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Operating instructions

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1. inside straddle 820 1220 mm bs Width across forks 570 720 mm hg Outrigger height 122 mm h43 Lowered fork height 100 mm e Fork width 160 mm s Fork thickness 50 mm Fork length see chapter 3 3 h4 Height 950 mm h3 Lift 80 mm Ce Net load centre of gravity 305 mm B4 0209 GB 0209 GB Truck types pallet formats stacking depth underlined Indication of technical data according to VDI 2198 Pallet size Pallet type Fork Load Loadcar Width Overall length centreof riage across Width 1 gravity length forks b4 c l4 bs 800 x 1200 EURO 780 400 1177 720 1340 P1 crosswise 1000 x 1200 INDU 980 500 1377 720 1340 P2 crosswise 1200 x 800 EURO 1180 600 1577 570 940 P3 lengthwise 1200 x 1000 INDU 1180 600 1577 570 1140 P4 lengthwise 800 x 1000 x EURO 980 500 1377 720 1340 1200 P5 INDU 600 crosswise switchable 1 600 mm for Euro pallet lg 800 mm as it includes the fork tips Load devices Use of the DIS load carriage is permitted for undamaged and specified pallets only Refer to the DIS order data enclosed with the truck documents in case of deviating dimensions Significant function restrictions and dangers can result from non observance of these stipulations Warranty shall be void in these cases B 5 49
2. DIS 2 11 01 Operating instructions 50137269 02 09 DUNGHEINRICH Machines Ideas Solutions 1009 GB Declaration of Conformity CE Jungheinrich AG Am Stadtrand 35 D 22047 Hamburg Manufacturer or authorized representative in the Community Type Option Serial No Year of Construction DIS 2 Additional information Authorised signatory Date EU Declaration of Conformity The signatories hereby certify that the specified powered industrial truck conforms to the EU Directive 2006 42 EC Machine Directive and 2004 108 EEC Electro Magne tic Compatibility EMC including their amendments as translated into national legisla tion of the member countries The signatories are individually empowered in each case to compile the technical documentation 49600 0108 GB oe H Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck The information is provided clearly and concisely The chapters are arranged by letter Each chapter starts with page 1 The page identification consists of a chapter letter and a page number For example Page B 2 is the second page in chapter B The operating instructions detail different truck models When operating and servicing the truck make sure that the instructions apply to your truck model Safety instructions and important explanations are indicated by
3. The battery cell screw caps must be kept dry and clean Ter minals and cable shoes must be clean lightly greased with pole grease and must be securely tightened Batteries with bare terminal posts must be covered using a non skid insulating mat Disposal of the battery Batteries must only be disposed of as stipulated in the na tional environmental protection regulations or waste disposal provisions The manu facturer s specifications for the disposal must be heeded Before closing the battery hood make sure that the battery cable cannot be dam aged Batteries contain dissolved acid which is toxic and caustic For this reason protective clothing and goggles must be worn whenever work is undertaken on batteries Avoid physical contact with battery acid If clothing skin or eyes accidentally come into contact with battery acid liberally flush the affected parts with clean water Consult a doctor when skin or eyes come into con tact with battery acid Spilled battery acid must be immediately neutralized Only batteries with closed tray may be used Battery weight and dimensions have considerable influence on operational safety of the truck Changing the battery equipment is not permitted without prior approval by the manufacturer D1 N Menu D2 Battery types The vehicle is equipped with maintenance free battery types refer to chapter B 3 1 You must not refill distilled water into these battery types The cell cove
4. truck forward The rescue person can knee or sit in the rescue truck depending on the channel height The radio control must not be applied during rescue Switch off the DIS 2 load carriage key switch on the right hand side of the DIS load carriage Insert the tow cable into the DIS 2 load carriage by inserting the karabiner hook at the cable end into the attachment eye on the base plate in front of the centre panel Prepare the cable winch so that the cable can be unwound Move the rescue truck back to the start of the channel and unwind the cable at the same time Couple the rescue truck to the forklift To do this call out to the truck driver to raise by approx 100 mm Secure the rescue truck with a retaining pin The rescue truck is now connected to the forklift The rescue truck operator must be satisfied that the retaining pin is in the correct po sition before instructing the other person to pull out the rescue truck E 21 E 22 The rescue person gives the instruction to the truck driver to pull the rescue truck and rescuer out of the channel and to stop before the rack The cable pulley must be at the same height as the mounting point on the DIS Pull the DIS 2 load carriage to the start of the channel with the cable winch Ask the truck driver to lower the truck by approx 1m and loosen the karabiner hook of the cable from the DIS 2 load carriage Remove the karabiner hook of the
5. 60c0 B 6 0209 GB 3 4 3 5 EN standards Continuous sound level 66 dB A according to prEN 12053 as stipulated in ISO 4871 The continuous sound level is a value averaged according to standard regulations taking the sound pressure level into account when driving lifting and idling The sound pressure level is measured at the ear Electromagnetic compatibility EMC The manufacturer confirms compliance with the limit val ues for electromagnetic emission and interference immu nity as well as testing of static electricity discharge ac cording to prEN 12895 and the references to other standards contained therein Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained Conditions for application Standard version in operation 0 C to 40 C 24 h average max 25 C Industrial trucks must be specially equipped and approved for continuous use in en vironments with temperatures below 5 C or in cold stores respectively with extreme temperatures or humidity changes Cold store version in operation 30 C to 0 C Operating mode 4 trucks that generally remain in the cold store during operation and only briefly leave it to transfer loads but not including shock freezer operation Technical Group Guidline 1006 of 04 09 2002 No cold warm change formation of hoar frost Allow the truck to dry completely before you enter the cold store a
6. A user within the meaning of these operating instructions is de fined as any natural or legal person who either uses the fork lift truck himself or on whose behalf it is used In special cases e g leasing or renting the user is conside red the person who in accordance with existing contractual agreements between the owner and the user of the fork lift truck is charged with the observance of the opera ting duties The user must ensure that the truck is not abused and only used within its design li mits and that all danger to life and limb of the operator or third parties is avoided In addition to this it must be ensured that the relevant accident prevention regulations and other safety related provisions as well as the operating servicing and mainte nance guidelines are observed The user must also ensure that all persons operating the truck have read and understood these operating instructions If these operating instructions are not observed the warranty becomes void The same applies if improper works are carried out at the device by the customer and or third parties without permission of our Customer Service Mounting of attachments The mounting or installation of any attachments which will interfere with or supplement the functions of the truck is permitted only after writ ten approval by the manufacturer has been obtained If necessary the approval of local authorities has to be obtained Any approval obtained from
7. Prior to decommissioning Charge the battery refer to chapter D Disconnect and clean the battery Apply pole grease to the battery poles In addition to this all instructions given by the battery supplier must be observed Spray all exposed electrical contacts with a suitable contact spray Measures to be taken during decommissioning Every 6 months Charge the battery refer to chapter D Regular recharging of the battery is very important otherwise exhaustive depletion of the battery caused by self discharging would occur Owing to sulfatisation this will result in the destruction of the battery When permanent trickle charging is used it is not necessary to the charge the battery every 6 months as protection against exhaustive discharge Recommissioning the truck after being taken out of service Thoroughly clean the truck Clean the battery Grease the pole screws using pole grease and reconnect the battery Charge the battery refer to chapter D Check if the hydraulic oil contains condensed water and change if required Bring the truck into service refer to chapter E Perform several brake tests immediately after recommissioning the truck F7 X 7 1 X F8 Safety checks to be performed at regular intervals and following any untoward incidents Perform a safety check in accordance with national regulations Jungheinrich recom mends the truck be checked
