ERD 220 - Jungheinrich

ERD 220 - Jungheinrich
ERD 220
Operating instructions
50428242
09.10
11.03 -
G
Declaration of Conformity
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or his authorized representative in the Community
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or his authorized representative in the Community
Type
Option
Serial No.
Year of construction
Type
Option
Serial No.
Year of construction
Additional information
Additional information
Authorised signatory
Authorised signatory
Date
Date
G EU Declaration of Conformity
G 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-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatories are individually empowered in each
case to compile the technical documentation.
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-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatories are individually empowered in each
case to compile the technical documentation.
09.10 EN
ERD 220
09.10 EN
ERD 220
3
3
4
4
09.10 EN
09.10 EN
Foreword
Foreword
Notes on the operating instructions
Notes on the operating instructions
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 and the pages are
numbered continuously.
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 and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating
instructions.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating
instructions.
Safety notices and text mark-ups
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following graphics:
Safety instructions and important explanations are indicated by the following graphics:
DANGER!
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
t
o
09.10 EN
Z
Used before notices and explanations.
Used before notices and explanations.
t
o
Indicates standard equipment
Indicates optional equipment
Copyright
09.10 EN
Z
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Copyright of these operating instructions remains with JUNGHEINRICH AG.
5
Indicates standard equipment
Indicates optional equipment
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
5
Am Stadtrand 35
22047 Hamburg - Germany
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
www.jungheinrich.com
6
09.10 EN
Jungheinrich Aktiengesellschaft
09.10 EN
Jungheinrich Aktiengesellschaft
6
Table of contents
Table of contents
9
A
Correct Use and Application ...................................................
9
1
2
3
4
5
General....................................................................................................
Correct application...................................................................................
Approved application conditions ..............................................................
Proprietor responsibilities ........................................................................
Adding attachments and/or accessories..................................................
9
9
9
10
10
1
2
3
4
5
General....................................................................................................
Correct application...................................................................................
Approved application conditions..............................................................
Proprietor responsibilities ........................................................................
Adding attachments and/or accessories..................................................
9
9
9
10
10
B
Truck Description ....................................................................
11
B
Truck Description ....................................................................
11
1
1.1
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.1
4.2
4.3
Application ...............................................................................................
Truck models and rated capacity.............................................................
Assemblies and Functional Description...................................................
Assembly Overview .................................................................................
Functional Description .............................................................................
Technical Specifications ..........................................................................
Performance data ....................................................................................
Dimensions ..............................................................................................
Weights....................................................................................................
Tyre type..................................................................................................
EN norms.................................................................................................
Conditions of use.....................................................................................
Electrical requirements ............................................................................
Identification points and data plates ........................................................
Data plate ................................................................................................
Truck load chart.......................................................................................
Capacity...................................................................................................
11
11
12
12
13
15
15
16
18
18
19
20
20
21
22
23
24
1
1.1
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.1
4.2
4.3
Application ...............................................................................................
Truck models and rated capacity.............................................................
Assemblies and Functional Description...................................................
Assembly Overview .................................................................................
Functional Description .............................................................................
Technical Specifications ..........................................................................
Performance data ....................................................................................
Dimensions ..............................................................................................
Weights....................................................................................................
Tyre type..................................................................................................
EN norms.................................................................................................
Conditions of use.....................................................................................
Electrical requirements ............................................................................
Identification points and data plates ........................................................
Data plate ................................................................................................
Truck load chart.......................................................................................
Capacity...................................................................................................
11
11
12
12
13
15
15
16
18
18
19
20
20
21
22
23
24
C
Transport and Commissioning ................................................
25
C
Transport and Commissioning ................................................
25
1
2
3
Lifting by crane ........................................................................................
Transport .................................................................................................
Using the Truck for the First Time ...........................................................
25
26
27
1
2
3
Lifting by crane ........................................................................................
Transport .................................................................................................
Using the Truck for the First Time ...........................................................
25
26
27
D
Battery - Servicing, Recharging, Replacement .......................
29
D
Battery - Servicing, Recharging, Replacement .......................
