Translation of
Original User Manual
Version: 2016-UK-3
1
Local distributor & service partner:
Manufactured by:
GMV A/S
Industriparken 1
7182 Bredsten, Denmark
Denmark
Tel.: +45 7573 8247
www.gmvas.dk
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Important!
•
Read these user instructions carefully before use.
•
Familiarise yourself with the running and lifting characteristics of the
window robot, and
•
also with its driving characteristics and how it behaves, so that you can
use it safely, securely and efficiently.
•
Please remember that you as the user are responsible for the correct use
of the window robot without endangering other persons or property.
Index
El-8:an
Overview and Safety
4
Description
5
Safety instructions
6
Operation and safety
8
Safety test (before starting)
Use of Winlet 1000
8
Driving
9
Lifting and handling
Service/maintenance
14
Storage and lifting of the Winlet 1000
15
Servicing
15
Troubleshooting
15
Charging the batteries
16
Service/maintenance
19
Specifications
20
CE – EU declaration of conformity
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Dear Customer
Thank you for choosing a GMV A/S product. We have more than 25 years of experience in the construction,
manufacturing and other industries. We develop, produce and sell equipment for materials handling
designed for industrial use.
To find out more go to www.gmvas.dk
8
5
Description
6
7
1
3
2
4
Item Name
1 Protective screen
2 High traction, terrain-friendly
wheels
3 Guide wheel
4 Operating handle for running
5 Boom with telescopic arm
6 Lifting tower
7 Vacuum boom
8 Control panel
Description
The Winlet 1000 is a battery-powered window robot with a lifting capacity of 1000 kg. The truck is made by
GMV A/S to facilitate conveying and mounting of window elements or similar sealed items. Winlet 1000 can
also be equipped with other specially designed lifting and handling attachments to enable the conveying and
handling of other types of heavy loads. Winlet 1000 is driven by the machine's front, terrain-friendly wheels
and has an advanced, electro-hydraulic system for handling the items to be lifted.
The machine is supplied with an integrated vacuum system as standard. Please contact us concerning your
needs in relation to transporting items requiring special lifting and handling attachments.
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Safety instructions
General
•
The window robot must be used as described in these instructions and in accordance with the general safety regulations
applicable in the workplace and in the country where the Winlet 1000 is used.
•
Always wear steel-capped safety footwear when working with the Winlet 1000. Depending on the workplace and the type
of load, a helmet and protective gloves may also be required.
•
To prevent unauthorised personnel from using the window robot, never leave the key in the ignition.
•
Never leave the Window Robot on an inclined surface. The truck may begin to roll even though it is equipped with a
parking brake.
•
Before use, check that the Winlet 1000 is not damaged in any way that could impair safety.
•
Never use the Winlet 1000 when the battery indicator glows red, as this could ruin the battery. Instead, charge as
described elsewhere in this manual.
•
Never use or store the Winlet 1000 outdoors in wet weather. The machine is designed for use in the temperature range
from -10°C to + 40°C.
Driving
•
The user must be aware of his surroundings when using the window robot, and must allow a generous safety margin in
case unexpected situations arise.
•
Plan your route and make sure it is unobstructed and negotiable. Avoid surfaces where there is a risk that the window
robot could overturn or slide. Exercise great care at corners and junctions.
•
To avoid danger of overturning, the window robot's right-hand wheel set must always be at the same level as its left-hand
wheel set.
•
Always drive with the load lowered.
•
Remember that high speed in constricted spaces is a major safety risk.
•
Never make sharp turns at high speed. Turning reduces the stability of the window robot.
•
Only use the Winlet 1000 in locations with adequate lighting.
•
Always keep both hands on the steering handle when manoeuvring.
Vacuum
•
The Winlet 1000 is designed to transport and mount window elements and other sealed elements as well as other
materials using the specialist equipment supplied.
•
Always lift the item at its centre of gravity and in the middle; otherwise, the item may tear free from the suction plates.
•
Only activate the vacuum function when the suction cups are placed on a sealed, dry, clean surface. Any other use can
damage the vacuum system.
Lifting and handling
•
The Winlet 1000 has moving parts which could give rise to a risk of crushing injuries; accordingly, when lifting and
lowering loads, it is important to ensure no one is in the hazard zone where crushing could occur.
