Flexi VNA ACiON - Narrow Aisle Inc

Issue A 25/6/2019

Flexi ACiON

Operator Handbook

VNA

1000

1100

1200

1250

1350

1400

Contents

i

Flexi ACiON Operator Handbook

Contents Page

Technical Specification

Truck Capacity Plate ................................................................................................................................ 1

Standard Technical Data .......................................................................................................................... 2 Dimensions ............................................................................................................................................... 3 Installation ................................................................................................................................................ 4

Floors .................................................................................................................................................. 4 Racking ............................................................................................................................................... 4

Health and Safety

Foreword .................................................................................................................................................. 5 Warnings used in this Handbook .............................................................................................................. 5 Product Definition ..................................................................................................................................... 6

General ................................................................................................................................................ 6 Truck Specification .............................................................................................................................. 6 Service ................................................................................................................................................ 6 Guide To Correct Operation ................................................................................................................ 6 Safety Is Your Business ...................................................................................................................... 6

Warning Statements ................................................................................................................................. 7 Know The Equipment ..................................................................................................................... 7 Look Where You Are Going ........................................................................................................... 7 Know Your Loads ........................................................................................................................... 7 Know The Area............................................................................................................................... 7 Use Common Sense ...................................................................................................................... 7 Protect Yourself & Others .............................................................................................................. 7

Warning Labels ......................................................................................................................................... 9 Safety Precautions ................................................................................................................................... 8

General ................................................................................................................................................ 8 Safe Driving ......................................................................................................................................... 9 Battery Charging ............................................................................................................................... 10 Operating In Hazardous Areas .......................................................................................................... 10 Safe Driving On Gradients ................................................................................................................ 10

Transport and Commissioning

Transportation (Slinging Points) ............................................................................................................. 11 Commissioning ....................................................................................................................................... 11

Technical Description

Truck Layout ........................................................................................................................................... 13 Model Description ................................................................................................................................... 13

General .............................................................................................................................................. 13 Operator Protection Equipment ......................................................................................................... 13 Controls (Refer to Illustration on previous page.) ............................................................................. 13 Other Options .................................................................................................................................... 16

Pre Use Inspection

Pre Use Inspection ................................................................................................................................. 19 Operator Qualifications...................................................................................................................... 19 Pre-Operational Check ...................................................................................................................... 19 Operator Responsibilities .................................................................................................................. 19

NA Data Plate ................................................................................................................................. 1A

Contents ii


Contents (continued) Page

Operation

Operating Techniques ............................................................................................................................ 20 General .............................................................................................................................................. 20

Mounting/Dismounting ................................................................................................................. 20 Driving The Truck .............................................................................................................................. 20

Use of the tilt function ................................................................................................................... 20 Travel ........................................................................................................................................... 20 Steering ........................................................................................................................................ 20 Starting On A Gradient ................................................................................................................. 20

Turning in a Narrow Aisle .................................................................................................................. 21 Loading .............................................................................................................................................. 21 Stacking / De-stacking....................................................................................................................... 21 Stacking ............................................................................................................................................. 21 De-stacking ....................................................................................................................................... 21 Dynamic Method ............................................................................................................................... 22 Dynamic De-stacking ........................................................................................................................ 22 Dynamic Stacking .............................................................................................................................. 22 Operating Conditions......................................................................................................................... 22

Floor Surface ................................................................................................................................ 22 Gradients ...................................................................................................................................... 22

Limit Switch And Interlock Layout ..................................................................................................... 22

Maintenance

Maintenance ........................................................................................................................................... 24 General .............................................................................................................................................. 24

Operator Maintenance ............................................................................................................................ 24 Daily Maintenance ............................................................................................................................. 24 Weekly Maintenance ......................................................................................................................... 24 Routine Maintenance ........................................................................................................................ 23 Putting a Truck in Storage ................................................................................................................. 25 Moving a Disabled Lift Truck ............................................................................................................. 26 Towing a Lift Truck ............................................................................................................................ 26 Removal and Replacement of Forks ................................................................................................. 26

Battery Maintenance............................................................................................................................... 27 Battery Removal ................................................................................................................................ 27 Battery Servicing and Charging ........................................................................................................ 28

Safety Precautions ....................................................................................................................... 28 Battery Charging ............................................................................................................................... 28 Care of Battery out of Service ........................................................................................................... 28 Waterfill Systems ............................................................................................................................... 28 Battery Charger Connections ............................................................................................................ 29

Optional ExtrasAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA.AAAAA.31 Pre-Shift ChecklistAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA34

Technical Specification 1


Truck Capacity Plate

Feature Approval for use in / Measurement

Truck – as detailed above Normal environment – see Operator Handbook

Electromagnetic compatibility – Emissions Light Industrial – EN 50081-1 1992

Electromagnetic compatibility – Immunity Industrial environment – EN50082-2 1993

Noise – at the Operators ear LpAeq,T 73dB

Truck Model Rated Capacity Year of Manufacture

Actual Capacity Lift height to which Actual Capacity applies Reduced Capacity Lift height to which Reduced Capacity applies Load Centre

Technical Specification

1A

Flexi AC Operator Handbook



Standard Technical Data - Example

No. Feature Ref Description Units Value

1 Model FLEXI ACiON 1200

2 Rated Capacity kg 2000

3 Load centre mm 500

4 Chassis width - front B1 mm 1110

5 Chassis width - rear B mm 1200

6 Lift height h3 mm See Specification

7 Height of mast - lowered h1 mm See Specification

8 Height of mast - raised h4 mm See Specification

9 Height over guard h6 mm 2260

10 Height of seat h7 mm 1160

11 Fork length L mm See Specification

12 Fork section Width x Thickness mm 100 X 40

13 Fork spread B3 Maximum/minimum mm 800/265

14 Travel speed Laden / unladen kph 8.0/9.0

15 Lift speed Laden /unladen m/s 0.35/0.45

16 Lowering speed Laden /unladen m/s 0.40/0.20

17 Overall length L1 To face of fork mm 2560

18 Wheel base y mm 1745

19 Gradeability Laden/unladen % 8/10.5

20 Ground clearance m mm 46

21 Wheels Front / rear - Driven * 2*/2

22 Front tyre size Diameter x width mm 412 x 178 (see label)

23 Rear tyre size Diameter x width mm 457 x 150 (see label)

24 Weight of truck Unladen less battery kg See Capacity Plate

25 Battery voltage V 48

26 Battery capacity Ah 775

27 Battery weight Minimum/maximum kg 1180 / 1240 (See Label)

Note: These figures are representative and will vary according to exact truck specification.



Dimensions



Installation Installation Information for Very Narrow Aisle

Floors

Strength: With such compact equipment it is inevitable that the wheel loadings will be high. The wheels are normally fitted with super elastic rubber tyres. Wheel sizes are stated on a label mounted inside the overhead guard. Flatness: The main areas measured are the working aisles themselves, but guidance is also given for free movement areas. The industry guidelines set out below are taken from the report No. 34 Appx. C by The Concrete Society; they generally apply to guided VNA truck systems which normally do not have tilting lift masts and operate with aisle operating clearances of 100mm to 150mm each side. The Flexi AC range does not have the same operating restrictions as the lift mast can be tilted to overcome some degree of slope, the Flexi AC normally operates with a minimum of 300mm aisle clearance on each side so floor flatness is not as critical as guided alternatives. Therefore most Flexi AC installation have floors rated at category 2 or 3 depending on the lift height up to 13 metres.

Category For Use With Location

Superflat

VNA warehouses with min clearance between fixed and moving pallets: Max throughputs: Max truck speed: Max permitted racking height.

Defined Movement

1 VNA warehouses where the racking height varies between 8m and 13m.

Defined movement

2 VNA warehouses where the racking height is less than 8m.

Defined movement

3 Narrow and wide aisle warehouses Free movement

Racking

Full details of the erection tolerances for narrow aisle racking may be found in Guideline No. 2 in the SEMA publication - Erection tolerances for Static Racking.