29
1
2
3
4
5
Safety Regulations Governing the Handling of Lead-Acid Batteries .......
Battery types............................................................................................
Exposing the battery ................................................................................
Charging the battery ................................................................................
Battery removal and installation ..............................................................
29
30
32
33
34
1
2
3
4
5
Safety Regulations Governing the Handling of Lead-Acid Batteries .......
Battery types............................................................................................
Exposing the battery................................................................................
Charging the battery ................................................................................
Battery removal and installation ..............................................................
29
30
32
33
34
09.10 EN
Correct Use and Application ...................................................
09.10 EN
A
7
7
8
37
E
Operation ................................................................................
37
1
2
2.1
3
3.1
3.2
3.3
3.4
4
4.1
4.2
4.3
4.4
5
5.1
5.2
6
7
8
8.1
8.2
8.3
Safety Regulations for the Operation of the Forklift Truck.......................
Displays and Controls..............................................................................
Battery discharge indicator ......................................................................
Starting up the truck ................................................................................
Checks and operations to be performed before starting daily operation .
Preparing the truck for operation .............................................................
Parking the truck securely .......................................................................
Battery discharge monitor........................................................................
Industrial Truck Operation .......................................................................
Safety regulations for truck operation......................................................
Emergency Disconnect, Travel, Steering, Braking ..................................
Lifting, transporting and depositing loads ................................................
Switch Matrix / Safety Switch Height .......................................................
Troubleshooting.......................................................................................
Truck does not start.................................................................................
Load cannot be lifted ...............................................................................
Operating the truck without its own drive system ....................................
Load handler emergency lowering ..........................................................
Optional equipment .................................................................................
CANDIS display instrument .....................................................................
ISM access module .................................................................................
CanCode keypad.....................................................................................
37
39
42
43
43
45
46
47
48
48
50
55
57
59
59
59
60
61
62
63
65
67
1
2
2.1
3
3.1
3.2
3.3
3.4
4
4.1
4.2
4.3
4.4
5
5.1
5.2
6
7
8
8.1
8.2
8.3
Safety Regulations for the Operation of the Forklift Truck.......................
Displays and Controls..............................................................................
Battery discharge indicator ......................................................................
Starting up the truck ................................................................................
Checks and operations to be performed before starting daily operation .
Preparing the truck for operation .............................................................
Parking the truck securely .......................................................................
Battery discharge monitor........................................................................
Industrial Truck Operation .......................................................................
Safety regulations for truck operation......................................................
Emergency Disconnect, Travel, Steering, Braking ..................................
Lifting, transporting and depositing loads ................................................
Switch Matrix / Safety Switch Height .......................................................
Troubleshooting.......................................................................................
Truck does not start.................................................................................
Load cannot be lifted ...............................................................................
Operating the truck without its own drive system ....................................
Load handler emergency lowering ..........................................................
Optional equipment .................................................................................
CANDIS display instrument .....................................................................
ISM access module .................................................................................
CanCode keypad.....................................................................................
37
39
42
43
43
45
46
47
48
48
50
55
57
59
59
59
60
61
62
63
65
67
F
Industrial Truck Maintenance ..................................................
73
F
Industrial Truck Maintenance ..................................................
73
1
2
3
4
5
5.1
5.2
5.3
6
6.1
6.2
6.3
6.4
6.5
6.6
7
8
8.1
8.2
8.3
9
10
Operational Safety and Environmental Protection...................................
Maintenance Safety Regulations .............................................................
Servicing and Inspection .........................................................................
Maintenance checklist .............................................................................
Lubricants and Lubrication Schedule ......................................................
Handling consumables safely ..................................................................
Lubrication Schedule ...............................................................................
Consumables...........................................................................................
Maintenance and repairs .........................................................................
Preparing the truck for maintenance and repairs ....................................
Checking the drive wheel bearing and attachment..................................
Removing the front panel ........................................................................
Checking electrical fuses .........................................................................
Checking the hydraulic oil level ...............................................................
Restoring the truck to service after maintenance and repairs .................
Safety tests to be performed at intervals and after unusual incidents .....
Decommissioning the industrial truck ......................................................