•
Never lift an item until a sufficient vacuum has been achieved. If the vacuum level diminishes, set the item down
immediately.
•
Exercise great care when lifting and handling lifted items, as sudden movements or jolts can cause the item to break away
from the suction cups.
•
Be particularly aware of the capacity limitations of the machine (as stated elsewhere in this manual). The machine's
capacity is reduced when items are handled with the lifting arm extended or when lifting at the side of the machine. Pay
attention to the warning signals from the machine when maximum capacity is reached.
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Operation and safety
Safety functions when driving
4
3
5
1
2
6
Description
Item Name
Winlet 1000 is equipped with a standard type of manoeuvring
handle. The handle incorporates a number of safety features.
•
Safety switch ("stomach switch”); when activated,
stops the movement of the window robot. Once the
window robot has stopped, it moves in the opposite
direction to avoid risk of crushing.
•
Dead-man function, which ensures all functions stop if
the operating handle is moved to the very top
position.
1 Power key switch/EMERGENCY STOP
2 Battery indicator
3 Drive direction/speed regulator
4 Safety cut-out switch (stomach
switch)
5 Vacuum meter
6 Hi-speed / crawl switch
Winlet 1000 is equipped with a standard manoeuvring handle. The power switch also acts as EMERGENCY
STOP. As soon as the switch is turned to the "OFF" position, the power supply to all machine functions is
interrupted. The key switch is spring loaded so that on activation of the EMERGENCY STOP, it remains in
OFF. Both the drive with hydraulic cylinders or the drive motor then come to an immediate halt. On
activation of the emergency stop, there is ALWAYS negative pressure in the suction head - special vigilance
is therefore required as the vacuum pump also loses power after an emergency stop. Both vacuum circuits
are equipped with separate vacuum tanks to ensure sufficient vacuum for a min. of 5 minutes provided that
the system is free of leaks. The actual vacuum level in the suction cups can always be read on the 2 vacuum
meters. When the vacuum level is 60% or more, the machine is at full lift capacity.
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Safety functions when lifting and handling
3
Description
3
Item Name
6
9
8
1 Choice of hydraulic cylinder
2 LED indicator
3 Activation of vacuum
5
7
4
– cylinder
1
4 LED indicator
– vacuum load
5 LED indicator
– overload
6 LED indicator
– on/off
7 LED indicator
– “out of level”
8 Direction & speed regulator
2
–
cylinders
9 LED indicator 5-6-7 flashes on
error in the angle and distance
meter.
The Winlet 1000 is equipped with an operating panel from which all vacuum and hydraulic functions are
controlled. The integrated safety functions are:
•
•
•
•
•
•
2-button safety operation of the machine's vacuum system. Both buttons must be activated at once
either to pick up or to set down a load.
The double-circuit vacuum system of the machine is monitored by two vacuum regulators which, via
LED lamps, indicate if the vacuum is insufficient for safe lifting.
LED lamps show which cylinder is active.
LED lamp which indicates that the machine's front wheels are not in the same level
Intelligent overload protection shows when the machine reaches the limits of its capacity.
LED lamp 5-6-7 (error code 9) the load should be removed by moving into the neutral position and
detaching it.
Note that the machine's stability is impaired by lifting loads at the side of the machine and that these risks
are not monitored by the machine overload monitoring. Always use the outrigger when handling loads at
the side of the machine. Always exercise particular care when handling loads at the side of the
machine and, as the operator, always consider whether safety is assured and ensure that the
capacity of the machine is not exceeded.
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Safety test (before driving or lifting)
The window robot must be safety tested every day before use. This test must be carried out without load.
Important! If any of the items do not pass the safety test, the machine may not be used!
•
Carry out a visual inspection to ensure that the mechanical parts of the window robots are not worn
or damaged to such an extent that the safety of the machine is compromised.
•
Hold the operating arm down in the normal position and drive the Winlet 1000 back and forth. Move
the operating arm, without load, to the top position and try driving the machine forwards and
backwards. This should not be possible.
•
Drive the Winlet 1000 towards you and depress the safety switch on the handle. The machine must
stop immediately and move away in the opposite direction.
Important!This test must be carried out in an open space where there is no risk of your being
crushed between the window robot and any objects or walls.