Health and Safety 5


Foreword The range of lift trucks manufactured by Narrow Aisle Limited. comply with the latest safety regulations and are equipped with the most up-to-date technology. It is in your own interest to ensure that you are able to safely operate the truck and obtain full benefit from its operational efficiency. This handbook is intended to give you the necessary information. Read it carefully and follow the instructions before attempting to operate the truck. In this way you will avoid accidents, save yourself trouble and preserve your truck warranty. Operational efficiency depends upon:-

• Correct usage

• Daily checks by the operator before commencing work

• Regular maintenance We are constantly improving our products, which is why Narrow Aisle Limited reserve the right to introduce changes without notification. The truck for which this operator handbook has been written has been produced in conformance with the Machinery Directive 2006/42/EC and is accordingly CE marked and accompanied by a Declaration of Conformity. To maintain the validity of this Declaration you as the USER of this truck must not modify the truck in any way without the authorisation of the Manufacturer. If any changes to the truck are required, Narrow Aisle Limited should be consulted and they will approve any changes that will maintain the validity of the Declaration. If changes are made without consultation with Narrow Aisle Limited, the responsibility for conformance to the Machinery Directive may be transferred to you as the USER.

Warnings used in this Handbook The warnings and cautions used throughout this Handbook are described below:

WARNINGS

Failure to follow the information contained in a warning notice could result in serious personal injury or even death.

CAUTIONS Failure to follow the information contained in a caution notice could result in damage to the Fork Truck, racking or load. Notes: Notes give additional important information.

Modifications

No modifications or alterations to the truck which could affect, for example, capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the original truck manufacturer or their authorised representative. This includes changes affecting, for example, braking, steering, visibility and the addition of removable attachments. Only if the truck manufacturer is no longer in business and there is no successor in the interest to the business, may the user arrange for a modification or alteration to a powered industrial truck, provided, however, that the user a) Arranges for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety. b) Maintains a permanent record of the design, test(s) and implementation of the modification or alteration. c) Approves and makes appropriate changes to the capacity plate(s), decals, tags and instruction handbook. d) Affixes a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration and the name and address of the organisation that accomplished those tasks.

Health and Safety 6


Product Definition The model covered by this publication is THE NARROW AISLE LIMITED FLEXI ACiON RANGE.

General

These articulated fork lift trucks are designed for use in ambient thermal conditions between 0°C and +30°C if the correct hydraulic oils and greases are used. For operation outside these temperatures, please consult the manufacturers as special modifications and lubricants may be required. The standard truck must not be operated in areas where flammable products may be present, corrosive atmospheres, or in areas containing a high degree of dust contamination. Only trucks specifically designed to operate in these conditions, or modified with written approval, should enter such areas. The safe maximum load capacity of the truck with relation to the load centre and fork heights, which MUST NOT BE EXCEEDED, is stated on the capacity plate. The truck must be operated strictly in accordance with the operating instructions provided in this handbook and in conjunction with the safety regulations and recommendations of the country in which the fork lift truck is being operated.

Truck Specification

Modifications MUST NOT be carried out on the truck or its attachments which in any way may affect its operational performance, safety and stability without consultation and the prior written approval of the manufacturer Narrow Aisle Limited. The following are examples of notifiable modifications, but the list is not exhaustive. 1. Changing the specification of the lift mast. 2. Changing the specification of the wheels and or

tyres. 3. Addition or removal of ballast in the

counterweight of the truck. 4. Addition of an attachment.

5. Replacement of batteries and battery tank/

ballast.

6. Modification or repair to the Operators Overhead Safety Guard.

Service

Narrow Aisle Limited, Flexi ACiON trucks are built with high quality components. The use of inferior spare parts could result in inadequate safety and poor reliability. We strongly recommend the use of genuine Narrow Aisle Limited spares. Notwithstanding good engineering practice, servicing should only be carried out by technicians trained to a standard, and in accordance with guidelines, approved by Narrow Aisle Limited. We will not recognise any complaint resulting from the use of unauthorised spare parts.

Guide to Correct Operation

This Operator handbook is designed to provide information to the lift truck operator on how to operate the Flexi ACiON truck correctly. It is written as a permanent reference, and must be available for operator use at any time. You, as a trained operator, must operate the lift truck correctly to help prevent injury to yourself and others. Correct operation of the lift truck can help reduce injuries and deaths that occur each year because of industrial accidents. The handbook also describes the correct operating techniques that can help you become more efficient and increase your productivity. Increased efficiency and productivity can make you a more valuable employee.

Safety Is Your Business

You can only operate your lift truck safely if you observe the WARNINGS on the next page and follow the operating procedures described in this OPERATOR HANDBOOK.

Health and Safety 7


Warning Statements

WARNING This truck must only be operated by Authorised Trained Personnel

Know the Equipment

• KNOW operating, inspection and maintenance instructions and warnings in this MANUAL.

• DO NOT operate or repair truck unless trained and authorised.

• INSPECT truck before use. If truck needs repair do not operate. Label truck and remove key. Have truck repaired before use.

• USE the truck for intended purpose only.

Look Where You Are Going

• IF VISION IS BLOCKED, DON'T GO!

• On level ground TRAVEL in reverse if load blocks forward vision.

• SOUND horn at intersections and wherever vision is blocked.

• ALWAYS check the heights of doorways and any overhead restrictions to ensure that there is clearance for the truck to pass.

Know Your Loads

• HANDLE only stable loads within specified weight and load centre. See Capacity Plate on this truck.

• SPACE forks to support the load. Keep load against the vertical face of the forks.

• WHEN travelling, lower the forks to around 150mm of the floor.

Know the Area

• CHECK for adequate floor strength at ALL times.

• CHARGE battery only in designated area.

• AVOID bumps, holes, loose material and slippery areas.

Use Common Sense

• NEVER transport people on any part of the truck.

• DO NOT use truck to lift people unless an approved attachment is used. Additional safety considerations will apply.

• ALLOW NO ONE under or near lift mechanism or load.

• OPERATE truck only from operator's seat.

• KEEP arms, legs and head inside operator's compartment.

• OBEY traffic rules. Yield right-of-way to pedestrians.

• BE in complete control at all times.

• BEFORE DISMOUNTING, set parking brake and neutralise travel control, lower carriage, turn key switch to "O".

• WHEN PARKING, set parking brake, neutralise travel control, lower carriage, turn key switch to "O". Block wheels on inclines.

Protect Yourself & Others

• AVOID sudden movements. Operate all controls smoothly.

• NEVER turn on or angle across an incline. Travel slowly.

• TRAVEL on inclines with load uphill or unloaded with mast downhill.

• TILT mast slowly and smoothly. LIFT or LOWER with mast vertical or tilted slightly back. Use minimum tilt when stacking elevated loads.

• TRAVEL with carriage as low as possible and tilted back.

• SLOW DOWN before turning - especially without load. FAILURE to follow this instruction can cause the truck to tip over!

• In the event of tip over DO NOT JUMP off the truck. HOLD steering wheel firmly. BRACE your feet LEAN AWAY from impact. Always wear seat belt.

Health and Safety 8


Safety Precautions

General

Narrow Aisle Limited will only supply vehicles equipped with recommended safety devices and strongly urges that these vehicles be operated with the safety devices supplied.

Warning Labels

Health and Safety 9


Narrow Aisle Limited will not assume any liability for injuries or damage arising from or caused by the removal of any safety devices from their vehicles by the user. Fork lift trucks must only be operated by fully trained, qualified and authorised operators. Ensure that the truck is suitable for the area in which it is to be operated. Do not allow anyone to walk or stand beneath elevated forks. Do not exceed displayed load capacity of the truck. In no circumstances should counterweights be added to increase capacity. If the hoist mechanism malfunctions or becomes stuck in a raised position, operate the hoist control lever to eliminate any slack in the chains. DO NOT go under the elevated parts of the truck to attempt to carry out repairs.

WARNING Never lower the hoist mechanism with the load or forks supported by other means.

Safe Driving

Before moving off, look around and when clear, commence driving without causing inconvenience to other truck operators. Remember that pedestrians have right of way and must be safeguarded at all times. Operate truck smoothly without erratic movements avoiding fast turns. Regulate the speed of the truck to conform with prevailing conditions. Ensure that the truck can be brought to a halt safely. Maintain a safe driving distance from other vehicles. Always give clear indication of your intentions to other people. Do not carry passengers. When approaching crossings and areas where driving vision is restricted or obscured, reduce speed to a minimum and sound the horn - a series of short blasts is more effective than one long blast. Always travel with forks and mast in correct travelling position, i.e. mast fully tilted back and the lowest point of the forks or load approximately 150mm above the ground.

