BorMann PRO BWR2515 User manual

Art Nr:
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EN FR
BWR2515
053330
IT EL
BG SL
RO
v2.2

EN
SAFETY INSTRUCTIONS
Warning: Read the manual carefully before use. Failure to follow the warnings and instrucons may result in damage to the electric pallet
truck, physical injury and/or damage to property. Store the manual in a safe place for future reference.
Operator
• The electric pallet truck may only be driven by trained and authorised personnel.
• The operator must have read the operang instrucons contained in this manual before using the pallet truck.
• The operator must work only loads with that do not exceed the load capacity indicated on the nameplate.
• The operator must be fully aware of the nature and the stacking condion of the load that is being transported.
SYMBOLS
Stay clear of moving parts.
Moving parts can cut or crush
hands, feet, arms or legs.
Do not drive the pallet truck
in temperatures under 0°C or
over 45°C.
Do not drive the pallet
truck on wet, oily or muddy
surfaces.
Keep the pallet truck away
from rain.
Use the pallet truck only on
hard and at ground. Avoid
sharp objects.
Do not use the pallet
truck in excessively dusty
environments.
Use in corrosive environments
is prohibited.
Use in ammable
environments is prohibited.
Use in explosive
environments is prohibited.
Risks - Transporng the pallet truck
• Ensure that any packaging including the shipping pallet or crate are of sucient strength to bear
the weight of the pallet truck and large enough to accommodate the pallet truck.
• Ensure that the forks of the pallet truck are fully inserted into the shipping pallet.
• Make sure that the pallet truck's capacity is sucient to hold the combined weight of the pallet
truck and any packaging.
• Only li the pallet truck using the liing points marked on the pallet truck on the le and right
sides of the chassis.
Note: Avoid scratching the forks or covers of the pallet truck when loading, especially when inserng the forks into the shipping pallet. Do not drop the pallet
truck when loading.
Fig. 1 Fig. 2
• Never start the pallet truck if it is damaged or defecve. Operate the pallet truck only if it is in good condion.
•If the pallet truck needs to be repaired, place a clearly visible sign saying “OUT OF ORDER - DO NOT USE” on the pallet truck and remove the key from the
control panel.
• Do not use the pallet truck to li people.
• The warning and informaon decals must never be removed, painted over or made undecipherable. Should a decal be undecipherable, it must be replaced.
•Do not soak the baery in water. Do not recharge the baery in temperatures lower than 0°C.
Risks - Tipping over of the pallet truck
The main causes of pping over are:
• Turning too fast.
• Driving and turning on a slope.
• Driving with raised loads.
• Driving with a side-posioned load.
• Driving on a slope with a load facing downwards.
• Carrying loads that exceed the maximum loading weight.
• Carrying loads that are too big for the pallet truck.
• Driving with swinging loads.
• Transporng liquids.
• Ramps or steps.
• Loading operaons on a lorry, for example if the lorry engine is switched on while the forks are sll raised above the loading area, if the ramp is not in the
right posion or if a pallet truck wheel is beyond the edge/limit.
•Driving over rough ground.
Danger: If the pallet truck ps over, try and keep your body parts as far as possible from the point of impact with the ground.
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MAIN PARTS
1. Handle
2. Motor
3. Power switch (emergency power o)
4. Lithium-ion baery
5. Chassis
6. Cover
Fig. 3
• Handle numbers correspond to chassis numbers.
1. Disconnect the baery.
2. Remove the handle sha (2) from the handle socket.
3. Put the chassis connector through the wire supporng plate (5) and lock hole.
4. Install the handle assembly (1) to the handle socket. Be careful to avoid damaging the wire harness.
5. Install the handle sha through the handle assembly and handle socket. Install the spring pin (3) to the le side of handle sha.
6. Press down on the handle assembly and remove the spring holder (4).
7. Connect and lock the wire harness from the handle assembly to the chassis connector.
8. Fix the wire harness to the wire holder (6).
9. Reconnect the baery.
TECHNICAL DATA
Model BWR2515
Maximum loading weight 1.5 tons
Baery 48 V / 10 Ah lithium
Power 0.75 kW
Dimension of forks 1150 x 550 mm (for euro pallets)
Transformer 2 A
Minimum loading height 84 mm
Maximum liing height 110 mm
Operang me with fully charged baery 3 hours
Baery charging me 5 hours
Brake Electromagnec
Weight 116 kg
* The manufacturer reserves the right to make minor changes to product design and
technical specicaons without prior noce unless these changes signicantly aect
the performance and safety of the products. The parts described / illustrated in the
pages of the manual that you hold in your hands may also concern other models of the
manufacturer's product line with similar features and may not be included in the product
you just acquired.
