 6.2 HP 6.6 Lift motor rating at S3 4.5% Battery acc. to DIN 43531/35/36 A, B, C, no Battery voltage, nominal capacity K5 Batteryweight Energy consumption acc. to VDI cycle 8.1 Type of drive control 8.4 Sound level at driver`s ear acc. to EN 12053 4.32 4.33 Electric- engine Performance data 4.34 Additional data 1.97 Height, lowered t 4.15 5.3 5.8 6.3 6.4 6.5 Ast(in) 101.3 106.9 Ast(in) 101.3 106.9 Wa(in) 65.1 70.6 3.75/3.75 27.8/41.7 27.8/41.7 44.7/35.0 6/12 % Electromagnetic 1.77 2.99 V/Ah 4.08 4.1 B，2PzS B，3PzS 24/210 24/350 478.4 lbs kWh/h 2.36 AC- speed control dB(A) 69 Table 7: Mast table Mast table PS 15 Designation Lowered mast Free lift height Lift height Extended mast height height h1 (in) h2 (in) h3 (in) h4 (in) PS 15 76.8 58.3 112.8 132.7 90.6 72.0 140.4 160.2 Three-stage mast 81.9 59.8 179.7 201.4 FFL 107.9 84.9 234.8 259.8 Two-stage mast FFL 29 CE-DD-002 12. DECLARATION OF CONFORMITY (valid, if sold within the EU) [GB] CE Declaration of Conformity The signatory hereby declares that the specified machine conforms to the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatory is individually authorized to compile the technical documents. [D] EG-KONFORMITÄTSERKLÄRUNG Der Unterzeichner bescheinigt hiermit, dass die im Einzelnen bezeichnete Maschine den Europäischen Richtlinien 2006/42/EG (Maschinenrichtlinie) und 2004/108/EWG (Elektromagnetische Verträglichkeit - EMV) einschließlich deren Änderungen sowie dem entsprechenden Rechtserlaß zur Umsetzung der Richtlinien in nationales Recht entspricht. Der Unterzeichner ist bevollmächtigt, die technischen Unterlagen zusammenzustellen. [E] DECLARACIóN DE CONFORMIDAD CE El signatario certifico por medio de la presente que la máquina especificada cumple con las Normas Europeas 2006/42/CE (Normativa para maquinarias) y 2004/108/CE (Compatibilidad electromagnética), incluyendo sus respectivas odificaciones, así como con el decreto-ley para la adaptación de las normas al derecho nacional. El signatario dispone de una autorización individual que le permite compilar la documentación técnica. [F] DECLARATION DE CONFORMITE CE Par la présente déclaration, les soussignés certifient que le machines spécifié ci-dessus est conforme à la loi et aux directives européennes 2006/42/CE (directive sur les machines) et 2004/108/CEE (compatibilité électromagnétique - CEM), y compris aux modifications qui y sont apportées et à l’arrêté autorisant sa transposition en droit national. Chaque signataire est habilité à établir individuellement la documentation technique. [NL] EG-CONFORMITEITSVERKLARING Ondergetekenden verklaren hierbij dat - volgens de nationale wetgeving van de Lidstaten - de hierboven vermelde opgegeven machina beantwoordt aan de bepalingen qua veiligheid bij machines (EG richtlijn 2006/42/EC) en electro-magnetische compatibilteit (EG richtlijn 2004/108/EEC). Ondergetekenden zijn ieder individueel gemachtigd het technisch dossier samen te stellen. [P] DECLARAÇÃO DE CONFORMIDADE CE Pela presente, os signatários certificam que o máquina especificado está conforme às Directivas Europeias 2006/42/CE („Máquinas“) e 2004/108/CEE („Inocuidade Electromagnética - IEM“), incluindo as alterações das mesmas e o respectivo decreto-lei para a transposição em lei nacional. Cada um dos signatários está autorizado a proceder à elaboração da documentação técnica. [I] DICHIARAZIONE DI CONFORMITÀ CE I sottoscritti dichiarano che il veicolo per trasporti interni a macchina specificato soddisfa le Direttive Europee 2006/42/EC (Direttiva Macchine) e 2004/108/EEC (Compatibilità elettromagnetica - EMV) comprese le relative modifiche, come pure il rispettivo decreto legislativo per la conversione delle direttive in diritto nazionale. I sottoscritti sono singolarmente autorizzati alla creazione della documentazione tecnica. [BG] EВРОПЕЙСКА ОБЩНОСТ - ДЕКЛАРАЦИЯ ЗА СЪОТВЕТСТВИЕ Подписаните удостоверяват с настоящето, че подробно описаното машина средство отговаря на европейския норматив 2006/42/EG (норматив за машини) и на 2004/108/EG (електро-магнетична съвместимост), включително с техните промени, както и на съответния указ за прилагане на нормативите в националното право. Подписаните при това са упълномощении поотделно да съставят техническата документация. [CZ] EG - PROHLÁŠENÍ O SHODĚ Níže podepsaný tímto potvrzuje, že podrobný popis uvedené stroje odpovídá Evropským směrnicím 2006/42/EC (směrnice pro stroje) a 2004/108/EEC (elektromagnetická interference - EMV) včetně jejich pozdějších úprav, jakož i příslušným právním výnosům pro uplatnění příslušné směrnice v rámci národního práva. Každý z podepsaných jsou jednotlivě zplnomocněni k vytvoření technických podkladů. [DK] EF-OVERENSSTEMMELSESERKLÆRING Undertegnede attesterer hermed, at det specificerede maskine stemmer overens med de Europæiske Direktiver 2006/42/EU (maskindirektiv) og 2004/108/EØF (elektromagnetisk kompatibilitet - EMC) samt med den modsvarende lovvedtagelse til implementering af direktiver i den nationale lovgivning. De undertegnede er hver for sig beføjet til at sammenstille de tekniske dokumenter. [EST] EL vastavusavaldus Allakirjutanud tõendavad käesolevaga, et üksikasjaliselt kirjeldatud täpsustatud masin vastab Euroopa direktiividele 2006/42/EÜ (Direktiiv masinate kohta) ja 2004/108/EMÜ (Elektromagnetiline sobivus - EMS) kaasa arvatud nende muudatused ja nendele vastavatele õigusmäärustele direktiivide muutmiseks siseriiklikuks õiguseks. Iga allakirjutanu üksikult on volitatud koostama tehnilist dokumentatsiooni. [FIN] EU-YHDENMUKAISUUSSELOSTUS Allekirjoittaneet todistavat täten, että kukin erikseen mainittu omalla voimanlähteellä varustettu tehdaskone vastaa EU-direktiivien 2006/42/EC (koneenrakennusdirektiivi) ja 2004/108/EEC (sähkömagneettinen yhteensopivuus – EMC) määräyksiä sekä niiden muutoksia ja niiden kansalliseen lainsäädäntöön soveltamista koskevaa oikeussääntöä. Jokaisella allekirjoittaneista on oikeus itsenäisesti laatia asiaankuuluvia teknisiä asiakirjoja. [GR] ΔΗΛΩΣΗ ΣΥΜΜΟΡΦΩΣΗΣ ΕΟΚ Οι υπογράφοντες βεβαιώνουν διά της παρούσης ότι το συγκεκριμένο μηχάνημα συμμορφώνεται προς την Κοινοτική Οδηγία 2006/42/ΕΚ («Μηχανήματα») και 2004/108/ΕΟΚ (Ηλεκτρομαγνητικής Συμβατότητας, ΗΜΣ), καθώς και οι τροποποιήσεις τους, όπως μεταφράστηκε στην εθνική νομοθεσία των χωρών μελών. Οι υπογράφοντες είναι σε κάθε περίπτωση εξουσιοδοτημένοι ατομικά να καταρτίσουν τα τεχνικά έγγραφα. [H] EU KONFORMITÁSI NYILATKOZAT Alulírottak ezennel igazolják, hogy a részletesen leírt a megadott gép megfelel a 2006/42/EC (Gép-Irányelv) és a 2004/108/EEC (Elektromágneses összeférhetőség - EMV) Európai Irányelveknek, beleértve azok módosításait, valamint az irányelvek nemzeti jogba történő átültetésére irányuló megfelelő jogi rendelkezést. Továbbá az alulírottak mindegyike rendelkezik meghatalmazással arra nézve, hogy összeállíthatja a műszaki dokumentációt. [LT] ES atitikimơ deklaracija Žemiau pasirašę asmenys patvirtina, kad atskirai aprašytas nurodyta mašina atitinka Europos Sąjungos direktyvas 2006/42/EB (Mašinų direktyva) ir 2004/108/EEB (Elektromagnetinis suderinamumas – EMS) įskaitant jų pakeitimus, o taip pat ir atitinkamą teisės aktą dėl direktyvų įgyvendinimo nacionalinėje teisėje. Kiekvienas iš pasirašiusių asmenų turi teisę ruošti techninę dokumentaciją. [LV] ES atbilstības deklarācija Ar zemāk redzamajiem parakstiem tiek apliecināts, ka norādīts mašīna atbilst Eiropas Savienības normatīvām 2006/42/EG (Mašīnu normatīvas) un 2004/108/EWG (Elektromagnētiskā atbilstība – EMV), ieskaitot to izmaiņas, kā arī atbilstošos tiesiskos rīkojumus normatīvu pielāgošanai nacionālajai likumdošanai. Parakstu īpašnieki ir atsevišķi pilnvaroti sastādīt tehniskās dokumentācijas. [N] EU-KONFORMITETSERKLÆRING Undertegnede bekrefter hermed at de enkelte betegnede maskin med kraftdrift tilsvarer de europeiske retningslinjene 2006/42/EC (maskinretningslinje) 30 og 2004/108/EEC (elektromagnetisk fordraglighet - EMV) inklusiv disses endringer og den tilsvarende rettsforordning til omsetning av nasjonal rett. Hver undertegnede er fullmektig til å sette sammen de tekniske dokumentene. [PL] DEKLARACJA ZGODNOŚCI WE Niżej podpisani deklarują, że poniżej opisana maszyna spełnia wymagania określone w dyrektywach Europejskich 2006/42/EC (Dyrektywa Maszynowa) i 2004/108/EEC (Kompatybilności elektromagnetycznej - EMC) wraz z ich późniejszymi zmianami oraz odpowiednimi rozporządzeniami mającymi na celu przeniesienie tych dyrektyw do prawa krajów członkowskich. Sygnatariusz jest indywidualnie upoważniony do zestawiania dokumentacji technicznej. [RO] DECLARAŢIE DE CONFORMITATE CE Subsemnaţii adeveresc prin prezenta că vehiculul de specificat maşină descris individual corespunde directivelor europene 2006/42/CE (Directiva privind maşinile) şi 2004/108/CEE (Compatibilitatea electromagnetică - CEM) inclusiv modificărilor lor precum şi actului legislativ corespunzător prentru transpunerea directivelor în drept naţional. Subsemnaţii sunt fiecare în parte împuterniciţi să întocmească documentaţia tehnică. [RUS] Декларация соответствия стандартам ЕС Настоящим лица, подписавшие документ, удостоверяют, что машина с указанной спецификацией соответствует европейским стандартам 2006/42/EG (Транспортная директива) и 2004/108/EWG (Электромагнитная совместимость - ЕМС), включая изменения в них, а также соответствующим национальным стандартам и нормам. Каждое по отдельности лицо, подписавшее документ, имеет полномочия для составления технической документации. [S] EG-KONFORMITETSFÖRKLARING Undertecknarna intygar härmed att det i detalj betecknade maskin uppfyller de Europeiska direktiven 2006/42/EG (Maskindirektiv) och 2004/108/EEG (Elektromagnetisk tålighet - EMV), inklusive ändringarna i detta och den motsvarande rättsförordningen för att omsätta direktiven i nationell rätt. Undertecknarna har var för sig fullmakt att sammanställa den tekniska dokumentationen. [SK] vyhlásenie o zhode Dolu podpísaní týmto potvrdzujeme, že podrobný popis uvedené stroje Zodpovedá Európskym smerniciam 2006/42/EC (ernica pre stroje ) a 2004/108/EWG ( elektromagnetická tolerancia – EMV ) vrátane jeho neskorších úprav, rovnako zodpovedá aj príslušným právnym nariadeniam na uplatnenie smerníc v rámci národného práva. Každý z podpísaných je jednotlivo splnomocnený na vytvorenie technických podkladov. [SLO] EU IZJAVA O SKLADNOSTI Podpisani s tem potrjujemo, da posamično označeno določeno stroj vozilo odgovarja Evropski direktivi 2006/42/EC (Direktiva o strojih) in 2004/108/EEC (Elektromagnetna skladnost - EMV) vključno z njihovimi spremembami ter ustrezno pravno uredbo o prevzemu smernic v nacionalno pravo. Podpisniki so vsakokrat posamezno pooblaščeni za izdajanje tehnične dokumentacije. [TR] AB Uygunluk Açıklaması İmza sahibi şahıslar, ayrıntıları belirtilen makine aracının, 2006/42/EC (Makine Yönergesi) ve 2004/108/EEC (Elektromanyetik Uyumluluk – EMC) no'lu Avrupa Yönergelerine ve bunların değişiklik sonucu oluşan metinlerine ve yönergelerin milli hukuk hükümlerine dönüştürülmesine dair ilgili hukuk kararnamesine uygun olduğunu tasdik ederler. İmza sahibi şahıslar teknik dosyaları bir araya getirmek için münferiden vekil tayin edildi. (1) Type/ Typ/ Tipo/ Modello/ Tyyppi/ Tipo / ΤYΠΟΣ/ Típus/ Tip/ Тип/ Tips/ Tipas/ Tüüp: (2) Serial No./ Serien-Nr./ N°. de série/ Serienummer/ Nº de serie/ Numero di serie/ Serienr./ Sarjanro/ αυξάνων αριθμός/ Seriové číslo/ Szériaszám/ Nr.Seryjny/ Serijska številka/ Výrobné číslo/ Серийный номер/ Seri No./ Seerianr./ Sērijas Nr./ Serijos numeris: (3) Year of constr./ Baujahr/ Année de constr./ Bouwjaar/ Año de constr./ Anno di costruzione/ Produktionsår/ Byggeår/ Tillverkningsår/ Valmistusvuosi / Ano de fabrico / έτος κατασκευής/ Rok výroby/ Gyártási év/ Rokprodukcji / Letnik / Год изготовления / Üretim yılı / Väljalaskeaasta / Izgatavošanas gads / Gamybosmetai (4) Manufacturer or his authorized representative in Community/ Hersteller oder in der Gemeinschaft ansässiger Vertreter/ Fabricant ou son mandataire établi dans la Communauté/ Fabrikant of zijn in de Gemeenschap gevestigde gemachtigde/ Fabricante o representante establecido en la Comunidad/ Construtor ou Representante estabelecido na Comunidade/ Costruttore oppure il suo rappresentante nella Comunità/ Fabrikant eller dennesi Fællesskabet etablerede befuldmægtigede/ Produsent eller agent innen felleskapet/ Tillverkare eller representant inom EU/ Valmistaja tai yhteisömaassa oleva edustaja / V˘robce nebo jeho zastoupení/ Gyártó / producent albo jego przedstawiciel w EG (Wspólnota Europejska)/ Καηαζθεπαζηήο ή όκηινο ηνπηθώλ αληηπξνζώπσλ/ Üretici ya da Bölgedeki Yetkili Temsilci/ Proizvajalec ali pooblaščeni zastopnik s sedežem v EU/ Výrobca alebo zástupca so stálym bydliskom v EÚ / Изготовитель или его представитель, зарегистрированный в стране Содружества/ Tootja või organisatsioonis paiknev esindaja/ Ražotājs vai vietējais uzņēmuma pārstāvis / Gamintojas arba šalyje reziduojantis atstovas: (5) Date/ Datum/ Data/ Fecha/ datum/ Dato/ päiväys/ Kuupäev/ Datums/дата / Dátum/ dátum/ tarih/ ημερομηνία (6) Authorised signatory/ Im Auftrag/ pour ordre/ Incaricato/ Por orden de/ por procuração/ op last van/ på vegne af/ på uppdrag/ Etter oppdrag/ psta./ Ülesandel / pavedus / v.i. / По поручению / megbízásából /длъжностно лице / z pověření / z poverenia / po nalogu / na polecenie / din sarcina / adına / θαη' εληνιή (1) Type: XX XX – Self propelled industrial truck (2) Serial No: XXXXXXXX (3) Year of constr.: YYYY (4) Manufacturer or his authorized representative in Community: Company name/ Street / Postal code Town/ Country (5) Date: YYYY. MM.DD (6) Authorized signatory: Mr. Sample 31 INSTRUCTION HANDBOOK Electric Stacker WARNING Do not use the electric truck before reading and understanding these operating instructions. NOTE: Please check the designation of your present type at the last page of this document as well as on the ID-plate. Keep for future reference. Version 10/2014 PS 20-SMS-001-EN 1 FOREWORD Before operating the electric stacker, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation could create danger. This handbook describes the usage of different electric stackers. When operating and servicing the truck, make sure, that it applies to your type. Chapter 11 describes specialized stipulations and regulations for the American market. Follow these instructions and stipulations if you operate the truck within the American market! Keep this handbook for future reference. If this or the warning/ caution labels are damaged or got lost, please contact your local dealer for replacement. This truck complies with the requirements according to EN 3691-1 (Industrial trucks- safety requirements and verification, part 1), EN 12895 (Industrial trucks- electromagnetic compatibility), EN 12053 (Safety of industrial trucks- test methods for measuring noise emissions), EN 1175 (Industrial truck safety – electrical requirements), assumed the truck is used according to the described purpose. The noise level for this machine is 69 dB(A) according to EN 12053. The vibration is 0,85 m/s2 (if equipped with a platform) according to EN 13059. ATTENTION: Environmentally hazardous waste, such as batteries, oil and electronics, will have a negative effect on the environment, or health, if handled incorrectly. The waste packages should be sorted and put into solid dustbins according to the materials and be collected disposal by local special environment protection bureau. To avoid pollution, it’s forbidden to throw away the wastes randomly. To avoid leaking during the use of the products, the user should prepare some absorbable materials (scraps of wooden or dry duster cloth) to absorb the leaking oil in time. To avoid second pollution to the environment, the used absorbable materials should be handed in to special departments in terms of local authorities. Our products are subject to ongoing developments. Because this handbook is only for the purpose of operating /servicing the stacker, therefore please have understanding, that there is no guarantee out of particular features out of this handbook. NOTE: On this manual, the left sign means warning and danger, which can lead to death or serious injury if not followed. Copyright The copyright remains with the company, mentioned on the CE- certificate at the end of this document or, if sold within the USA, with the company, mentioned on the company sticker. 