Do not overtake at aisle intersections, in areas of limited visibility or in dangerous locations. Maintain a safe distance from railway lines, ramps, platforms, dock edges, etc. Cross railway lines slowly, only at authorised points and diagonally whenever possible. Be conscious of height and width restrictions and watch for sudden appearance of pedestrians from behind obstacles. Do not carry unsafe or insecure loads.

WARNING Keep arms, hands, head and legs within the operator's compartment when the truck is in motion.

WARNING Do not place arms, hands, head or legs between mast uprights and cross members or any other working parts of the truck.

Health and Safety 10


Battery Charging

Charging installations must be sited in designated areas that are well ventilated and properly equipped. Batteries contain sulphuric acid and generate explosive gasses when being charged. They must be charged in designated, well ventilated areas by trained and authorised personnel only. When checking electrolyte levels, do not use a naked flame eg.cigarette lighter or matches for illumination. When transporting, checking or charging batteries the operator should wear protective clothing and goggles and take particular care not to spill or come into contact with electrolyte (battery acid). Fire fighting equipment and a supply of fresh, clean water should be ready available in the charging area at all times in case of accidents. In the event of an accident flush acid away from the eyes and/or skin using plenty of plain water and obtain medical attention immediately. If battery acid is spilled on the floor, clean up promptly using a neutraliser such as baking soda.

WARNING Smoking and the use of naked lights in the charging area is strictly prohibited.

Operating In Hazardous Areas

No spark proofing is fitted to the truck as standard. Consequently it MUST NOT be used in flammable or explosive areas. For further details contact the manufacturer. The truck MUST NOT be used in corrosive atmospheres or in areas containing a high degree of dust contamination.

Safe Driving On Gradients

When differences in levels exist, low gradient ramps should be provided having smooth, gradual level changes at the top and bottom to prevent shocks to the load or fouling of the forks. Do not drive across, turn or stack on gradients. Correct gradient procedure should be followed at all times. Do not park on a gradient. In an emergency apply the Parking Brake and chock the wheels - but do not leave the truck unattended. Note: When carrying the maximum permitted load and the Parking Brake Lever is in the "On" position the brakes will hold the truck on a 10% (6º) gradient having a smooth, dry and clean concrete surface. When a load is being carried, the load should face uphill. When no load is being carried the forks should face downhill.

Maintenance Platforms (Cages)

Sometimes known as Working Platforms are attachments used to raise persons to a height. Such platforms, the truck used and the method of operation should all comply with the Guidance Note PM28 issued by the Health & Safety Executive.

Technical Description 11


Transportation (Slinging Points) There are two distinct methods of transporting a Flexi ACiON articulated truck: If the overall height of the mast is too great to transport the truck upright, the truck must be disassembled before transportation. The disassembly and re-assembly of the truck is a skilled operation and must be carried out by a competent engineer from Narrow Aisle Limited, or their authorised dealer. Otherwise the truck can be loaded for transportation as a complete truck.

If there is a need to lift the truck for loading or unloading using an overhead crane, use the following procedure:

• Raise the battery cover, disconnect the battery plug.

• Remove the battery cover from the truck and store in a safe place to avoid damage.

• Remove the battery as described in Battery Maintenance Section, starting on page 25.

• Note: For weight of battery and truck see the Capacity Plate mounted on the truck.

• Using an odd leg chain sling or lifting beam with 4 safety hooks or shackles with a safe working load of 8 tonnes minimum, locate the hooks or shackles at the lifting points of the truck, as shown with a lifting symbol.

• Carefully raise the truck, checking that the length of the slings will keep the truck horizontal. If this is not so, lower the truck and reduce the length of the offending chain by an approved method.

• When the lifting/lowering is complete, remove the chains and replace the battery (see Battery Maintenance Section, starting on page 25).

• Refit the battery lid.

• Reconnect the battery.

Commissioning Before operating the truck for the first time, ensure that the whole truck is assembled by a competent engineer from Narrow Aisle Limited, or their authorised agent. All hydraulic and electrical connections must be checked, especially those which have been disconnected for transportation. Some nuts and bolts must be tightened to designated settings and the oil level of the hydraulic tank must be checked. The commissioning of the truck in its designated work area may now commence. All this work should be carried out by Narrow Aisle Limited engineers or their authorised agents.

Located at the top of the mast

Use handle holes in OHG upright or Holes in main bulkhead



Controls Etc.



Model Description

General

This Operator's Handbook is for The Narrow Aisle Limited. Flexi ACiON Range. The operation of the Flexi ACiON Range is as follows: A battery supplies power for the traction motor, hydraulic pump motor, power steering pump motor and the control panel and instruments. The motors are controlled by an electronic control system. Forward or reverse travel selection is controlled by the Travel Direction Lever mounted to the right of the operator. The Accelerator Pedal controls travel speed. The truck has an electronic braking system in addition to service brakes. The Service Brake Pedal applies the hydraulic service brakes at the rear wheels and cuts power to the traction motor. The Parking Brake is applied by a lever situated to the right of the operator, this also cuts power to traction when applied. The truck is equipped with a multi function Display screen (8).

Operator Protection Equipment

The Overhead Guard is intended to offer protection to the operator from falling objects, but cannot protect against every possible impact. Therefore, it must not be considered a substitute for good judgement and care when handling loads. DO NOT REMOVE THE OVERHEAD GUARD. A Load Backrest Extension may be installed if required on your machine. Contact Narrow Aisle Limited for details.

Controls (Refer to Illustration on previous page).

Item 1 - Capacity Plate

The Capacity Plate is located to the right of the driving position and states the truck designation, rated and actual capacities at various lift heights and load centres. Ensure that these safe loading capacities are understood before handling any loads and are not exceeded.

Item 2 - Seat

The operator's Seat has been chosen to minimise fatigue and maximise comfort. Comprehensive adjustment may be carried out to the seating position. (Refer to illustration).

Item 2a - Seat Belt

A simple lap Seat Belt is provided for operator protection. IT IS STRONGLY RECOMMENDED THAT THE SEAT BELT BE WORN AT ALL TIMES.

Item 2b - Fore and Aft Adjustment

Pull this lever upwards to adjust the Fore and Aft position of the Seat. Slide the Seat forwards or backwards to the required position and release the lever. Move the Seat slightly until the lever latches into position. The Seat must be latched in position before the truck is operated.

Item 2c - Seat Back Rake Angle

To adjust the Rake Angle of the Seat Back, pull the handle upwards and slide the seat cushion forwards or backwards until the required angle is achieved. Release the lever to secure the Seat in position.

Item 2d - Operator Weight Adjustment

To adjust the Seat to suit the weight of the operator, push down firmly on the handle until the correct operator weight is indicated. If the indicated weight is too great, press down firmly on the handle until it reaches the end of travel and allow the handle to rise to the required weight.

Item 3 - Armrest

The Armrest hinges up to give access to the storage area beneath.

Item 4 - Steering Column Adjuster

The angle of the Steering Column may be adjusted to suit the operator. Turn the adjusting lever anticlockwise to release the column. Turn the lever clockwise to lock. Once locked, the position of the lever can be changed by depressing the button in the centre and turning. The column must be locked in position when driving.

Item 5 - Emergency Stop

This is sited at the right hand side of the steering column support for ease of access and is connected to the truck electrical system.

2c

2b

2a

2d



The Emergency Stop is used as a master isolator to disconnect the battery in an emergency. In the unlikely event that an electrical failure causes the truck to become uncontrollable, press the Red button fully in until it latches. This will immobilise the truck. In the event of the power supply to the truck being interrupted, for example by operating the Emergency Stop, the isolator must be reset by twisting the button counter-clockwise until it resets. The Key Switch (8) must then be turned to the 'O' position and turned back to 'I' in order to re-energise the electrical system.

Item 6 - Charger - Not Shown

The charger is connected to recharge the battery. It must NOT be connected to the Battery Isolator Socket (5). (See Battery Maintenance starting page 26).