8. Under no circumstances should you move the lowered DIS 2 load carriage along the ground and do not attempt cornering Any movement at an angle to the direction of turn could damage the wheels Retrieving the furthermost pallet in the channel manual mode Enter the forks of the DIS load carriage in the front pallet and lift it clear Retrieve the pallet from the pallet channel by retracting the mast or reversing the truck The DIS 2 is used in this instance only as a load handler 4 7 4 8 E 12 Adjusting the pallet stop option If you are using different pallet formats DIS 2 type P5 the pallet type can be set as follows Adjust the stop rail on the fork to the desired measure allow the locking bolts to latch Set the pallet length on the hand operating unit to do so press the key once to the left Pallet L max Select pallet size with 1 or L key and confirm with ENTER Attention Possible error If the push stop remains in the rear position the smaller pallet format will be collected too far on the fork shank an will be placed in the channel too far away from other stored pallets loss of pallet space If the push stop is always in the front position the larger pallet format will be collected too far on the fork tip the load centre of gravity will be excessively high and will over load the DIS load carriage This is not a suitable load condition and should be avoid ed If agreed during th
9. carriage may be keep key pressed down mechanically blocked e g Otherwise Pull back the DIS through foreign bodies or an ob load carriage using the rescue stacle on the rail or due to faulty truck Determine the cause rail tracking too narrow too Decommission the DIS load wide carriage and notify JH service Load wheel sensor monitoring department may be faulty ERR Trav Sensore B3 load carriage uncou The truck must be recovered el amp B3 pled active while DIS travels in via REVERSE pallet channel Sensor faulty decommission Sensor control the DIS load carriage and no Stop after 150mm travel distance tify JH service department ERR Motor Drive motor overheated Allow the truck to cool down temp Temperature switch faulty before operating it again Oth erwise Decommission the DIS load carriage and notify JH service department ERR F rail No contact with DIS rack rail Raise DIS load carriage again After issuing a travel command until DIS Docked appears START the load carriage was then press START and car not lowered correctly onto the DIS riage out the Depositing Low rails The load carriage may be at ering process Make sure the an angle on the DIS rails guide _ truck is at right angles in front rollers for example not engaged of the rack Possible missing or faulty entry If the rail sensor is faulty de guide plates at channel start commission the DIS load car Faulty r
10. chapter F and the documenta tion for the fork lift truck when mounting and connecting the device Mounting in the visual and reaching range of the driver e g at the holder of the over head guard mounting bracket not included in the scope of delivery Electrical connection only by authorised specialists Supply voltage DC 16 48 V fuse 2 A continues supply if possible Connecting cable 2 m included Plug cable assignment 1 brown 3 blue Voltage peaks that damage the docking station occur in lift trucks with thyristor cont rol A filter or DC DC converter must be connected upstream in these device C1 3 Commissioning A Only drive the truck with the battery container installed Do not drive with trailing ca ble In order to prepare the truck for work following delivery or transportation the following operations must be performed Check the truck for completeness and satisf actory condition of the equipment If required install the battery and make sure not to damage the battery cable and connec tor Charge the battery refer to chapter D Mount the lift truck coupling to the FEM fork carrier of the fork lift approved for this purpo se lift snap lock bar 4 and lock in lifted posi tion Slide the coupling centrically onto the FEM fork carrier allow snap lock bar to latch in the centre latch position Tighten the lower adjusting screws 5 and counter lock The re
11. local authorities does not however make the approval by the manufacturer unnecessary A1 49 c0 0 A2 0209 GB Description of the truck Design and Application The DIS 2 load carriage truck is a forklift attachment used in the Jungheinrich DIS rack for transporting goods on pallets The fork lift truck to be used must be approved by Jungheinrich for each intended application The truck s capacity is reduced due to the increased load centre of gravity The driver A must check the load before lifting it and if necessary he must check the adjustable pal let stop is positioned correctly type P5 Overloading will cause the truck to tip over The capacity and load centre of gravity can be taken from the data plate The required residual capacity of the truck depends on the truck model and the cor responding load centre of gravity For DIS 2 operation an additional capacity diagram must be attached to the truck and observed The following pallet types may be used for DIS operation Euro pallets industrial pal lets or a combination of the two B1 2 B2 Description of assembly groups and functions e ke 7 f 7 8 lt S je ot eS W Ni VS Ly a gt gt i Item DIS 2 Designation 1 Truck coupling with locating 0006 2 Enclosure 3 O Battery container changing container 4 O Battery exchange t
12. ration Target not reached after given time Truck travelling too slow me chanically hard to manoeuvre see above ERR Travel FWD Pallet sensor braking or channel end sensor outrigger tips identi fies a foreign body and switches to crawl speed Example Part ofa pallet or shrink wrap hanging off the side Reverse the DIS load carriage back to the start of the channel using the REVERSE function keep key pressed down or Pull back the DIS load car riage using the rescue truck Determine the cause Otherwise Decommission the DIS load carriage and notify JH service department ERR Stop sen sor Stop sensor identified LH outrig ger without pre cutout sensor crawl speed sensor Stop sensor may be configured incorrectly e g pallet not not re ceived far enough or excessive pallet overhang Crawl speed fails if foremost pal let is faulty e g RH pallet support missing or reflex sheet channel end missing Faulty sensor Note correct pallet receipt Check pallet overhang against agreed distance only use full pallets Quickly check the sensors with a box in the light beam the switch status is indicated by LED 0209 GB 0209 GB Display Meaning Action ERR Blocked Truck does not move Load Reverse the DIS load carriage wheels stand still drive rotates back to the start of the channel however using the REVERSE function This DIS load
13. request MESSAGES E 13 DIS 2 spare fork instructions assembly status ETV coupling E 14 Quick reference card oo eceecececceeeeeseeeeeeseeeeeeeeeeeeeaeeeeeaeeeeeaeeaeeaes E 15 Operating instructions for the Jungheinrich DIS rack 6 E 16 Jungheinrich DIS rack FIFO operating mode O c eceeeseeeees E19 Rescuing a DIS 2 truck from the channel DIS load carriage E 21 Maintenance of the fork lift truck Operational safety and environmental protection F 1 Safety regulations applicable to truck maintenance F 1 Servicing and inspection ceeeccccceeeee eee eeeeeeeeeeeeeeeeeeaeeeeeeseeteeeeeeees F3 Wartungs Checkliste cccccccccssccecsececsseeesssseeeeseeeessaeeesseeessseeeenes F3 Lubrication Schedule 22228 one een netitess F4 Notes on maintenance eee scence eeeeeeteeeeeteeeeeeeeaeeeeseaneesenneeeenaeees F5 Preparing the truck for servicing and maintenance operations F5 Removing front hood and front wall Checking the electric fuses oo eee cceceteceeeseeeeeseeeeesseeeessteeeeseeeeesaes Recommissioning the truck 0 cccccecceeeeceeeeeeeeeeeeeeeeeeeeeaeeeeeeeneees Decommissioning the truck 0000 00 Prior to dec
14. rope from the DIS 2 load carriage Attach the truck coupling to the DIS 2 load carriage and drive out of the rack chan nel completely Lower carefully The DIS 2 load carriage lock on the coupling is not closed There must be nobody present in the hazardous area when the DIS 2 load carriage is being lowered 0209 GB 0209 GB gt Maintenance of the fork lift truck Operational safety and environmental protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists Modifications of fork lift truck assemblies especially of the safety installations are not permitted On no account must the operational speeds of the truck be changed Only original spare parts have been certified by our quality assurance service To en sure safe and reliable operation of the fork lift truck only spare parts of the manufac turer must be used Used parts oils and fuels must be disposed of in accordance with the applicable environmental protection regulations For oil changes the oil service of the manufacturer is available to you Upon completion of any checking and servicing activities the operations contained in the section Recommissioning must be performed refer to chapter F Safety regulations applicable to truck maintenance Servicing and maintenance personnel The fork lift truck must only be serviced and maintained by train
15. the cone is visibly free Reset the truck Parking on the ground Full extend the side shift Lower the mast until the DIS 2 load carriage is placed on the ground Press the START key The lock hook goes up green indicator goes out The locking hook opens Lower the mast until the cone is clearly free no beep Reset the truck Switch off the device key switch and connect it to a charger if necessary see sec tions D 4 and 5 after having separated the DIS load carriage from the fork lift truck 4 10 Status and request messages Display Meaning DIS The DIS load carriage has returned to the start of the channel and is ready Ready for docking coupling onto the truck DIS The DIS load carriage is securely connected to the truck the coupling cone Docked is fixed in its receptacle and the mechanical lock is closed Only in this and green condition may the DIS load carriage be moved out of the rack indicator is lit DIS Reverse mode activated with REVERSE button DIS load carriage Reverse _ reverses slowly e g for troubleshooting DIS Request to deposit the DIS load carriage onto the DIS rail by lowering with Depositing the truck DIS When the DIS load carriage has been deposited you are prompted to Lower continue lowering the DIS coupling until the cone is free beep DIS Distance covered in the rack in mm rack depth The distance covered in Distance