2 3 TABLE OF CONTENTS 1. 2. CORRECT APPLICATION ............................................................................................5 DESCRIPTION OF THE STACKER ..............................................................................6 a. Overview of the main components.............................................................................6 b. Main technical data ....................................................................................................7 c. Description of the safety devices and warning labels (Europe and other, excepting USA) .................................................................................................................................8 d. Identification plate ......................................................................................................9 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS ..................................9 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING ....................................10 a. Commissioning ........................................................................................................10 b. Lifting/ transportation................................................................................................10 c. Decommissioning..................................................................................................... 11 5. DAILY INSPECTION ................................................................................................... 11 6. OPERATING INSTRUCTIONS ...................................................................................12 a. Parking.....................................................................................................................12 b. Residual lift diagram.................................................................................................12 c. Lifting .......................................................................................................................13 d. Lowering ..................................................................................................................13 e. Travelling .................................................................................................................13 f. Steering....................................................................................................................14 g. Braking.....................................................................................................................14 h. Malfunctions.............................................................................................................15 i. Emergency...............................................................................................................15 7. BATTERY CHARGING AND REPLACEMENT ...........................................................15 a. Replacement............................................................................................................16 b. Battery Indicator.......................................................................................................16 c. Charging ..................................................................................................................16 8. REGULAR MAINTENANCE........................................................................................17 a. Maintenance checklist..............................................................................................17 b. Lubricating points .....................................................................................................19 c. Check and refill hydraulic oil ....................................................................................19 d. Checking electrical fuses .........................................................................................19 e. Removing, reattaching guarding ..............................................................................20 9. TROUBLE SHOOTING ...............................................................................................20 10. WIRING/ CIRCUIT DIAGRAM.....................................................................................22 a. Electrical circuit diagram ..........................................................................................22 b. Hydraulic circuit........................................................................................................23 11. SPECIALIZED STIPULATIONS FOR THE US- AMERICAN MARKET .......................24 a. Foreword/ Compliance .............................................................................................24 b. Description warning labels (only US- market) ..........................................................25 c. Technical data for US market ...................................................................................28 12. DECLARATION OF CONFORMITY (valid, if sold within the EU)................................30 4 1. CORRECT APPLICATION It is only allowed to use this electric stacker according to this instruction handbook. The trucks described in this handbook are self propelled pedestrian controlled electric power stacker, with electrically powered low height lifting function. The trucks are designed for stacking operations in dedicated racking by lifting and lowering the palletized load up to the desired lifting height. A wrong usage can cause human injuries or can damage equipment. The operator/ the operating company has to ensure the correct usage and has to ensure, that this truck is used only by staff, which is trained and authorized to use this truck. The truck has to be used on substantially firm, smooth, prepared, level and adequate surfaces. The truck is intended to be used for indoor applications with ambient temperatures between +5C and + 40C and for intensive operations without crossing permanent obstacles or potholes. Operating on ramps is not allowed. While operating, the load must be placed approximately on the longitudinal centre plane of the stacker. Lifting or transporting people is forbidden. If travelling the load must be lowered to the lifting point. It is not allowed to use this truck on tail lifts or loading ramps. The capacity is marked on the load diagram as well on the Identification plate. The operator has to consider the warnings and safety instructions. Operating lighting must be minimum 50 Lux. Modification No modifications or alterations to this truck which may affect, for example, capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof. This includes changes affecting, for example braking, steering, visibility and the addition of removable attachments. When the manufacturer or its successor approve a modification or alteration, they shall also make and approve appropriate changes to capacity plate, decals, tags and operation and maintenance handbooks. By not observing these instructions, the warranty becomes void. 5 2. DESCRIPTION OF THE STACKER a. Overview of the main components Fig. 1: Overview main components 1. Foldable platform 2. Main cover 3. Protective arm cover 4. Protective arms 5. Upper cover 6. Tiller 7. Safety (belly) button 8. Accelerator (butterfly button) 9. Middle cover 10. Battery cover 11. Mast 12. Assembly board 13. Protective board 14. Load backrest 15. Load wheels 16. Forks 17. Pallet 18. Key switch 19. Discharge indicator and charging indicating LED 20. Emergency button 21. Chassis 6 b. Main technical data Fig. 2: Technical data Table1: Main technical data for standard version Dimensions Tires, chassis Weight Distinguishing mark Type sheet for industrial truck acc. to VDI 2198 PS 20 1.2 Manufacturer`s type designation 1.3 Power (battery ,diesel, petrol, gas, manual) 1.4 Operator type 1.5 Load Capacity / rated load Q (t) 2 1.6 Load centre distance C (mm) 600 1.8 Load distance ,centre of drive axle to fork X (mm) 760 1.9 Wheelbase Y(mm) 1508 2.1 Service weight 2600 2900 3600 Battery Pedestrian kg 1440 1460 1515 1250 /2210 1270 /2245 2.2 Axle loading, laden front/rear kg 1245 /2195 2.3 Axle loading, unladen front/rear kg 1020 /420 3.1 Tires 3.2 Tire size, front x w (mm) 3.3 Tire size, rear x w (mm) 84×70 3.4 Additional wheels(dimensions) x w (mm) 124x60 3.5 Wheels, number front/rear(x=driven wheels) 3.6 Tread, front b10 (mm) 766 3.7 4.2 Tread, rear b11 (mm) 400/515 Lowered mast height h1 (mm) 4.3 Free lift height h2 (mm) 4.4 Lift h3 (mm) 2515 2815 3515 4.5 Extended mast height h4 (mm) 3187.5 4187.5 4.9 Height of tiller in drive position min./ max. h14 (mm) 3487.5 964/1326 4.15 Height, lowered h13 (mm) 85 7 1030 1070 /430 /445 Polyurethane (PU) 230×75 1x+2/4 1930 2080 2430 - Performanc e data Electricengine Addition al data 4.19 Overall length l1 (mm) 2083 4.20 Length to face of forks l2 (mm) 933 4.21 Overall width b1 (mm) 1000 4.22 Fork dimensions s/e/l (mm) 60/185/1150 4.25 Distance between fork- arms b5 (mm) 570/685 4.32 Ground clearance, centre of wheelbase m2 (mm) 25 4.33 Aisle width for pallets 1000X1200 lengthways Ast (mm) 2572 4.34 Aisle width for pallets 800X1200 lengthways Ast (mm) 2520 4.35 Turning radius Wa (mm) 1725 5.1 Travel speed, laden/unladen Km/h 5.2/5.5 5.2 Lift speed, laden/ unladen m/s 0.11/0.16 5.3 Lowering speed, laden/ unladen m/s 0.1/0.1 5.8 Max. gradeability performance, laden/ unladen % 5.10 Service brake 6/12 Electromagnetic 6.1 Drive motor rating S2 60min kW 1.3 6.2 Lift motor rating at S3 15% 6.3 Battery acc. to DIN 43531/35/36 6.4 Battery voltage, nominal capacity K5 V/Ah 24/350 6.5 Battery weight kg 288 6.6 8.1 Energy consumption acc. to VDI cycle Kwh/h 2.83 AC- speed control 8.4 Sound level at driver’s ear according to EN 12053 dB(A) 69 kW A, B, C, no 3.0 B，3PzS Type of drive control c. Description of the safety devices and warning labels (Europe and other, excepting USA) For the USA –market, the description of the safety and warning labels is mentioned in chapter 11. A B C E F G L Crane hook label Warning decal: Do not step under or on the forks Residual lift capacity sticker Never reach through Identification plate (ID-plate) Sticker to read and follow these instructions Sign of filling point The truck has an emergency button (20) which stops all lifting-, lowering-, driving- functions and engages the failsafe electromagnetic brake when it is pushed. By pulling this button, the truck can be operated after the controller checked the functions. Before operating, insert the key and turn the switch (18) clockwise. To prevent against unauthorized access, turn the key anti-clockwise 8 Fig.3: Safety and warning labels and remove it, if you not operate this truck. The truck is equipped with a safety (belly) button (7) which switches the driving function away from the operator, if the truck travels towards the operator and the tiller is activated in the tillers operating zone. Follow also the instructions given on the decals. Replace the decals if they are damaged or missing. d. Identification plate 1 2 3 4 5 6 Designation, type Serial number Rated capacity in kg Supply voltage in V Own mass (self weight) in kg without battery Name and address of manufacturer) 7 Battery weight minimum/ maximum 8 Nominal power in kW 9 Load center distance 10 Manufacturing data 11 Option 1 2 3 11 4 10 5 9 8 7 6 Fig. 4: Identification plate If sold to the EU, here the place of the CE marking 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS DO NOT Drive outside the stacking operation with a lifted load higher than the lifting point. Put foot or hand under or into the lifting mechanism. Allow other person than the operator to stand in front of or behind the truck when it is moving or lifting/lowering. Overload the truck. Put foot in front of the wheels, injury could result. Lift people. People could fall down and suffer severe injury. Push or pull loads. Use this truck on ramps. Use the truck without a removed protective screen (fig.1, pos. 17/ guarding). 9 Side or end load. Load must be distributed evenly on the forks. Use the truck with unstable, unbalanced not stable load. Use truck without manufacturer’s written consent. Lifted loads could become unstable at wind forces. In the case of wind forces do not lift the load if there is any influence to the stability Watch difference in floor levels when driving. Load could fall down or the truck could get uncontrollable. Keep watching the condition of load. Stop operating the truck if load becomes unstable. Brake the truck and activate the emergency button (11) by pushing when sliding load on or off the truck. If the truck has any malfunctions, follow chapter 8. Practice maintenance work according to regular inspection. This truck is not designed to be water resistant. Use the truck under dry condition. Prolonged continuous operation might cause damage of the power pack. Stop operation if temperature of hydraulic oil is too high. When operating the truck, the operator has to wear safety shoes. The truck is intended to be used for indoor applications with ambient temperatures between +5C and + 40C. The operating lighting must be minimum 50 Lux. It is not allowed to use the truck on ramps. To prevent unintended sudden movements when not operating the truck (i.e. from another person, etc.) switch off the truck and remove the key. 