* To ensure the safety and reliability of the product and the warranty validity, all repair,
inspecon or replacement work, including maintenance and special adjustments,
must only be carried out by technicians of the authorized service department of the
manufacturer.
* Always use the product with the supplied equipment. Operaon of the product with
non-provided equipment may cause malfuncons or even serious injury or death. The
manufacturer and the importer shall not be liable for injuries and damages resulng from
the use of non-conforming equipment.
ASSEMBLY INSTRUCTIONS
Installing the tiller handle (See appendix 1 at page 65)
1. Combine the screw (#1), block (#2) and washer (#3) as shown.
2. Align the mounng hole and ghten the screw.
Installing the baery protecon stopper
Fig. 4
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Preparing the pallet truck aer transportaon
Following transportaon, the pallet truck must be prepared for use in order to ensure its correct operaon. Take the following steps:
1. Inspect the truck to make certain there is no damage and there are no parts missing.
2. Install the baery, making sure not to damage any electrical wires.
3. Charge the baery.
4. Check the baery charge level (Indicator).
5. Test the li and lower system.
6. Make a general inspecon of the controls and instrumentaon.
OPERATING INSTRUCTIONS
Note: It is normal for wheels to show some deecon or distoron in shape aer the pallet truck is parked for an extended period. The wheels will restore to
their original shape aer the pallet truck is driven for a me.
Steering ller
• The steering ller in posion ''M'' enables the pallet truck to be driven.
• If the steering ller is in posion ''B'', it will not be possible to drive the pallet truck or li/lower loads and the display
will read SRO ERR.
• Push the throle in the desired direcon to move the pallet truck. The more the throle is pressed, the faster the pallet
truck will move.
• Use the steering ller to steer the pallet truck.
Regenerave braking
• Release the throle.
Hard braking
To brake the pallet truck more quickly, you can either:
• Release the steering ller.
• Move the steering ller to posion “B’.
• Pull the steering ller down to the lowest posion.
Warning: When the throle is released, it should return to neutral posion immediately. If it does not, have the pallet truck repaired immediately to reduce
the risk of personal injury or property damage.
Fig. 6
B
M
B
Warning: When the steering ller is in the "B" posion, the pallet truck should stop moving unl the throle is pressed again. If the pallet truck moves with the
handle in the "B" posion, have the truck repaired immediately to reduce the risk of personal injury or property damage.
Precauons - General rules
• Operators have to inspect the unit and have a specialist perform maintenance on a regular basis.
• The rules of parking are as follows:
- No parking on ramps.
- The forks must be lowered completely.
- Press down the emergency stop buon.
• Before using the pallet truck:
- Users have to stand in the operaonal posion.
- Put the handle in the driving posion.
- Test liing, steering, speed, operaon, alarm and brake to ensure all funcons work normally.
• Ensure the availability of reghng equipment in the workplace. Do not use a are to check the baery and hydraulic system.
• Check braking, driving, alarm and safety system on a regular basis.
• Keep the nameplate and warning sckers clean and readable.
• Check and maintain liing system regularly.
• Check and maintain the hydraulic system regularly. Ensure that there is no oil leak in the cylinder, hydraulic valve and other hydraulic system parts.
• Park the electric pallet truck in clean areas, to ensure the lowest possibility of re.
• Unauthorized modicaon of the unit is forbidden.
• Check and maintain the liing system regularly.
• Take the utmost care when transporng dangerous materials: ammable liquids, acids, etc. must be transported in appropriate closed containers.
• Where possible, avoid routes with holes, bumps and obstacles. If this proves to be impossible, drive the pallet truck with extreme cauon. Take steps to
ensure that all holes, bumps and obstacles are removed wherever possible.
1. Put in the baery, rotate the stopper against the baery and ghten the screw.
2. Loosen the screw, rotate the stopper in the opposite direcon, and pull out the baery vercally.
Fig. 5
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7
Fig. 9 Fig. 10
1. Horn buon
2. Throle
3. Baery discharge indicator (BDI), hour meter,
fault code display
4. Lower buon
5. Li buon
6. Belly switch - Reversing buon
7. Power switch (emergency stop buon)
Proper use
1. Posion the pallet truck in line with the load to be lied.
2. Move slowly when moving the forks into posion under the load and make sure that the load is correctly centred on the forks.