Item 7 - Key Switch

The Key Switch has two positions, "O" and "I". Insert the key and turn clockwise to the "I" position to enable the truck to function.

Item 8 - Display Unit

• Power On Indication When the Key Switch (8) is turned to the "I" position, the Display will illuminate, indicating that the truck is ready for operation.

• State of Charge Indication The battery state of charge indication (Battery Level) is shown by a number of bars, each representing 10% of capacity. As the battery is discharged, the bars will progressively reduce. When the remaining battery charge reaches 40%, the bars will start to blink. When the residual charge reaches 20%, the battery symbol will also blink and the hydraulic functions (Lift, Tilt & Sideshift) will be disabled. Traction remains operational allowing the truck to be driven to the recharge point. Low Battery LED - This will light when the battery voltage is 40% or less than the nominal voltage (48v)

• Hour Meter This shows the total number of operating hours worked by the truck.

• Spanner Warning Shows that maintenance is due or one of a number of alarm codes. The display will indicate the alarm state, showing a code corresponding to the type of alarm. The information supplied by this display can be extremely useful. Failures can be quickly

identified by the Service Technician thereby providing the fastest solution to the problem. In this situation note the code number and controller following the error code (eg: A226 on PUMP) and discontinue use of the truck. Contact Narrow Aisle Limited or your authorised service agent.

• Creep Speed Indicates that the mast is raised above the 'free lift' portion and the slow speed safety interlock is activated. • Selection Keys These are used by authorised service technicians to amend performance parameters.

Item 9 - Steering Wheel The Steering Wheel is sited approximately central to the operator and inclined to reduce fatigue. Power steering is fitted as standard and is active when the Parking Brake is released, the operator is seated and the steering wheel is turned. The power steering will cut out a short while after the wheel is released. To keep the power steering energised, keep pressure on the wheel.

Item 10 - Travel Direction Lever

To travel forward, move the lever forward until it latches into position. To travel in reverse, move the lever in the opposite direction. To prevent accidents, if a direction is still selected when the operator dismounts the truck, the system will automatically reset to neutral. Before reselecting a direction, the Travel Direction Lever must first be returned to the neutral (centre) position. This lever is also used for electronic braking in conjunction with the Accelerator Pedal (11). (See Operation Section, starting on page 18).

Item 11 - Accelerator Pedal

The pedal is mounted on the cab floor and is operated with the right foot. . This pedal is also used for electronic braking in conjunction with the Travel



Direction Lever (10). (See Operation Section, starting on page 18).

Item 12 - Service Brake Pedal

Depressing this pedal applies the service brakes at the rear wheels. To prevent misuse, an incorporated switch disables traction when this pedal is depressed. (See Starting on a Gradient page 20).

Item 13 - Parking Brake Lever

Pull this lever upwards to apply the parking brake. Push the button on the end of the lever to release. A switch is incorporated in the lever to prevent steering and traction when the brake is applied. (See Starting on a Gradient, page 20).

Item 14 - Horn Button

The Horn Button is fitted to the front electrical cover above the Parking Brake Lever. Pressing the button will sound the horn. An additional horn button is located to the Left side of the footplate for easier use when reversing.

Item 15 - Lift Lever

Pull the lever to raise the forks. Push the lever to lower the forks.

Item 16 - Mast Tilt Lever

Pull the lever to tilt the mast backwards. Push the lever to tilt the mast forwards past the vertical. (See page 18 for full details of use of the tilt function).

Item 17 - Side Shift Lever

This lever controls the sideways movement of the forks for minor positioning adjustments. Pull the lever back to move the forks to the right, push the lever forwards to move the forks to the left. Always centralise the forks when travelling.

Item 18 - Work Lights

Work lights are added to provide additional illumination. A switch is fitted on the seat pan to the left of the operator to turn the lights on/off.

Item 19 - Flashing Beacon

This is fixed to the top of the overhead guard to warn pedestrians and other drivers that the truck is operational. The light is switched on automatically by the Key Switch (8). Blue Point Warning Light This is fitted to project a blue spot of light on the floor either behind or in front of the truck to warn pedestrians.

WARNING

When illuminated, do not look directly into the light for extended periods. This is not deemed to be dangerous as the natural instinct is to close the eyes or look away. Options A weatherproof cab may be fitted consisting of a rigid front windscreen, and a flexible fabric cover around the sides, top and rear.

Windscreen Wiper (Optional) - Not Shown

This is activated by a switch on the rear of the windscreen wiper motor cover.

CAUTION

Do not operate the windscreen wiper when the windscreen is dry. Permanent marking of the surface will result.

Height Override Switch (Optional) - Not Shown

When the forks reach a predetermined height the hydraulic functions are disabled to prevent overhead collisions. To operate the hydraulic functions further it is necessary to turn the height override key switch to the 'ON' position (or operate the push button) then operate the appropriate lever. In these circumstances the operator must take care to avoid colliding with lights, roof trusses or other obstructions. Turning the height override key switch to the 'ON' position below height cut-out will result in the loss of all hydraulic functions. Item 20 – Seat Latch This latch retains the seat pan and prevents it rising inadvertently. To release the latch, remove the battery lid and reach under the seat pan, to locate the circular handle. Pull this to allow the latch to disengage and tilt the seat back a small amount. Withdraw your hand before tilting the seat further. The latch engages automatically when the seat is lowered.

Pre Use Inspection 16


Other Options

Keypad Entry (Electronic Code Switch ECS)

Indication Lamps (LED’s)

In normal operating mode, the red LED will flash each time a correct keystroke occurs. To indicate the switch is ON, the green LED is activated. When the ECS is in the programming mode, the red LED is on. Now the green LED will indicate a correct keystroke.

User Pin Codes

Up to 15 individual PIN codes can be programmed. Each PIN code consists of at least 4 and a maximum of 8 digits. To be sure no accidental keystrokes remain, press the CE key before entering your PIN code. Terminate your PIN code with the ON/OFF key to switch ON. Once the switch is activated it can be turned OFF by pressing the ON/OFF key again. The switch will be turned OFF immediately. If an incorrect PIN code is entered just press the CE key and restart entering the correct PIN code followed by the ON/OFF key. Master Pin Code

With the master code you can program all PIN codes and also the switch OFF delay. Keep your personal master code in a safe place. WARNING: If the master code is forgotten or lost, the ECS can not be reprogrammed and must be returned for resetting. The cost for resetting will be charged. For supervisors instructions, contact Narrow Aisle Limited.

Switch Off Delay

It is possible to configure the switch to turn OFF after being switched ON for the programmed number of minutes. If connected through the seat switch, the ECS will shut down after the programmed delay which starts when the driver leaves the seat. For supervisor’s instructions, contact Narrow Aisle Limited.

Pyroban System 4000

A truck may be fitted with Pyroban System 4000 if it is operated in hazardous areas. To operate a vehicle fitted with this system it is necessary to follow the following start-up sequence.

• Insert key and turn fully clockwise, release and allow to return to the ON position. This will activate the System 4000.

• The System 4000 display will show the progress of the start-up sequence.

• When requested to do so by the System 4000, operate the gas bottle test valve to enable a sufficient amount of gas into the gas sensing head.

• The System 4000 will indicate when the gas test is complete and the gas is being purged from the system.

• When the sequence is completed satisfactorily the System 4000 will display SYSTEM OK. The truck can now be operated.

• Any other fault code MUST be reported to your Pyroban Trained Engineer.

Note: Trucks fitted with a Pyroban system MUST only be maintained or repaired by Pyroban Trained Personnel. For further information on any of the above options please contact the manufacturer.

Pre Use Inspection 17


Pre Use Inspection The following instructions should be read in conjunction with the other sections of this handbook. Before operating a truck the USER AND OPERATOR should be familiar with all sections of this publication. The term "USER" refers to the person or organisation responsible for the operational activity of the truck and the term "OPERATOR" refers to trained, authorised personnel.

Operator Qualifications

Trucks must only be operated by Authorised Trained Personnel. Note: Flexi Training are specialists in Flexi operator training and offer several conversion courses where operators can be trained to safe standards of skill and efficiency. For further information contact Flexi Training. on +44 (0) 1246 555222

Pre-Operational Check

Before operating the truck for the first time, ensure that the truck has been fully commissioned by a Narrow Aisle Limited engineer in the work area for which the truck is intended. Each day or shift, prior to use, the truck should be checked for damage or malfunctions and the Daily Maintenance Procedures must be carried out. (Refer to Daily Maintenance on page 22).