Before taking the truck out of service ......................................................
Action to be taken during decommissioning: ...........................................
Restoring the truck to service after decommissioning .............................
Final de-commissioning, disposal............................................................
Human vibration measurement ...............................................................
73
73
77
78
81
81
83
84
85
85
86
87
88
89
90
91
92
93
94
95
96
96
1
2
3
4
5
5.1
5.2
5.3
6
6.1
6.2
6.3
6.4
6.5
6.6
7
8
8.1
8.2
8.3
9
10
Operational Safety and Environmental Protection...................................
Maintenance Safety Regulations .............................................................
Servicing and Inspection .........................................................................
Maintenance checklist .............................................................................
Lubricants and Lubrication Schedule ......................................................
Handling consumables safely ..................................................................
Lubrication Schedule ...............................................................................
Consumables...........................................................................................
Maintenance and repairs .........................................................................
Preparing the truck for maintenance and repairs ....................................
Checking the drive wheel bearing and attachment..................................
Removing the front panel ........................................................................
Checking electrical fuses.........................................................................
Checking the hydraulic oil level ...............................................................
Restoring the truck to service after maintenance and repairs .................
Safety tests to be performed at intervals and after unusual incidents .....
Decommissioning the industrial truck ......................................................
Before taking the truck out of service ......................................................
Action to be taken during decommissioning: ...........................................
Restoring the truck to service after decommissioning .............................
Final de-commissioning, disposal............................................................
Human vibration measurement ...............................................................
73
73
77
78
81
81
83
84
85
85
86
87
88
89
90
91
92
93
94
95
96
96
8
09.10 EN
Operation ................................................................................
09.10 EN
E
Appendix
JH Traction Battery Operating Instructions
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB
Z
Appendix
1
1
2
2
0506.GB
0506.GB
A Correct Use and Application
A Correct Use and Application
1
1
General
General
The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property.
2
The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property.
Correct application
2
Correct application
NOTE
The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.
The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.
–
–
–
–
–
–
–
–
–
–
Lifting and lowering of loads.
Transporting lowered loads.
Do not travel with a raised load (>500 mm).
Do not carry or lift passengers.
Do push or pull load units.
Approved application conditions
Operation in industrial and commercial environments.
Permissible temperature range +5°C to +40°C.
Operation only on secure, level surfaces with sufficient capacity.
Operation only on routes that are visible and approved by the proprietor.
Negotiating inclines up to a maximum of 15 %.
Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
Operation in partially public traffic.
Approved application conditions
Z
Special equipment and authorisation are required if the truck is to be used in extreme conditions.
The truck is not authorised for use in areas at risk of explosion.
09.10 EN
Z
–
–
–
–
–
–
–
3
Lifting and lowering of loads.
Transporting lowered loads.
Do not travel with a raised load (>500 mm).
Do not carry or lift passengers.
Do push or pull load units.
–
–
–
–
–
–
–
Operation in industrial and commercial environments.
Permissible temperature range +5°C to +40°C.
Operation only on secure, level surfaces with sufficient capacity.
Operation only on routes that are visible and approved by the proprietor.
Negotiating inclines up to a maximum of 15 %.
Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
Operation in partially public traffic.
Special equipment and authorisation are required if the truck is to be used in extreme conditions.
The truck is not authorised for use in areas at risk of explosion.
09.10 EN
3
NOTE
9
9
4
Proprietor responsibilities
4
For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that
all users have read and understood these operating instructions.
For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that
all users have read and understood these operating instructions.
NOTE
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.
Adding attachments and/or accessories
5
10
Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
09.10 EN
Adding accessories
09.10 EN
5
Proprietor responsibilities
10
B Truck Description
B Truck Description
1
1
Application
The truck is a wheel-based, electric tiller-operated stacker with a folding operator platform that can be used for lifting and stacking pallets and horizontal transportation. For
stacking operations the capacity with 1000 kg with a load centre distance of 600 mm.
For horizontal transport 2000 kg can be raised on a pallet or max. 2 x 1000 kg on two
pallets on top of each other.