3. Aer ng the forks in the pallet, slightly li the load just enough to move it.
Controls
Picking up the load from the ground
1. Put the load on the ground.
2. Lower the forks.
3. Move slowly to remove the forks from the pallet.
Pung the load down on the ground
Warning:
• When picking up/pung down loads, use the machine at the lowest possible speed that can perform a given operaon reliably.
• Always make sure that nearby persons are at a safe distance from the pallet truck.
Load stability
Warning:
• Only work with stable loads.
• Do not handle a load, composed of a number of separate parts, when any one of them is precariously
balanced and in danger of falling.
• Do not carry swinging loads.
Posioning the load
• Make sure that the weight of the load is equally distributed and balanced on the forks so that the
load will not overturn during turns.
Warning: A load that is placed in an unbalanced posion on the forks will increase the risk of
overturning.
Fig. 7: Centred load Fig. 8: Non-centred load
Throle
• The operaon of the throles permits movement both in the operator side direcon and in the fork side direcon.
• Turning the throttles toward the operator, the pallet truck moves in the operator direction.
• Turning the throttles toward the forks, the pallet truck moves in the fork direction.
• The pallet truck speed increases proportionally according to the angle of rotation of the throttles.
• Reversing the throle causes a progressive deceleraon of the truck to a stop.
• On releasing the buery controls, they return to their neutral posion, causing a progressive deceleraon with subsequent engaging of the electromechanical
brake.
Horn buon
• Press this buon to operate the horn.
Plug braking
To brake quickly with more control, use controlled braking or ''plugging''.
• Release the throle.
• Move the throle in the direcon opposite the current direcon of travel.
• When the pallet truck starts to move in the opposite direcon, release the throle.
Warning: Use hard braking or plugging when an unexpected situaon arises and it is necessary to stop quickly.
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Power switch (emergency stop buon)
• When the power switch is pressed, the baery supply is disconnected and all electric controls are disabled.
- Buon down: electrical system disconnected.
• To reset, pull the buon and move the steering ller to the vercal posion.
- Buon up: electrical system connected.
• The power switch also acts as an emergency brake when it is pressed (the electromagnec brake engages).
Belly switch - Reversing buon
• The belly switch reverses the direcon of movement of the pallet truck when it is bumped.
• To reset the pallet truck funcons it is necessary to turn the pallet truck o and then on again.
Turtle speed
• Turtle speed allows the truck to move at a reduced speed.
• Normal top speed for the pallet truck is 5 km/h. When turtle speed is acve, the top speed is 2 km/h.
• To acvate or deacvate turtle speed, hold the horn buon, then press (but do not hold) the throle toward the forks two mes.
Up-right drive
• Up-right drive allows the truck to be driven with the ller in the fully vercal posion. Use up-right drive to maneuver the truck in ght quarters.
• To acvate up-right drive on pallet trucks, turn the pallet truck o, put the ller into the fully vercal posion, then press and hold the belly switch - reversing
buon and push the throle toward the forks and hold. When the pallet truck is powered on, it will start in up-right drive mode.
• When up-right drive mode is acve, the top speed is 2 km/h.
Smart funcons
Brake release mode (service mode)
• The pallet truck is ed with an electromagnec brake. When the pallet truck has no power, the brake is closed and the pallet truck will not move.
• If the pallet truck has no power but must be moved to a service locaon, turn on brake release mode so that the pallet truck can be moved manually.
• Take the following steps to turn on brake release mode:
1. Make sure the power is o and the power buon is down.
2. Press and hold the horn buon, then li the power buon to provide power to the pallet truck.
- The display will read NO BRAKE and the pallet truck will beep to indicate that the brake release mode is acve.
3. Manually pull the pallet truck to the service locaon.
Repair procedures
Warning: The brake release mode is for service use only. To reduce the risk of injury, do not use brake release mode during normal operaon.
Li buon
• Press this buon to li the forks.
Baery discharge indicator (BDI) and error code indicator
• The display screen will show remaining charge le in the baery and also will list any acve fault codes.
Lower buon
• Press this buon to lower the forks.
MAINTENANCE
Replacing the drive wheel (Fig. 11)
1. Disconnect the baery.
2. Support the pallet truck on blocks so that the drive wheel (9) is o the ground.
3. Remove 3 bolts (8) from the controller cover (7), then remove the controller cover.
4. Remove 4 bolts (4) from the nut cover (3), the remove the nut cover.
5. Remove the nut (2).
6. Gently tap the wheel sha (10) and pull it out of the drive wheel.
7. Remove the drive wheel.
8. To install the drive wheel, perform these steps in reverse order.
9. Reconnect the baery.
Fig. 11
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Replacing the load wheels (Fig. 12)
1. Turn o the pallet truck, remove the baery, and turn over the pallet truck. Be careful to avoid damaging
the ller handle.
