logitrans EHL 1004 Guide

EHL 1004EHL 1004
EHL 1004EHL 1004
EHL 1004
Instruction ManualInstruction Manual
Instruction ManualInstruction Manual
Instruction Manual
Maintenance

1.0 Beforethefirstlift...
Thehighlifterismanufacturedinaccordancewithsafety
directives.
Among the subjects dealt with in this Instruction Manual are:
- Proper application
- Physical limitations of the product
- Risks with improper use
Therefore please read this Instruction Manual carefully!

8
2.0 Theremustbeacurrentsupply
2.1 Battery specifications
The manufacturer offers three different battery types recommended
forEHL1004:
Note 1: Battery life: 300 cycles at 80% = approx. 600 cycles at 50%
Note 2: Longest battery life obtained when the battery is charged on being 80%
discharged. 1 charge = 1 cycle
Note 3: Charging voltage of 14.4 V or higher will damage the battery.
Note 4: The battery can be charged, irrespective of how much it is discharged.
Battery life: 600 cycles at 60%. To avoid shortening the life of the battery, it
should never be discharged to more than 25%.
Dry-charged batteries must be filled with battery acid 37.5% H2SO4specific gravity 1.28
before they are used for the first time.
Semi-trak
986034 Tubular cell 986024 Maintenance free 986040
Voltage 12 V 12 V 12 V
Capacity 60Ah/5h 56Ah/5h 50Ah/5h
Recommended for Normal use Severe daily use Where maintenance
work is not desired
Life in cycles at
80% discharge Approx. 300 -See note 1 Approx. 1200 -See note 2 Approx. 800 -See note 4
Maintenance
Liquid inspection Acid level must be min. 5 mm and max. 10 mm above cells. Add distilled water if necessary None
Maintenance
Poles Verdigris to be removed from poles regularly.Poles to be greased after cleaning.
Charge condition to
be measured with: Acidometre, voltmetre or electrical capacity metre. Voltmetre or capacity metre
Charging frequency Daily or as required.
-See note 1 At 80% discharged battery. -See note 2 Daily or as required
..
-See note 4
Charging voltage
measured accross
poles during charging 15,2 V 15,2 V 14,2 V (See note 3)
No. of lifts with
correct usage.
Load 500 kg 175 lifts 170 lifts 170 lifts
Load 1000 kg 50 lifts 50 lifts 50 lifts
Battery dimensions
LxBxH 278x175x190 19,8 kg 271x172x225 21 kg 275x175x190 20 kg

9
2.2 Checking the battery
MethodAforSEMI-TRAKandTUBULARCELL:
Check acid density in the six battery cells with an acidometer.
Checkeachcell - max.differencebetween each cell0.04 kg/l.
MethodBforallthreebatterytypes:
To measure the voltage, use a digital voltmeter (DC) on the battery poles. The truck
must not have been in use for the previous 30 minutes.
DENSITY
1.26 - 1.28 kg/l Fully charged
1.19 - 1.20 kg/l 1/2 charged
1.16 - 1.17 kg/l 1/4 charged
1.10 - 1.11 kg/l Discharged
2.3 Battery charging
Charging must be performed with a charger correctly set with the charging voltage for
the battery type, see point 2.1. For connection and operation, see the instructions
accompanying the charger. The manufacturer recommends a charger of 20 amp
capacity. During charging, the temperature in the battery must not
exceed 50°C.Charging simultaneously with truck operation is not advised.
2.4 Warnings and information on battery
Avoid the use of naked flame in the vicinity of tubular cell and SemiTrak batteries.The
charging of tubular cell and Semi-Trak batteries gives off gases that can be explosive.
Therefore charging should be performed in a ventilated room.At temperatures around
freezing point, battery capacity is reduced by 30%.
Approx. 12.7 V Fully charged
Approx. 12.2 V 1/2 charged
Approx. 12.0 V 1/4 charged
Approx. 11.6 V Discharged

10
A
C
B
2.6 Safety system
A:Fuses: motor protector and protection against electrical
overload.
Fuses-replacement
There are 3 fuses in the electrical circuit.
A) 80 amp fuse in main supply from battery
B) 30Amp fuse for built-in charger
C) 5 amp fuse in control current circuit
2.5 Battery indicator
The battery indicator shows the battery charge in %.
The most accurate reading can be obtained after the battery has been allowed to
remainidle for 5-10minutes.
Yellow: Batterycapacity:25%-50%
The battery can still be used; charging is
recommended.
Red: Battery capacity less than 25%
Do not use the battery, otherwise it might
become damaged.
Green: Batterycapacity:50%-100%
The battery is ready for use and need not be
charged.