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. Commissioning Table 2: Commissioning data Type PS 20 / 2600 PS 20 / 2900 PS 20 / 3600 Commissioning weight [kg] 1475 1495 1550 Version/ Lift [mm] 2600 2900 3600 After receiving our new truck or for re-commissioning you have to do following before (firstly) operating the truck: Check if are all parts included and not damaged Eventually installation and charging the batteries (follow chapter 7) Do the work according to the daily inspections as well as functional checks. b. Lifting/ transportation For transporting, remove the load, lower the forks to the lowest position and fix the truck safe with dedicated lifting gear according to the following figures. 10 Fig.5: Lifting with a crane Lifting USE DEDICATED CRANE AND LIFTING EQUIPMENT DO NOT STAND UNDER THE SWAYING LOAD DO NOT WALK INTO THE HAZARDOUS AREA DURING LIFTING Lower the forks and park the truck securely. Fasten the truck according to fig.6 by fixing dedicated lashing belts to each side of the truck’s crane hook holes and fasten the other side at the transporting truck. Transportation Fig. 6: Fixing points DURING TRANSPORTATION ON A LORRY OR TRUCK ALWAYS FASTEN THE TRUCK SECURELY Lower the forks and park the truck on the iron plate securely. Fixe the forks by the iron sheet with two screws. Fasten the truck by fixing dedicated lashing belts according to fig. 6 and fasten the other side at the transporting truck. c. Decommissioning For storage, remove the load, lower the truck to the lowest position, grease all in this handbook mentioned greasing points (regular inspection), eventual protect the truck against corrosion and dust. Remove the batteries and jack the truck safely, so that there will be no flattening after storage. For final decommissioning hand the truck to a designated recycling company. Oil, batteries and electric components must be recycled due to legal regulations. 5. DAILY INSPECTION This chapter describes pre-shift checks before putting the truck into operation. Daily inspection is effective to find the malfunction or fault on this truck. Check the truck on the following points before operation. Remove load from truck and lower the forks. DO NOT USE THE TRUCK IF ANY MALFUNCTION IS FOUND. Check for scratches, deformation or cracks. Check if there is any oil leakage from the cylinder. Check the vertical creep of the truck. Check the chain and rollers for damages or corrosion. Check the smooth movement of the wheels. Check the function of the emergency brake by activating the emergency button. 11 Check, the tiller arm- switch braking function Check the lifting and lowering functions by operating the buttons. Check if the protective screen has no damages and that is correctly assembled. Check the audio warning signal. Check if all bolts and nuts are tightened firmly. Check the function of the key switch. Check the speed limitation switch. Visual check if there are any broken hoses or broken electric wires. If supplied with a backrest extension, check it for damages and correct assembling. 7 6. OPERATING INSTRUCTIONS 8 BEFORE OPERATING THIS TRUCK, PLEASE FOLLOW THE WARNINGS AND SAFETY INSTRUCTIONS (CHAPTER 3). BEFORE OPERATING THIS TRUCK, ENSURE THAT THE LOAD OR OTHER EQUIPMENT NOT CAUSES INSUFFICIENT VISIBILITY! 22 23 Make sure, that the load is palletized and stable and that Fig.7: Tiller operating controls the daily inspection is carried out. For starting, insert the key and turn it clockwise to the “ON”- position. Eventually before inserting the key switch (18), the emergency button (20) must be pulled carefully. Press the horn button (22) to activate the audible warning signal. a. Parking DO NOT PARK THE TRUCK ON INCLINED SURFACES Fig.8: Key switch The truck is equipped with an electromagnetic failsafe stopping and parking brake. Always lower the forks fully and drive the truck to a safe area. Turn the key anti- clockwise to the “Off” – position and remove the key. b. Residual lift diagram The residual lift diagram indicates the maximum capacity Q [kg] for a given load centre c [mm] and the corresponding lift height H [mm] for the truck with horizontal load. The white markings on the mast indicate if the specific lifting limits reached. For instance with a load centre of gravity distance c of 600 mm and a maximum lift height H of 3600 mm, the max. capacity Q is 2000 kg. 12 Fig. 9: Residual lift diagram c. Lifting DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 2000 kg. LIFT ONLY CAPACITIES ACCORDING TO THE RESIDUAL LIFT DIAGRAM. Travel with the lowered forks fully underneath the pallet and press the lifting button (fig. 7, 22) until you reached the desired lifting height. d. Lowering If the forks are in the racking, firstly travel out of the racking carefully with or without the pallet. By travelling out of the racking, take care that the forks are not touching the racking. Press the lowering button (fig. 7, 23) carefully. Lower the load until the forks are clear of the pallet, then drive the truck carefully out of the load unit. Fig.10: Load facing uphill e. Travelling TRAVEL ON INCLINES ONLY WITH THE LOAD FACING UPHILL. DO NOT TRAVEL ON INCLINES MORE THAN SPECIFIED WITH THE TECHNICAL DATA. TRAVELLING IS ONLY ALLOWED IF THE FORKS ARE LOWERED DOWN TO THE LIFTING POINT (<300MM). Fig.11: Operating direction After starting the truck by turning the inserted key to the “ON”- position (fig. 8),; and eventually by pulling the emergency button carefully, move the tiller to the operating zone (‘F’, fig.11). Turn the accelerator button to the desired direction forward ‘Fw.’ Or backwards ‘Bw.’(fig. 11). Control the travelling speed by moving the accelerator button (8) carefully until you reached the desired 13 speed. If you move the accelerator button back to the neutral position, the controller decelerates the truck until the truck stops. If the truck stopped, the parking brake will be engaged. Drive carefully the truck to the destination. Watch the route conditions and adjust the travelling speed with the accelerator- button. THE TRUCK CAN BE EQUIPPED OPTIONAL WITH A FOLDABLE PLATFORM AND SIDEWAYS PROTECTIVE ARMS. PAY ATTENTION, THE BEHAVIOR FOR THE RIDE ON MODE IS DIFFERENT TO THE PEDESTRIAN MODE. Besides the pedestrian mode, following travelling modes can be used: Travelling with platform (1) folded downside and sideways arms (4) in protective position Travelling with maximum speed. Travelling with platform (1) folded downside and sideways arms (4) folded downside Depending on the Controllers parameter setting, the speed might be lower, but not higher than 5.5km/h. Travelling with platform (1) folded upright and sideways arms (4) folded downside Depending on the Controllers parameter setting, the speed might be lower, but not higher than 5.5km/h. f. Steering OPTIONAL THE TRUCK CAN BE EQUIPPED WITH AN ELECTRIC STEERING SYSTEM. TAKE CARE BY OPERATING A TRUCK WITH THIS KIND OF SYSTEM; THE BEHAVIOR OF THE TRUCK MIGHT BE DIFFERENT THAN TO A TRUCK WITHOUT ELECTRIC STEERING SYSTEM. You steer the truck by moving the tiller to the left or right side. g. Braking THE BRAKING PERFORMANCE DEPENDS ON THE TRACK CONDITONS AND THE LOAD CONDITONS OF THE TRUCK The braking function can be activated on several ways: By moving the accelerator button (8) back to the initial ‘0’ position or by releasing the button, the regenerative braking is activated. The truck brakes until it stops. By moving the accelerator button (8) from one driving direction directly to the opposite direction, the truck brakes regenerative until it starts travelling into the opposite direction. The truck brakes, if the tiller is moved up or down to the braking zones (‘B’). If the tiller is released, the tiller moves automatically up to the upper baking zone (‘B’). The truck brakes until it stops. 14 The safety (belly) button (7) prevents the operator from being crushed. If this button is activated, the truck decelerates and/ or starts travelling into the backwards direction (‘Bw.’) for a short distance and stops. Please consider, that this button also operates, if the truck is not travelling and the tiller is in the operating zone. h. Malfunctions If there are any malfunctions or the truck is inoperative, please stop using the truck and activate the emergency button (20) by pushing it. If possible, park the truck on a safe area, turn the key switch (18) anti- clockwise and remove the key. Inform immediately the manager and, or call your service. If necessary, tow the truck out of the operating area by using dedicated towing/ lifting equipment. i. Emergency In emergencies or in the event of tip over (or off dock), keep safe distance immediately. If possible push the emergency button (20). All electrical functions will be stopped. 7. BATTERY CHARGING AND REPLACEMENT Only qualified personnel are allowed to service or charge the batteries. The instructions of this handbook and from the battery- manufacturer must be observed. The batteries are liquid acid traction batteries. Optional maintenance free batteries are available; for these batteries re- filling is prohibited. Recycling of batteries undergoes national regulations. Please follow these regulations. By handling batteries, open fire is prohibited, gases could cause explosion! In the area of battery charging neither burning materials nor burning liquids are allowed. Smoking is prohibited and the area must be ventilated. Park the truck securely before starting charging or installing/changing the batteries Before finishing the maintenance work, make sure, that all cables are connected correctly and that there are no disturbing towards other components of the truck. Depending on the version, the truck is equipped with following liquid acid traction battery- type: 1 pc 3PzS 24V/ 350 Ah (C5) [624x284x627 (LxWxH)] IT IS ONLY ALLOWED TO USE LIQUID ACID TRACTION BATTERIES. THE WEIGHT OF THE BATTERIES HAS AN INFLUENCE TO THE TRUCKS OPERATING BEHAVIOR. PLEASE CONSIDER THE MAXIMUM OPERATING TEMPERATURE OF THE BATTERIES. 15 a. Replacement Park the truck securely and switch off the stacker with the key (18) and activate the emergency button (20). Open the battery cover and pull out the hinge. Then remove the battery cover, unscrew and remove the battery fixing plate, pull out the battery plug (Fig.14), and take the batteries out with a crane. The installation is in the reverse order of the removal. Please connect the positive terminals firstly. Otherwise the tuck could be damaged. b. Battery Indicator The discharge status is indicated by ten red LED segments. Fig. 12: battery replacement Battery discharged Battery charged Fig.13: Battery discharge indicator Only when the battery is properly charged, the most right LED lit. As the battery’s state-of-charge decreases, successive LEDs light up, only one on at a time. The 2nd from left LED flashes, indicating “energy reserve” (70% depth of discharge). The 2 most left LEDs alternately flash, indicating “empty” (80% depth of discharge). c. Charging Before charging ensure that you are using an appropriate charger for charging the installed battery! Before using the charger, please fully understand the instructions of the charger instructions. Always follow these instructions! The room, where you are charging must be ventilated. The exactly charge status can be only checked from the dischrge indicator. To control the status, the charging must be interrupted and the truck must be started. Park the truck at a dedicated secured area with a deidcated power supply. 16 Fig.14: Battery charging Lower the forks and remove the load. Open the battery cover and let it stay upright. Switch the truck off and connect the battery plug to the charging plug of the charger. The charger starts charging the battery if the charger is connected to the main power supply. Disconnect the battery plugs after the charger finished charging. Connect the battery plug with the plug at the truck. Close the battery cover. 8. REGULAR MAINTENANCE Only qualified and trained personnel are allowed to do maintenance on this truck. Before maintaining, remove the load and lower the forks to the lowest position. If you need to lift the truck, follow chapter 4 b by using designated lashing or jacking equipment. Before working, put safety devices (for instance designated lift jacks, wedges or wooden blocks) under the truck to protect against accidental lowering, movement or slipping. Please pay attention by maintain the tiller arm. The gas pressure spring is pre-loaded by compression. Carelessness can cause injury. Use approved and from your dealer released original spare parts. Please consider that oil leakage of hydraulic fluid can cause failures and accidents. It is allowed to adjust the pressure valve only from trained service technicians. If you need to change the wheels, please follow the instructions above. The castors must be round and they should have no abnormal abrasion. Check the items emphasized maintenance checklist. a. Maintenance checklist Table 3: Maintenance checklist Interval (Month) 1 3 6 12 Hydraulic 1 Check the hydraulic cylinder, piston for damage noise and leakage 2 Check the hydraulic joints and hose for damage and leakage 3 Inspect the hydraulic oil level, refill if necessary 4 Refill the hydraulic oil ( 12 month or 1500 working hours) 5 Check and adjust the function of the pressure valve (1500 kg +0/ +10%) Mechanical system 6 Inspect the forks for deformation and cracks 7 Check the chassis for deformation and cracks 8 Check if all screws are fixed 9 Check mast and chain for corrosion, deformation or damages, replace if necessary 10 Check the gearbox for noise and leakage 11 Check the wheels for deformation and damages, replace if necessary 12 Lubricate the steering bearing 13 Inspect and lubricate the pivot points 17 14 Lubricate the grease nipples 15 Replace the guarding and/or protective screen if it is damaged Electric system 16 Inspect the electric wiring for damage 17 Check the electric connections and terminals 18 Test the Emergency switch function 19 Check the electric drive motor for noise and damages 20 Test the display 21 Check if correct fuses are used, if necessary replace. 