16. the hand operating unit the locking mechanism 4 opens Lower the mast until cone 5 is free Reverse the lift truck by approx 0 5 m 0209 GB 0209 GB Switch off the load carriage at the key switch 13 Approach the battery change trolley 7 with the empty compartment 8 to the bat tery compartment of the load carriage and center it Pull up the locking knob 12 Pull the battery container 6 from the load carriage onto the change trolley Secure the battery container 6 with the locking knob 9 Shift the change trolley so that the charged battery is located at the battery com partment of the load carriage Pull up locking knob 10 and push the charged battery container 11 into the load carriage while pulling up the locking know 12 10 cm in front of the stopping point and releasing it when the battery container is at the limit stop The battery make contact automatically To lock the battery container correctly in place the locking knob 12 must slide down completely flush with the truck covering after completely pushing the battery con tainer into the truck Check correct locking If the battery container is not locked correctly it may roll out and fall down when lifted by the truck Switch on the load carriage at the key switch 13 Pick up the load carriage with the lift truck the lock automatically closes after docking D5 49 60c0 D 6 0
17. to FEM guideline 4 004 Jungheinrich has a safety de partment with trained personnel to carry out inspections The truck must be inspected at least annually refer to national regulations or after any unusual event by a qualified inspector The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects uninfluenced by any company or economic circumstances The inspector must be adequately in formed and experienced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork lift trucks The inspection must comprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects Apart from this the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals The user has to ensure that all defects are eliminated without delay As visual proof that the fork lift truck has passed the safety inspection a plaque is af fixed to it This plaque indicates in which month of which year the next test will be due Fault location and error recognition Fault location Fault Possible cause Remedial action Truck
18. 209 GB Operation Safety regulations governing the operation of the fork lift truck DIS load carriage Driving permission The fork lift truck must only be operated by persons who have been trained in the operation of trucks who have demonstrated to the user or his rep resentative their capability of moving and handling loads and who have expressly been charged by the user or his representative with the operation of the truck Rights duties and conduct of the driver The driver must be informed of his rights and duties trained in the operation of the fork lift truck and familiar with the contents of these operating instructions All necessary rights must be granted to him If the fork lift truck can be used in the pedestrian controlled mode the driver must wear Safety boots when operating the truck Prohibition of unauthorised use The driver is responsible for the fork lift truck dur ing working time He must forbid unauthorised persons to drive or operate the fork lift truck The transport or lifting of persons is forbidden Damage and defects Damage or defects noted on the fork lift truck or on the attach ments must immediately be brought to the notice of the person in charge fork lift trucks that cannot be safely operated e g due to worn tyres or defective brakes must not be used until they have been properly repaired Repairs Without specific training and express authorisation the driver is not allowed to perform any r
19. 5 1 5 2 5 3 Operating the industrial truck DIS load carriage E5 Safety regulations applicable when operating the truck E5 Picking Up the device cccccceeccccceceeeeeeeeeeeeeeseeeeaeeeeeeeseenaeeeeeeetees E6 Travelling arcsin a E e E E N E7 Picking up a pallet from the ground ccccccceseceesseeeesteeeesteeeesneees E7 Stacking a pallet enn hann a eR a E7 Introducing and removing the DIS load carriage to the pallet channel in channel automatic mode not for stacking the last pallet in the channel E7 Stacking the furthermost pallet in the channel manual mode E 10 Retrieving a pallet ss sssests mines aa eA a aaan E 10 Introducing and removing the DIS load carriage to the pallet channel in channel automatic mode not for retrieving the furthermost pallet in the channel E11 Retrieving the furthermost pallet in the channel manual mode E11 Adjusting the pallet stop option Stacking and Retrieving Pallets on Contact Disconnecting the DIS 2 load carriage from the truck safe parkings ane en entente ln annees E 13 Parking in the rack ceeeeeccecceeeecceeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeneeeeeeess E 13 Parking on the ground E 13 Status and
20. Capacity Plate lk An additional capacity chart must be at Seu X XXXX XX XX tached to the carrying truck so that it is visi 550 600 ble to the driver 1105 850 Ker 1250 850 The capacity plate gives the capacity Q of the truck in kg with a vertical mast The max imum capacity is shown as a table with a standard load centre of gravity distance C 26 in mm and the required lift height H in mm The standard load centre of gravity distance takes into account the width as well as the height of the load Example of how to calculate the maximum capacity 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 1105 kg B9 49 60c0 B 10 0209 GB X Transportation and commissioning Loading on lift trucks Use only fork lift trucks with sufficient carrying capacity and position the load lifting device with the wheel arm tips pointing away from the lift truck transport weight 550 kg incl pallet and lift truck coupling without attachments The vehicle 1 is delivered on a special shipping rack 3 that also contains the lift truck coupling 2 Put the vehicle down on level surface loosen the lashing straps Mounting the docking station at the lift truck As power supply and fixture for the hand operating unit a docking station must be mounted at the fork lift truck Observe all maintenance safety instructions refer to
21. IS load carriage The owner must take organisational measures to ensure this does not happen Same procedure as for stacking but place unladen load carriage in the channel the charge status is automatically identified The load carriage goes as far as the last stored pallet in the channel raises it and returns Connect the load carriage again at the start of the channel and using the truck lift it clear by approx 5 cm with the truck The lock closes automatically Green indicator is lit Check the display until the Docked message appears Remove the load carriage from the rack by reversing the truck or retracting the mast The load carriage lowers the forks after approx 2 seconds Place the pallet on the ground the DIS 2 load carriage should remain clear of the ground Stop First check that Docking is displayed and the green indicator is lit then take the load carriage out of the channel The Docked message indicates there is a phys ically secure connection between the truck and the load carriage Once the DIS load carriage has been introduced to the pallet channel the truck can carry out another job Stop First check that DIS Free is displayed then move the truck back from the rack or retract the mast The Free message indicates that there is no mechanically se cure connection between the truck and the load carriage The green indicator should not be lit
22. a cable winch and steel cable The rescue truck has a mesh protection that can be adapted to the height of the channel Lower the DIS coupling onto the fork carriage with the forklift truck To do this you may have to move the forklift back Attach the rescue truck to the receptacle cone of the forklift coupling Insert the retaining pin and secure it Deposit DIS load carriage hand operating unit into the recovery trolley operation from the lift truck is not possible The rescue person must be satisfied that the rescue truck is securely fitted to the cone and that the retaining pin has been inserted and is also secure The rescue person must wear a hard hat The rescue truck entry door must be closed and locked The rescue person must hold onto the railing of the rescue truck during lifting and low ering must not leave it and should not lean out of the railing of the rescue truck The forklift truck operator must not leave the truck during the rescue The two persons must communicate by calling out to each other Raise the rescue truck and the rescue person to channel height and place it on the rails in the DIS channel Undo the retaining pin and call out to the forklift driver to lower approx 100 mm The rescue truck is now separate from the forklift The rescue person moves the rescue truck to the DIS 2 load carriage Through sheer muscle strength he pulls on the rack beams and in this way moves the rescue
23. acking in accordance with FEM 10 2 04 are binding for the user This also applies to the following stipulations Breach or non ob servance of the above will render the Jungheinrich warranty void The following sec tions in particular cover correct handling of the rack Some of these topics have been covered before Instructions for Introducing the DIS Load Carriage to the Rack The freely movable carrier truck with the DIS load carriage and pallet picked up posi tions at right angles to the rack face with its longitudinal axis Position the truck s load bearing wheels against the approaching aid where such an aid has been installed on the ground This ensures a rectangular position to the rack Actuate the side shifting device to readjust the lateral DIS load carriage positions in relation to the channel en try When entering the pallet channel the lift of the carrying truck must provide for an excess lift of at least 30 mm between the wheels of the DIS load carriage or the bottom face of the pallet and the DIS rail while the DIS load carriage is pushed into the channel Lifting the DIS load carriage too high results in the wheel arms being positioned above the entry plates The centring device is disabled the DIS load carriage cannot be inserted in a controlled manner There is a risk that the load wheels will be damaged by the edges of the entry plates On the lower rack levels the driver s view of the DIS load carriage outriggers c