With its compact design and application as both stacker and for horizontal transportation, the ERS 220 is especially suited for use in retail environments, workshops,
small warehouses and for assisting lorry loading and unloading.
The capacity of the truck is shown on the data plate or the data capacity plate Qmax.
1.1
Application
The truck is a wheel-based, electric tiller-operated stacker with a folding operator platform that can be used for lifting and stacking pallets and horizontal transportation. For
stacking operations the capacity with 1000 kg with a load centre distance of 600 mm.
For horizontal transport 2000 kg can be raised on a pallet or max. 2 x 1000 kg on two
pallets on top of each other.
With its compact design and application as both stacker and for horizontal transportation, the ERS 220 is especially suited for use in retail environments, workshops,
small warehouses and for assisting lorry loading and unloading.
The capacity of the truck is shown on the data plate or the data capacity plate Qmax.
Truck models and rated capacity
1.1
The rated capacity depends on the model. The rated capacity can be derived from
the model description.
Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model description.
Tabelle 1: EJD220
EJD
2
20
Tabelle 1: EJD220
Model Description
Series
Rated capacity x 100 kg
EJD
2
20
The rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack.
09.10 EN
09.10 EN
The rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack.
Model Description
Series
Rated capacity x 100 kg
11
11
2
Assemblies and Functional Description
2
Assemblies and Functional Description
2.1
Assembly Overview
2.1
Assembly Overview
1
2
3
5
6
7
1
2
4
3
5
6
7
8
8
9
9
10
10
11
11
12
13 10
13 10
14
14
15
15
Model
Travel switch
Tiller
Mast
CanCode
Emergency Disconnect switch
CanDis
Key switch
Wheel arms
Item
9 t
10 o
11 t
12 t
13 t
14 o
15 o
Model
Folding side arm
Castor wheel
Folding operator platform
Skirt
Drive wheel
Fixed operator platform
Deadman button
Item
1 t
2 t
3 t
4 o
5 t
6 o
7 t
8 t
o = Option
Model
Travel switch
Tiller
Mast
CanCode
Emergency Disconnect switch
CanDis
Key switch
Wheel arms
t = Standard version
09.10 EN
t = Standard version
12
12
Item
9 t
10 o
11 t
12 t
13 t
14 o
15 o
Model
Folding side arm
Castor wheel
Folding operator platform
Skirt
Drive wheel
Fixed operator platform
Deadman button
o = Option
09.10 EN
Item
1 t
2 t
3 t
4 o
5 t
6 o
7 t
8 t
4
12
Functional Description
2.2
Functional Description
Safety Mechanisms
Safety Mechanisms
– An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck.
– The wheels are surrounded by a solid skirt.
– Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations.
– An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck.
– The wheels are surrounded by a solid skirt.
– Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations.
Hydraulic system
Hydraulic system
– Lifting and lowering are activated via the lift and lower buttons.
– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder.
– Lifting and lowering are activated via the lift and lower buttons.
– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder.
Emergency Stop safety feature
Emergency Stop safety feature
– The emergency stop is activated by the traction controller.
– The steering controller sends a system status signal which is monitored by the traction controller. If the signal fails to appear or a fault is identified the truck automatically brakes to a halt. Control displays on the driver’s display indicate the
emergency stop.
– Each time the truck is switched on the system performed an automatic diagnosis.
– The emergency stop is activated by the traction controller.
– The steering controller sends a system status signal which is monitored by the traction controller. If the signal fails to appear or a fault is identified the truck automatically brakes to a halt. Control displays on the driver’s display indicate the
emergency stop.
– Each time the truck is switched on the system performed an automatic diagnosis.
Operator Position
Operator Position
– All travel and lift operations can be performed sensitively without having to reach.
– Tiller for reliable control of the industrial truck.
– The industrial truck has a fixed standing platform and rigid side arm. The industrial
truck can also optionally be equipped with a folding standing platform and movable
side arm.
– All travel and lift operations can be performed sensitively without having to reach.
– Tiller for reliable control of the industrial truck.
– The industrial truck has a fixed standing platform and rigid side arm. The industrial
truck can also optionally be equipped with a folding standing platform and movable
side arm.