22 Test the audio warning signal 23 Check the contactors 24 Check the frame leakage (insulation test) 25 Check function and wear of the accelerator 26 Check the electrical system of the drive motor Braking system 27 Check brake performance, if necessary replace the brake disc or adjust the air gap Battery 28 Check the battery voltage 29 Clean and grease the terminals and check for corrosion and damage 30 Check the battery housing for damages Charger 31 Check the main power cable for damages 32 Check the start-up protection during charging Function 33 Test the audio warning signal 34 Check the air gap of the electromagnetic brake 35 Test the emergency braking 36 Test the reverse and regenerative braking 37 Test the safety (belly) button function 38 Check the steering function 39 Check the lifting and lowering function 40 Check the tiller arm switch function 41 Test the key switch of damages and function 42 Test the speed limitation switch (lifting height >~300mm) General 43 Check if all decals are legible and complete 44 Check if the protective screen and or guarding is not damaged 45 Inspect the castor, adjust the height or replace it, if worn out 46 Carry out a test run 18 b. Lubricating points Lubricate the marked points according to the maintenance checklist. The required grease specification is: DIN 51825, standard grease. 1 2 3 4 5 6 Bearings in wheels Main frame post Chain Hydraulic system Steering bearing Gear box c. Check and refill hydraulic oil The required hydraulic fluid- type is H-LP 46, DIN 51524 Viscosity is 41.4 - 47 Depending on the type the amount Is 8.5L Fig. 15: Lubricating points Waste material like oil, used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company. The oil level height shall be in the not lifted position min.8.4L to 8.6L. If necessary add oil at the filling point. d. Checking electrical fuses Remove the main cover. The fuses are located according to fig. 16; the size is according to table 4. Table 4: Size of the fuses FU1 FU2 FU3 FU01 FU02 19 Rate 10A 0.5A 15A 150A 200A Fig. 16: Location fuses e. Removing, reattaching guarding DO NOT USE THIS TRUCK, IF THE GUARDING IS DAMAGED OR NOT CORRECTLY ASSEMBLED! If the guarding needs to be removed, unbolt the fixing screws and remove the screen carefully. The screws will remain with the screen. For reattaching place the screen to the right position and fix each screw correctly. If you need to replace parts, please call your next service partner. Move the clips for the protective screen sideways and remove the screen. Assembling is in the opposite direction. Please make sure that the the screen is fixed correctly and that the fixing elements are not damaged. 9. TROUBLE SHOOTING If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 5: Trouble shooting TROUBLE CAUSE Load weight too high Battery discharged Lifting fuse faulty Hydraulic oil level too low Load can’t be lifted Oil leakage Lifting stops at 1800mm Lifting stops at 1800mm Oil leakage from air breathing Height sensor for 1800mm height defect Excessive quantity of oil. Battery is charging REPAIR Lift only the max. capacity, mentioned on the ID-plate Charge the battery Check and eventually replace the lifting fuse Check and eventually refill hydraulic oil Repair the hoses and/or the sealing of the cylinder Move the protective arms into the downside position Check the sensor for the protective arm Check the height sensor on the mast Reduce oil quantity. Charge the battery completely and then remove the main power plug form the electrical socket. Connect the battery correctly Check and eventually replace fuses Charge the battery Stacker not starts operating Battery not connected The fuse is faulty Battery discharged Combined emergency switch is activated 20 De-activate the combined emergency switch by insert and pull the knob. Tiller in the operating zone Only travelling in one direction Protective arms in the upright position, platform folded upright Foldable platform or protective arms in one of the allowed positions Foldable platform or protective arms not in one of the allowed positions The accelerator and the connections are damaged. The battery is discharged. The electromagnetic brake is engaged. The relating tiller cables are disconnected or damaged The stacker only travels very slowly Defective height sensor for reduced speed at 300mm height Electric system overheated Defective heat sensor The stacker starts up suddenly The controller is damaged. The accelerator not moves back to its neutral position. Move the tiller firstly to the braking zone. Move the protective arms into the downside position Check the proximate sensors for the arms and platform Check the correct function of the arms and/or platform Check the accelerator and the connections. Check the battery status at the discharge indicator Check the electromagnetic brake Check the tiller cables and connections. Check the sensor Stop using and cool down the truck Check and if necessary replace the heat sensor Replace the controller. Repair or replace the accelerator. If the truck has malfunctions and can’t be operated out of the working zone, jack the truck up and go with a load handler under the truck and safe the truck securely. Then move the truck out of the aisle. 21 10. WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram Fuses CS 15 FU1 : 10 A FU2 : 0,5 A FU3 : 15 A FU01 : 150 A FU02 : 200 A Fig. 17: Electric diagram 22 b. Hydraulic circuit Fig. 18: Hydraulic circuit 23 11. SPECIALIZED STIPULATIONS FOR THE US- AMERICAN MARKET The content in this chapter is specialized for the US-American market. a. Foreword/ Compliance Operating this truck requires knowledge which can be acquired from this instruction handbook. This handbook must be kept available throughout the entire period of use of the industrial truck. IT IS LAW; YOU MUST BE TRAINED AND CERTIFIED TO OPERATE THIS TRUCK! READ AND OBEY ALL WARNINGS AND INSTRUCTIONS IN THIS MANUAL AND ON THE TRUCK! Only properly trained operators are allowed to operate a powered industrial truck. Your employer must train you and certify, that you are qualified to operate this truck (required by OSHA § 1910.178). The training must satisfy OSHA requirements and as minimum the topics mentioned in this handbook. Depending on the context in this operating manual, the user can refer to several people, including the owner of the truck, anyone who leases or borrows this truck, and the operator as defined in ASME B56.1. Please pay attention to the section in ASME B56.1 concerning the operator. In this standard, it is defined that the safe operation is the responsibility of the operator (ASME B56.1-2003, Part II, section 5.1.1). You and others can be seriously injured or even killed if you don’t use this truck correctly. Before operating your truck, inspect your truck and ensure that it is in correct working order. This truck was designed and built to current industry and government standards. For more information see following: - ASME B56.1 (American Society of Mechanical Engineers) - OSHA §1910.178 (Occupational Safety and Health Act) - UL 583 (Underwriters Laboratory) - ANSI Z535.4 (American National Standards Institute) This sign indicates hazard situations, if not avoided, will result in serious injury or death. The instructions or precautions to this message must be observed to avoid the potential risk of injury or death. If not followed, warning indicates hazard situations which may lead to moderate injury. The instructions or precautions to this message must be observed to avoid the potential risk of injury or death. If not followed, caution indicated situations which may lead to minor injury. Instructions or precautions must be observed to avoid minor injury. 24 b. Description warning labels (only US- market) Fig. 19: Warning labels and safety devices (only USA) A C F G H I Crane hook label Residual lift capacity sticker Identification plate (ID-plate) Sticker to read and follow these instructions Sign warning electrical devices Sign danger not riding J Sign danger being crushed K Sign not under, on forks L Sign oil filling point M Sign warning stay clear stop truck N Sign danger battery The truck is equipped with an emergency button (20) which stops all lifting-, lowering-, driving- functions and engages the failsafe electromagnetic brake when it is pushed. The function is described in chapter 2c. Follow the instructions given on the decals. Replace the decals if they are damaged or missing. 25 Sign read and follow this instruction (G) Sign not under, on forks (K) Sign warning electrical devices (H) Sign danger not riding (I) (only if not equipped with a foldable platform) Sign oil filling point (L) Sign warning stay clear stop truck (M) Sign danger being crushed (J) 26 Sign danger battery (N) 27 c. Technical data for US market Drawing see page 7 Table 6: Main technical data for standard version(USmarket) Performa nce data Dimensions Tires, chassis Weight Distinguishing mark Type sheet for industrial truck acc. to VDI 2198 PS 20 1.2 Manufacturer`s type designation 1.3 Power (battery ,diesel, petrol, gas, manual) 1.4 Operator type 1.5 Load Capacity / rated load Q (lbs) 4409.2 1.6 Load centre distance C (in) 23.6 1.8 Load distance ,centre of drive axle to fork X (in) 29.9 1.9 Wheelbase Y(in) 59.4 2.1 Service weight lbs 2.2 Axle loading, laden front/rear lbs 2.3 Axle loading, unladen front/rear lbs 3.1 Tires 3.2 Tire size, front x w (in) 9.1×3.0 3.3 Tire size, rear x w (in) 3.3×2.8 3.4 Additional wheels(dimensions) x w (in) 4.9x2.4 3.5 Wheels, number front/rear(x=driven wheels) 3.6 Tread, front b10 (in) 30.2 3.7 Tread, rear b11 (in) 15.7/20.3 4.2 Lowered mast height h1 (in) 4.3 Free lift height h2 (in) 4.4 Lift h3 (in) 101.0 112.8 140.4 4.5 Extended mast height h4 (in) 126.5 138.3 165.8 4.9 Height of tiller in drive position min./ max. h14 (in) 38.0/52.2 4.15 Height, lowered h13 (in) 3.3 4.19 Overall length l1 (in) 82.0 4.20 Length to face of forks l2 (in) 36.7 4.21 Overall width b1 (in) 39.4 4.22 Fork dimensions s/e/l (in) 2.4/7.3/45.3 4.25 Distance between fork- arms b5 (in) 22.4/27.0 4.32 Ground clearance, centre of wheelbase m2 (in) 0.98 4.33 Aisle width for pallets 1000X1200 lengthways Ast (in) 101.3 4.34 Aisle width for pallets 800X1200 lengthways Ast (in) 99.2 4.35 Turning radius Wa (in) 67.9 5.1 Travel speed, laden/unladen mph 3.2/3.4 5.2 Lift speed, laden/ unladen fpm 21.7/31.5 5.3 Lowering speed, laden/ unladen fpm 19.7/19.7 5.8 Max. gradeability performance, laden/ unladen % 6/12 2600 2900 3600 Battery Pedestrian 3174.7 3218.7 3340.0 2744.8/48 2755.7/4 2799.8/49 39.1 2248.7/92 872.2 2270.7/9 49.4 2359.0/98 6.0 48.0 1.0 Polyurethane (PU) 1x+2/4 28 76.0 81.9 95.7 - Electric- engine Additiona l data Electromagnetic 5.10 Service brake 6.1 Drive motor rating S2 60min HP 1.77 6.2 Lift motor rating at S3 15% HP 4.1 6.3 Battery acc. to DIN 43531/35/36 6.4 Battery voltage, nominal capacity K5 V/Ah 24/350 6.5 Battery weight lbs 478.4 6.6 Energy consumption acc. to VDI cycle Kwh/h 2.83 8.1 Type of drive control 8.4 Sound level at driver’s ear according to EN 12053 A, B, C, no B，3PzS AC- speed control 29 dB(A) 69 CE-DD-002 12. DECLARATION OF CONFORMITY (valid, if sold within the EU) [GB] CE Declaration of Conformity The signatory hereby declares that the specified machine conforms to the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatory is individually authorized to compile the technical documents. [D] EG-KONFORMITÄTSERKLÄRUNG Der Unterzeichner bescheinigt hiermit, dass die im Einzelnen bezeichnete Maschine den Europäischen Richtlinien 2006/42/EG (Maschinenrichtlinie) und 2004/108/EWG (Elektromagnetische Verträglichkeit - EMV) einschließlich deren Änderungen sowie dem entsprechenden Rechtserlaß zur Umsetzung der Richtlinien in nationales Recht entspricht. Der Unterzeichner ist bevollmächtigt, die technischen Unterlagen zusammenzustellen. [E] DECLARACIóN DE CONFORMIDAD CE El signatario certifico por medio de la presente que la máquina especificada cumple con las Normas Europeas 2006/42/CE (Normativa para maquinarias) y 2004/108/CE (Compatibilidad electromagnética), incluyendo sus respectivas odificaciones, así como con el decreto-ley para la adaptación de las normas al derecho nacional. El signatario dispone de una autorización individual que le permite compilar la documentación técnica. [F] DECLARATION DE CONFORMITE CE Par la présente déclaration, les soussignés certifient que le machines spécifié ci-dessus est conforme à la loi et aux directives européennes 2006/42/CE (directive sur les machines) et 2004/108/CEE (compatibilité électromagnétique - CEM), y compris aux modifications qui y sont apportées et à l’arrêté autorisant sa transposition en droit national. Chaque signataire est habilité à établir individuellement la documentation technique. [NL] EG-CONFORMITEITSVERKLARING Ondergetekenden verklaren hierbij dat - volgens de nationale wetgeving van de Lidstaten - de hierboven vermelde opgegeven machina beantwoordt aan de bepalingen qua veiligheid bij machines (EG richtlijn 2006/42/EC) en electro-magnetische compatibilteit (EG richtlijn 2004/108/EEC). Ondergetekenden zijn ieder individueel gemachtigd het technisch dossier samen te stellen. [P] DECLARAÇÃO DE CONFORMIDADE CE Pela presente, os signatários certificam que o máquina especificado está conforme às Directivas Europeias 2006/42/CE („Máquinas“) e 2004/108/CEE („Inocuidade Electromagnética - IEM“), incluindo as alterações das mesmas e o respectivo decreto-lei para a transposição em lei nacional. Cada um dos signatários está autorizado a proceder à elaboração da documentação técnica. [I] DICHIARAZIONE DI CONFORMITÀ CE I sottoscritti dichiarano che il veicolo per trasporti interni a macchina specificato soddisfa le Direttive Europee 2006/42/EC (Direttiva Macchine) e 2004/108/EEC (Compatibilità elettromagnetica - EMV) comprese le relative modifiche, come pure il rispettivo decreto legislativo per la conversione delle direttive in diritto nazionale. I sottoscritti sono singolarmente autorizzati alla creazione della documentazione tecnica. [BG] EВРОПЕЙСКА ОБЩНОСТ - ДЕКЛАРАЦИЯ ЗА СЪОТВЕТСТВИЕ Подписаните удостоверяват с настоящето, че подробно описаното машина средство отговаря на европейския норматив 2006/42/EG (норматив за машини) и на 2004/108/EG (електро-магнетична съвместимост), включително с техните промени, както и на съответния указ за прилагане на нормативите в националното право. Подписаните при това са упълномощении поотделно да съставят техническата документация. [CZ] EG - PROHLÁŠENÍ O SHODĚ Níže podepsaný tímto potvrzuje, že podrobný popis uvedené stroje odpovídá Evropským směrnicím 2006/42/EC (směrnice pro stroje) a 2004/108/EEC (elektromagnetická interference - EMV) včetně jejich pozdějších úprav, jakož i příslušným právním výnosům pro uplatnění příslušné směrnice v rámci národního práva. Každý z podepsaných jsou jednotlivě zplnomocněni k vytvoření technických podkladů. [DK] EF-OVERENSSTEMMELSESERKLÆRING Undertegnede attesterer hermed, at det specificerede maskine stemmer overens med de Europæiske Direktiver 2006/42/EU (maskindirektiv) og 2004/108/EØF (elektromagnetisk