24. ail sensor riage and notify JH service department ERR Rotary Zero or too many rotary transmit Sensor faulty decommission transmitter ter impulses Sensor control the DIS load carriage and no tify JH service department ERR B3 amp B12 Error sensor B3 and sensor B12 simultaneously active Sensor control Sensor faulty decommission the DIS load carriage and no tify JH service department F 11 F 12 Display Meaning Action ERR Connec No radio connection between DIS tion controller and radio terminal Distance between radio terminal and DIS load carriage too great During operation position i e beyond range from approx truck before pallet channel 50 m and if necessary remove radio Radio shadow or highly absorb terminal from docking station ent material on radio path e g fire and operate outside of the wall or truck radio terminal antenna screened Incorrect truck no ID set in the Set correct truck number on radio controll r radio terminal E 3 3 Load carriage switched off Insert key switch Emergency Stop applied Unlock Emergency Stop ERR Truck ID Incorrect or no truck ID non de Getthe JH service department fined truck ID 000 to assign the truck and radio terminal correctly ERR Battery Battery in radio terminal dis charged Operation possible only with docking station on truck Charge radio termina
25. an be hindered e g by loads overhanging the side Special attention is required otherwise the entry plates will be considerably damaged Issue the START command on the DIS hand operating unit only when the DIS load carriage has fully vanished in the rack contour The DIS load carriage rear edge is then flush with the DIS rail front edge The load carriage must not be moved further into the channel as pallets lying there could be moved and truck components damaged For further procedures see chapter 4 3 When lowering the last pallet in the channel only the pallet not the DIS load carriage will rest on the DIS rail The carrier truck may either wait in front of the rack with the mast lifted or when it is to handle several DIS load carriages execute another task while the DIS load car riage moving inside the rack is automatically performing its assignment 0209 GB 0209 GB DIS rack safety devices The DIS rails feature mechanical safety stops on both sides of the channel Using a butting piece the DIS load carriage moves between these two stops During opera tion these stops are not touched The stops prevent the DIS load carriage from drop ping out of the rack in case of a controller or sensor failure The mechanical end stops on the DIS rails must be checked regularly for missing parts and for damage Missing or damaged safety stops must be immediately replaced Otherwise the affected channel must be closed Reflex plates ar
26. ceptacle cone 6 and the centring pieces 9 of the truck coupling or the re ceptacle plate 7 and the wear plates 8 on the load carriage must be lubricated before commissioning e g multi purpose grease or a good adhesive Molykote gre ase if necessary de wax before lubricating Bring the truck into service as prescribed refer to chapter E When the truck is parked the running surfaces of the tyres may flatten The flattening will disappear after a short operating time of the truck C2 0209 GB 0209 GB gt o gt Battery Servicing recharging replacement Safety regulations governing the handling of lead acid batteries The truck must be parked and rendered safe before any operations on batteries are undertaken refer to chapter E Servicing staff Recharging servicing and replacing of batteries must only be per formed by qualified personnel The instructions contained in this operating manual and the instructions of the manufacturer of the battery and of the battery recharging station must be observed when performing the above operations Fire protection measures Smoking and naked flames are not permitted when han dling batteries No inflammable substances or spark generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharg ing The location must be well ventilated and fire fighting equipment must be kept ready Servicing of batteries
27. ck refer to operating instructions of the lift truck Switch on the hand operating unit The display shows the basic menu with the message DIS Ready Green LED lights up Lift truck and DIS 2 are now ready for operation Selecting the load carriage Up to 10 different DIS load carriages on a truck can be operated by a hand terminal Enter the truck number to make the selection Scroll to the right three times using the gt key Select number with f or 4 key and confirm with ENTER You can also select and more quickly by using Shift n n truck number 1 to 0 10 0209 GB 0209 GB 4 1 Operating the industrial truck DIS load carriage Safety regulations applicable when operating the truck Driving lanes and work areas Only such lanes and routes that are specially allo cated for truck traffic must be used Unauthorized persons must stay away from work areas Loads must only be stored at places specially provided for this purpose Driving conduct Do not carry passengers or lift other people The truck must be driven at slow speed when negotiating bends or narrow passages when passing through swing doors and at blind spots The driver must always observe an adequate braking distance between the fork lift truck and the vehicle in front and he must be in control of his truck at all times Sudden stopping except in emergencies rapid U turns and overtaking at dangerous or blind spots is not per
28. d to prevent the load e g boxes from falling down from the pallet It is prohibited to trans port loose goods Danger of falling down items Safety sensors The safety relevant sensors B1 channel end and B11 guide rail detection must be checked regularly E1 2 Description of operating and display elementst Item Control Display DIS 2 Function 1 Hand terminal 2 Display screen Displays operating status and parameters 3 READY indicator green Load carriage ready 4 IRUN indicator yellow Driver prompts 5 START button Starts a travel command 6 REVERSE button Load carriage reverses slowly 7 RESET button Stops the DIS load carriage deletes the current travel command powers down and restarts the truck computer followed by a Ready display approx 4 seconds 8 O button Switches the control current for the hand terminal on off 9 ERROR indicator red Error Display Optional text message on display screen 10 Docking station Power supply charging and bracket for hand terminal 11 Locking adjuster Adjusts the fixed position of the hand terminal on the docking station 12 Battery lock Pull it up to loosen the battery container 13 Lock hook Locks the load carriage to the truck 14 Charge indicator LED Indicates the battery charge status see Chapter D 15 Charging connector on The battery
29. does not Emergency Stop pressed disconnect 230 V connection move Battery not charged yet Plug the plug into the receptacle Plug not in receptacle Switch on the truck Key switch turned off Charge the battery Battery discharged Check the fuses Fuse F1 F4 defective Load cannot Truck not ready for Perform all remedial actions listed un be lifted operation der the fault Truck does not move Check the fuses Fuse F2 defective Check according to circuit diagram Contactor K1 defective Check load Load to heavy Check oil level and refill if required Oil level too low Load cannot Solenoid valve V1 Check according to circuit diagram be lowered defective Lubricate and loosen if required Lifting fork sluggish Battery does Fuse F3 defective Check the fuses not charge If the fault cannot be eliminated take the truck out of service and notify the the service organisation 0209 GB 0209 GB 7 2 Error messages The DIS controller is in an error condition after an error message ERROR Press RESET to restore operating status This restarts the DIS controller therefore you must wait at least 4 seconds until the next operation can be started Display Meaning Action ERR Receptacle The DIS load carriage is not secure on the cone during attachment Audible and visual warning per manent beep noise fla
30. e is displayed then move the truck back from the rack or retract the mast The Free message indicates that there is no mechanically secure connection between the truck and the load carriage The green indicator must not be lit If the load carriage is lowered with lateral pressure on introduction to the channel the mast correspondingly springs back when the load carriage is lowered This can cause the lower sensor B3 load carriage uncoupled not to be applied and the load carriage will not move There is no Free message and no beep In this case apply the side shift generally to the left As soon as the coupling is roughly centrally aligned with the DIS channel the load carriage enters the channel Without the adjustment the load carriage may not align correctly on return This action may not be sufficient with heavy loads or at high lift heights mast deflec tion In this case correct the mast backward tilt or fork forward tilt until the load car riage can be lowered horizontally Note take into account the fact that the empty mast will spring back i e before the load carriage comes back restore the tilt to the neutral position With some ETV trucks the forks can be set horizontally by pressing a button optional fork tilt only If the load carriage still fails to move it can be started at any rate by pressing START E9 4 5 2 4 6 E 10 The lock can only be opened when the carriage is docked I