Operator Responsibilities

Always ensure that the truck is in good working order before commencing work. Familiarise yourself with your truck and take a pride in operating the truck safely. Do not attempt any repairs but report defects immediately. Report any damage or operational problems that may develop (damaged pallets, ground surface breaking up, etc.) which could not only reduce safety but also cause damage to the truck. Never attempt to exceed your trucks handling capacity and take all precautions to ensure safety of others as well as yourself. Stop working and switch the truck off if for any reason, in your opinion, the truck becomes unsafe or defective.

Operation 18


Operating Techniques

General

The Flexi ACiON articulated truck is designed to operate in stacking aisles that are narrower than those for conventional fork lift trucks. Consequently there are special operating techniques that must be practised. Before attempting to drive this machine, ensure that you are familiar with the controls. (See Controls starting on page 13).

Mounting / Dismounting

It is usual to mount and dismount the truck from the left to avoid the control levers. Handgrips are provided on the overhead guard upright and the front cowl. A step is provided with non-slip surface to assist in reaching the operator’s position. Face inwards toward the seat when mounting and dismounting and ensure that the appropriate grip is held firmly.

Driving the Truck

Check that the Battery Isolator Plug (23) is connected to the Battery Isolator Socket (22). Turn the Key Switch (7) to the ‘I’ position. The Display (8) should now be illuminated. Before moving off, raise the forks to approx. 150mm clear of the ground by pulling the Lift Lever (15), and then tilt the mast back by pulling the Mast Tilt Lever (16).

Use of the tilt function

Operation of the tilt function must be carried out as smoothly as possible at all times. Forward tilt should only be used when loading and unloading a transport vehicle, where the truck is standing on a level surface. Do not use forward tilt above a lift height of 1500mm. Backward tilt of the mast is used to stabilise the load against the rear face of the forks. When raising or lowering a load, ensure that the mast is in the vertical position.

Travel

To drive the machine, move the Travel Direction Lever (10) to the desired direction of travel. Release the Parking Brake Lever (13) and depress the Accelerator Pedal (11) with the right foot. The amount of movement of the accelerator pedal will determine the acceleration and final speed of the machine. To prevent accidents, if a direction is still selected when the operator dismounts the truck, the system will automatically reset to neutral. Before reselecting

a direction, the Travel Direction Lever must first be returned to the neutral (centre) position. There are two braking systems on the Flexi ACiON articulated truck: 1. For precise speed control and braking during the

normal operation of the truck, use the electronic braking system. To stop the truck using electronic braking system, release Accelerator Pedal (11) and the truck will come to a controlled stop. It is also possible to ‘Plug Brake’ the truck by moving the Travel Direction Lever (10) to the opposite direction of travel, depress the Accelerator Pedal (11) and the truck will come to controlled stop. As soon as the truck has stopped release the Accelerator Pedal or the truck will accelerate in the reverse direction of travel.

2. For more rapid braking use the service brakes

on the rear axle. To stop the truck, depress the Service Brake Pedal (12) with the right foot.

Steering

When steering, the front wheels of the truck will turn in the direction that the Steering Wheel (9) is turned. To become familiar with the controls, practise some simple manoeuvres in an open area. Drive around some obstacles and try starting and stopping including an emergency stop. When the operator leaves the truck unattended the forks must be lowered to floor level, the Parking Brake must be applied, and the Key Switch must be turned to the "O" position. The key should be removed to prevent unauthorised use.

Starting on a Gradient

Uphill slope The Parking Brake (13), when applied, prevents the operation of the drive motor, so a special technique is required for starting on an uphill slope. The sequence is as follows:

• Apply Parking Brake (13).

• Select Travel Direction (10).

• Depress the Accelerator Pedal (11) with the right foot (enough to prevent the truck from rolling backwards), and at the same time lower the Parking Brake Lever (13).

• Start moving uphill. Note: To prevent damage to the brakes, if the Parking Brake Lever is not fully released within 4 seconds of pressing the accelerator, power to the drive motor is cut.

Operation 19


Downhill slope When travelling down the slope use the right foot to apply the Service Brake Pedal and so control the speed. The speed will also be controlled by the control system.

Turning in a Narrow Aisle

Drive the truck down the aisle. Identify the load location and position the truck to the opposite side of the aisle leaving a clearance from the racking of about 125mm at the front wheels and 150mm at the rear wheels. The truck should now be alongside chosen pallet with steering straight. Position the front wheel opposite the centre line of the chosen pallet stack. Turn the steering wheel to full lock. The footbrake or handbrake should not be applied. The forks are now in line for entering the pallet. Reverse the procedure to straighten the truck to proceed along the aisle.

Loading

WARNING

Do not exceed the rated capacity of the truck as overloading can cause truck instability. If in doubt, check with Capacity Plate (1). Loads which are to be transported and placed in storage must be securely packaged. This ensures that the centre of gravity does not move during loading and that no small parts are able to drop out. When manoeuvering to pick up a load, avoid erratic movements that could result in damage to the load or the truck. Always approach the load with the centre line of the truck in line with the load. Apply Parking Brake, raise load 150mm to 200mm above ground level and tilt the mast back to stabilise if required. When picking up a load, ensure that it is centrally positioned on the forks and that the forks are inserted as far under the load as possible. The pallet/load should contact the vertical face of the forks. When carrying a load always travel with the mast and fork carriage in the correct travelling position i.e. Mast fully tilted back and the lowest point of the forks or load approximately 150mm to 200mm above the ground. Note that the truck is designed to be operated as a means of transporting and handling goods. Thus lifting operations should form no more than 20% of the operating cycle. Failure to observe this may result in overheating of the hydraulic system.

Stacking / De-stacking

There are two methods of stacking/de-stacking loads. The relationship between the aisle width and the load size will determine which of the two methods should be used.

Stacking

• Pick up the load as described in Loading (this page). Drive down the aisle and position the truck as described in Turning in a Narrow Aisle (this page).

• Apply the Parking Brake and reduce the back tilt to an amount sufficient to stabilise the load.

• Raise the load to the required height for stacking.

• When the load is clear of the chosen rack beam, release the Parking Brake and move slowly forward and at the same time smoothly turn the Steering Wheel to keep the load parallel to the rack end frame.

• When the load is over the rack, stop and apply the Parking Brake.

• Bring the mast to the vertical position and lower the load onto the rack.

• Release the Parking Brake and slowly reverse, at the same time turning the Steering Wheel to keep the forks perpendicular to the rack, until the forks are clear.

• Apply the Parking Brake, lower the forks carefully to the travel position, and then tilt the mast back.

• Release the Parking Brake and move off. (See Turning in a Narrow Aisle, this page).

De-stacking

• Drive the truck down the aisle and position the in line with the pallet as described in Turning in a Narrow Aisle (this page) and apply Parking Brake.

• Bring the mast to the vertical position and raise the forks to a height that will allow clear entry into the pallet. Release the Parking Brake.

• Insert the forks by slowly driving forward and at the same time smoothly turning the Steering Wheel so as to keep the forks parallel with the pallet. Apply the Parking Brake.

• Lift the load until clear of the rack and carefully apply sufficient backward tilt to stabilise the load.

• Release the Parking Brake, slowly reverse and at the same time turn the Steering Wheel to keep the load square with the racks. Take care not to dislodge adjacent loads.

Operation 20


• Apply the Parking Brake and lower the load carefully and smoothly to the correct travel position.

• Release the Parking Brake, turn the Steering Wheel to straighten the truck, apply full backward tilt and move off.

Dynamic Method

When aisle widths are restricted or loads overhang the pallet etc., use of the sideshift may be required with a modified driving technique. The Flexi AC articulated truck is designed to give sufficient stability to handle loads in a dynamic condition i.e. turning the load in the elevated position. This operation must only be carried out at creep speed.

Dynamic De-stacking

Operation to left side of aisle

• Drive truck into aisle approximately 200mm from right hand racking.

• 1m before reaching chosen pallet, steer slightly right so that when front left wheel is opposite left corner of chosen pallet face the front right wheel is 100mm away from racking as described in Turning in a Narrow Aisle Page 20.