kompatibilitet - EMC) samt med den modsvarende lovvedtagelse til implementering af direktiver i den nationale lovgivning. De undertegnede er hver for sig beføjet til at sammenstille de tekniske dokumenter. [EST] EL vastavusavaldus Allakirjutanud tõendavad käesolevaga, et üksikasjaliselt kirjeldatud täpsustatud masin vastab Euroopa direktiividele 2006/42/EÜ (Direktiiv masinate kohta) ja 2004/108/EMÜ (Elektromagnetiline sobivus - EMS) kaasa arvatud nende muudatused ja nendele vastavatele õigusmäärustele direktiivide muutmiseks siseriiklikuks õiguseks. Iga allakirjutanu üksikult on volitatud koostama tehnilist dokumentatsiooni. [FIN] EU-YHDENMUKAISUUSSELOSTUS Allekirjoittaneet todistavat täten, että kukin erikseen mainittu omalla voimanlähteellä varustettu tehdaskone vastaa EU-direktiivien 2006/42/EC (koneenrakennusdirektiivi) ja 2004/108/EEC (sähkömagneettinen yhteensopivuus – EMC) määräyksiä sekä niiden muutoksia ja niiden kansalliseen lainsäädäntöön soveltamista koskevaa oikeussääntöä. Jokaisella allekirjoittaneista on oikeus itsenäisesti laatia asiaankuuluvia teknisiä asiakirjoja. [GR] ΔΗΛΩΣΗ ΣΥΜΜΟΡΦΩΣΗΣ ΕΟΚ Οι υπογράφοντες βεβαιώνουν διά της παρούσης ότι το συγκεκριμένο μηχάνημα συμμορφώνεται προς την Κοινοτική Οδηγία 2006/42/ΕΚ («Μηχανήματα») και 2004/108/ΕΟΚ (Ηλεκτρομαγνητικής Συμβατότητας, ΗΜΣ), καθώς και οι τροποποιήσεις τους, όπως μεταφράστηκε στην εθνική νομοθεσία των χωρών μελών. Οι υπογράφοντες είναι σε κάθε περίπτωση εξουσιοδοτημένοι ατομικά να καταρτίσουν τα τεχνικά έγγραφα. [H] EU KONFORMITÁSI NYILATKOZAT Alulírottak ezennel igazolják, hogy a részletesen leírt a megadott gép megfelel a 2006/42/EC (Gép-Irányelv) és a 2004/108/EEC (Elektromágneses összeférhetőség - EMV) Európai Irányelveknek, beleértve azok módosításait, valamint az irányelvek nemzeti jogba történő átültetésére irányuló megfelelő jogi rendelkezést. Továbbá az alulírottak mindegyike rendelkezik meghatalmazással arra nézve, hogy összeállíthatja a műszaki dokumentációt. [LT] ES atitikimơ deklaracija Žemiau pasirašę asmenys patvirtina, kad atskirai aprašytas nurodyta mašina atitinka Europos Sąjungos direktyvas 2006/42/EB (Mašinų direktyva) ir 2004/108/EEB (Elektromagnetinis suderinamumas – EMS) įskaitant jų pakeitimus, o taip pat ir atitinkamą teisės aktą dėl direktyvų įgyvendinimo nacionalinėje teisėje. Kiekvienas iš pasirašiusių asmenų turi teisę ruošti techninę dokumentaciją. [LV] ES atbilstības deklarācija Ar zemāk redzamajiem parakstiem tiek apliecināts, ka norādīts mašīna atbilst Eiropas Savienības normatīvām 2006/42/EG (Mašīnu normatīvas) un 2004/108/EWG (Elektromagnētiskā atbilstība – EMV), ieskaitot to izmaiņas, kā arī atbilstošos tiesiskos rīkojumus normatīvu pielāgošanai nacionālajai likumdošanai. Parakstu īpašnieki ir atsevišķi pilnvaroti sastādīt tehniskās dokumentācijas. [N] EU-KONFORMITETSERKLÆRING Undertegnede bekrefter hermed at de enkelte betegnede maskin med kraftdrift tilsvarer de europeiske retningslinjene 2006/42/EC (maskinretningslinje) 30 og 2004/108/EEC (elektromagnetisk fordraglighet - EMV) inklusiv disses endringer og den tilsvarende rettsforordning til omsetning av nasjonal rett. Hver undertegnede er fullmektig til å sette sammen de tekniske dokumentene. [PL] DEKLARACJA ZGODNOŚCI WE Niżej podpisani deklarują, że poniżej opisana maszyna spełnia wymagania określone w dyrektywach Europejskich 2006/42/EC (Dyrektywa Maszynowa) i 2004/108/EEC (Kompatybilności elektromagnetycznej - EMC) wraz z ich późniejszymi zmianami oraz odpowiednimi rozporządzeniami mającymi na celu przeniesienie tych dyrektyw do prawa krajów członkowskich. Sygnatariusz jest indywidualnie upoważniony do zestawiania dokumentacji technicznej. [RO] DECLARAŢIE DE CONFORMITATE CE Subsemnaţii adeveresc prin prezenta că vehiculul de specificat maşină descris individual corespunde directivelor europene 2006/42/CE (Directiva privind maşinile) şi 2004/108/CEE (Compatibilitatea electromagnetică - CEM) inclusiv modificărilor lor precum şi actului legislativ corespunzător prentru transpunerea directivelor în drept naţional. Subsemnaţii sunt fiecare în parte împuterniciţi să întocmească documentaţia tehnică. [RUS] Декларация соответствия стандартам ЕС Настоящим лица, подписавшие документ, удостоверяют, что машина с указанной спецификацией соответствует европейским стандартам 2006/42/EG (Транспортная директива) и 2004/108/EWG (Электромагнитная совместимость - ЕМС), включая изменения в них, а также соответствующим национальным стандартам и нормам. Каждое по отдельности лицо, подписавшее документ, имеет полномочия для составления технической документации. [S] EG-KONFORMITETSFÖRKLARING Undertecknarna intygar härmed att det i detalj betecknade maskin uppfyller de Europeiska direktiven 2006/42/EG (Maskindirektiv) och 2004/108/EEG (Elektromagnetisk tålighet - EMV), inklusive ändringarna i detta och den motsvarande rättsförordningen för att omsätta direktiven i nationell rätt. Undertecknarna har var för sig fullmakt att sammanställa den tekniska dokumentationen. [SK] vyhlásenie o zhode Dolu podpísaní týmto potvrdzujeme, že podrobný popis uvedené stroje Zodpovedá Európskym smerniciam 2006/42/EC (ernica pre stroje ) a 2004/108/EWG ( elektromagnetická tolerancia – EMV ) vrátane jeho neskorších úprav, rovnako zodpovedá aj príslušným právnym nariadeniam na uplatnenie smerníc v rámci národného práva. Každý z podpísaných je jednotlivo splnomocnený na vytvorenie technických podkladov. [SLO] EU IZJAVA O SKLADNOSTI Podpisani s tem potrjujemo, da posamično označeno določeno stroj vozilo odgovarja Evropski direktivi 2006/42/EC (Direktiva o strojih) in 2004/108/EEC (Elektromagnetna skladnost - EMV) vključno z njihovimi spremembami ter ustrezno pravno uredbo o prevzemu smernic v nacionalno pravo. Podpisniki so vsakokrat posamezno pooblaščeni za izdajanje tehnične dokumentacije. [TR] AB Uygunluk Açıklaması İmza sahibi şahıslar, ayrıntıları belirtilen makine aracının, 2006/42/EC (Makine Yönergesi) ve 2004/108/EEC (Elektromanyetik Uyumluluk – EMC) no'lu Avrupa Yönergelerine ve bunların değişiklik sonucu oluşan metinlerine ve yönergelerin milli hukuk hükümlerine dönüştürülmesine dair ilgili hukuk kararnamesine uygun olduğunu tasdik ederler. İmza sahibi şahıslar teknik dosyaları bir araya getirmek için münferiden vekil tayin edildi. (1) Type/ Typ/ Tipo/ Modello/ Tyyppi/ Tipo / ΤYΠΟΣ/ Típus/ Tip/ Тип/ Tips/ Tipas/ Tüüp: (2) Serial No./ Serien-Nr./ N°. de série/ Serienummer/ Nº de serie/ Numero di serie/ Serienr./ Sarjanro/ αυξάνων αριθμός/ Seriové číslo/ Szériaszám/ Nr.Seryjny/ Serijska številka/ Výrobné číslo/ Серийный номер/ Seri No./ Seerianr./ Sērijas Nr./ Serijos numeris: (3) Year of constr./ Baujahr/ Année de constr./ Bouwjaar/ Año de constr./ Anno di costruzione/ Produktionsår/ Byggeår/ Tillverkningsår/ Valmistusvuosi / Ano de fabrico / έτος κατασκευής/ Rok výroby/ Gyártási év/ Rokprodukcji / Letnik / Год изготовления / Üretim yılı / Väljalaskeaasta / Izgatavošanas gads / Gamybosmetai (4) Manufacturer or his authorized representative in Community/ Hersteller oder in der Gemeinschaft ansässiger Vertreter/ Fabricant ou son mandataire établi dans la Communauté/ Fabrikant of zijn in de Gemeenschap gevestigde gemachtigde/ Fabricante o representante establecido en la Comunidad/ Construtor ou Representante estabelecido na Comunidade/ Costruttore oppure il suo rappresentante nella Comunità/ Fabrikant eller dennesi Fællesskabet etablerede befuldmægtigede/ Produsent eller agent innen felleskapet/ Tillverkare eller representant inom EU/ Valmistaja tai yhteisömaassa oleva edustaja / V˘robce nebo jeho zastoupení/ Gyártó / producent albo jego przedstawiciel w EG (Wspólnota Europejska)/ Καηαζθεπαζηήο ή όκηινο ηνπηθώλ αληηπξνζώπσλ/ Üretici ya da Bölgedeki Yetkili Temsilci/ Proizvajalec ali pooblaščeni zastopnik s sedežem v EU/ Výrobca alebo zástupca so stálym bydliskom v EÚ / Изготовитель или его представитель, зарегистрированный в стране Содружества/ Tootja või organisatsioonis paiknev esindaja/ Ražotājs vai vietējais uzņēmuma pārstāvis / Gamintojas arba šalyje reziduojantis atstovas: (5) Date/ Datum/ Data/ Fecha/ datum/ Dato/ päiväys/ Kuupäev/ Datums/дата / Dátum/ dátum/ tarih/ ημερομηνία (6) Authorised signatory/ Im Auftrag/ pour ordre/ Incaricato/ Por orden de/ por procuração/ op last van/ på vegne af/ på uppdrag/ Etter oppdrag/ psta./ Ülesandel / pavedus / v.i. / По поручению / megbízásából /длъжностно лице / z pověření / z poverenia / po nalogu / na polecenie / din sarcina / adına / θαη' εληνιή (1) Type: XX XX – Self propelled industrial truck (2) Serial No: XXXXXXXX (3) Year of constr.: YYYY (4) Manufacturer or his authorized representative in Community: Company name/ Street / Postal code Town/ Country (5) Date: YYYY. MM.DD (6) Authorized signatory: Mr. Sample 31 ECL10-BPT-001 SPAREPARTS LIST Electric Stacker PS 15 Version 10/2014 From truck identification number: 30130700011 PS 15-BPT-004-EN Catalogue Fig. 1 Label (for EU).........................................................................................3 Fig. 2 Label (for US).........................................................................................4 Fig. 3 Outline (Three-stage mast Full Free Lift/ Straddle leg)...........................5 Fig. 4 Outline (Two-stage mast/ Straddle leg) ..................................................7 Fig. 5 Outline (Two-stage mast Full Free Lift) ..................................................9 Fig. 6 Chassis (Three-stage mast Full Free Lift/ Two-stage mast Normal/ Two-stage mast Full Free Lift)........................................................................ 11 Fig. 7 Chassis (Three-stage/Two-stage mast Straddle Leg) ..........................12 Fig. 8 Chassis system (Three-stage mast Full Free Lift)................................13 Fig. 9 Chassis system (Three-stage mast Straddle Leg) ...............................14 Fig. 10 Chassis system (Two-stage mast Normal/ Full Free Lift) ...................16 Fig. 11 Chassis system (Two-stage mast Straddle Leg) ................................17 Fig. 12 Steering wheel assembly ...................................................................19 Fig. 13 Load wheel assembly (tandem roller) ................................................20 Fig. 14 Truck body .........................................................................................21 Fig. 15 Power supply .....................................................................................23 Fig. 16 Instrument assembly ..........................................................................25 Fig. 17 Battery cover assembly......................................................................26 Fig. 18 Mast system (Three-stage mast Full Free Lift/Straddle Leg)..............27 Fig. 19 Mast system (Two-stage mast Normal/Straddle Leg).........................29 Fig. 20 Mast system (Two-stage mast Full Free Lift) .....................................31 Fig. 21 Mast lifting system (Three-stage mast Full Free Lift) .........................32 Fig. 22 Mast other accessories (Three-stage mast Full Free Lift) ..................34 Fig. 23 Mast lifting system (Two-stage mast Normal/Straddle Leg) ...............35 Fig. 24 Mast lifting system (Three-stage mast Full Free Lift) .........................37 Fig. 25 Hydraulic system (Three-stage mast Full Free Lift/Straddle Leg) ......39 Fig. 26 Hydraulic system (Two-stage mast Normal/Straddle Leg)..................42 Fig. 27 Hydraulic system (Two-stage mast Full Free Lift) ..............................44 1 Fig. 28 Outer cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg)46 Fig. 29 Middle cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg) .......................................................................................................................48 Fig. 30 Cylinder (Two-stage mast Normal/Straddle Leg)................................50 Fig. 31 Cylinder (Two-stage mast Full Free Lift) ............................................52 Fig. 32 Manual steering wheel carrier ............................................................53 Fig. 33 Electric power assisted steering wheel carrier ...................................55 Fig. 34 Electric steering assembly .................................................................57 Fig. 35 Drive wheel assembly 7EL-AC-1.3 ....................................................59 Fig. 36 26EL-AC-1.3KW-R Drive wheel assembly .........................................63 Fig. 37 Handle lever.......................................................................................67 Fig. 38 CANBUS Handle head.......................................................................69 Fig. 39 High pressure pump station system（3.0KW 2.6 high pressure delivery capacity）.........................................................................................71 Fig. 40 Pump station system（3.0KW 3.2 delivery capacity）.......................73 Fig. 41 Pump station system（2.2KW 2.2 delivery capacity）.......................75 Fig. 42 Main circuit wiring (Electrical steering） ............................................77 Fig. 43 Main circuit wiring（Manual steering） ..............................................78 Fig. 44 General electrical parts ......................................................................79 Fig. 45 Electric control assembly(Electrical steering).....................................81 Fig. 46 Electric control assembly(Manual steering)........................................84 Fig. 47 Foldable platform ...............................................................................87 Fig. 48 Protective arm....................................................................................90 Fig. 49 Backrest (Normal) ..............................................................................92 Fig. 50 Backrest (Straddle Leg) .....................................................................93 Easy worn parts list ........................................................................................94 2 Fig. 1 Label (for EU) Fig. 1 Label (for EU) No. Parts No. Item Qty. A 9000005967 Crane hook label 2 B 9000003923 C 9000008650 D 9000003573 ‘No passengers’ decal 1 E 9000008561 Never reach through 1 F 9000008649 1 G 9000003570 L 9000008555 Identification plate Sticker to read and follow these instructions Filling sticker Warning decal: Do not step under or on the forks Residual lift capacity sticker 3 2 1 1 1 Note Fig. 2 Label (for US) Fig. 2 Label (for US) No. Parts No. Item Qty. A 9000005967 Crane hook label 2 B 9000008555 Filling sticker 1 C 9000008650 Residual lift capacity sticker 1 D 9000003575 Warning label 1 E 9000003577 Warning label 1 F 9000008649 Identification plate (ID-plate) 1 G 9000003570 Sticker to read and