31. e fitted to ensure correct stopping process These are sensed by the infrared light scanners on the DIS load carriage When the reflection plates are bent a DIS load carriage stop under normal operating conditions is not performed and the DIS hits against the mechanical stops This can result in consequential damage and is not the usual operating mode The reflex plates must be checked at regular intervals Safety Regulations for Operating the DIS Rack The owner must provide clearly visible signs with the wording No access to racking for unauthorised personnel Entry plate Reflection plate Mechanical P Pallet depth 75 C 225 C Pallet depth D 49 60c0 E 18 0209 GB 4 14 gt gt Jungheinrich DIS rack FIFO operating mode The FIFO operating mode first in first out allows for storage and retrieval from both sides of the rack This requires the following changes to be made to both the racking and the DIS load carriage On the DIS racking The rails are fitted with four mechanical stops Instead of the reflection plates magnets are fitted onto retaining plates at the ends of the channel On the DIS load carriage Magnet switch mounted on the right outrigger Seen in the fork direction Mechanical stop below the chassis only on the right hand
32. e project planning DIS order sheet enclosed up to 3 different pal let positions may appear The available stacking depths 800 1000 1200 can be assigned to the corresponding pallet formats Stacking and Retrieving Pallets on Contact Normally pallets in the pallet channel are stacked at a distance to each other If agreed during the project planning stacking by contact may also be applied On stacking the DIS load carriage travels at crawl speed after braking until it is stopped by a positioned pallet The controller identifies this as the depositing position lowers and returns to the start of the channel This operating mode is used especially with pallets with a large overhang Requirements the load can withstand minor impacts and vertical movement free lifting lowering smooth load edge on contact surface no protruding edges Pallet weight at least 200 kg resistance against moving away On retrieval the pallet is collected with a suitable mechanical stop 0209 GB 0209 GB 4 9 4 9 1 4 9 2 Disconnecting the DIS 2 load carriage from the truck safe parking Parking in the rack Drive the truck into the rack Lower mast until the guide rail is touched Press the START key The lock hook goes up green indicator goes out The locking hook opens Press the RESET button prevents the truck from receiving a start command while lowering Lower the mast until
33. e racking Faulty sensor channel Risk of crashing ERR Lock Error when locking the locking Raise DIS load carriage again until DIS Docked appears then press START and car riage out the Depositing Low ering process Otherwise decommission the DIS load carriage and forklift truck and inform the JH serv ice department Do not remove the DIS load carriage from the racking channel Risk of crashing F9 F 10 Display Meaning Action ERR Travel Forward travel error Reverse the DIS load carriage FWD Drive motor does not move de __ back to the start of the channel spite being applied using the REVERSE function Truck mechanically blocked keep key pressed down sudden halt e g travel against Pull back the DIS load car mechanical stop riage using the rescue truck Faulty sensor incremental Determine the cause transmitter ERR Travel Reverse travel error Pull back the DIS load car REV Drive motor does not move de riage using the rescue truck spite being applied Truck mechanically blocked sudden halt e g travel against mechanical stop Faulty sensor incremental transmitter Determine the cause ERR Hyd lifting Hydraulic lift sensor not recog nised DIS load carriage notify JH service department ERR Hyd low ering Hydraulic lower sensor not recog nised DIS load carriage notify JH service department ERR Travel du
34. ed personnel of the manufacturer The service organization of the manufacturer has external technicians trained especially for these assignments We thus recommend signing a maintenance contract with the relevant service location of the manufacturer Lifting and jacking up When a fork lift truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When the truck is to be jacked up suitable measures must be taken to prevent the truck from slipping or tip ping over use of wedges wooden blocks Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength Cleaning operations No inflammable liquids must be used when cleaning the fork lift truck Prior to commencing cleaning operations all safety measures that are re quired to prevent sparking e g by short circuits have to be taken For battery oper ated fork lift trucks the battery plug must be removed Only weak indraft weak com pressed air and non conducting antistatic brushes must be used for the cleaning of electric or electronic assemblies If the fork lift truck is to be cleaned using a water jet or a high pressure cleaner all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning Cleaning by means of a steam jet is not permitted Upon completion of cleaning work the opera
35. eeeseeaeeeseaeeeseneeesenneeeeenaees B7 Conditions for application cccccccescceeeseecesseeeeesseeeeesteeeeseeeeseee B7 Label positions and identification plates Truck identification plate 7 Capacity Plates fans eens Minime ti wees B9 Transportation and commissioning Loading on lifttrUCkS esns mere hice srl enr N eds C1 Mounting the docking station at the lift truck c eee C1 COMMISSIONING 55 54 e dees nee sense C2 Battery Servicing recharging replacement Safety regulations governing the handling of lead acid batteries D1 Battery types Aichi e a denna D2 Battery charge condition 0 0 0 eect eee eeeeeeeeeeeeeeeeaeeeeeeeeeettaeeeeeeeees D2 Charging the battery with AC 230 V D 3 Changing the battery 0 00 0 ccccceccsscecsseeeeeneeeesseeeeesneeeeesteeeeseeeeeeee D4 Operation Safety regulations governing the operation of the fork lift truck DIS load Carriage Description of operating and display elementst Starting up the truck 20 0 0 eeceeeeeseeeeeeeeeeeeeeeeeeeees Switching on the truck Preparing the lift truck Selecting the load carriage 4 1 4 2 4 3 4 4 4 5 4 5 1 4 5 2 4 6 4 6 1 4 6 2 4 7 4 8 4 9 4 9 1 4 9 2 4 10 4 11 4 12 4 13 4 14 4 15 WN 3 1 4 1 4 2 4 3 4 4
36. epairs or modifications on the fork lift truck Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective Danger area A danger area is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork lift truck or its load lifting devices e g fork or attachments or by the loads being transported This also in cludes the area within reach of falling loads or falling lowering truck attachments Especially when entering the rack you must ensure that no persons are located be tween rack and load Unauthorised persons must be asked to leave the danger area The driver must give a warning signal whenever a situation presenting danger to persons might develop The fork lift truck must immediately be brought to a standstill if persons although asked do not leave the danger area Safety devices and warning labels The safety devices warning labels and warning notes described in the present operating instructions must always be heeded Rack The vehicle is exclusively designed for operation with the Jungheinrich DIS rack and must be operated within it and with protective fences up to 2 5 m high mounted only In particular pay attention to correct installation of safety devices see section 4 13 mechanical stops deflection and drive in plates Load protection Depending of the load type a suitable load protection is require
37. essage DIS _ Undocked Yellow LED lights up Load carriage automatically enters the channel Beacon active while truck is moving If the load carriage is set down with lateral pressure when manoeuvring in the chan nel the mast springs back accordingly when the load carriage is set down This may cause lower sensor B3 load carriage decoupled to be unoccupied and the load carriage does not move The message Unoccupied and the beep are missing In this case you must actuate the side shift in most cases to the left As soon as the coupling is positioned roughly in the DIS channel centre the load carriage drives into the channel Without correction the load carriage may fail to correctly track in upon return It may happen that the lower sensor B3 load carriage decoupled is not occupied in case of high loads or great lifting heights mast deflection and the load carrier may fail to start Correct by tilting the mast or fork backward first until the load carrier can be deposited in horizontal position Please note Tilt back to the neutral position be fore docking the load carrier again The load carrier can be started in any case by pressing the START key if it should not start in spite of this The locking mechanisms can only be opened in docked condition Lift the load car riage free for about 5 cm and set down again after having pressed the START key if the START key was not pressed prior to lowering of the load carr
38. f you forget to press START before lowering the lock remains closed lift the load carriage again by ap prox 5 cm and press START before lowering again After opening the lock START button the load carriage must be lowered within ap prox 8 seconds and the coupling lowered otherwise the lock will close again safety time window e g if the START button is accidentally pressed If when the DIS load carriage is lowered and the truck coupling is subsequently low ered no Free message appears no beep and lock closed the truck number in the display may be wrong Select the correct truck number section 3 3 and raise and lower the DIS load carriage again With heavy loads or large lift heights after the load carriage has been lowered in the rack the discharged mast can spring back so far that the coupling cone can no longer find the receptacle when raised again outside the catchment area To ensure better docking on the load carriage the truck should be moved slightly nearer to the rack or the mast fork tilt moved forward Failure to make this adjustment will result in excess wear to the coupling cone and the receptacle plate The slightly raised load carriage rolls back into the rack and the top of the cone rubs on the deflector bevel at great pressure This blunts the top and causes grooving on the receptacle plate With this adjustment the operator can avoid excessive wear It also ensures uninter rupted work processes by