• Stop.

• Truck should now be facing slightly away from chosen pallet with steering straight.

• Sideshift fully to the left using the Side Shift Lever (17) with the mast vertical. Lift to chosen pallet height.

• Simultaneously turn towards chosen pallet while feathering forward traction. (Axle should rotate around stationary left wheel).

• Once forks begin to enter pallet, move sideshift to Right while straightening the steering.

• Once forks have fully entered pallet, they should be centrally located and side shift mostly to right, if not fully.

• Pick up pallet and tilt mast back. (Tilt back helps pallet extraction in higher racking).

• Once pallet is secured, engage reverse direction. Slowly steer to left lock and feather side shift to left, keeping pallet square to racking and fairly close to next pallet on left.

• Reach full lock and side shift. Pallet should now be clear of racking.

• Slowly straighten steering while using small amounts of forward traction. Side shift to centre of carriage and ensure pallet clears the racking on both sides.

• Slowly lower forks to travel position and drive away.

Dynamic Stacking

Stacking is the reverse of the above procedure.

Operating Conditions

Floor Surface

Floor and road surfaces must be of adequate load capacity and free from potholes.

Gradients

When differences in levels exist, low gradient ramps must be provided having smooth, gradual level changes at top and bottom to prevent shocks to the load or fouling of the forks. Maximum gradient for use will depend on the frequency of travel. As a guide, the truck is suitable for use on gradients not exceeding 10% for a maximum of 10 operations/shift. DO NOT turn the truck on a gradient. Correct gradient driving procedure should be followed at all times. (See Starting on a Gradient page 19). Do not park on a gradient. In an emergency, apply Parking Brake and chock the wheels. Do not leave the truck unattended.

CAUTION

When travelling laden, up or down a gradient, the load should face uphill. When travelling unladen, up or down a gradient, the forks should face downhill.

Limit Switch and Interlock Layout

A range of safety switches are fitted to protect the truck and to prevent the operator from misusing the truck. Details are:

• Seat switch cuts off power to traction, power steer and lift when the operator dismounts from the truck.

Operation 21


• Creep speed microswitch reduces traction to creep speed at maximum free lift or at 2000mm - if fitted

• Parking Brake switch cuts off power to steering and traction when applied.

• Service Brake Pedal switch cuts off power to traction when applied.

• (OPTIONAL) Height limit micro-switch which disables the hydraulic functions when the forks reach a height specified by the customer. The height limit may be overridden by a switch on the control console.

Maintenance 22


Maintenance

General

This section contains a MAINTENANCE SCHEDULE and the instructions for maintenance and inspection. Industrial trucks are thoroughly examined, tested and lubricated before leaving the factory; however, regular maintenance and lubrication are necessary to ensure smooth running and long life. The recommended maintenance periods are for trucks operating in normal, clean conditions. For abnormal temperatures, dust contamination areas or moist conditions, etc., more frequent maintenance will be required. The maintenance work covered in this manual is divided into sections: 1 The checks and adjustments where no special

skills are required and may be performed by the operator.

2 Repairs and adjustments that must be done by

trained service people.

WARNING Do not make repairs or adjustments unless specifically authorised to do so. Repairs and adjustments must done by trained service people.

WARNING Do not operate a lift truck that needs repairs. Report the need for repairs immediately. If repair is necessary, put a "DO NOT OPERATE" label in the operator's area. Remove the key from the key switch.

WARNING Before conducting a maintenance procedure ensure the battery is disconnected, and the mast and forks are fully lowered.

Operator Maintenance

Daily Maintenance

These checks must be carried out before putting the truck into operation.

• Check battery electrolyte level (just above plate tops)

• Reconnect the battery and check that all the truck functions are operating correctly.

• Check that any lights fitted are working.

• Check for oil leaks.

• Check that any warning devices are working.

• Ensure machine is kept clean.

Weekly Maintenance

• Carry out daily checks.

• Check cleanliness of battery terminals, smear with petroleum jelly.

• Check operation of safety switches by raising the mast to full height and ensuring that the truck will only travel at creep speed.

• Check hydraulic hoses, pipes and connections. Inform your Supervisor if any are loose.

• Check oil level in hydraulic tank via dipstick on Right side of hydraulic tank. If additional oil is required, inform your Supervisor.

Maintenance 23


Routine Maintenance

All routine maintenance must be carried out by fully trained Service Engineers from Narrow Aisle Limited or their authorised agents, or Engineers who have been trained by Narrow Aisle Limited to carry out this work in a safe manner in accordance with the Workshop Maintenance Manual. Narrow Aisle Limited recommend that you enter into a routine maintenance contract. A qualified service engineer will make regular visits dependant upon the number of hours the truck is used per week in conjunction with the operational environment. Regular Service intervals in normal use are:

• Three months, or 500 hours (whichever comes first).

• Annually, or 2000 hours (whichever comes first). As part of, or in addition to the regular maintenance of the truck, there is a statutory requirement for a recorded examination at maximum of 12-monthly intervals depending on use. During this examination, all working parts of the truck, including the lift chains will be examined to check if they are in working order. A certificate will be issued by the examiner detailing the condition of the truck. More frequent examination is required for trucks operating in arduous or hazardous conditions, extended operating hours or when used to lift personnel. The Narrow Aisle Limited Service Engineer or authorised dealer service engineer will call at your request.

Electrical Diagrams

A copy of the electrical schematic diagram for your particular truck is included with this operator handbook. This should be retained with the truck at all times as the qualified Service Engineer may need it to diagnose a fault.

Disposing of Waste Materials

Your Narrow Aisle Limited Service Engineer or their agent will supervise the disposal of any waste material such as oil or battery acid that may result from a service visit.

Putting a Truck in Storage

To prevent problems, the lift truck must be correctly serviced and maintained during storage. Components that need extra care during storage are electric motors, hydraulic components and electric truck batteries. Electric trucks can best be protected by being operated for a short period of time each month. Before putting any truck in storage, you must choose an area which is clean, dry and free from dust or fumes that can harm the lift truck. Electric drive motors should be operated to keep them free of rust and dirt caused by condensation over periods when the truck is not used. Operate the truck for at least five minutes. Before operating a truck each month, make a visual inspection for leaks or signs of wear or damage. Take care of any problems immediately. Also, check the fluid level in the hydraulic tank and brake master cylinder. Electric trucks should not have batteries installed during storage. A fully charged battery must be available to operate a lift truck.

CAUTION Do not use a battery charger as a power source for any reason. All hydraulic cylinders should be put through a complete operation cycle several times each month. This will help keep the seals active and coat the interior walls with oil. Operate each cylinder to the stop in both directions. To protect the lift cylinder rods, park your truck with the mast tilted fully forward (cylinders fully retracted). When parked with the power off, operate each control handle to release hydraulic pressure. Masts should be stored fully lowered. Coat any exposed part of all cylinder rods with fresh high grade engine oil. Put chocks at the front and rear of a drive tyre when parked - do not use the Parking Brake.

Maintenance 24


Moving a Disabled Lift Truck

WARNING Use extra care when moving a lift truck if there is a problem with any of the following: a. Brakes do not operate correctly. b. Steering does not operate correctly. c. Tyres are damaged. d. Traction conditions are bad. e. The lift truck must be moved on a slope. If the steering pump motor does not operate, there is no power available for the hydraulic power steering. This condition can make the lift truck difficult or impossible to steer. Poor traction can cause the disabled lift truck or towing vehicle to slide. A slope will also make the lift truck more difficult to stop. Never lift a disabled truck unless it MUST be moved and cannot be towed. A lift truck used to lift the disabled lift truck MUST have a capacity rating equal or greater than the weight of the disabled lift truck. The capacity of the lift truck used to lift a disabled lift truck must have a load centre equal to half the width of the disabled lift truck. See the Capacity Plate of the disabled lift truck for the approximate total weight. The forks must extend the full width of the disabled lift truck. Put the weight centre of the disabled truck on the load centre of the forks. Be careful to not damage the under side of the lift truck.

Towing a Lift Truck

• The towed lift truck must have an operator.

• Tow the lift truck slowly.