follow these instructions 1 H 9000003579 Warning label 1 I 9000003580 Warning label 1 J 9000005970 Warning label 1 K 9000005971 Warning label 2 4 Note Fig. 3 Outline (Three-stage mast Full Free Lift/ Straddle leg) 5 Fig. 3 Outline (Three-stage mast Full Free Lift/ Straddle leg ) No. Art No. Description Qty. 1 9000008061 Main cover 1 2 9000008063 Protective arm cover 1 3 9000008062 Upper cover 1 4 9000008065 Middle cover 1 5 9000008229 Battery cover 1 6 9000008230 5000 9000009063 4300 9000009064 Protective board 1 5500 9000009066 6000 9000008231 5000 9000009060 9000009061 Protective board block Standard 4600 9000009065 9000009059 7 Note 4300 2 4600 5500 6000 9000009062 8 0000023519 Screw 8 M6×10 9 9000007785 Nut 8 M6 10 0000023555 Screw 4 M6×16 GB/T70.2=ISO7380 11 0000025010 Washer 4 6 GB/T93 12 0000023055 Washer 4 6 GB/T95 13 9000008233 Protective board 1 14 9000007803 Rivet 10 15 1000423003 Screw 2 M10×30 16 9000007793 Screw 1 M10×10 17 9000008234 Right protective cover 1 18 9000008235 Left protective cover 1 1 9000007862 Platform assembly 1 2 9000007891 Protective arm assembly 1 6 GB/T70.2=ISO7380 Fig. 4 Outline (Two-stage mast/ Straddle leg) 7 Fig. 4 Outline (Two-stage mast/ Straddle leg) No. Art No. Description Qty. 1 9000008061 Main cover 1 2 9000008063 Protective arm cover 1 3 9000008062 Upper cover 1 4 9000008065 Middle cover 1 5 9000008984 Battery cover 1 9000008977 6 9000008978 9000008979 Note 2900 Protective board 1 9000008980 3200 3600 4000 7 9000007782 Spring buckle 10 8 9000008972 Upper protective board 1 9 1000423003 Screw 2 M10×30 10 9000007793 Screw 1 M10×10 1 9000007862 Platform assembly 1 2 9000007891 Protective arm assembly 1 8 1 Fig. 5 Outline (Two-stage mast Full Free Lift) 9 Fig. 5 Outline (Two-stage mast Full Free Lift ) No. Art No. Description Qty. 1 9000008061 Main cover 1 2 9000008063 Protective arm cover 1 3 9000008062 Upper cover 1 4 9000008065 Middle cover 1 5 9000008984 Battery cover 1 Protective board 1 6 9000008997 9000008998 Note 2900 3600 7 9000007782 Spring buckle 10 1 8 1000423003 Screw 2 M10×30 9 9000007793 Screw 1 M10×10 1 9000007862 Platform assembly 1 2 9000007891 Protective arm assembly 1 10 Fig. 6 Chassis (Three-stage mast Full Free Lift/ Two-stage mast Normal/ Two-stage mast Full Free Lift) Fig. 6 Chassis (Three-stage mast Full Free Lift/ Two-stage mast Normal/ Two-stage mast Full Free Lift) No. Art No. Description Qty. Note 1 2220511001 Compound roller 4 1 2 2000435002 Magnet steel 1 9000008236 Welded chassis (570×1150) 9000009006 Welded chassis (680×1150) 9000008958 Welded chassis (570×1150) 9000008959 Welded chassis (680×1150) 3 11 Three-stage mast Full Free Lift 1 Two-stage mast Normal/ Two-stage mast Full Free Lift Fig. 7 Chassis (Three-stage/Two-stage mast Straddle Leg) Fig. 7 Chassis (Three-stage/Two-stage mast Straddle Leg ) No. Parts No. Item Qty. 2220511001 1 Compound roller 4 2330511001 Note Three-stage mast Straddle Leg Two-stage mast Straddle Leg 2 2000435002 Compound roller 1 3 2090500001 Fork 2 W 100 4 0000023080 Screw 2 M10x16 9000009067 5 Fork carrier 1 9000008988 12 Standard Three-stage mast Straddle Leg Two-stage mast Straddle Leg GB/T70.1=ISO4762 Fig. 8 Chassis system (Three-stage mast Full Free Lift) Fig. 8 Chassis system (Three-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard 1 0000023067 Screw 4 M8×16 GB/T70.1=ISO4762 2 9000008237 Damping pad 1 PU Welded chassis 1 3 9000008238 9000009081 570x1150 685x1150 4 2040400001 Castor assembly 2 5 0000025002 Washer 8 10 GB/T95 6 0000023006 Washer 8 10 GB/T93 7 0000023029 Screw 8 M10×35 GB/T70.1=ISO4762 8 0000023156 Screw 2 M12×25 GB/T70.1=ISO4762 9 0000025032 Washer 2 12 GB/T95 10 0000025024 Washer 2 12 GB/T93 □1 9000010408 Castor complete 2 13 Fig. 9 Chassis system (Three-stage mast Straddle Leg) 14 Fig. 9 Chassis system (Three-stage mast Straddle Leg ) No. Parts No. Item Qty. Note Standard 1 0000023067 Screw 4 M8×16 GB/T70.1=ISO4762 2 9000008237 Damping pad 1 PU 3 9000009070 Welded chassis 1 4 2040400001 Castor 2 5 0000025002 Washer 8 10 GB/T95 6 0000023006 Washer 8 10 GB/T93 7 0000023029 Screw 8 M10×35 GB/T70.1=ISO4762 8 0000023156 Screw 2 M12×25 GB/T70.1=ISO4762 9 0000025024 Washer 2 12 GB/T93 10 0000025032 Washer 2 12 GB/T95 11 0000023490 Screw 4 M16x20 GB/T77=ISO4026 12 9000009071 Welded front leg 1 13 9000009072 Welded right front leg 1 14 0000023453 Screw 4 M20x60 GB/T70.1=ISO4762 15 0000025033 Washer 4 20 GB/T93 16 0000025031 Washer 4 20 GB/T95 17 9000009074 Positioning pin 2 18 9000009073 Press plate 2 19 9000009069 Support components 2 □1 9000010408 Castor complete 2 15 Fig. 10 Chassis system (Two-stage mast Normal/ Full Free Lift) Fig. 10 Chassis system (Two-stage mast Normal / Full Free Lift ) No. 1 Parts No. 9000008985 9000008986 Item Qty. Welded chassis 1 Note Standard 570X1150 685X1150 2 0000023156 Screw 2 M12×25 GB/T70.1=ISO4762 3 0000025024 Washer 2 12 GB/T93 4 0000025032 Washer 2 12 GB/T95 5 0000023029 Screw 8 M10×35 GB/T70.1=ISO4762 6 0000023006 Washer 8 10 GB/T93 7 0000025002 Washer 8 10 GB/T95 8 2040400001 Castor 2 □1 9000010408 Castor complete 2 16 Fig. 11 Chassis system (Two-stage mast Straddle Leg) 17 Fig. 11 Chassis system (Two-stage mast Straddle Leg ) No. Parts No. Item Qty. Note Standard 1 9000008989 Welded chassis 1 2 2040400001 Castor 2 3 0000025002 Washer 8 10 GB/T95 4 0000023006 Washer 8 10 GB/T93 5 0000023029 Screw 8 M10×35 GB/T70.1=ISO4762 6 0000023156 Screw 2 M12×25 GB/T70.1=ISO4762 7 0000025024 Washer 2 12 GB/T93 8 0000025032 Washer 2 12 GB/T95 9 0000023490 Screw 4 M16x20 GB/T77=ISO4026 10 9000008990 Welded front leg 1 11 9000008991 Welded right front leg 1 12 0000023453 Screw 4 M20x60 GB/T70.1=ISO4762 13 0000025033 Washer 4 20 GB/T93 14 0000025031 Washer 4 20 GB/T95 15 9000009074 Positioning pin 2 16 9000009073 Press plate 2 17 9000009069 Support components 2 □1 9000010408 Castor complete 2 18 Fig. 12 Steering wheel assembly Fig. 12 Steering Wheel Assembly No. Parts No. Item Qty. Note Standard 1 0000026008 Circlip 1 30 GB/T894.1 2 2000405001 Bearing seat 1 3 0000027013 Ball bearing 2 7206C/DB GB/T292 4 2000413001 Sleeve 1 5 0000026010 Circlip 1 62 GB/T893.1 6 0000024015 1 M14 GB/T889.1=ISO7040 7 2000401007 8 0000023111 Lock nut Rear wheel carrier welding Bolt 1 M14×100 GB/T5782=ISO4014 9 2000413002 Shaft sleeve 1 10 1000525001 Washer 2 11 0000027001 Ball bearing 2 6204 GB/T276 12 2020416001 Castor 1 124×60 13 9000003638 Castor wheel 2 1 19 Fig. 13 Load wheel assembly (tandem roller) Fig. 13 Load Wheel Assembly (tandem roller) No. Parts No. Item Qty. 1 2000405002 Linking plate 2 2 0000028009 Dowel pin 4 3 2000407001 Castor shaft 2 4 2000416002 Load wheel 2 80×70 5 0000027001 Ball bearing 4 6204 GB/T276 6 0000030001 Press-on grease cup 2 6 JB/T7940.4=ISOB1575 7 9000010398 Load wheel set 2 □1 2000600001 Load wheel 2 20 Note Standard 5×35 GB/T879.1=ISO8752 Fig. 14 Truck body 21 Fig. 14 Truck Body No. Parts No. Item Qty. Note Standard 1 9000007940 Instrument assembly 1 2 0000023020 Screw 4 M6×20 GB/T70.1=ISO4762 3 9000007791 Screw 4 M10×35 4 9000007783 Nut 13 M10 5 9000007790 Screw 2 M10×55 6 1000423003 Screw 1 M10×30 7 0000023029 Screw 4 M10×35 GB/T70.1=ISO4762 8 0000023006 Washer 8 10 GB/T93 9 0000025002 Washer 8 10 GB/T95 10 0000023034 Screw 4 M10×20 GB/T70.1=ISO4762 11 0000025024 Washer 4 12 GB/T93 12 0000025032 Washer 4 12 GB/T95 13 9000008240 Board 1 14 9000008069 Electronic control assemble board 1 15 9000007923 Right vent components 1 16 9000007920 Left vent components 1 17 0000023082 Screw 4 M12×35 GB/T70.1=ISO4762 18 0000023455 Screw 2 M8×35 GB/T70.1=ISO4762 19 0000024026 Nut 2 M8 GB/T6170=ISO4032 9000008241 20 Welded body 1 Upper plate of protective board 2 9000009082 Three-stage mast Two-stage mast 5 4 M5x10 4 Only used for Two-stage mast Washer 1 6 GB/T93 0000023053 Screw 1 M6x12 GB/T70.1=ISO4762 9000009545 YGE rubber pipe clamp 1 21 9000009080 22 0000025014 23 0000023311 24 0000025010 25 26 Washer Screw 22 GB/T95 GB/T70.1=ISO4762 Fig. 15 Power supply 23 Fig. 15 Power Supply No. Parts No. Item Qty. Note Standard 1 0000023106 Screw 2 M6×30 GB/T70.1=ISO4762 2 0000023055 Washer 2 6 GB/T95 9000010147 Charger 24V/45A(Asia in Chinese) 9000010148 Charger 24V/45A(Asia in English) 9000010194 Charger 24V/45A(For EU) 1 Three-stage mast 1 Two-stage mast 9000010195 Charger 24V/45A(For AUS) 9000010196 Charger 24V/45A(For UK) 9000010197 Charger 24V/45A(For USA) 9000010116 Charger 24V/30A(Asia in Chinese) 9000010117 Charger 24V/30A(Asia in English) 9000010118 Charger 24V/30A(For EU) 3 9000010120 Charger 24V/30A(For AUS) 9000010121 Charger 24V/30A(For UK) 9000010146 Charger 24V/30A(For USA) 9000009083 Power supply（210Ah） welded type 9000008322 Power supply（350Ah） welded type 9000003990 Power supply（210Ah） bolt type 9000008935 Power supply（350Ah） bolt type 9000003988 Connector components （350Ah） (Three-stage mast) 4 5 6 7 9000008585 Connector components （210Ah） (Two-stage mast) 9000009832 Bolt 1 1 1 24 24 Two-stage mast Three-stage mast Two-stage mast Three-stage mast Only used for bolt type battery Fig. 16 Instrument assembly Fig. 16 Instrument Assembly No. Parts No. Description Qty. Note Standard 1 0000023685 Screw 2 M3×25 GB/T818-2000=ISO7045 2 9000008516 Emergency 1 ZDK32-350 3 0000024002 Nut 2 M3 4 1000434025 Indicator 1 CURTIS 5 9000008326 Key switch 1 LKS-101A 6 9000008519 Key 1 7 9000007938 Plastic plate 1 8 0000023215 Screw 2 9 9000007939 Fi×ing plate 1 10 0090000272 Screw 4 11 9000008517 Pro×imity switch 1 12 9000008515 DC power 1 25 GB/T6170=ISO4032 M5×10 GB/T70.3=ISO10642 M4×12 GB/T6560 ZDK32-350 Fig. 17 Battery cover assembly Fig. 17 Battery Cover Assembly No. Parts No. Item Qty. Note Standard 1 0000023073 Screw 2 M4×10 GB/T70.1=ISO4762 2 0000025018 Washer 2 4 GB/T93 3 0000025019 Washer 2 4 GB/T95 4 9000008795 Pin 1 5 0000023306 Screw 1 M5×20 GB/T70.1=ISO4762 6 0000025015 Washer 1 5 GB/T93 7 0000025014 Washer 1 5 GB/T95 8 0090000636 Nut 1 M5 GB/T6172.1=ISO4035 26 Fig. 18 Mast system (Three-stage mast Full Free Lift/Straddle Leg) 27 Fig. 18 Mast system (Three-stage mast Full Free Lift / Straddle Leg ) No. Parts No. Item Qty. 9000008242 9000009043 1 9000009044 9000009045 1 4600 5500 9000008243 5000 9000009049 3 4300 Outer mast welding 6000 9000009048 4300 Middle mast welding 1 4600 5500 9000009050 6000 9000008244 5000 9000009051 4300 9000009052 Standard 5000 9000009046 9000009047 2 Note Inner mast welding 1 4600 9000009053 5500 9000009054 6000 4 2040511001 Compound roller for mast 8 5 0000023079 Bolt 4 M18×40 GB/T5783=ISO4017 6 0000025022 Washer 4 18 GB/T93 7 0000025023 Washer 4 8 GB/T95 28 Fig. 19 Mast system (Two-stage mast Normal/Straddle Leg) 29 Fig. 19 Mast system (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. 9000008968 1 2 9000008969 9000008970 Note 2900 Outer mast welding 1 3200 3600 9000008971 4000 9000008973 2900 9000008974 9000008975 Standard Inner mast welding 1 9000008976 3200 3600 4000 3 2220611001 Compound roller for mast 2 4 0000023079 Bolt 4 M18×40 GB/T5783=ISO4017 5 0000025022 Washer 4 18 GB/T93 6 0000025023 Washer 4 18 GB/T95 7 0000023056 Screw 2 M4x12 GB/T70.1=ISO4762 8 0000025018 Washer 2 4 GB/T93 9 0000025019 Washer 2 4 GB/T95 10 9000008981 Limit block 1 11 2040511001 Compound roller for mast 2 30 Fig. 20 Mast system (Two-stage mast Full Free Lift) Fig. 20 Mast system (Two-stage mast Full Free Lift ) No. 1 2 Parts No. 9000008994 9000008995 9000008999 9000009000 Item Qty. Outer mast welding 1 Inner mast welding 1 Note Standard 2900 3600 2900 3600 3 2220611001 Compound roller for mast 2 4 0000023079 Bolt 4 M18×40 GB/T5783=ISO4017 5 0000025022 Washer 4 18 GB/T93 6 0000025023 Washer 4 18 GB/T95 7 0000023056 Screw 2 M4x12 GB/T70.1=ISO4762 8 0000025018 Washer 2 4 GB/T93 9 0000025019 Washer 2 4 GB/T95 10 9000008981 Limit block 1 11 2040511001 Compound roller for mast 2 31 Fig. 21 Mast lifting system (Three-stage mast Full Free Lift) 32 Fig. 21 Mast lifting system (Three-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard 1 0000024042 Nut 6 M16×1.5 GB/T6171=ISO8673 2 0000028011 Split pin 3 3×40 GB/T91=ISO1234 3 9000008260 Bolt 3 4 0000028030 Hinge pin 6 6×45 GB/T882=ISO2341 5 0000028010 Split pin 6 2×20 GB/T91=ISO1234 0090000540 Chain LH1066×135 5000 GB/T6074=ISO4347 0000029237 Chain LH1066×121 4300 GB/T6074=ISO4347 0090000455 Chain LH1066×127 4600 GB/T6074=ISO4347 0090000543 Chain LH1066×151 5500 GB/T6074=ISO4347 0090000544 Chain LH1066×167 6000 GB/T6074=ISO4347 7 9000007762 Chain wheel for mast 2 8 0000026049 Retainer ring for shaft 2 45 GB/T894.1 9 0000024010 Nut 2 M16 GB/T6172.1=ISO4035 10 0000025029 Washer N 16 GB/T95 11 9000008245 Bearing sleeve 1 12 9000008246 Pulley 1 13 0000023123 Bolt 1 M16×70 GB/T5782=ISO4014 14 2230305002 Side cover 1 15 2000302002 Adjusting washer 2 2 16 0000027012 2 6206 GB/T276 17 9000010331 18 0000026008 Ball bearing Middle cylinder chain wheel Retainer ring for shaft 30 GB/T894.1 19 2230307001 Chain wheel shaft 1 20 2230305001 Chain wheel seat 1 21 0000023094 Screw 1 M12×30 GB/T70.1=ISO4762 22 9000009831 Hoop assembly 1 6 23 2 1 2 0000029068 Chain LH1066×79 5000 GB/T6074=ISO4347 0090000539 Chain LH1066×73 4300 GB/T6074=ISO4347 0090000483 Chain LH1066×75 4600 GB/T6074=ISO4347 0000029057 Chain LH1066×89 5500 GB/T6074=ISO4347 0000029085 Chain LH1066×97 6000 GB/T6074=ISO4347 33 1 Fig. 22 Mast other accessories (Three-stage mast Full Free Lift) Fig. 22 Mast Other Accessories (Three-stage mast Full Free Lift No. Parts No. Item Qty. Note Standard 1 0000023047 Screw 4 M8×25 GB/T70.1=ISO4762 2 0000025001 Washer 4 8 GB/T93 3 0000025011 4 8 GB/T95 4 9000008248 5 9000010332 6 0000023040 Washer Cylinder fixing plate Limit switch mounting plate Screw 2 M6×16 GB/T70.1=ISO4762 7 0000025010 Washer 2 6 GB/T93 8 0000023055 Washer 2 6 GB/T95 2 1 34 Fig. 23 Mast lifting system (Two-stage mast Normal/Straddle Leg) 35 Fig. 23 Mast lifting system (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. Note Standard 1 0000023510 Screw 2 M16x35 GB/T77=ISO4026 2 0000024014 Nut 2 M16x1.5 GB/T6173=ISO8675 3 2010310001 Chain wheel 1 4 0000027012 Ball bearing 2 6206 GB/T276 5 2000302002 Adjusting washer 2 2 6 0000023158 Screw 2 M10x30 GB/T70.1=ISO4762 7 0000023006 Washer 2 10 GB/T93 8 0000025002 2 10 GB/T95 9 2030301001 1 10 0000023103 Washer Chain wheel shaft components Screw M6x8 GB/T70.3=ISO10642 11 2010305001 Chain wheel carrier 1 12 0000028011 Split pin 2 3x40 GB/T91=ISO1234 13 9000008983 Chain tension bar 1 14 0000024042 Nut 2 M16x1.5 GB/T6171=ISO8673 15 0000028010 Split pin 2 2x20 GB/T91=ISO1234 16 0000028014 Hinge pin 2 8x40 GB/T882=ISO2341 2900 GB/T6074=ISO4347 3200 GB/T6074=ISO4347 3600 GB/T6074=ISO4347 4000 GB/T6074=ISO4347 M12x25 GB/T5783=ISO4017 M16x1.5 GB/T6173=ISO8675 17 0000029012 Leaf chain LH1244x91 0000029013 Leaf chain LH1244x99 0000029014 Leaf chain LH1244x109 0000029015 Leaf