39. iage The lock will close again if the load carriagefails to detect the rack rail within ca 5 to 8 seconds after the lock was opened e g in case the START key was inadvertently pressed The load carriage moves the pallet to the next available space at the back and then lowers it automatically with a gap of approx 5 cm Display message Riek Yellow LED lights up DIS _ Dist Travelling distance in mm 0209 GB 0209 GB X load carriage travel back to the channel start Display message If the truck is still in the starting position in front of the channel raise the mast until the load carriage has been raised approx 5 cm Otherwise Reposition the truck before the DIS load carriage to be collected The locking mechanism closes automatically Display message Green LED lights up DIS Docked Signal tone Check the display until the Docked message appears The green indicator is lit Slowly move the truck and the DIS load carriage out of the channel and lower the mast Stop First check that Docking is displayed and the green indicator is lit then take the load carriage out of the channel The Docked message indicates there is a phys ically secure connection between the truck and the load carriage Once the DIS load carriage has been introduced to the pallet channel the truck can carry out another job Stop First check that DIS Fre
40. ion DIS 2 spare fork instructions assembly status ETV coupling on a pallet rack The spare fork is used for occasionally handling pallets not raised with the DIS e g diately A The DIS 2 spare fork must only be used by trained personnel E 14 For provide for operation with an ETV cou me pling both hooked tie plates must be fitted FE with the clamping lever power stretcher and catch in the upper position for operation with an EFG coupling these parts must be in the 21 lower position f Lift up the catch 21 red Slightly loosen the clamping lever 23 red Move the power stretcher 22 black down to loosen it Raise the spare fork with the receptacle cone of the truck coupling Using the power stretcher raise the hooked tie plate on both sides so that the lugs 24 se lt curely lock into the FEM fork carriage The power stretcher must be set so that the hooked tie plate is fixed and the power stretcher s dead centre has been overcome Tighten the clamping lever Lift down the top catch Check the locking lug overhang min height overhang 8 mm Check that the spare fork is correctly located on the cone The lower lock should en gage correctly The spare fork must be securely locked onto the FEM carriage Check the spare fork for damage before using it Replace any damaged parts imme 0209 GB 0209 GB 4 12 Quick
41. is charged when the mains board charger with safety connector is inserted into a 230 volt mains switch socket 16 Key switch Switches control current on and off Removing the key prevents the truck from being switched on by unauthorised personnel 17 SHIFT key Press this together with a digit to select the truck 18 Green indicator Indicates the docked status 19 Beacon Beacon active when drive motor active 20 Emergency Stop Emergency Stop switches the DIS off E2 Standard equipment Optional equipment 0209 GB E3 3 1 3 2 3 3 E 4 Starting up the truck Before starting or operating the truck or before lifting any loads the driver has to make sure that nobody is within the danger area Checks and operations to be performed before starting daily work Check entire truck especially wheels and load carriage for damages Check that the receptacle cone and receptacle plate are well lubricated and lubri cate if required see chapter C 3 Switching on the truck Check whether the charging plug 15 is plugged in Insert the key into the key switch 16 and turn it clockwise to the stop Check whether the locking hook 13 is open Preparing the lift truck Check whether the locating coupling has been correctly mounted refer to chapter C Switch on the lift tru
42. l on docking station approx 6 hours the carrier truck s pow er supply must remain on dur ing this period Final de commissioning disposal Final proper decommissioning or disposal of the truck must be performed in accord ance with the regulations of the country of application In particular regulations gov erning the disposal of batteries fuels and electronic and electrical systems must be observed 0209 GB
43. mitted It is forbidden to lean out of or reach beyond the working and operating area Visibility The driver must look in the direction of travel and must always have a clear view of the route ahead When loads blocking the view are carried the fork lift truck must be driven with the load at the rear If this is not possible a second person must walk in front of the fork lift truck to give suitable warnings Negotiating slopes and inclines Negotiating of slopes and inclines is permitted only when they are recognised lanes when they are clean and non slipping and when the technical specification of the truck permits safe driving on such slopes or inclines Loads must always be carried at that end of the truck facing uphill U turns cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted Inclines must only be negotiated at slow speed with the driv er ready to brake at any moment Use of lifts and driving on loading platforms Lifts and loading platforms must only be used if they are of adequate load bearing capacity if suitable for driving on and if authorised by the user of the truck for truck traffic The fork lift truck driver has to sat isfy himself accordingly before driving into lifts or on to loading platforms The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft Persons
44. n and yellow LEDs are flashing The green indicator is lit 0209 GB 0209 GB OO 4 4 4 5 4 5 1 Travelling During travel the load carriage must never touch the ground When placed on the ground the DIS load carriage stands on the load wheels and on skids on the drive side so that the drive wheels are clear of the ground Only travel with the covering closed and the battery correctly locked Never put the load carriage down on the ground and tow at the locking hook Observe the larger swivelling radius with attached DIS 2 For travelling instructions refer to the operating instructions of the corresponding lift truck Picking up a pallet from the ground Set mast or fork tilt to neutral home position Lower mast and slowly drive into the pallet until it makes contact with the fork limit stop The DIS 2 load carriage must be lifted clear of the ground The pallet must be positioned approximately 3 cm further back than the wheel arm tips Lift the pallet Stacking a pallet Introducing and removing the DIS load carriage to the pallet channel in chan nel automatic mode not for stacking the last pallet in the channel Do not operate the DIS pallet channel with more than one DIS load carriage The owner must take organisational measures to ensure this does not happen Travel to the desired channel Compare the truck number 1 2 n on the DIS load carriage wi
45. nt wall Loosen lock nuts 2 Carefully remove the coverings F5 4 3 Checking the electric fuses Prepare the truck for servicing and maintenance works refer to section 4 1 Remove coverings refer to section 4 2 If required dismount the cover 7 Check all fuses for their correct value according to the table and replace if required For cold store trucks the fuses are located in an insulated housing together with the drive system drivers Wi 7 Fe Item Description To protect Rating 3 F1 Main fuse 50 A 4 F2 Hydraulic unit K1 30 A 5 F3 Charger 10 A 6 F4 Controller 5A 7 5 Beacon 2A 4 4 Recommissioning the truck Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operation has been performed Self test of the control system after switching on F6 0209 GB 0209 GB 5 1 5 2 Ni 5 3 Decommissioning the truck If the fork lift truck is to be decommissioned for more than 6 months it must be parked in a frost free and dry location and all measures to be taken before during and fol lowing decommissioning must be performed as detailed below During decommissioning the fork lift truck must be jacked up ensuring that the wheels are clear of the ground Only this will ensure that wheels and wheel bearings do not suffer damage
46. ommissioning Measures to be taken during decommissioning Recommissioning the truck after being taken out of service F7 Safety checks to be performed at regular intervals and following any untoward incidents eceeeeeeeeteeeeeneeeeeneeeeenneeeees F8 0209 GB Fault location and error recognition Error messages Final de commissioning disposal 0209 GB 49600 14 0402 GB Correct use and application of the truck The Guidelines for the Correct Use and Application of Industrial Trucks VDMA are included in the scope of delivery for this truck The guidelines are part of these ope rating instructions and must always be heeded National regulations are fully applica ble The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads It must be used operated and maintained according to the information in these ope rating instructions Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property Above all overloading caused by excessively heavy or unbalanced loads must be avoided The max admis sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck The fork lift truck must not be operated in spaces subject to fire or explosion hazards or in spaces where corrosive or very dusty atmospheres pre vail Duties of the user
47. r correct amperage Check the warning devices and safety circuits for cor rect functioning Electric motors Check the motor for secure attachment Batteries Check the terminals for secure attachment and apply grease Check the battery cables for damage renew if neces sary In case of special operating and environmental conditions the maintenance intervals must be adapted accordingly 3 2 Lubrication Schedule The receptacle cone 6 and the centring pieces 9 of the truck coupling or the recep tacle plate 7 and the wear plates 8 on the load carriage must be lubricated at reg ular intervals The multi purpose grease material no 14038650 is suitable for this Alternatively a good adhering Molykote grease material no 29201270 can be used y ff F4 0209 GB 0209 GB 4 1 4 2 Notes on maintenance Preparing the truck for servicing and maintenance operations All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations The following prerequisites must be es tablished Park and lock the truck refer to chapter E Switch off the truck at the key switch 1 When working under a raised lift truck secure it to prevent it from tipping or sliding away When lifting the truck the instructions contained in chapter Transportation and commissioning have to be observed Removing front hood and fro