• Raise the carriage and forks approximately 300mm from the ground. Install a chain to prevent the carriage and mast channels from moving.

• If another lift truck is used to tow the disabled lift truck, that lift truck must have an equal or larger capacity than the disabled lift truck. Install approximately ½ of a capacity load on the forks of the lift truck that is being used to tow the disabled lift truck. This half-capacity load will increase the traction of the lift truck. Keep the load as low as possible.

• If the hydraulic steering motor does not operate, the towed truck may be impossible to steer.

Removal and Replacement of Forks

WARNING Forks are heavy. Great care must be used in any operation involving the movement of one or more forks. Use appropriate lifting methods and equipment to ensure safe handling. If in doubt, GET HELP.

• Lift the carriage to a convenient height to allow work to take place safely.

• Remove the M8 cap head screw from the lower part of the carriage.

• Disengage the fork latch and slide fork across carriage until the bottom heel aligns with the gap at the bottom of the carriage.

• Lifting the tip of the fork upwards a small amount will allow the bottom heel of the fork to be disengaged from the carriage which will then allow the fork to be lifted from the carriage.

• Refitting a fork is achieved by engaging the top claw of the fork onto the top of the carriage and lowering the bottom heel through the gap in the bottom edge of the carriage.

• Slide the fork across to the required position and engage the fork latch to secure the fork in place. Repeat as necessary with the other fork.

• Fit and secure the M8 cap head screw to prevent the forks from accidentally disengaging from the carriage.

Maintenance 25


Battery Maintenance Correct operation of the battery charger is important. Follow the instructions of the charger manufacturer. Never fully top up battery cells just before a charge cycle. (Just check they are not ‘dry’) Never permit the battery to discharge below the minimum value given by the battery manufacturer. Always use a battery charger approved by the battery/truck manufacturer. Only use deionised / distilled water to top up cells. Never permit a battery to stay discharged for long periods. Always fully top up battery cells immediately after charge cycle. The truck uses a 48V DC battery, with various Amp-Hour capacities to suit the truck’s duty cycle. Always consult the truck’s technical specification before attempting to fit or connect a battery to the truck’s electrical system. It is also important to check the charger specification to ensure that it is compatible with the battery before charging. Read the charger handbook before connecting. Note: Battery chargers should only be installed by a qualified electrician.

Battery Removal

• Remove battery lid.

• Disconnect Truck Connector (22) from Battery Connection (23) under lid.

• Lift seat pan.

• Lift battery retaining latch.

• Lift battery using a forklift truck of suitable

capacity Note: Only lift battery approx. 20mm (3/4")

• Withdraw battery from chassis.

• Lower battery to floor.

• Replacement is the reverse of the above procedure.

When charging the battery in-situ, the Charger Connection (21) must be connected to the Battery Connection (23). (See page 28).

CAUTION Do not attempt to fit Charger Connection (21), to the Truck Connection (22), or serious damage will be done to the truck electronics. When replacing the battery onto the truck, the battery tank must be carried vertically and the truck approached squarely. In order to ensure that the battery tank is held securely by the battery latch, push the battery firmly up to the bulkhead before lowering. The battery latch will automatically lift and then engage. Note: For full details of the charging and maintenance of the battery and operation and maintenance of the battery charger see the separate battery and charger handbooks.

Maintenance 26


Battery Servicing and Charging

Safety Precautions

WARNING Keep all flames and lit cigarettes away from the battery, especially during or soon after charging, as the gases involved can produce an explosive mixture.

WARNING Never do anything that could cause an electric spark on or near the battery.

WARNING Never lay tools on top of the battery.

WARNING Isolate electrical connections before working on the battery. Use only insulated tools.

WARNING Wear suitable protective clothing and eye protection when working on the battery.

WARNING Charge batteries only in the special area allocated for charging of batteries. When charging batteries, keep the vent plugs clean. The battery charger area must have ventilation to remove the explosive fumes. Open the battery cover and secure in position during charging.

WARNING The acid in the battery electrolyte can cause injury if it is spilled. Make the acid neutral with a solution of sodium bicarbonate (soda) and water.

WARNING ADD NOTHING TO THE CELLS BUT PURE (Deionised / distilled) WATER and do this often enough to keep the separator guard always covered (electrolyte visible). Top up electrolyte with the battery in its fully charged condition.

WARNING To comply with current legislation, the battery container on this truck does not have any drain holes. Be extra careful NOT to spill any water or electrolyte into the battery container. Should any spillage occur, this may be syphoned out.

WARNING Ensure that battery vent plugs are replaced after charging.

CAUTION

Never connect the Charger Connection (21) to the Truck Connection (22). You can damage the traction control circuit.

CAUTION

Ensure that the charger voltage is the correct voltage for the battery.

CAUTION

Always switch off charger before disconnecting battery.

Battery Charging

Do not “opportunity” charge the battery during the shift as it will damage the cells causing premature failure. If special ‘Trakair’ batteries and chargers are fitted, then cells can be charged during the shift. However if the charge is more than 90 minutes then a charge cycle will be consumed. Charging cycle times should be completed in full to the specified charging time. Failure to conform will result in premature battery failure and invalidate any manufacturer's warranty.

Care of Battery out of Service

If a battery is to be taken out of service for a time, or if a new charged battery cannot be put into service immediately, it should be given an equalising charge and stored in a cool dry place. Disconnect detachable connectors. Every month, check acid levels and give an equalising charge. If a truck is used at irregular intervals, the battery should be given an equalising charge every month and the battery disconnected from the truck during idle periods.

Waterfill Systems

Refer to manufacturer's manual / Charging Procedure

Maintenance 27


1. Drive truck to charging area

2. Lower forks and select Neutral

3. Turn Keyswitch to ‘O’

4. Operate Emergency Stop button (5)

5. Remove battery lid

6. Disconnect battery at connector (22/23)

7. Switch ‘ON’ the charger at the wall

connection (isolator)

8. Connect the charger lead (21) to the battery

connector (23) labelled ‘CHARGE’

9. The charging cycle will start automatically

(Hoppecke & Tebetron chargers)

10. After the FULL charge cycle (See truck

specification for cycle time) the charger will

switch off automatically (Tebetron chargers).

Hoppecke chargers should be switched

‘OFF’ at the front panel.

11. If it is necessary to terminate the charge

cycle BEFORE completion (not

recommended), switch off the charger by

pressing the switch labelled (Tebetron)

or RED button (Hoppecke) on the front panel

of the charger. Note: press once only, further

presses will recommence the charge cycle.

12. Switch ‘OFF’ at the isolator

13. Disconnect the charger from the battery

(labelled CHARGE)

14. Check that the top-up container is filled with

deionised water

15. Connect the water top-up bottle to the battery

using the quick release connector

16. Pressurise the top-up bottle using the hand pump

until water starts to flow into the cells.

NB: Do not overpressurise.

17. Alternatively use a manual method or electric

trolley to ‘top-up’ the cells such that the

electrolyte level touches the indicator inside the

cell.

18. Continue until ALL the cells show a green

indicator on the cap (Hoppecke)

19. Remove the top-up bottle via the quick

release coupling

20. Note: Ensure that cells are not overfilled.

21. Re-connect the battery to the truck via the

‘CHARGE’ connector

22. Reset the Emergency Stop Button.

23. The truck is now ready for use

Note: Suitable acid resistant protective clothing (gloves and protective glasses) should be worn when working with batteries Note: For further details of charger display and sequences - Consult the charger manual

Charging Procedure

Maintenance 28


Optional Extras 29


CCTV

Installation

• Do not install the unit in an extremely hot or humid environment or in a place subject to direct sunlight, excessive dust.

• The monitor is not waterproof.

General Cleaning Information

• If your vehicle has been parked in direct sun light resulting in a considerable rise in temperature of the unit, allow the unit to cool off before operating.

• Clean the unit with a slightly damp, soft cloth. Use mild household detergent. Never use strong solvents such as thinner or benzene as they might damage the finish of the unit.

Functions

• Power There is a sliding switch mounted on the right hand edge of the unit (hidden by the holder). Ensure that this is set to ‘On’. To turn the unit on in general use, press the POWER button mounted centrally on the front panel. When the red LED is turned on, it indicates power on. To switch off, press the POWER button again.