Operator platform
Operator platform
– Travel functions are only released when the driver stands on the operator platform.
– Travel functions are only released when the driver stands on the operator platform.
Drive system
Drive system
– A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox.
– The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking with
energy regeneration.
– The driver can choose from 3 travel programs, depending on the load and the environment. from maximum performance to energy saving.
– A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox.
– The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking with
energy regeneration.
– The driver can choose from 3 travel programs, depending on the load and the environment. from maximum performance to energy saving.
Steering
Steering
– The driver steers with a tiller.
– The steering motion is transmitted directly from the steering controller via a steer
motor directly to the ring gear of the pivoted drive system.
– The progressive electric steering allows for a 90° turn of the drive wheel when the
tiller is turned only 70°.
– The driver steers with a tiller.
– The steering motion is transmitted directly from the steering controller via a steer
motor directly to the ring gear of the pivoted drive system.
– The progressive electric steering allows for a 90° turn of the drive wheel when the
tiller is turned only 70°.
Electric steering (o)
Electric steering (o)
– The electric steering system is self-monitoring.
The steering controller permanently monitors the entire steering system. If an error
– The electric steering system is self-monitoring.
The steering controller permanently monitors the entire steering system. If an error
13
09.10 EN
09.10 EN
2.2
13
is detected the traction controller interrupts travel, brakes regeneratively and the
magnetic brake is applied.
is detected the traction controller interrupts travel, brakes regeneratively and the
magnetic brake is applied.
– 24 volt system.
– Standard electronic traction, lift and steering control are standard.
Controls and Displays
Controls and Displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel operations.
– The battery discharge indicator shows the available battery capacity.
– The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and event messages.
– Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel operations.
– The battery discharge indicator shows the available battery capacity.
– The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and event messages.
14
09.10 EN
Electrical System
– 24 volt system.
– Standard electronic traction, lift and steering control are standard.
09.10 EN
Electrical System
14
3
Technical Specifications
Z
3.1
3
Technical Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
Performance data
3.1
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
Performance data
ERD 220
Q
c
Rated capacity
Load centre distance with standard fork length
kg
mm
Travel speed, rider fast w / w.o. rated load
Travel speed, rider slow w / w.o. rated load
7,2 / 8,2
5,0 / 5,5
km/h
km/h
Travel speed, fixed platform with / without rated
load
5,0 / 8,2
Travel speed, pedestrian w. / w.o. load
Q
c
2000
600
kg
mm
Travel speed, rider fast w / w.o. rated load
Travel speed, rider slow w / w.o. rated load
7,2 / 8,2
5,0 / 5,5
km/h
km/h
km/h
Travel speed, fixed platform with / without rated
load
5,0 / 8,2
km/h
Rated capacity
Load centre distance with standard fork length
4,3 / 4,5
km/h
Travel speed, pedestrian w. / w.o. load
4,3 / 4,5
km/h
Lift speed with / without rated load
Lowering speed with / without load
0,13 / 0,22
0,21 / 0,15
m/s
m/s
Lift speed with / without rated load
Lowering speed with / without load
0,13 / 0,22
0,21 / 0,15
m/s
m/s
Max. gradeability (5 min) w / w.o. load
8,0 / 15,0
%
Max. gradeability (5 min) w / w.o. load
8,0 / 15,0
%
Z
Travel speed reduced to "rider slow" at Q>350 kg in mast lift (only with 1000 / 1000
kg load distribution).
09.10 EN
Travel speed reduced to "rider slow" at Q>350 kg in mast lift (only with 1000 / 1000
kg load distribution).
09.10 EN
Z
ERD 220
2000
600
15
15
3.2
Dimensions
3.2
Dimensions
ERD 220 (ZT/ZZ)
1250, 1425, 1700 /
1700
0 / 1219
ERD 220 (ZT/ZZ)
h1
Height (mast-dependent)
mm
h1
Height (mast-dependent)
h2
Free lift
h3
Rated lift
1660,2010, 2560 /
2500
h4
2106, 2456, 3006 /
2981
125
mm
90
mm
mm
h14
mm
mm
h2
Free lift
mm
h3
Rated lift
1660,2010, 2560 /
2500
mm
mm
h4
2106, 2456, 3006 /
2981
125
mm
h5
extended mast height (mast-dependent)
Initial lift
mm
h13
Lowered height
90
mm
1250 / 1490
mm
mm
h5
extended mast height (mast-dependent)
Initial lift
h13
Lowered height
h14
1250 / 1490
x
Tiller height in travel position min./
max.