11
OEV


ö

µ
PP
PP
OEV
NJ
NJ




µ
Replacement:
Before replacing fuse, disconnect battery + pole. The old fuse can then be removed
and replaced by a new one of the same size.
Do not insert a larger fuse; the fuse acts as a protector for the pump motor.
Find out why fuses blow!
B: Safety/pressurereliefvalve:protection against mechanical
and hydraulic overload.
Factory-set for maximum design load
Emergency stop
The highlifter has an emergency stop. When activating
the emergency stop, the main current supply is switched
off. The movement of the forks stops immediately when
activating the emergency stop.
2.7 Wiring connections
Muchoperational disturbanceiscausedbypoor connectionsintheelectrical
circuit.Make sureconnectionsareinorder.
Check connections regularly for damage at insulating caps or looseness at plugs,
etc.
Verdigris must be removed from lead plugs. Keep all screw/nut connections tight.

12
A
B
3.0 Longlivethehighlifter
Regular inspection and the replacement of worn or defective parts in good time will
prolong the life of the highlifter.
"Prevention is better than repair", therefore ensure:
- Correct usage
- Regular cleaning
- Periodic service inspection
3.1 Lubrication and oil change
Under normal operating conditions the highlifter requires no lubri-
cation. All ball bearings are sealed and lubricated for life. Moving
parts have self-lubricating bearings or are treated with molybde
num disulphide grease.
The correct hydraulic oil is ISO VG 32 containing an additive:
-Wynn’s Hydraulic Systems Concentrate.
The proportion of concentrate is 2.5%. The concentrate reduces
friction and wear, and protects against corrosion.
3.2 Oil change 1. Bring the forks down into lowered position.
2. Remove the 4 clips (A) on the oil tank and
remove the tank itself.
3. Clean the tank and filters, then refit the
tank.
4. Through the filling hole (B), fill the tank
with approx. 1.0 litre hydraulic oil
The oil level must be up to the filler
opening.
5. Bleed the hydraulic system (see point 3.4).

13
A
B
C
3.3 Cold and humid operating conditions affect the oil!
Oil becomes thicker as it becomes colder. Therefore avoid allowing
the highlifter to stand unused in the cold.In severe cold, water in the hydraulic
system can condense, with breakdown of gaskets and oil as a consequence.
The highlifter will lower more slowly when the oil is cold.The oil is suitable for use
in the temperature range-10to +50°C.Athinner oil is recommended for
temperatures lower than -10° C, (if necessary, contact your distributor).
3.4 Bleeding the hydraulic system
With a load of 50-100 kg, the forks must be raised and lowered to top and bottom
position 2-3 times.
4.12Adjustment of the fork height
The fork height can be adjusted as follows 85...93 mm.
The fork height is adjusted by picking out the plug (A)
Adjustment of the fork height (B):
Turning right:the fork height is raised
Turning left: the fork height is lowered
Hereafter the plug is
fastened again (C)
3.6 Cleaning
When cleaning the highlifter, do not direct the jet onto bearings and seals. Other-
wise the grease will be washed out and the life of the equipment shortened.

14
A
B
C
D
E
F
4.0 Fault location key
When the HIGHLIFTER is used every day, adjustments and the replacement of
worn parts might be necessary.
If a fault appears during daily operation of the highlifter, first check:
Oil supply
Electricity supply
Condition of leads and fuses
If faults cannot be traced to these sources, contact your dealer, but ....
BEFOREASKINGTHE DEALERFORASSISTANCE...
...TRY THE FAULT LOCATION KEY!
SYMPTOMS AND OBSERVATIONS
Pump does not run when the UP button is pressed
Truck does not lift when the UP button is pressed
Truck does not lift to max. height
Forks fall after being raised
Forks do not fall when DOWN button is pressed
Forks cannot be lowered fully

15
]]]
]]]]
]
]]
]]]
]
A
B
C
D
E
F
]
]
]
Oildeficiency
Cause Mending
Battery discharged
Fuse blown
Leads defective
Max. load exceeded
Pressure relief valve incorrectly
adjusted
Hyd. hose defective
Air in hydraulic system
See point 3.1 / 3.2
See point 2.3
See point 2.6
See point 2.7
See point 2.6
See point 3.4
Contact the
distributor
Contact the
distributor
Contact the
distributor
Contact the
distributor
If the problem cannot be solved
by using the fault location key...
...pleasecontact yourdealer!
Lifting cylinder damaged
Valve damaged
(solenoid and flow valve)
Emergency stop activated See point 2.6