• Camera Selector Button (Ca Select) The cameras in use can be selected in turn as follows.

CA 1 - CA 2 - CA 3 - A/V Press repeatedly to select correct camera.

• Menu Button If you press the MENU button, the list of selectable functions appear on the monitor. It will disappear within 5 seconds unless you choose the function or any other input signal. Selectable function lists disappear within 5 seconds if there is no new input. You can control any function available on the function list.

Method of Adjustment

1. Scale Control While driving, the distance from other vehicles or objects behind can be measured with an electronic scale. To set up the scale, please follow the instructions below.

• Press the ‘Menu’ button

• Move the cursor to select ‘Scale’ by using the ‘Channel’ button

• Press the ‘C.A. SEL’ button

• Select one of three scale types with the ‘Channel’ button

• To select press ‘C.A. SEL’

• Press the ‘Menu’ button 2. Ca1 (Mirror) Control To select a normal / mirror image, follow the instructions below:


• Select ‘CA1’ by the ‘C.A. SEL’ button

• Choose mirror or normal image by using the ‘Channel’ button

• To select your choice press ‘C.A. SEL’

• Press the ‘Menu’ button 3. Colour Control

• Press the button ‘Menu’

• Select the ‘Colour’ button by pressing ‘C.A.SEL’

• Adjust the colour by pressing ‘CH’

• Press the ‘Menu’ button when you complete the set- up. This will go back to the original screen or the OSD will disappear automatically within 5 seconds

4. Contrast Control


• Select ‘Contrast’ by pressing ‘C.A. SEL’

• Adjust it using ‘CH’

• Press the menu button to exit the set-up

Vol Buttons These have no function in this installation Bri Buttons Used to adjust the brightness of the image

Optional Extras 30


Timotex Supaweigh XL

Supaweigh Function Keys

To switch on Supaweigh

To switch off Supaweigh

To zero current weight at weighing position.

To tare off the weight of an empty pallet/ container.

To enter a preset digital tare value. To cancel a tare. To identify the tare and zero values.

To freeze/ unfreeze the current displayed weight. To change manually the weighing mode, e.g. from ---- to a weight.

To change the date and time (printer model only). Supervisory functions to program the unit.

To toggle unit of measurement from kg to lb.

To enter a product code for subsequent loads (printer model only).

To enter a target load for the current totaliser.

To print out the current totaliser memory and the period totals.

Adds current weight to total weight or subtracts from target weight. Transfers current weight and product code to the printer store. Confirms to the unit the data keyed in either with the numeric or function keys

Activates printer after PRINT has been pressed

Resets total weight to zero or target weight to preset load value Deletes incorrect numeric key entry Clears printer memory (press within 15 seconds of end of printing).

SUPAWEIGH LIFT TRUCK SCALE - SINGLE WEIGHT DISPLAY FOR ELECTRIC TRUCKS Switch on truck. Raise fork carriage up and down 3 or 4 times to fill hydraulic cylinders and warm up hydraulic oil. LOWER FORKS TO GROUND. TO PREPARE THE SCALE Switch on the display by pressing ON. If necessary, press CLEAR to reset the totaliser on the top line. The bottom line of the display should read + Gross Wt: ---- kg. If it reads -, press TARGET, then 0, then ENTER. If Nett, press TARE and 3. TO ZERO DISPLAY (at start of day or shift and every hour). Start with empty pallet forks on the ground and hydraulic pressure relaxed. The display should show 4 bars (---- kg). If not, press HOLD. With mast vertical, smoothly raise the empty forks and stop when the two horizontal marks (one on the mast and one on the fork carriage) are exactly level. As the forks lift you should hear a bleep. Press ZERO and, when prompted, press ENTER. Wait a second or so and the display should read 0. Lower the forks and watch for the display to change to 4 bars (---- kg) as the magnet on the fork carriage passes the switch on the mast. TO WEIGH Now pick up a load and raise the forks as described above. The load weight is shown on the bottom line of the display. Do not forget to press ENTER if you wish to add the load to the totaliser on the top line. The weighing procedure is now complete and the truck is ready for normal handling duties. TO OPERATE A TARE If you know the tare weight press TARE, then 1, key in the weight and press ENTER. Alternatively, weigh an empty container on the forks, press TARE then 2. TO CANCEL A TARE Press TARE and 3. TO ACCUMULATE A TOTAL WEIGHT FOR A NUMBER OF LOADS While the display shows the weight, press ENTER.

0

ZERO

O

TARE

CHECK

HOLD

DATE/ TIME

KG/LB

PROD

TARGET

TOTAL

(ENTER)

CLEAR

Optional Extras 31


Timotex Supaweigh XL (Cont) To clear the totalled weight on the top line of the display, press CLEAR. TROUBLE-SHOOTING If you see bars (---- kg) at the weighing position, press HOLD and start again. If you can no longer hear the bleep as the forks are raised, check the magnet on the fork carriage is still 10mm from the read switch on the mast. If the weight reading is under, check if there is a tare in operation. If the weight reading is under or over, follow the procedure to ZERO the display.

InfoLok System In stand-by mode, the InfoLok displays a blinking green LED fitted to the dashboard area. This indicates that the truck will allow only authorised drivers issued with InfoLok driver keys to have access to the fork lift trucks.

Log-on Procedure

1. Activate seat switch. 2. Touch the driver key into the dashboard stainless

steel read-head; a. Solid green LED = Authority to drive

truck b. Solid red LED to blinking green = No

authority for truck c. Flashing red LED to solid green indicates

that you have had an impact (s) recorded against you. See your line manager to discuss the incident and have the key reset.

d. Three red flashes to blinking green indicates you have had 3 impacts recorded against you and are unable to start ANY truck! See your line manager to have incidents investigated and the key reset.

Impact Procedure

1. The truck horn sounds on & off continuously. You still have full truck control.

2. Make a mental note of the exact location and reason for the incident.

3. If and only when safe to do so, lower the forks and switch the truck off. The horn will stop.

4. Log back onto the truck. The red LED flashes as a reminder to report the incident.

5. Report the incident details to your line manager immediately, or as soon as possible. Your manager will investigate the incident.

NOTE: Your managers have set the InfoLok Impact Sensor to suit the truck duties and working environment. PLEASE DRIVE SAFELY AT ALL TIMES.

OTHER OPTIONAL EXTRAS FITTED TO FLEXI ARTICULATED TRUCKS. Please consult the appropriate manual supplied with the truck.

Daily Check Sheet 32


.

Daily Pre-Shift Checks

No: Feature Checks Required

1 Tyres Visual. Check for damage, swarf, embedded materials

2 Wheel Nuts Visual to ensure all wheel nuts in place

3 Parking Brake Functional check, efficient operation / security

4 Foot / Service Brake Functional check. Operate brakes in forward / reverse

5 Steering System Steer in both directions – Listen for knock / noises

6 Horn/Reverse Bleeper Operating correctly – Sufficiently loud

7 Lights All functioning

8 Battery Visual check – Electrolyte level, not leaking, Fully charged. Securely retained.

9 Hydraulic System No leaks, check where truck has been standing

10 Mast Elevate to full height. Check for leaks. No scraping or untoward noises

11 Tilt & Sideshift Fully operate both ways. Check for leaks, erratic movement or untoward noise

12 Functions Check for correct operation of all controls. Correct operation of interlocks and safety switches

13 Display Unit Check – No error codes showing

14 General Visual check

Weekly Checks (In addition to 1-13)

15 Forks Visual – Check damage at tip, cracks or wear at heel. Locating pins operational. No distortion

16 Lift Chain Visual check for wear, broken links or pins. Chain anchors secure

17 Chain Adjustment Heel of forks clear of floor – mast vertical

18 Battery Check terminals clean

19 Battery Cables Visual check for damage

20 Hydraulic Oil Check Level

21 Overhead Guard Visual check – Security, no cracks

22 Wheels Visual check for damage

23 Seat / Seat Belt Visual check – condition of seat and belt. Functional check of seat belt

24 General Visual check – General condition Rating Plate in position and legible

Forklift Truck Daily / Weekly Pre-Shift Check Record

Daily Check Sheet 33


Truck Serial Number MMMMMMMM..

Date Comments Sign Date Comments Sign

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