Load distance
1000
mm
x
Tiller height in travel position min./
max.
Load distance
1000
mm
y
Wheelbase *)
1520 / 1780
mm
y
Wheelbase *)
1520 / 1780
mm
l1
l2
Overall length
Headlength
2093 / 2130
977 / 995
mm
mm
l1
l2
Overall length
Headlength
2093 / 2130
977 / 995
mm
mm
Truck width
Outside straddle
Fork length
Turning radius *)
Working aisle width for pallets 800 x
1200 length *)
Net weight:
770
570
1190
1800 / 1980
2365 / 2380
mm
mm
mm
mm
mm
b1
b5
l
Wa
Ast
Truck width
Outside straddle
Fork length
Turning radius *)
Working aisle width for pallets 800 x
1200 length *)
Net weight:
770
570
1190
1800 / 1980
2365 / 2380
mm
mm
mm
mm
mm
b1
b5
l
Wa
Ast
See truck data plate
See truck data plate
09.10 EN
*) Load section lowered +70mm
09.10 EN
*) Load section lowered +70mm
16
1250, 1425, 1700 /
1700
0 / 1219
16
L2
214
a
2
95
h13
y
390
Wa
a
2
Ast
17
L2
l1
214
s
c
a
2
95
h13
m2
125
Q
b4 e
b11
b5
390
s
m2
c
b2
b4 e
b11
b5
b2
Q
125
1250
1250
x
l
h3
h4
h4
h1
1490
h3
h1
1490
l
09.10 EN
09.10 EN
x
y
l1
Wa
a
2
Ast
17
3.3
Weights
3.3
3.3.1 Weights
Weights
3.3.1 Weights
ERD 220
Axle load, w.o. load
front/rear + battery (depending on fork
length)
Battery weight
3.4
ERD 220
876
kg
2028 / 1068
kg
278 / 818
kg
220
kg
Net weight excl. battery (depending on fork
length)
Axle load, w. load
front/rear + battery (depending on fork
length)
Axle load, w.o. load
front/rear + battery (depending on fork
length)
Battery weight
Tyre type
ERD 220
230 / 77
85 / 75
140 X 54
mm
mm
mm
3 - 1x / 4
18
kg
2028 / 1068
kg
278 / 818
kg
220
kg
ERD 220
230 / 77
85 / 75
140 X 54
mm
mm
mm
Tyre type
Tyre size, drive
Tyre size, load section
Castor wheel (twin roller)
Wheels, number front/rear
(x = driven)
09.10 EN
Tyre size, drive
Tyre size, load section
Castor wheel (twin roller)
Wheels, number front/rear
(x = driven)
3.4
876
3 - 1x / 4
09.10 EN
Net weight excl. battery (depending on fork
length)
Axle load, w. load
front/rear + battery (depending on fork
length)
18
Z
Z
3.5
EN norms
Noise emission level
Noise emission level
– ERD 220: 68 dB(A)
– ERD 220: 68 dB(A)
in accordance with 12053 as harmonised with ISO 4871.
in accordance with 12053 as harmonised with ISO 4871.
Z
The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
Vibration
– ERD 220: 0,67 m/s²
– ERD 220: 0,67 m/s²
in accordance with EN 13059
in accordance with EN 13059
Z
The vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in
the vertical direction. It is calculated when travelling over bumps at constant speed.
These recordings were taken on a single occasion and must not be confused with
the human vibrations of the "2002/44/EC/Vibrations" operator directive. The manufacturer offers a special service to measure these human vibrations, see "Human
vibration measurement" on page 96.
The vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in
the vertical direction. It is calculated when travelling over bumps at constant speed.