•
Drive the Winlet 1000 away from you and release the operating arm. The spring pressure in the
operating arm must take the operating arm to the no-load top position, after which the machine
must stop at approximately 0.5 m and the truck functions must not be usable until the operating
handle is back down in the operating position.
•
Check the window robot vacuum system for leaks:
Leak testing procedure
Place all suction cups on a level, dry and airtight surface (e.g. a window).
Start the Winlet 1000 at the on/off button and wait until the red lamps go out on the operating
panel. Now activate the vacuum by actuating both buttons on the operating panel at the same time.
Both vacuum meters now show the current vacuum in each vacuum circuit. Once a full vacuum has
been achieved in both circuits (a vacuum level of approximately 75%), turn the Winlet 1000 off
again at the on/off button. Now look at both vacuum meters; the vacuum level must not drop more
than 10% in the course of 5 minutes.
If the vacuum loss is greater than 10% in 5 minutes, check all hose connections and tighten any
connections as required. Also check the condition of the suction pads. The seals must not show any
signs of scratches.
Driving
Forward/reverse
The speed is infinitely adjustable, and is adjusted by turning the regulator to a greater or lesser degree.
•
Keep the operating arm in the normal position and then turn the drive direction and speed regulator
to the desired position. Release the regulator to stop the machine.
Braking
•
When the speed regulator is released, the window robot brakes and stops. Releasing the speed
regulator slowly can produce gentle braking. This is the normal braking method.
•
When the operating arm is released, the transport truck stops suddenly and the parking brake kicks
in. This function is only intended to be used in an emergency.
Important!To maximise the service life of the Winlet 1000, it is recommended to release the speed
regulator first, and only to release the operating arm once the machine has stopped.
•
When driving with lifted items, all lifting cylinders must always be in the inner position.
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Manual pull/push of the machine in the event of breakdown of the electrical
drive
The electrically-powered drive shaft, which powers the front wheel-set
of the machine, can be disengaged in the brake. This is useful in the
event of a breakdown of the machine.
•
Remove the green protective screen
•
Press the “push” button on the PCB.
Press to
release
the brake
Lifting and handling
Vacuum lift
The Winlet 1000 is equipped with an integrated double circuit vacuum system with intelligent vacuum
monitoring, which gives an alarm to indicate insufficient vacuum level. The vacuum pump is equipped with
Power Save, to save the batteries when there is sufficient vacuum.
Using the vacuum function
Start the Winlet 1000 with the on/off button. Press both buttons for the vacuum function on the operating
panel and wait a moment until both red LED lamps go out. During this time, a vacuum of at least 60% has
been created in the vacuum system.
Picking up a load
Place the suction plates on the item. Press both buttons at the same time on the operating panel. The item
is firmly held by suction once both vacuum meters show more than 60% and the red lamps have gone out;
only then can lifting and transporting proceed!
! Make sure the vacuum level is above 60% in both circuits.
! Always lift the item at its centre of gravity and in the middle; otherwise, the item may tear
free from the suction plates.
Moving a load
After picking up the item by suction power, move the item to the desired position by driving the Winlet
1000.
Pay attention to the following points:
! No persons and/or objects may be present in the working area.
Danger of collision damage/injury!
! No-one may be present under a raised load!
Danger from falling load!
! If the vacuum level in only one of the 2 vacuum circuits drops below 60%, set the load
down immediately!
! If one of the red lamps lights up, set the load down immediately!
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Setting down the load.
Convey the lifted item to the desired place, and set it down. When the load has been placed securely, press
both buttons on the operating panel simultaneously. Air can now flow to the suction pads. The load is
released immediately. A new task can now be carried out.
! Make sure the load is placed securely and that it cannot slide after being set down!
Manipulating load (use of hydraulic cylinders)
The Winlet 1000 is equipped with an electro-hydraulic system which makes it possible to move the lifting
arm of the machine in 6 different axes:
1.
2.
3.
4.
5.
Rotation
Lateral displacement
Main cylinder, which positions the item roughly in the vertical position.
Telescopic cylinder, which moves the item forward along the longitudinal axis of the machine.
Tilting cylinder, which moves items from a horizontal floor – to a horizontal ceiling (180
degrees).