chain LH1244x119 1 1 18 2010302001 Cylinder fixing plate 1 19 0000023101 Bolt 1 20 2010319001 Cushion pad 1 21 0000024014 Nut 2 22 9000009005 Chain tension bar 1 36 Fig. 24 Mast lifting system (Three-stage mast Full Free Lift) 37 Fig. 24 Mast lifting system (Two-stage mast Full Free Lift ) No. Parts No. Item Qty. Note Standard 1 0000023067 Screw 8 M8x16 GB/T70.1=ISO4762 2 0000025001 Washer 6 8 GB/T93 3 0000025011 Washer 6 8 GB/T95 4 9000009003 Holder 1 1 5 9000009002 Holder 1 2 6 2010305001 2 7 2030301001 8 0000023103 Chain wheel carrier Chain wheel shaft components Screw 9 2010310001 Chain wheel 2 10 0000027012 Ball bearing 11 2000302002 12 2 M6x8 GB/T70.3=ISO10642 4 6206 GB/T276 Adjusting washer 4 2 9000009001 Welded tension bar seat 2 13 2000301002 Welded pulley carrier 1 14 0000025031 Washer 1 20 GB/T95 15 0000026003 Retainer ring for shaft 1 20 GB/T894.1 16 2000310002 Pulley 1 17 0000028011 Split pin 4 3x40 GB/T91=ISO1234 18 9000009005 Chain tension bar 4 19 0000024014 Nut 4 M16x1.5 GB/T6173=ISO8675 20 0000024042 Nut 8 M16x1.5 GB/T6171=ISO8673 21 0000028010 Split pin 8 2x20 GB/T91=ISO1234 2900 GB/T6074=ISO4347 3600 GB/T6074=ISO4347 22 0090000484 Chain LH1244x61 0000029017 Chain LH1244x69 2 2 23 0000028060 Hinge pin 4 8x35 GB/T882=ISO2341 24 0000025098 Washer 4 16 GB/T849 25 0000025099 Washer 4 16 GB/T850 26 2010319001 Cushion pad 2 38 Fig. 25 Hydraulic system (Three-stage mast Full Free Lift/Straddle Leg) 39 Fig. 25 Hydraulic System (Three-stage mast Full Free Lift / Straddle Leg ) No. Parts No. Item Qty. Note Standard 1 0000023090 Screw 4 M6×35 GB/T70.1=ISO4762 2 9000008796 DC hydraulic power unit body 1 High pressure pump station 3 0000023044 Screw 2 M8×20 GB/T70.1=ISO4762 4 0000025001 Washer 2 8 GB/T93 5 0000025011 Washer 2 8 GB/T95 6 2000303001 Hydraulic oil tank cover 1 7 9000008249 Oil tank welding 1 8 9000007832 G end direct connection pipe joint 1 9 9000007838 Steering connecting elbow 1 10 9000010283 Tube 1 11 9000008250 Pump station outlet steel pipe 1 12 9000008252 Left cylinder steel pipe 1 13 9000008251 Right cylinder steel pipe 1 14 9000007841 Four-way joint 1 9000008253 9000009055 15 9000009056 9000009057 5000 Middle cylinder steel pipe 4300 1 5500 9000009058 16 0000023053 6000 Screw 2 9000010287 9000010284 17 9000010286 9000010288 4600 M6×12 GB/T70.1=ISO4762 5000 4300 Hydraulic tube assembly 1 4600 5500 9000010289 6000 18 9000008325 Screw 3 19 0000023020 Hydraulic tube assembly 1 M6×20 20 9000008254 YGE rubber pipe clamp 1 1 40 GB/T70.1=ISO4762 21 9000007842 Screw 3 22 2000337001 Safety valve 3 9000008255 9000009027 23 9000009028 9000009029 4300 High pressure middle cylinder 1 4600 5500 9000009030 6000 9000008256 5000 9000009007 24 5000 9000009008 9000009009 High pressure outer cylinder 4300 2 4600 5500 9000009010 6000 25 0000023094 Screw 3 M12×30 GB/T70.1=ISO4762 26 0000025032 Washer 3 12 GB/T95 27 0000023042 Screw 2 M6×10 GB/T70.1=ISO4762 28 0000023055 Washer 2 6 GB/T95 29 9000010307 Anti-vibration pad 1 41 Fig. 26 Hydraulic system (Two-stage mast Normal/Straddle Leg) 42 Fig. 26 Hydraulic System (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. Note Standard 1 0000023090 Screw 4 M6×35 GB/T70.1=ISO4762 9000008867 9000007854 DC hydraulic power unit body 1 3 0000023044 Screw 2 M8×20 GB/T70.1=ISO4762 4 0000025001 Washer 2 8 GB/T93 5 0000025011 Washer 2 8 GB/T95 6 2000303001 Hydraulic cylinder cover 1 7 9000008249 Welded cylinder 1 8 9000007832 G end direct connection pipe joint 1 9 9000007838 Steering connecting bend 1 10 9000010282 Tube 1 11 9000008987 Pump station outlet steel pipe 1 12 9000008325 YGE rubber pipe clamp 2 13 0000023042 Screw 2 M6×10 GB/T70.1=ISO4762 14 9000007820 Hydraulic tube assembly 1 15 9000007842 Direct pipe joint 1 16 2000337001 Safe anti-explosion valve 1 2 9000008960 17 18 9000008961 9000008962 2900 2900 Cylinder assembly 1 3200 3600 9000008963 4000 9000008964 2900 9000008965 9000008966 Oil return tube assembly 1 9000010307 3200 3600 4000 9000008967 19 3200/3600/4000 Anti-vibration pad 1 43 Fig. 27 Hydraulic system (Two-stage mast Full Free Lift) 44 Fig. 27 Hydraulic System (Two-stage mast Full Free Lift) No. Parts No. Item Qty. Note Standard 1 0000023090 Screw 4 M6×35 GB/T70.1=ISO4762 9000008867 9000007854 DC hydraulic power unit body 1 3 0000023044 Screw 2 M8×20 GB/T70.1=ISO4762 4 0000025001 Washer 2 8 GB/T93 5 0000025011 Washer 2 8 GB/T95 6 2000303001 Hydraulic cylinder cover 1 7 9000008249 Welded cylinder 1 8 9000007832 G end direct connection pipe joint 1 9 9000007838 Steering connecting bend 1 10 9000010282 Tube 1 11 9000008987 Pump station outlet steel pipe 1 12 9000008325 YGE rubber pipe clamp 3 13 0000023042 Screw 2 M6×10 GB/T70.1=ISO4762 14 9000007820 Hydraulic tube assembly 1 15 9000008887 Steering connecting bend 1 16 0000023053 Screw 2 M6x12 GB/T70.1=ISO4762 17 0000025010 Washer 2 6 GB/T93 18 0000023055 Washer 2 6 GB/T95 19 2000302005 Tube card board 1 9000008992 9000008993 Hydraulic cylinder assembly 2 21 0000023101 Screw 2 22 0000025032 Washer 2 9000008888 9000005537 Hydraulic tube assembly 1 24 9000009004 Steel tube 1 25 0000024068 Nut 1 26 9000007842 Direct pipe joint 2 27 2000337001 Safety valve 2 28 9000010307 Anti-vibration pad 1 29 0000023310 Screw 1 2 20 23 45 3600 2900 2900 3200 M12×25 GB/T5783=ISO4017 GB/T95 2900 3600 M6 GB/T6170=ISO4032 M6x20 GB/T5781=ISO4018 Fig. 28 Outer cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg) 46 Fig. 28 Outer cylinder seal kit(Three-stage mast Full Free Lift / Straddle Leg ) No. 1 Parts No. Item Qty. Note 9000009011 5000 9000009012 4300 9000009013 Piston rod 1 Standard 4600 9000009014 5500 9000009015 6000 2 9000009075 Dust cover 1 32X40X5/6.5 3 0090000487 O ring 1 38X3.1 4 9000009079 Seal ring for shaft 1 32X42X6/7 5 9000008953 Seal ring 1 32X42.7X4.2 6 9000008954 Support ring for shaft 1 32X36X5 7 0000022029 O ring 2 50X3.1 GB1235-76 8 9000009016 Guide sleeve 1 9 0000023415 Screw 1 M8X10 GB/T70.1=ISO4762 10 0000022026 Combination washer 1 8 JB/T982 11 12 9000009017 5000 9000009018 4300 9000009019 Cylinder body 1 4600 9000009020 5500 9000009021 6000 9000009022 5000 9000009023 9000009024 Bushing 1 9000009025 4300/4600 5500 6000 13 9000009026 Piston 1 14 9000008955 Support ring for hole 2 □1 9000003636 Outer cylinder seal kit 2 47 36X40X10 GB/T3452.1=ISO3601-1 Fig. 29 Middle cylinder seal kit (Three-stage mast Full Free Lift/Straddle Leg) 48 Fig. 29 Middle cylinder seal kit(Three-stage mast Full Free Lift / Straddle Leg ) No. 1 Parts No. Item Qty. Note 9000009031 5000 9000009032 4300 9000009033 Piston rod 1 Standard 4600 9000009035 5500 9000009034 6000 2 9000009076 Dust cover 1 45X53X5/6.5 3 9000009078 Seal ring for shaft 1 45X55X6/7 4 9000009036 End cap 1 5 9000008957 Retainer ring 1 55X60X1.5 6 0000022055 O ring 1 60X3.1 GB/T3452.1=ISO3601-1 7 0000023415 Screw 1 M8X10 GB/T70.1=ISO4762 8 9000009077 Copper sleeve 1 45X50X30 9 9000009037 5000 9000009038 4300 9000009039 1 4600 9000009040 5500 9000009041 6000 10 9000009042 11 9000008956 12 0000022026 1 □ Cylinder body 9000003637 Piston Support ring for hole Washer Middle cylinder seal kit 1 1 48X52X15 1 8 1 49 JB/T982 Fig. 30 Cylinder (Two-stage mast Normal/Straddle Leg) 50 Fig. 30 Cylinder (Two-stage mast Normal / Straddle Leg ) No. Parts No. Item Qty. 9000009922 1 9000009923 9000009924 Note 2900 Piston rod 1 9000009925 3200 3600 4000 2 9000009926 Dust cover 1 40x48x5/6.5 3 9000009927 Support ring for shaft 1 40X44X10 9000009928 4 9000009929 9000009930 Standard 2900 Cylinder body 1 9000009931 3200 3600 4000 5 9000009932 O ring 1 44.4X3.1 6 9000009933 Support ring for hole 1 45X50X10 7 9000009934 O ring 2 24.4X3.1 8 9000009178 Y ring for hole 1 40X50X6/7 9 9000009935 Piston 1 10 0000025100 Washer 1 24 GB/T93 11 0000024072 Nut 1 M24x1.5 GB/T6171=ISO8673 12 9000009936 Coer 1 1 □ 9000009943 Cylinder seal kit 1 51 Fig. 31 Cylinder (Two-stage mast Full Free Lift) Fig. 31 Cylinder (Two-stage mast Full Free Lift ) No. 1 Parts No. 9000009937 9000009938 Item Qty. Piston rod 1 Note 2900 3600 2 9000009926 Dust cover 1 40x48x5/6.5 3 9000009927 Support ring for shaft 1 40X44X10 Cylinder body 1 4 9000009939 9000009940 2900 3600 5 9000009932 O ring 1 44.4X3.1 6 9000009933 Support ring for hole 1 45X50X10 7 9000009934 O ring 2 24.4X3.1 8 9000009178 Y ring for hole 1 40X50X6/7 9 9000009941 Piston 1 10 0000025033 Washer 1 11 0000024074 Nut 1 12 9000009942 Guide bushing 1 1 □ 9000009944 Cylinder seal kit 2 52 Standard GB/T93 M20x1.5 GB/T6171=ISO8673 Fig. 32 Manual steering wheel carrier 53 Fig. 32 Manual Steering Wheel Carrier No. Parts No. Item Qty. Note Standard 1 0000023042 Screw 8 M6×10 GB/T70.1=ISO4762 2 0000025010 Washer 8 6 GB/T93 3 2000202006 End cover 4 4 2000231001 Spring 4 5 2000207001 Spring spindle 4 6 0000023099 Screw 6 M10×45 GB/T70.1=ISO4762 7 0000023006 Washer 18 10 GB/T93 8 0000025002 Washer 18 10 GB/T95 9 2000202004 V type outer block 2 10 2000202008 Roller 24 11 2000202005 V type inner block 2 12 0000023025 Screw 6 M10×40 GB/T70.1=ISO4762 13 0000023099 Screw 6 M10×45 GB/T70.1=ISO4762 14 2000201005 Wheel carrier welding 1 15 2000202003 Cushion block 2 16 2000201004 Supporting frame welding 1 17 0090000602 Screw 4 M10×25 GB/T821 18 0000024012 Thin nut 4 M10 GB/T6172.1=ISO4035 19 9000008321 Top plate 1 20 0000023095 Full thread bolt 2 M14×60 GB/T5783=ISO4017 21 2000223001 Screw 2 M10×180 22 2000208001 Spring guide sleeve 2 23 2000231002 Spring 2 24 2000212001 Spring guide rod 2 25 0000025024 Washer 4 12 GB/T93 26 0000023094 Screw 4 M12×30 GB/T70.1=ISO4762 27 0000023098 Screw 1 M12×10 GB/T70.1=ISO4762 28 0000025032 Washer 4 12 GB/T95 29 9000008257 30 0000023172 Handle shaft welding Screw 10 M8×30 GB/T70.1=ISO4762 31 0000025001 Washer 10 8 GB/T93 32 0000025011 Washer 10 8 GB/T95 33 2000202001 Limit block 2 34 9000007774 Vertical type drive 1 1 □ 2000200003 Spring assembly 2 1 54 7EL-AC-1.3 Fig. 33 Electric power assisted steering wheel carrier 55 Fig. 33 Electric Power Assisted Steering Wheel Carrier No. Parts No. Item Qty. Note Standard 1 0000023042 Screw 8 M6×10 GB/T70.1=ISO4762 2 0000025010 Washer 8 6 GB/T93 3 2000202006 End cover 4 4 2000231001 Spring 4 5 2000207001 Spring spindle 4 6 0000023099 Screw 6 M10×45 GB/T70.1=ISO4762 7 0000023006 Washer 18 10 GB/T93 8 0000025002 Washer 22 10 GB/T95 9 2000202004 V type outer block 2 10 2000202008 Roller 24 11 9000007685 V type inner block 2 12 0000023025 Screw 6 M10×40 GB/T70.1=ISO4762 13 0000023099 Screw 6 M10×45 GB/T70.1=ISO4762 14 9000007680 Wheel carrier welding 1 15 2000202003 Cushion block 2 16 2000201004 Supporting frame welding 1 17 0090000602 Screw 4 M10×25 GB/T821 18 0000024012 Thin nut 4 M10 GB/T6172.1=ISO4035 19 2000202002 Top plate 1 20 0000023095 Bolt 2 M14×60 GB/T5783=ISO4017 21 2000223001 Screw 2 M10×180 22 2000208001 Spring guide sleeve 2 23 2000231002 Spring 2 24 2000212001 Spring guide rod 2 25 0000025024 Washer 4 12 GB/T93 26 0000023094 Screw 4 M12×30 GB/T70.1=ISO4762 27 0000023098 Screw 1 M12×10 GB/T70.1=ISO4762 28 0000025032 Washer 4 12 GB/T95 29 9000007686 Electronic steering assembly 1 30 9000007779 Drive wheel assembly 1 1 □ 2000200003 Spring assembly 2 56 Fig. 34 Electric steering assembly 57 Fig. 34 Electric Steering Assembly No. Parts No. Item Qty. Note Standard 1 9000007422 Bearing seat welding 1 2 9000000240 Ball bearing 2 65×50×7 GB/T276 3 0000023042 Screw 3 M6×10 GB/T70.1=ISO476 4 0000023034 Screw 4 M10×20 GB/T70.1=ISO476 5 9000007423 Fixing seat welding 1 6 0000026043 Retainer ring for shaft 1 50 GB/T894.1 7 9000007806 Damper 1 8 9000007421 Transition linking block 1 9 9000007693 10 0000023032 Potentiometer fixing plate Washer 4 5 GB/T95 11 0000025015 Washer 4 5 GB/T93 12 0000023311 Screw 4 M5×10 GB/T70.1=ISO476 13 9000007424 Linking block 1 14 0000023073 Screw 4 M4×10 GB/T70.1=ISO476 58 1 Fig. 35 Drive wheel assembly 7EL-AC-1.3 59 Fig. 35 Drive Wheel Assembly 7EL-AC-1.3 No. Parts No. Item Qty. Note Standard 1 9000009493 Gear box 1 2 9000009494 Retainer ring 1 3 0090000116 Bearing 1 30208 GB/T297 4 0090000505 Oil seal 1 50×80×8 GB/T9877 5 9000009496 Bushing 1 6 0000027031 Bearing 1 32010 GB/T297 7 9000009497 Adjusting washer 1 8 9000009498 Gear 1 9 9000009499 Drive wheel 1 10 0090000117 Roll pin 2 4×12 GB/T119.1=ISO2338 11 9000009500 Retainer ring 1 12 9000009501 Bolt 1 13 0090000502 Bearing 1 32304 GB/T297 14 0090000503 Bearing 1 32204 GB/T297 15 9000009502 Gear 1 16 9000009503 Outer thimble 1 17 9000009504 Inner thimble 1 18 9000009505 Adjusting washer 1 19 9000009506 Adjusting washer 1 20 9000009507 Shaft block 1 21 0000025012 Washer 8 5 GB/T93 22 0000023675 Screw 4 M5×16 GB/T70.2=ISO7380 23 0000022036 Combination washer 3 12 JB/T982 24 0090000506 Plug 25 9000009508 Big gear 1 26 9000009509 Washer 1 27 0000025066 Washer 1 14 GB/T856 28 0090000090 Nut 1 M14×1.5 GB/T6173=ISO8675 29 9000009510 Washer 1 30 9000009511 Side cover 1 31 9000009512 Upper cover 1 32 9000009513 Dust cover 1 JB/ZQ4444 60 Fig. 35 Drive Wheel Assembly 7EL-AC-1.3 61 Fig. 35 Drive Wheel Assembly 7EL-AC-1.3 No. Parts No. Item Qty. 33 9000009514 Bolt 5 34 9000009515 Drive wheel 1 35 0000028027 Roll pin 2 6×30 GB/T119.1=ISO2338 36 0000025006 Washer 22 6 GB/T93 37 0000023020 Screw 11 M6×20 GB/T70.1=ISO4762 38 9000009495 Vent plug 1 39 9000009516 Rotating support 1 40 0000023106 Screw 6 M6×30 GB/T70.1=ISO4762 41 0090000504 Roll pin 2 6×26 GB/T119.1=ISO2338 42 0000022037 O seal ring 2 125×2.65 GB/T3452.1=ISO3601-1 43 9000009517 Small gear 1 44 9000009518 Drive motor 1 45 9000009519 Shaft sleeve 1 46 0000026013 Retainer ring for shaft 1 25 GB/T894.1 47 9000009520 Brake 1 48 9000009521 Dust cover 1 49 9000009522 Flange 2 50 9000009523 Speed sensor gear 1 51 9000009524 Speed sensor 1 52 9000009525 Spacer 1 53 0000023311 Screw 4 M5×10 GB/T70.1=ISO4762 54 0000022059 O seal ring 1 20×2.65 GB/T3452.1=ISO3601-1 55 9000009526 Bracket 1 56 0000025001 Washer 3 8 GB/T93 57 0000023047 Screw 3 M8x25 GB/T70.1=ISO4762 58 0000036003 Flat key 1 A 6×18 GB/T1096 59 0000026003 Retainer ring for shaft 1 20 GB/T894.1 60 9000009527 Dust cover 1 61 0000023563 Screw 3 M6×65 GB/T70.1=ISO4762 62 9000009528 Adjusting washer 1 63 0000028137 Roll pin 2 6×30 GB/T879.1=ISO8752 64 0090000321 Screw 2 M6×45 GB/T70.1=ISO4762 65 0000022038 O seal ring 1 65X2.65 GB/T3452.1=ISO3601-1 62 Note Fig. 36 26EL-AC-1.3KW-R Drive wheel assembly 63 Fig. 36 26EL-AC-1.3KW-R Drive Wheel Assembly No. Parts No. Item Qty. Note Standard 1 9000009493 Gear box 1 2 9000009494 Retainer ring 1 3 0090000116 Bearing 1 30208 GB/T297 4 0090000505 Oil seal 1 50x80x8 GB/T9877 5 9000009496 Bushing 1 6 0000027031 Bearing 1 32010 GB/T276 7 9000009497 Adjustng washer 1 8 9000009498 Gear 1 9 9000009499 Drive shaft 1 10 0090000117 Roll pin 2 4x12 GB/T119.2-2000 11 9000009500 Retainer ring 1 12 9000009501 Locking bolt 1 13 0090000502 Bearing 1 32304 