These recordings were taken on a single occasion and must not be confused with
the human vibrations of the "2002/44/EC/Vibrations" operator directive. The manufacturer offers a special service to measure these human vibrations, see "Human
vibration measurement" on page 96.
Electromagnetic compatibility (EMC)
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
Z
No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
09.10 EN
Z
EN norms
No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
09.10 EN
3.5
19
19
3.6
Z
3.7
Conditions of use
3.6
Ambient temperature
Ambient temperature
– operating at +5°C to +40°C
– operating at +5°C to +40°C
Z
Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations.
Electrical requirements
3.7
Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations.
Electrical requirements
09.10 EN
The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.
09.10 EN
The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.
20
Conditions of use
20
4
Identification points and data plates
4
1000 kg
X.XXXX.XX.XX
2000 kg
max
QQmax
19
16
max
100 mm
1600
Hmm
Q max
600
Dmm
Identification points and data plates
2000 kg
max
QQmax
600
18
17
19
20
21
1000 kg
X.XXXX.XX.XX
max
2000 kg
Q max
Dmm
max
2000 kg
600
20
22
23
24
24
16
16
25
25
26
21
26
27
21
27
mV
mV
1,5 V
1,5 V
Item
16
17
18
19
20
21
22
23
24
25
26
27
Model
Strap points for crane lifting
Load chart
Capacity
"Do not reach through the mast" warning
“Do not step under the load handler” warning
“Read operating instructions” warning
Serial number
Data plate
Battery data plate
Test plaque
Model name
Caution: Low voltage electronics
09.10 EN
Model
Strap points for crane lifting
Load chart
Capacity
"Do not reach through the mast" warning
“Do not step under the load handler” warning
“Read operating instructions” warning
Serial number
Data plate
Battery data plate
Test plaque
Model name
Caution: Low voltage electronics
09.10 EN
Item
16
17
18
19
20
21
22
23
24
25
26
27
600
18
17
21
22
23
16
max
100 mm
1600
Hmm
21
21
Data plate
28
Item
28
29
30
31
32
33
30
31
32
Description
Type
Serial number
Rated capacity (kg)
Battery voltage (V)
Net weight w.o. battery (kg)
Option
33
Item
34
35
36
37
38
39
22
Data plate
34
28
29
30
31
32
33
34
35
35
36
36
37
37
38
38
39
39
Description
Year of manufacture
Load centre (mm)
Output
Min./max. battery weight (kg)
Manufacturer
Manufacturer’s logo
Item
28
29
30
31
32
33
Z
For queries regarding the truck or ordering spare parts always quote the truck serial
number (29).
09.10 EN
Z
29
4.1
Description
Type
Serial number
Rated capacity (kg)
Battery voltage (V)
Net weight w.o. battery (kg)
Option
Item
34
35
36
37
38
39
Description
Year of manufacture
Load centre (mm)
Output
Min./max. battery weight (kg)
Manufacturer
Manufacturer’s logo
For queries regarding the truck or ordering spare parts always quote the truck serial
number (29).
09.10 EN
4.1
22
4.2
Truck load chart
4.2
X.XXXX.XX.XX
3600
Truck load chart
X.XXXX.XX.XX
17
1105
3600
600
17
1105
600
The load chart (17) indicates the maximum capacity Q (in kg) for a given load centre
D (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load.
The load chart (17) indicates the maximum capacity Q (in kg) for a given load centre
D (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load.
Example of how to calculate the maximum capacity:
With a load centre distance C of 600 mm and a maximum lift height H of 3600 mm.
the max. capacity Q is 1105 kg.
Example of how to calculate the maximum capacity:
With a load centre distance C of 600 mm and a maximum lift height H of 3600 mm.
the max. capacity Q is 1105 kg.
The arrow shape markings ("40" and "40") on the inner
mast and bottom cross member indicate to the driver
when he has exceeded the height limits specified by the
capacity plate (21).
The arrow shape markings ("40" and "40") on the inner
mast and bottom cross member indicate to the driver
when he has exceeded the height limits specified by the
capacity plate (21).