48. ransport procedure Ten key keypad for special situations Service mode Drive system Bevel gearing directly seated on drive shaft CD 24 V 0 37 kW KB 60 minutes traction motor with digital tachometer and thermal sensor Lifting drive Hydraulic unit with pump tank and cylinder Electrical connections Potential free operation Protection class IP 65 for connectors sensors and housing Batteries 2 x Lead gel batteries 12 V 60 Ah in series in battery container with auto matic contacting B3 3 Technical data Indication of technical data according to VDI 2198 Subject to modification and sup plementing 3 1 Performance data for standard trucks DIS load carriage Description DIS 2 Q Rated capacity 1200 kg C Load centre of gravity see chapter 3 3 Fwd rev travel speed 0 5 m s 1 8 km h Lift speed w w o load 0 01 0 02 m s Lowering speed w w o load 0 04 0 02 m s Net weight of load carriage including battery and cou 440 kg pling Battery weight 58 kg Battery 2x12V 60 kg Ah in series Range with a single battery charge approx 8 h depending on application conditions 10 Truck coupling weight depending on model 30 kg Motor output 0 37 kW 3 2 Dimensions Description DIS 2 l Stacking depth pallet length 800 1200 mm Load carriagelength see chapter 3 3 b4 Truck width 940 1340 mm b4 Width
49. rea Batteries are always charged outside the freezer area The truck must be removed from the freezer zone for operating intervals of more than 30 minutes When switched off the truck must always be parked outside the freezer zone B7 4 B 8 Label positions and identification plates Item Designation 14 Warning label No passengers allowed 15 Capacity 16 Truck identification plate 17 Warning label CAUTION Low voltage electronics 0209 GB 0209 GB 4 1 18 19 20 21 Truck identification plate 28 XXXX xxx XXX 27 Tee XXXXX XXXXXXX 200000000000 XXXXXXXXXXXXXXX ma el 26 2000000000000X 200000000000 2000000000 x 25 XXXXXXXXXXX XXXXXXXXX Ta 2000000000000000X 7 XXXXXXXXXXXXXXX De ea EN 24 XXXXXXXX XXXXXXXX 23 CE Item Designation Item Designation 18 Type 24 Min max battery weight in kg 19 Serial No truck No 25 Output kW 20 Rated capacity in kg 26 Load centre distance in mm 21 JBattery Voltage V 27 Year of manufacture Ampere hours Ah 22 Net weight without battery 28 Option e g TK 23 Manufacturer For queries relating to the truck or spare parts orders please state the model refer ence 18 and truck serial no 19
50. reference card The laminated quick reference card comes with every DIS load carriage and must be visibly fastened at the truck s operator station Quick start guide Driver action Shuttle response Hand terminal display Switch on DIS 2 shuttle Switch on hand terminal Ready Lift shuttle Lock closes Docked Green indicator is lit Approach rack channel Lock closed Docked Green indicator is lit Shuttle in channel raised 5 cm Press START Lock opens for approx 8 seconds Deposit Lower mast deposit shuttle Lower When lowered far enough Cancel Lower Shuttle sets off Free beep Green indicator goes out Shuttle travels in channel route indicator Shuttle is back truck coupling in correct position Ready Raise mast lift shuttle Lock closes Green indicator is lit Docked beep Pull shuttle out of rack Green indicator is lit Docked Attention Operation by authorised personnel only A Only when Docked is displayed and the green indicator is lit can the DIS load carriage be removed from the channel 4 13 pe L MES E 16 Operating instructions for the Jungheinrich DIS rack For the operation of DIS racks the guidelines and safety regulations of the associa tions for warehouse equipment and machinery BGR 234 previously ZH 1 428 and the guidelines for the safe use of secure r
51. riding in the lift together with the fork lift truck must only enter the lift after the fork lift truck has come safely to a standstill and must leave the lift before the fork lift truck Nature of loads to be carried The operator must make sure that the load is ina satisfactory condition Only carry loads that are positioned safely and carefully Use suitable precautions e g a load guard to prevent parts of the load from tipping or falling down Towing of trailers with mounted load carriage is not allowed E5 E6 Picking up the device The DIS 2 has been designed for use at different fork lift truck types Therefore the operation of the lift truck itself with respect to position and handling of the truck op erating elements cannot be explained in detail Refer to the operating instructions of the corresponding lift truck The device is switched on and ready for operation refer to section 3 Drive the lift truck towards the device so that the locating cone 17 is positioned some centimeters below the cone hole of the support plate 18 If required correct the lateral position by means of the side shift The lower centering pieces 20 are inserted into the wearing plates 19 Slowly lift the mast The locking hook 13 automatically closes when the cone 17 is fully seated in the hole lifting point The following response is shown at the hand operating unit Display message DIS Docked Gree
52. rolley 5 Coupling plate with locating cone 6 1 0 switch key switch 7 Battery charge plug AC 230 V integrated charger 24 V 9 A 8 Lifting fork 9 Load wheel 10 O Pallet stop adjustable 11 Drive wheel 12 Docking station including charger 13 Hand operating device Series equipment O Optional equipment 0209 GB 0209 GB 2 1 Truck Construction The DIS 2 is a four wheel vehicle with 2 load wheels and 2 drive wheels that are connected fixed via a straight through shaft Due to its easily dis mountable cover all components are well accessible The device is operated via a re mote radio control from the lift truck Safety devices Arobust appropriately dimensioned and actively controlled locking hook prevents unintended separation of the load carriage from the lift truck Sensors detect guide rail and channel end The redundant distance measurement provides a high safety level when travelling in the channel Mechanical limit stops reliably prevent the load carriage from falling out even in case of total failure of the control system and the power electronics Operating and display instruments Handy control terminal with bracket for the truck and power supply docking station from the truck battery 18 to 60 volts Can also be used as a hand terminal with a buffer battery Including LCD to display the truck status Defined function keys for programmed t
53. rs are tightly closed Opening the covers will destroy the battery The battery weights can be seen on the battery identification plate Battery charge condition The battery charge condition is detected via the control system and is indicated at the hand operating unit The following conditions are possible Charging Red LED Vehicle function condition 30 100 off full function 20 30 flashing full function below 20 flashing no longer accepts travel orders When the red LED starts flashing the vehicle can still be operated for approximately 1 hour To achieve a longer service life however the battery should not be dis charged exhaustively The current battery voltage can be directly displayed at the hand operating unit press the key to scroll once to the right 0209 GB 0209 GB X Charging the battery with AC 230 V The mains cable of the charger can be accessed from the outside Switch off the truck at the key switch Remove the mains plug 1 from its receptacle 2 at the charger and plug into a suitable mains socket 230 V 10 The LED 3 flashes green and indicates that the charger is connected to mains and that the charging operation is active Charge the battery until the LED 3 lights up green continuously Unplug the plug 1 from mains and insert it into the receptacle of the safety switch at the truck 2 Mains connection Main
54. ruck failure and poses a potential hazard to personnel and equipment Chassis superstructure Check all load bearing elements for damage Check all bolted connections Check skids under the drive axle for wear and damage Skid height 28 mm 2 mm Check side guide rollers for wear and damage Width between guide rollers front load axle 1213 mm 1 mm rear drive 1208 mm 2 mm The skids and guide rollers suffer excess wear if the DIS load carriage is pushed or pulled along the gound operator error Always operate the DIS 2 clear of the ground Chapters 4 3 and 4 4 DIS coupling on truck receptacle plate Replace tip of cone if excessively worn Tip radius new R 2 mm Urgent replacement required if condition lt gt Receptacle plate on DIS load carriage Replace receptacle plate if considerable signs of groov ing present Urgently required if condition C Drive Check transmission for noise and leaks Check for wear and damage Check bearing and secure attachment Check wheel bolts for tight seat and retighten if re quired Lifting device Check function and wear Check load section and kinematics for wear and dam age F3 Hydraulic system Check performance Check hydraulic unit for leaks and damages Electrical system Check function Check cables for secure connection and damage Check the fuses fo