6. Fine-adjustment cylinder, which moves the item in a 100% horizontal direction.
Using the multi-movable front
The front of Winlet 1000 can also be rotated at the side of the machine and thus facilitate access through
doors and narrow openings.
When the front has been brought to the desired position, it must always be relocked.
Use of hydraulic cylinders
Press the desired cylinder on the operating panel. An LED lamp will now show the selected cylinder.
The cylinder can then be moved in the desired direction at the desired speed by engaging the direction and
speed regulator.
Pay attention to the following points:
! No persons and/or objects may be present in the working area.
Danger of collision damage/injury!
! No-one may be present under a raised load!
Danger of falling loads!
! If the vacuum level in only one of the 2 vacuum circuits drops below 60%, set the load
down immediately!
! If one of the red lamps lights up, set the load down immediately!
Important! Be aware that the capacity of the machine is reduced when using the hydraulic
cylinders.
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Maximum length of Beam -Capacity
WLL on vacuum beam
Capacity of the vacuum front is depending on position of
the cups. The chart shows capacity depending on
distance from cup (center of cup) to attachment of
beam.
A: Vacuum circuit 1
B: Vacuum circuit 2
1
Length L mm
Capacity kg
500
550
600
650
700
750
800
850
900
950
1.000
1.050
1.100
1.000
1.000
1.000
944
877
818
767
722
682
646
614
584
558
2
Only support
Only support
pic. 2
Cups in distance L2 is only extra support and does not
add to WL
3
4
pic. 3 + 4
Length on LONGEST arm is determining WLL
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“Gyro function”
Winlet 1000 is equipped with a "gyro function" with a sensor which holds the front in a given vertical
position. When the feature is enabled, there is an automatic adjustment at the front to ensure that this
remains the same angle when the master cylinder is used (cylinder 3). Gyro is activated as follows:
•
•
Press the cylinder 5 button and hold for 2 seconds. The LED lamp for cylinder 5 will now
flash and LED lamp for cylinder 3 will light permanently. The Winlet 1000 will now hold
the item at the desired angle.
To deactivate the Gyro, the button for cylinder 5 is pressed until the LED lamp stops
flashing.
Gyro is most accurate with load in the front and at an angle of +- 45 degrees from the vertical.
The stated values are for reference. And based on a 100% level surface.
The Winlet 1000 is equipped with load monitoring, whereby a red lamp flashes on the operating panel when
approaching the max. capacity in a given position. At this warning, all cylinders must be retracted.
If you continue running the cylinders "outwards", the warning lamp will remain on constantly and there is a
risk of the machine overturning. Now you can only use features that reduce loading and minimize the risk of
overturning.
! It is always the responsibility of the operator to ensure that the machines used within the
capacity limits. This also applies if the overload system is inoperative.
! Note: The safety function uses oil pressure gauges, which measure changes in the pressure of
the master cylinder (cylinder 3). This means that use of the extension cylinder (cylinder 4) may
result in situations in which the safety function may be "delayed". The user must therefore pay
extra attention to the machine's capacity limits when the cylinder 4 is used. To ensure that the
overload function operates, the user must always ensure that the cylinder 3 is activated within
other hydraulic functions are used.
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Note that using the machine on non-level terrain/driving surface impairs the stability of the machine, and
that these risks are not monitored by the machine's overload monitoring system. Always use the support
wheel if the machine is not being operated on level terrain/driving surface. Always exercise particular
care where the machine is being used on non-level terrain/driving surface, and, as the
operator, always consider whether safety is assured and ensure that the capacity of the
machine is not exceeded.
Transport of machine (driving)
The machine must not driven crossways to a slope with an inclination of 7 degrees to the longitudinal axis of
the machine. This incurs the risk of tipping. This risk is not countered by the machine's safety system.
Out-of-level alarm
If the Winlet 1000 is used on unlevel ground (both front wheels in the same level) a LED lamp will flash on
the control panel and an acoustic signal will sound.
Using the multi-movable front
The machine’s front door is locked against movement on the side of the machine. If it is desired to move the
front to the side of the machine, the two locks (top and bottom of the front) are unlocked.
When the front has been brought to the desired position, it must always be relocked.
Influence of wind on the Winlet 1000
•
Machine may not be used when exposed to wind speeds exceeding 10 m/s.
Use in wind speeds in excess of 10 m/s is associated with a great risk of tipping.