2. Remove the snap ring (1) with snap ring pliers, the remove the sha (2).
3. Remove the spring pin (3), then remove the wheel fork sha (4).
4. Remove the load wheel assembly (5 for tandem wheel, 13 for single wheel).
5. Remove the spring pin (6 or 9), then remove the wheel sha (7 or 10) and remove the load wheel.
6. Replace the load wheel (8 for tandem wheel, 12 for single wheel). For single wheels, install nylon gasket
(11).
7. Reinstall the wheel sha and spring pin.
8. Reinstall the load wheel assembly into the frame, then repeat steps 1 through 3 in reverse order to
complete installaon.
Fig. 12
Replacing the hydraulic cylinder (Fig. 13)
1. Disconnect the baery.
2. Lower the forks completely, raise up the pallet truck, and put a 200 mm block underneath the ends of the
fork closest to the main frame.
3. Remove the screw (4) and remove the wire clamp (5), then remove the 4 screws (7) with a hex wrench.
4. Remove the oil pipe (6), remove the piston rod sha end (1) and sha gland (3).
5. Press down the piston rod, allow the cylinder to separate from the frame, and remove the cylinder assembly
from the pallet truck.
6. Remove the oil pipe joint (8) and install the new cylinder assembly.
7. Place the new cylinder on the cylinder holder and install the locking screw (7).
8. Reinstall the piston sha, pull up on the piston rod and connect the sha gland to the frame.
9. Connect and ghten the oil pipe, then reinstall the wire clamp.
10. Take the pallet truck o of the 200 mm block, then remove the baery.
11. Open the screw on the tank, then ll the tank with L-HV 32 hydraulic oil, close the screw on the tank, then install and connect the baery.
12. Loosen the screw (11), then use the pallet truck to li a pallet with a load of at least 500 kg. Li and lower the pallet 2 or 3 mes to bleed air from the
cylinder, then ghten the screw.
13. Reconnect the baery.
Fig. 13
Cauon: To avoid damage to the seal ring and oil leaks, always bleed the air from the cylinder aer
replacement.
Replacing the seal kits (Fig. 14)
1. Disconnect the baery.
2. Use a hook head wrench to unscrew the upper part of the cylinder (1), and remove the upper part from the rest
of the cylinder (2).
3. Remove the guide ring (3) and guide sleeve (4).
4. Pull out the piston (5).
5. Remove the dust ring (6), seal ring (7), and step seal (8). Replace all with new parts.
6. Reinstall the piston into the top of the upper cylinder.
7. Install in the direcon of the arrow in the image, and be careful not to damage the seals.
8. Reinstall the guide sleeve and guide ring. Reinstall the upper cylinder into the rest of the cylinder.
9. Reconnect the baery.
Fig. 14
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TROUBLESHOOTING
General problems
Problem Possible cause Soluon
No power Loose terminal or bad switch connecon causes
interrupted current
Check baery and wire harness terminals, ghten screw
connecons, and keep switch contacts clean
Li speed not uniform Air in the hydraulic cylinder Bleed air from the cylinder as described in the cylinder
replacement procedure
No li
Hydraulic oil is low Fill with hydraulic oil L-HV 32
Low baery Recharge the baery
Oil leak Inspect and repair hydraulic system, replace seal kit, or
ghten oil pipe connecon screws
Overload Reduce the load weight
Li limit switch failure Repair the limit switch
Abnormal noise during
liing
Hydraulic assembly is loose Tighten the retaining screw
Hydraulic motor or gear pump failure Inspect the hydraulic motor and gear pump
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Fault code troubleshoong
Code Descripon Possible cause Soluon
SRO Operaon sequence wrong Li, lower or movement commanded before
handle is set in the operaon posion
Turn pallet truck power o and then on and be sure
to set the handle into the operang posion before
commanding li, lower or movement
11 Parameters incorrectly set Parameters seng is incorrect Adjust the parameters or replace the controller
12 Overcurrent Motor short or controller fault or Hall signal
interference Replace the motor or controller
14 M+ current zero bit detecon error Controller failure Replace controller
15 - current zero bit detecon error Controller failure Replace controller
16 Emergency reverse buon has signal
when turning on power
Emergency reverse buon stuck or LCD
monitor fault Check or replace the belly switch
18 Motor Ηall fault Motor Hall fault, connector fault or controller
fault
Check the motor wiring, replace the motor, or replace
the controller
19 Temperature sensor fault Temperature sensor failure or damaged
sensor wiring Check the motor wiring or replace the motor
21 Potenometer fault Potenometer failure or fault in potenometer
wiring
Check the potenometer wiring or replace the
potenometer