55. s voltage 230 V 10 Mains frequency 50 Hz 4 All electrical functions are disconnected during the charging operation electronic move protection The truck cannot be operated Charging times The charging time can take up to 8 hours depending on the battery discharge status Trickle charge After a few hours the charger then switches to a compensation charge Charging in cluding the trickle charge lasts up to 40 hours and is completed when the connector is removed Trickle charging for example at the weekend increases the battery s useful life Partial charging The charger automatically adapts to the current charge status when connected to a partially charged battery This keeps battery wear to a minimum A red flashing LED 3 means that the battery is faulty or the charge current circuit has been interrupted D3 D 4 Changing the battery For multi shift operation as well as for cold store usage the battery can be changed Battery change trolleys with integrated charger and additional battery containers are available as accessories For changing the battery the load carriage must be standing on level surface and there must be approx 1 5 m free space at the battery side and approx 0 5 m to the lift truck Load carriage is coupled and switched on Lower the mast until the load carriage almost reaches the ground same as for pick ing up a pallet from the ground Press Start at
56. shing LED The load carriage has been raised from the DIS rail without having docked correctly The coupling cone is not secure in the recepta cle plate the lock is still open If necessary push the load carriage back fully into the channel lower it carefully and attach again to the coupling until the Docked message appears on the display Otherwise decommission the DIS load carriage and forklift truck and inform the JH serv ice department Do not remove the DIS load carriage from the racking channel Risk of crashing hook The hook was not fully closed within a timeframe Mechanical locking hook jam ming The locking motor current control may have applied during exces sive kinetic resistance e g forklift coupling lowered while locking hook was closing resulting in blocking Faulty sensor ERR Unlock Error when unlocking the locking Raise DIS load carriage again hook The hook was not fully until DIS Docked appears opened within a timeframe then press START and car Mechanical locking hook jam _ 10896 out the Depositing Low ming ering process Locking motor current control Otherwise decommission the may have applied during exces DIS load carriage and forklift sive kinetic resistance e g forklift truck and inform the JH serv coupling lowered first onto the ice department locking hook and then START Do not remove the DIS load pressed carriage from th
57. side seen in the fork direction Do not operate the DIS pallet channel with more than one DIS load carriage The owner must take organisational measures to ensure this does not happen The mechanical end stops on the DIS rails must be checked regularly for missing parts and for damage Replace any missing or damaged end stops Otherwise block the affected channel for use Magnetic plates are fitted to ensure the correct stopping process These are sensed by the magnetic switch on the DIS load carriage If any magnetic plates are missing the DIS will not stop correctly and the DIS will strike the mechanical end stops This can result in consequential damage and is not the correct operating mode The magnetic plates must be checked at regular intervals E 19 Entry plate 49 60c0 C 225 Magnet bracket P Pallet depth 75 Mechanical C Pallet depth 1 1 1 1 1 1 1 1 1 1 i Magnet bracket E 20 0209 GB 4 15 Rescuing a DIS 2 truck from the channel DIS load carriage Two trained and authorised personnel are required to rescue a DIS 2 truck The DIS 2 rescue truck must only be used in conjunction with a DIS 2 carrier truck DIS truck equipped with a DIS 2 coupling A non functioning DIS 2 load carriage in the pallet channel is removed from the chan nel with the aid of the DIS 2 rescue truck option
58. taking preventative measures Stacking the furthermost pallet in the channel manual mode The furthermost pallet of a channel is brought in by simply lowering the DIS load car riage including the pallet Lower the fork until it is free once the pallet has been de posited and pull out the fork by either retracting the mast or backing the lift truck Make sure not to press the START button during this process The DIS load carriage is only introduced to the channel as far as the rear edge of the pallet the drive section remains outside the rack block Otherwise safety devices on the DIS load carriage of the rack system may be damaged Retrieving a pallet The load carriage automatically recognises the loading condition The procedure is the same as for stacking however the load carriage must be set into the channel without load The load carriage travels to the next pallet into the channel lifts it up and returns Pick up the load carriage The lock closes automatically Green indicator is lit Remove the load carriage from the rack The load carriage lowers the forks after approx 2 seconds Place the pallet on the ground 0209 GB 0209 GB 4 6 1 o u gt X Introducing and removing the DIS load carriage to the pallet channel in chan nel automatic mode not for retrieving the furthermost pallet in the channel Do not operate the DIS pallet channel with more than one D
59. th the display on the hand terminal top right of display If they differ select the right truck number see section 3 3 Adjust the lifting height in such a way that the load carriage has a free lift of approx imately 5 cm as opposed to the rack Attach indicators on the lifting mast or use the optional height preselection according to the truck s scope of delivery if applica ble Extend mast and approach the rack at right angles up to the approaching aid op tional If required correct the lateral stacking position by means of the side shift Correct mast inclination great lifting height by tilting mast or fork backward The load carriage must be fully within the rack contour i e the load carriage flush with the guide rail Lower the truck coupling cone further down a further 10 cm from the load carriage attachment point until the display appears and an audible signal beep is heard Stop lowering Press START at the hand operating unit the lock opens Display message Green and yellow LEDs are flashing DIS Put down The green indicator goes out E7 E8 Lowering The message changes as soon as the load carriage detects the guide rail and the cone is free Display message Green and yellow LEDs are flashing Continue to lower from the contact point of the load carriage some 10 cm more An acoustic signal beep is heard when lowered low enough CMD Display m
60. the DIS channel is permanently displayed forward and back The 12345 maximum distance pallet position remains stored until the next travel command START can be selected by pressing a key shift F0 DIS Free DIS load carriage is uncoupled free of the truck When the DIS coupling has been deposited and lowered the mechanical connection to the truck is completely released Load carriage travels automatically into the channel Only in this condition may the truck be moved away from the rack 4 11 Display DIS Meaning Unlock DIS Prompt to open the lock Usually this means START was not pressed beforehand Raise DIS load carriage again carefully press START and then start the Depositing Lowering process Charge battery DIS The DIS load carriage battery is discharged The charge level has fallen However the DIS 2 returns to the start of the channel below 20 the truck controller does not accept further travel commands Channel end The channel end has been identified The DIS load carriage had entered the channel to retrieve and did not find any pallets DIS returns to start of channel DIS Lag Reverse travel addition activated When reversing to the start of the channel the DIS load carriage stops before the docking position and continues travelling at crawl speed up to the truck coupling or the DIS rail mechanical stop defined docking posit
61. the following graphics Used before safety instructions which must be observed to avoid danger to personnel Used before notices which must be observed to avoid material damage Used before notices and explanations Used to indicate standard equipment Used to indicate optional equipment Our trucks are subject to ongoing development Jungheinrich reserves the right to alter the design equipment and technical features of the truck No guarantee of particular features of the truck should therefore be inferred from the present operating instructions Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg GERMANY Telephone 49 0 40 6948 0 www jungheinrich com 9 8010 0209 GB Table of Contents A B ND O BR ND m 3 1 3 2 3 3 Correct use and application of the truck Description of the truck Design and Application ccccccccceccceeeeeeneeeeeeseeeeeeeeeeeseeteeeeeeeenes B1 Description of assembly groups and functions B 2 TUCK riens nr me nr a nn nn ee RN B 3 Technical data ss ann nn den detente B 4 Performance data for standard trucks DIS load carriage B4 Dimensions Sees wal Reh Hie EN a a ciel eee B4 Truck types pallet formats stacking depth underlined B5 EN standards 0 ceeeeccceeesceeeenneeeeeneeeseneeeesen
62. tions detailed in the section Recommis sioning must be performed F 1 F2 Work on the electric system Work on the electric system of the truck must only be performed by personnel specially trained for such operations Before commencing any work on the electric system all measures required to prevent electric shocks have to be taken For battery operated fork lift trucks the truck must also be depow ered by removing the battery plug Welding operations To prevent any damage to electric or electronic components these have to be removed from the fork lift truck before any welding operations are undertaken Settings When repairing or replacing hydraulic electric or electronic components or assemblies all truck specific settings have to be retained Tyres The quality of the tyres greatly affects the stability and the driving behaviour of the fork lift truck The factory mounted tyres must only be replaced by original spare parts of the manufacturer since otherwise the specification of the data sheet cannot be met When replacing wheels or tyres it must be ensured that the fork lift truck remains level tyres and wheels must always be replaced in pairs i e left and right together 0209 GB 0209 GB 3 1 Servicing and inspection Wartungs Checkliste Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck Failure to perform regular servicing can lead to t

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