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Storage and lifting of the Winlet 1000
•
After use, check the charging level of the batteries via the battery indicator, and recharge as
required. See below concerning instructions with regard to recharging.
•
Never use the Winlet 1000 when the battery indicator glows red.
Important! Batteries stored for a prolonged period must have a maintenance charge (be fully
charged) to avoid damage to the batteries.
•
Turn off the window robot. To do so, turn the ignition key/press the off button.
Important!
When storing for an extended period, turn off the machine to avoid damaging the batteries. This is because
there is always a residual current flow as long as the ignition is on.
•
•
•
•
•
The Winlet 1000 must only be raised by the attachment points are shown on the pictures: 1. front
by sprockets and 2. under counterweight.
Lifted with a lifting sling supplied as an accessory for the Winlet 1000.
The lifting sling is attached with M12 X 130 mm in the same bolt holes as used for the lashing lugs.
Attachment points used for lashing of the machine during transport.
No strain must be applied to the arms during transport - this will cause damage to the machine.
Sling attachment point at counterweight:
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Sling attachment points at the drive wheel:
14
Servicing
Carry out regular checks of the window robot to ensure that it is fault-free when it is to be used.
Check that:
•
The mechanical parts of the window robot have not become worn or damaged to such an extent
that the safety or performance of the machine is compromised.
•
The suction cups of the window robot have not become worn or damaged to such an extent that the
safety or performance of the machine is compromised.
•
The manoeuvring handle is securely seated and is not damaged.
•
All functions on the manoeuvring handle are working correctly.
•
The operating panel is not damaged.
•
All functions on the operating panel are working correctly.
•
The wheels are not damaged or worn to the point that they need
replacing.
•
There are no leaks from the gearbox, hydraulic pump, cylinders or
batteries.
•
Vacuum hoses must be inspected for the abrasion and pinching.
•
All visible electric cables and hydraulic hoses are intact.
Troubleshooting
If the window robot does not work,
check that:
• the ignition key/switch is
in the correct position.
• the batteries are not flat.
• the operating arm is not at the top
position.
Charging/batteries
General
•
Never charge the Winlet 1000 if damage is evident on the battery charger connection cable. This
could be fatal!
•
Charging must always be done at the designated location, which must be dry and well ventilated. At
this location, there may be no sparks from angle grinders, open flames or smoking etc.
•
Do not start charging the batteries immediately after the truck has been in use. Allow the batteries
to cool first.
•
Batteries stored for a prolonged period must have a maintenance charge (be fully charged), to avoid
damage to the batteries.
Charging
•
Always charge after use.
•
Turn the machine off with the ignition key/at the off-button.
•
Connect an earthed plug with voltage 230 V (110V). Charging time is approximately 12 hours, if the
batteries are completely flat.
Wheel attachment
•
The wheel bolts are tightened with a torque of 225Nm.
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Service/maintenance
General
The Winlet 1000 is designed to cope with the demands and the conditions on construction sites, but its
service life and safety can be reduced considerably if the stated service/maintenance items are not complied
with.
All mechanical joints must be checked at regular intervals to ensure that no components have worked loose.
In general, special attention is required after the initial hours of operation when the machine is brand-new,
as well as after the machine has been taken apart/any repairs.
Servicing by specialist personnel
As a minimum requirement, a full overhaul must be carried out by specialist personnel every 12 calendar
months. Contact GMV A/S for further information.
Cleaning
Clean the machine regularly with a damp sponge, brush or vacuum cleaner.
Important! Do not wash the machine with running water, as this could destroy truck components.
Lubrication
The Winlet 1000 is primarily constructed with maintenance-free bearings in all moving parts. All these parts
must be kept free of dirt, but lubrication is not required. This means the machine should only be lubricated
with grease at the bearing assemblies as required:
Extension arm
Should not normally be lubricated during everyday use, but only on annual inspection, at least every 12
months. It may be necessary to lubricate the bearing if the movements of the extension arm become
sluggish. This is done by removing the holder for the slide block (see graphic) and greasing the point where
the sliding blocks are mounted at the front of the extension arm. This must also be checked in the annual
inspection and possibly replaced in the case of obvious wear.
The holder should be
dismantled at the annual
check, with if necessary
replacement of wear pads
and holders if obvious signs
of wear are present.