22 Overheat current limit Controller overheated and within the current
limit
Wait 15-25 minutes for the controller to cool before
operang it
23 Overheat protecon Controller overheated and shut down Wait 15-25 minutes for the controller to cool before
operang it
25 Motor overheat limit Motor temperature is too high, output limited Wait 15-25 minutes for the controller to cool before
operang it
26 Motor stalling Motor stall protecon acve Replace the motor
27 Brake fault Brake failure, or damaged brake wiring Check and repair the brake wiring or replace the brake
29 Motor open Damaged motor cable or motor fault Check and repair the motor cabling or replace the
brake
31 Baery voltage low current limit Low baery voltage and within the current
limit Charge or replace the baery
32 Low baery voltage protecon Shut down due to low baery voltage Charge or replace the baery
33 Baery overvoltage Baery voltage is too high Wait 15-35 minutes for voltage to level before
operang
35 Contactor error Controller fault Replace the controller
38 Communicaon error Display wiring fault or display fault
Check and repair the display wiring, replace ller
handle harness, replace the display or replace the
controller
39 Version error Controller version is incorrect Replace the controller
Note: The controller is not included.
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SAFETY INSTRUCTIONS - LITHIUM-ION BATTERY
Warning: Improper installaon or use of the baery may cause excessive heat and other hazardous condions. Failure to follow the
instrucons may pose risks to life and property damage.
• Read the baery warning labels.
• Do not subject the baery to re or heat.
• Do not use metal to connect the baery anode and cathode directly to short-circuit the baery.
• Do not disassemble or modify the baery in any way.
• Do not immerse the baery in water. Keep it in a cool and dry environment when not in use.
• Do not turn the baery upside down.
• Do not transport or store baeries with metal objects such as hairpins, coins, or tools.
• Do not strike, drop, throw, crush, or step on the baery.
• Direct welding on baeries is prohibited.
• Do not piece the baery with nails or other sharp objects.
• If the baery leaks and electrolyte comes into contact with skin or clothing, rinse immediately with plenty of clean water.
• lf the baery is hot or emits a peculiar smell, becomes discolored or deformed, or shows any other abnormality during use, storage, or charging, immediately
remove the baery from the device or charger to a safe place and stop using.
• Keep baeries out of reach of children.
• Cover waste baeries with insulang paper to reduce the risk of re or explosion.
• If you nd deformaon, heang, or peculiar smells upon receiving the baery, contact the manufacturer.
• The baery should be stored at room temperature and charged to about 30-50% of capacity. When storing for a long me, it is recommended to charge the
baery every 3 months to prevent over-discharge.
• Do not use unqualied equipment when charging and discharging, and follow the instrucons.
• Do not mix baeries of dierent manufacturers or dierent types and models. Do not use old and new baeries together.
• Use only the appropriate charger to charge the pallet truck baery.
• Do not use the pallet truck charger to charge other baeries.
RECHARGING INSTRUCTIONS
Baery charge status
• The baery provided by the manufacturer is already correctly charged and lled with electrolyte to the right level.
• The charge level of the baery is shown by the baery charge indicator located on the pallet truck display.
Recharging environment
• The baery should be recharged in a special well-venlated room separated from the work area
because the baeries generate ammable gases that may cause explosions if they come into
contact with ames or sparks.
• The baery should be charged in a dry area.
Cauon: To avoid damaging the baery, never charge the baery in an environment with a
temperature of 0°C or less. Usage environment Baery capacity
55°C ≥95%
25°C ≥100%
-10°C ≥50%
Recharging procedure (Fig. 15-16)
• Before charging the baery, let it cool down.
1. Take the pallet truck to an area that is appropriate for charging.
2. Turn o the pallet truck, then press down the power switch (1).
3. Disconnect the baery connector (2).
4. Connect the charger to the baery connector and begin the charging cycle according to the baery and charger manufacturer's
instrucons.
Charging me
• With a 2A external charger, it takes about 5 hours to achieve a full charge.
• When the pallet truck or a baery is in storage for an extended period, charge the baery to 30-50% every three months.
1
2
Fig. 15
Connect charger
Put plug into the socket
Connect charger
Put plug into
the socket
Fig. 16
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