GB/T276 14 0090000503 Bearing 1 32204 GB/T276 15 9000009502 Gear 1 16 9000009503 Outter sleeve 1 17 9000009504 Inner sleeve 1 18 9000009505 Adjustng washer 1 19 9000009506 Adjustng washer 1 20 9000009507 Bearing seat 1 21 0000025015 Washer 8 5 GB/T93 22 0000023107 Screw 4 M5x16 GB/T70.1=ISO4762 23 0000022036 Combination washer 3 12 JB/T982 24 0090000506 Bolt 3 M12x1.25 JB/ZQ4444-2006 25 9000009508 Big gear 1 26 9000009509 Washer 1 27 0090000090 Nut 1 M14x1.5 GB/T6173=ISO8675 28 9000009511 Side cover 1 29 9000009513 Dust cover 1 30 9000009514 Tyre bolt 5 31 9000009515 Drive wheel 1 32 0000025010 Washer 20 6 GB/T93 33 0000023106 Screw 8 M6x30 GB/T70.1=ISO4762 34 9000009495 Vent plug 1 35 0090000504 Roll pin 2 6x26 GB/T119.1=ISO2338 36 0000022037 O ring 2 125x2.65 GB/T3452.1=ISO3601-1 37 9000009517 Small gear 1 38 9000009824 Paper washer 1 39 9000009825 Upper cover 1 40 9000009826 Strring big gear 1 41 9000009745 Rotating bearing 1 64 Fig. 36 26EL-AC-1.3KW-R Drive Wheel Assembly 65 Fig. 36 26EL-AC-1.3KW-R Drive Wheel Assembly No. Parts No. Item Qty. Note 42 0000025001 Washer 6 8 GB/T93 43 0000023455 Screw 6 M8x35 GB/T70.1=ISO4762 44 0090000151 Oil seal 1 45 9000009532 Assembling board 1 46 9000009827 Motor 1 47 0000023172 Screw 6 48 9000009522 Locking flange 2 49 9000009523 Speeed sensor gear 1 50 9000009524 Speeed sensor 1 51 9000009748 Bearing 1 52 9000008854 Bushing 1 53 0000026013 Retainer ring for axle 54 0000023311 55 GB/T9877 M8x30 GB/T70.1-2000 1 25 GB/T894.1 Screw 4 M5x10 GB/T70.1=ISO4762 9000009525 spacer 1 56 0000022059 O seal ring 1 20x2.65 GB/T3452.1=ISO3601-1 57 9000009749 Bushing 1 58 0000036001 Flat key 1 6x16 GB/T1096 59 0000026003 Retainer ring for axle 1 20 GB/T894.1 60 9000009521 Dust cover 1 61 9000009528 Adjustng washer 1 62 0000025066 Washer 1 14 GB/T856 63 9000009750 Brake 1 64 0090000526 Bolt 3 M6x20 GB/T5782=ISO4014 65 0000023020 Screw 9 M6x20 GB/T70.1=ISO4762 66 9000006304 Steering carbon brush 1 67 9000009726 Steering motor 1 68 0090000119 Screw 8 M6x22 GB/T70.1=ISO4762 69 9000009828 Steering small gear 1 70 0000026040 Retainer ring for axle 1 22 GB/T894.1 71 0090000118 Flat key 1 6x28 GB/T1096 72 0000023106 Screw 12 M6x30 GB/T70.1=ISO4762 66 Fig. 37 Handle lever 67 Fig. 37 Handle lever No. Parts No. Item Quantity Note Standard 1 1100100001 Canbus control tiller 1 2 0000023232 Bolt 2 M8×25 GB/T5783=ISO4017 3 1000123003 Screw 4 M4×8 GB/T70.2=ISO7380 4 9000007926 Cover board 1 5 9000007925 Welded tiller arm 1 6 9000008327 Proximity switch 1 7 0000023075 Screw 2 M3×20 GB/T70.1=ISO4762 8 1000113001 Shoulder harness 2 17×19×11 9 9000007928 Tiller axle 1 10 0000028003 Elastic roll pin 1 4×24 11 1000123001 Screw 1 M8×20 12 9000007930 Left tiller cover 1 13 1010121001 Air spring 1 400N S≥55 14 0000023005 Lock nut 2 M10 GB/T889.1=ISO7040 15 9000007929 Tiller seat 1 16 9000007931 Right tiller cover 1 17 0000023519 Screw 4 M6×10 GB/T70.2=ISO7380 68 GB/T879.1=ISO8752 Fig. 38 CANBUS Handle head 69 Fig. 38 CANBUS Handle head No. Parts No. Item Qty. 1 1010114001 Left driving button 1 2 1000114015 Horn button 1 3 1000131009 Spring for horn button 5 4 1000113004 Bushing for camshaft 2 5 1000137001 Magnetic substance 4 6 1000131010 Spring for urgent reversing button 4 7 0000023058 Screw 3 GB/T70.1=ISO4762 8 0000023057 Screw 2 GB/T70.1=ISO4762 9 0000025017 Washer 2 GB/T95 10 1010114003 Right driving button 1 11 1000107002 Shaft for driving button 1 12 1000137002 Circlip for PCB board 1 13 1000134005 Load censor 2 14 1000103012 Upper part of handle 1 15 1000103013 Under part of handle 1 16 1000114017 Left button 1 17 1000137003 Magnetic substance seat 2 18 1000131011 Torsional spring 2 19 1000114018 Seat for Spring for urgent reversing button 1 20 1000114020 Cover for Spring for urgent reversing button 1 21 1000114021 Cover for option switch 1 22 1000114022 Right button 1 23 0000023060 Screw 1 24 1000134006 LED bi-color light 1 25 1000103014 Seat for LED bi-color light 1 26 1000131012 Torsional spring for right driving button 1 27 1000131013 Torsional spring for left driving button 1 28 1100135001 PCB 1 70 Note Standard GB/T845=ISO7049 Fig. 39 High pressure pump station system（3.0KW pressure delivery capacity） 71 2.6 high Fig. 39 High Pressure Pump Station Syste（3.0KW 2.6 High Pressure Delivery Capacity） No. Parts No. Item Qty. 1 2040334001 Pump contactor 1 2 9000003582 Carbon brush(assembly) 1 3 9000003583 Motor 1 4 2000323001 Plug 1 5 2000300002 Valve body 1 6 2000335003 Solenoid valve 1 7 2000335004 Check valve 1 8 2000323002 Screw 4 9 9000008828 Flow control valve 1 10 2000323003 Bolt 1 11 2040315003 Overflow valve 1 12 2000322004 O ring 1 13 2000317008 Oil return pipe 1 14 2040317008 Oil return pipe 1 15 9000008829 Gear pump 1 16 2040317009 Oil suction pipe 1 17 2000300004 Filter 1 1 □ 9000008796 DC power unit 72 1 Note 9.5L/min 3.0KW 2.6 high pressure delivery capacity 9.5L check valve Fig. 40 Pump station system（3.0KW 3.2 delivery capacity） 73 Fig. 40 Pump Station System（3.0KW 3.2 Delivery Capacity） No. Parts No. Item Qty. 1 2040334001 Pump contactor 1 2 9000003582 Carbon brush(assembly) 1 3 9000003583 Motor 1 4 2000323001 Plug 1 5 2000300002 Valve body 1 6 2000335003 Solenoid valve 1 7 2000335004 Check valve 1 8 2000323002 Screw 4 9 9000008870 Flow control valve 1 10 2000323003 Bolt 1 11 2040315003 Overflow valve 1 12 2000322004 O ring 1 13 2000317008 Oil return pipe 1 14 2040317008 Oil return pipe 1 15 9000008874 Gear pump 3.2cc/r 1 16 9000008873 Oil suction pipe 1 17 2000300004 Filter 1 1 □ 9000008867 DC power unit 74 1 Note 7.5L/min L=250.50mm Pump Station System 3.0Kw， 3.2 delivery capacity Fig. 41 Pump station system（2.2KW 2.2 delivery capacity） 75 Fig. 41 Pump Station System（2.2KW 2.2 Delivery Capacity） No. Parts No. Item Qty. 1 2000335001 Pump contactor 1 2 2000335002 Carbon brush(assembly) 1 Iskra 3 2000334001 Motor 1 Iskra 4 2000323001 Plug 1 5 2000300002 Valve body 1 6 2000335003 Solenoid valve 1 7 2000335004 Check valve 1 8 2000323002 Screw 4 9 2000335005 Flow control valve 1 10 2000323003 Bolt 1 11 2000335006 Overflow valve 1 12 2000322004 O ring 1 13 2000317008 Oil return pipe 1 14 2000317009 Oil return pipe 1 15 2000300003 Gear pump 1 16 2000317010 Oil suction pipe 1 17 2000300004 Filter 1 1 □ 2000300001 DC power unit 76 1 Note 2.2kw 2.2 delivery capacity (Iskra motor) Fig. 42 Main circuit wiring (Electrical steering） Fig. 42 Main Circuit Wiring (Electrical steering) No. Parts No. Name Qty. 1 9000008444 Drive motor cable 1 2 9000008361 Pump motor cable 1 3 9000008362 Power supply cable 1 4 9000008371 FU+ cable 1 5 9000008446 Steering controller cable 1 6 9000008520 Steering motor cable 1 77 Note Fig. 43 Main circuit wiring（Manual steering） Fig. 43 Main Circuit Wiring (Manual steering) No. Parts No. Name Qty. 1 9000008368 Drive motor cable 1 2 9000008361 Pump motor cable 1 3 9000008362 Power supply cable 1 4 9000008371 FU+ cable 1 78 Note Fig. 44 General electrical parts 79 Fig. 44 General Electrical Parts No. Parts No. Name Qty. Note Standard 1 0000023083 Screw 4 M3×8 GB/T70.2=ISO7380 2 9000008332 Magnet switch 2 HWK23 3 0000023033 Screw 2 M4×25 4 2040634001 Proximity switch 1 XZ-15GW22-B 5 9000010040 Proximity switch protective cover AP-B 1 6 9000008360 Limit control wiring harness 1 9000008448 Tiller sensor BD-MS-3 9000000239 Tiller sensor BD-MS 8 0000025026 Washer 3 3 9 0000023216 Screw M3×8 3 10 0000023056 Screw M4×12 4 11 0000025019 Washer 4 4 9000001159 Position sensor BD-PS 9000008451 Position sensor BD-PS-3 7 12 13 9000008355 9000008359 Main control wiring harness GB/T70.1=ISO4762 1 Only for electronical steering truck GB/T95 GB/T818-2000=ISO7045 GB/T70.1=ISO4762 GB/T95 1 电子转向 1 手动转向 80 Fig. 45 Electric control assembly(Electrical steering) 81 Fig. 45 Electric Control Assembly(Electrical steering) No. Parts No. Name Qty. 1 9000008069 Controller assemble plate 1 2 9000000235 Controller 1 9000000236 Steering controller 1 3 9000008584 Note CURTIS1232E-2121 BD-SC-24/10 BD-SC-24/10-3 4 9000008376 Aluminium plate 1 5 1020434002 Wiring terminal 1 BD-M8 6 9000008586 Fuse seat 1 BD-2×10A-1 7 1000434041 Relay 1 ACR01F-F 1C 8 9000007679 9 1000434021 Plug fixing plate Fuse seat Standard 1 1 BD-1×10A 1000434006 Traction motor contactor 1 C100/120 11 9000008598 Main contactor assembly plate 1 12 1020434003 Copper bar 1 13 1000434007 Fuse seat 2 SYY 14 1020434001 Fuse 1 200A 15 2210434004 Fuse 1 150A 16 9000008374 Copper bar 1 17 9000008373 Copper bar 1 18 1000434040 Fuse 1 10A 19 3042434014 Fuse 1 15A 20 0090000082 Screw 2 M4×30 GB/T70.1=ISO4762 21 0000025018 Washer 12 4 GB/T93 22 0000025019 Washer 12 4 GB/T95 23 0000023073 Screw 2 M4×10 GB/T70.1=ISO4762 24 0000023019 Screw 2 M4×30 GB/T818-2000=ISO7045 25 0000023307 Screw 4 M4×10 GB/T818-2000=ISO7045 10 82 26 0000023211 Screw 4 M4×16 GB/T818-2000=ISO7045 27 0000025010 Washer 9 6 GB/T93 28 0000023055 Washer 9 6 GB/T95 29 0000023478 Screw 5 M6×12 GB/T70.1=ISO4762 30 0000023923 Screw 4 M6×18 GB/T70.1=ISO4762 31 0000025001 Washer 12 8 GB/T93 32 0000025011 Washer 11 8 GB/T95 33 0000024086 Nut 12 M8 GB/T6170=ISO4032 34 0000023067 Screw 4 M8×16 GB/T70.1=ISO4762 35 0000023516 Screw 1 M5×10 36 0000025015 Washer 1 5 GB/T93 37 0000025014 Washer 1 5 GB/T95 38 0000023070 Screw 2 M3×25 GB/T70.1=ISO4762 39 9000008356 Controller 1 40 9000008372 Copper bar 1 41 1000434015 Horn 1 DC24V 42 0000023727 Screw 2 M4×6 83 GB/T818-2000=ISO7045 GB/T818-2000=ISO7045 Fig. 46 Electric control assembly(Manual steering) 84 Fig. 46 Electric Control Assembly(Manual steering) No. Parts No. Name Qty. 1 9000008375 Controller 1 2 9000008069 Controller assembly plate 1 3 9000000235 Controller 1 CURTIS1232E2121 4 1000434040 Fuse 1 10A 5 9000008376 Aluminium plate 1 6 1020434002 Wiring terminal 1 BD-M8 7 9000008586 Fuse seat 1 BD-2×10A-1 8 1000434041 Relay 1 ACR01F-F 1C DC24V 9 9000007679 Plug fixing plate 1 10 1000434006 Traction motor contactor 1 11 9000008598 Main contactor assemble plate 1 12 1020434003 Copper bar 1 13 1000434007 Fuse seat 2 SYY 14 1020434001 Fuse 1 200A 15 2210434004 Fuse 1 150A 16 9000008374 Copper bar 1 17 9000008373 Copper bar 1 18 0000025014 Washer 1 5 GB/T95 19 0000023516 Screw 1 M5×10 GB/T818-2000=IS O7045 20 0000025015 Washer 1 5 GB/T93 21 0000025018 Washer 12 4 GB/T93 22 0000025019 Washer 12 4 GB/T95 23 0000023073 Screw 2 M4×10 GB/T70.1=ISO476 2 24 0000023019 Screw 2 M4×30 GB/T818-2000=IS O7045 25 0000023307 Screw 4 M4×10 GB/T818-2000=IS O7045 26 0000023211 Screw 4 M4×16 GB/T818-2000=IS O7045 27 0000025010 Washer 9 6 GB/T93 28 0000023055 Washer 9 6 GB/T95 85 Note Standard C100/120 DC24V 29 0000023478 Screw 5 M6×12 GB/T70.1=ISO476 2 30 0000023923 Screw 4 M6×18 GB/T70.1=ISO476 2 31 0000025001 Washer 12 8 GB/T93 32 0000025011 Washer 11 8 GB/T95 33 0000024086 Nut 12 M8 GB/T6170=ISO40 32 34 0000023067 Screw 4 M8×16 GB/T70.1=ISO476 2 35 9000008372 Copper bar 1 36 1000434015 Horn 1 DC24V 37 0000023727 Screw 2 M4×6 86 GB/T818-2000=IS O7045 Fig. 47 Foldable platform 87 Fig. 47 Foot Pedal Assembly No. Art No. Description Qty. 1 9000007867 Pedal pad 1 2 9000007869 Rotating shaft 1 3 9000007799 Shoulder harness 4 4 9000007863 Welded foot platform 1 5 6 0000023555 2000421001 Screw Air spring 2 1 M6×16 GB/T70.2=ISO7380 7 0000024014 Nut 1 M16×1.5 GB/T6173=ISO8675 8 9000007873 Cam 1 9 9000007866 Cam shaft 1 10 0000025012 Washer 2 5 GB/T93 11 0000023032 Washer 2 5 GB/T95 12 0000023107 Screw 2 M5×16 GB/T70.1=ISO4762 13 9000009799 Switch transition plate 1 14 9000008328 Proximity switch 1 NBN5-F7-E2 15 0000023075 Screw 2 M3×20 GB/T70.1=ISO4762 16 9000007864 17 0090000048 Welded assemble seat Washer 4 12 GB/T97.1-2002 18 0000025024 Washer 4 12 GB/T93 19 9000007874 Line hanging board 1 20 0000024006 Lock nut 4 M12 GB/T889.1=ISO7040 21 0090000450 Screw 4 M12×45 GB/T70.2=ISO7380 22 9000007865 Cushion 2 23 9000007872 Anti-vibration pad 2 24 9000007871 Anti-vibration washer 2 25 0000031001 Spring 8 16.3×31.5×1.75 GB/T1972-2005 26 9000007870 Fixed bolt 2 27 0000028033 Split pin 2 3.2×20 GB/T91=ISO1234 28 9000007868 29 0000025010 Assemble seat cover Washer 6 6 GB/T93 30 0000023045 Screw 6 M6×12 GB/T70.2=ISO7380 Note Standard 20×23×16.5 1 1 88 31 9000008897 Suspension components 2 89 Fig. 48 Protective arm 90 Fig. 48 Protective Arm No. Art No. 1 9000007895 2 Description Qty. Note Standard M8×20 GB/T70.2=ISO7380 0090000448 Right protective arm cover Screw 5 3 9000007896 Left protective arm cover 1 4 9000007894 Welded protective arm 1 5 9000007780 Air spring 1 6 0000023045 Screw 3 M6×12 GB/T70.2=ISO7380 7 0000025010 Washer 3 6 GB/T93 8 9000007897 Positioning spring 1 9 0000023075 Screw 2 M3×20 GB/T70.1=ISO4762 10 9000008329 Proximity switch 1 NBN5-F7-E2 11 0000025012 Washer 2 5 GB/T93 12 0000023032 Washer 2 5 GB/T95 13 0000023107 Screw 2 M5×16 GB/T70.1=ISO4762 14 9000009799 Switch transition plate 1 15 9000007892 Welded protective arm seat 1 16 0000023006 Washer 4 10 GB/T93 17 0090000447 Screw 4 M10×25 GB/T70.2=ISO7380 18 9000007893 19 0000023099 M10×45 GB/T70.1=ISO4762 1 Protective arm clamp block Screw 2 4 91 Fig. 49 Backrest (Normal) Fig. 49 Backrest No. Parts No. 1 9000008259 2 Name Qty. Note Standard 0000023088 Backrest frame welding Screw 2 M10×25 GB/T70.1=ISO4762 3 0000025002 Washer 4 10 GB/T95 4 0000023006 4 10 GB/T93 5 0000023029 2 M10×35 GB/T70.1=ISO4762 1 Standard spring washer Screw 92 Fig. 50 Backrest (Straddle Leg) Fig. 50 Backrest (Straddle Leg) No. Parts No. Name Qty. 1 0000023156 Screw 4 2 0000025032 Washer 4 12 GB/T93 3 0000025024 Washer 4 12 GB/T95 4 9000009068 Backrest frame welding 1 93 Note Standard GB/T70.1=ISO4762 Easy worn parts list No. Art No. 1 2220511001 2 2330511001 3 Description Compound roller 1 Qty. Fig./Position Note 4 Fig.6/1 Fig.7/1 Chassis Fig.7/2 2040511001 Compound roller 1 8 Fig.18/4 2 Fig.19/11 Fig.20/11 2 Fig.19/3 Fig.20/3 Mast system 4 2220611001 5 9000003638 Castor 2 Fig.12/13 Steering wheel 6 9000007806 Damper 1 Fig.34/7 Electric steerig 7 9000010398 Load wheel set 2 Fig.13/7 Load wheel 8 1010121001 Air spring (S≥55) 1 Fig.37/13 Tiller 9 9000003582 Carbon brush 1 Fig.39/2 Pump 10 1020434001 Fuse 200A 1 Fig.45/14 11 2210434004 Fuse 150A 1 Fig.45/15 12 1000434040 Fuse 10A 1 Fig.45/18 13 3042434014 Fuse 15A 1 Fig.45/19 14 9000007799 Shoulder harness 4 Fig.47/3 15 2000421001 Air spring (S≥70) 1 Fig.47/6 16 9000008897 Suspension components 2 Fig.47/31 17 9000007780 Air spring (S≥36) 1 Fig.48/5 Protective arm 18 9000003636 Outer cylinder seal kit 2 1 Fig.28/□ 19 9000003637 Middle cylinder seal kit 1 1 Fig.29/□ Three-stage mast Full Free Lift / Straddle Leg Electric Control Foot pedal 20 9000009943 Cylinder 1 1 Fig.30/□ Two-stage mast Normal / Straddle Leg 21 9000009944 Cylinder 2 1 Fig.31/□ Two-stage mast Full Free Lift 1 Fig.8/□ 22 9000010408 Castor complete 2 1 Fig.9/□ 1 Fig.10/□ 1 Fig.11/□ 94 Chassis system