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Overhaul
The machine is equipped with grease nipples - for checking purposes and topping up with grease at each
overhaul (at least every 12 months)
Grease nipples on
top of extension
cylinder.
Grease nipples in
precision hoist on both
sides.
Grease nipples in later
displacement unit are
the same at top and
bottom.
Grease nipples at top
and bottom of main
cylinder.
Remove the back cover to access the angle and
distance indicator.
Important!
Remember that all prolonged and
repeated contact with oils and lubricants
constitutes a risk to health; whenever
necessary, wear protective gloves and
goggles when implementing the points
below.
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Maintenance of the hydraulic system
•
Change the oil after every 1500 operating hours or at least once a year (oil type Gulf Harmony ZF
HVI 32 or similar).
Maintenance of the vacuum system
•
•
•
•
The vacuum pump contains wearing parts. If the pump cannot achieve a vacuum level of min. 70%
(-70 kPa), it must be replaced or serviced by qualified personnel.
Do not dismantle the vacuum pump while it is under warranty – this would invalidate the warranty.
The vacuum system is fitted with a filter. The filter is located in the machine's motor compartment,
beside the two vacuum tanks. The filter must be cleaned at appropriate intervals, depending very
much on how clean and particle-free the items being lifted are.
The window robot's vacuum system must have all the hose clamps re-tightened as required.
Important! The screwed-on fittings must not be re-tightened because they are sealed
with floating, self-hardening thread sealant. Re-tightening them could give rise to a risk
of leakage. If they are accidentally re-tightened, the error must be rectified immediately
by re-sealing the fittings.
Drive shaft lubrication/maintenance
•
•
•
•
•
•
Do not open the drive shaft/motor while under warranty – opening it will invalidate the warranty.
Service the carbon brushes after every 500 hours of operation – if the length is less than 12 mm,
they should be replaced.
Service the brake function after every 500 hours of operation – the air gap must be 0.3–0.4mm.
Check the oil level after every 500 operating hours.
Service seals and re-tighten bolts after every 1000 operating hours.
Change the oil after every 1500 operating hours or at least once a year (oil type SAE80W90 GL3).
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Specifications:
Max. load
Width
External length
Intrinsic weight
Min. extension
Max. extension
Max. height of centre lifting yoke
Lateral displacement
Precision hoist in tower
Rotation
Suction cups
Motor
Speed – min./max.
Raising-lowering function
Battery
Charging – integrated charger
1000 kg
890 mm
2100 mm
1850 kg
600 mm
2500 mm
4,100 mm
75 mm
200 mm
180 degrees
4 x ø410 mm
24 Volt
0–6 km/h
Electric-hydraulic
24 Volt - 2 x 150 Ah
230V(110v)
Sound pressure level
The sound pressure level of the machine has been tested during driving with the machine's driving gear,
with the machine's vacuum pump running simultaneously. The following values were measured:
A-weighted sound pressure level: Below 70 dB(A)
C-weighted maximum sound pressure level: Below 63 Pa (130 dB compared to 20 µ Pa).
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CE – EU Declaration of conformity
Manufacturer
Company name:
Address:
Post code:
Tel.:
GMV A/S
Industriparken 1
7182 Bredsten, Denmark
+45 7573 8247
Responsible for the technical dossier
Authorised to prepare the technical dossier:
Jesper Faurskov
GMV A/S
Industriparken 1
7182 Bredsten, Denmark
hereby declares that
Machine
Name:
Winlet
Type:
1000
Machine no.:
a) conforms to the following Directive:
i. Machinery Directive 2006/42/EC
b) Manufactured in accordance with the following national/international standards and
technical specifications:
i. The Danish Working Environment Authority, "anvisninger om tekniske
hjælpemidler" (instructions concerning technical aids")
ii. The Danish Working Environment Authority, "meddelelser om tekniske
hjælpemidler" (notifications concerning technical aids")
iii. The Danish Working Environment Authority, "vejledninger om tekniske
hjælpemidler" (guidelines concerning technical aids")
c) Manufactured in partial accord with the following harmonised standards:
i. EN 13155-2003
Signature
Name:
Jesper P. Faurskov
Title:
Director
Company:
GMV A/S
Date:
Signature:
-------------------------------------------
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