40
40
09.10 EN
40
09.10 EN
40
23
23
4.3
Capacity
4.3
Capacity
18
18
700
750
2000
Q max
A
210
Hmm
Q max
600 Dmm
C
A
No transporting with a raised load
Max. capacity for horizontal transporting with raised wheel arms without
mast lift
Double deck:
Max. high level lift height
Max. high level capacity
A=
B=
C=
09.10 EN
C=
2000
kg
Q max
24
700
750
B
kg
kg
210
Hmm
600 Dmm
Q max
C
No transporting with a raised load
Max. capacity for horizontal transporting with raised wheel arms without
mast lift
Double deck:
Max. high level lift height
Max. high level capacity
09.10 EN
A=
B=
B
kg
24
C Transport and Commissioning
C Transport and Commissioning
1
1
Lifting by crane
WARNING!
WARNING!
Improper lifting by crane can result in accidents
The use of unsuitable lifting gear can cause the truck to crash when being lifted by
crane.
Prevent the truck from striking other objects when it is being raised, and avoid any
involuntary movements. If necessary secure the truck with guide ropes.
XThe truck should only be handled by people who are trained in using lifting slings
and tools.
XWear safety shoes when lifting the truck by crane.
XDo not stand under a swaying load.
XDo not walk into or stand in a hazardous area.
XAlways use lifting gear with sufficient capacity (for truck weight see truck data
plate).
XAlways attach the crane slings to the prescribed strap points and prevent them from
slipping.
XUse the lifting gear only in the prescribed load direction.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
Lifting the truck by crane
Lifting by crane
16
Improper lifting by crane can result in accidents
The use of unsuitable lifting gear can cause the truck to crash when being lifted by
crane.
Prevent the truck from striking other objects when it is being raised, and avoid any
involuntary movements. If necessary secure the truck with guide ropes.
XThe truck should only be handled by people who are trained in using lifting slings
and tools.
XWear safety shoes when lifting the truck by crane.
XDo not stand under a swaying load.
XDo not walk into or stand in a hazardous area.
XAlways use lifting gear with sufficient capacity (for truck weight see truck data
plate).
XAlways attach the crane slings to the prescribed strap points and prevent them from
slipping.
XUse the lifting gear only in the prescribed load direction.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
16
Lifting the truck by crane
Tools and Material Required
– Lifting gear
– Crane lifting gear
Tools and Material Required
– Lifting gear
– Crane lifting gear
Procedure
• Secure the crane lifting gear to the
attachment points (16).
Procedure
• Secure the crane lifting gear to the
attachment points (16).
The industrial truck can now be lifted
by crane.
The industrial truck can now be lifted
by crane.
16
09.10 EN
Requirements
– Park the industrial truck securely,
see "Parking the truck securely" on
page 46.
09.10 EN
Requirements
– Park the industrial truck securely,
see "Parking the truck securely" on
page 46.
16
25
25
2
Transport
2
WARNING!
WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious accidents.
XLoading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct
measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe lorry / trailer must have fastening rings.
XUse wedges to prevent the truck from moving.
XUse only tension belts or tie-down straps or with sufficient strength.
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious accidents.
XLoading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct
measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe lorry / trailer must have fastening rings.
XUse wedges to prevent the truck from moving.
XUse only tension belts or tie-down straps or with sufficient strength.
Securing the truck for transport
Securing the truck for transport
Tools and Material Required
– Tension belts/tie down straps
Tools and Material Required
– Tension belts/tie down straps
Procedure
• Move the truck onto the transporting
truck.
• Park the truck securely, see "Parking
the truck securely" on page 46.
• Strap the belts (41) around the truck
and tension them sufficiently.
Procedure
• Move the truck onto the transporting
truck.
• Park the truck securely, see "Parking
the truck securely" on page 46.
• Strap the belts (41) around the truck
and tension them sufficiently.
41
41
09.10 EN
The truck can now be transported.
09.10 EN
The truck can now be transported.
26
Transport
26
3
Using the Truck for the First Time
3
CAUTION!
Using the Truck for the First Time
CAUTION!
Only operate the truck with battery current. Rectified AC current will damage the electronic components. Cable connections to the battery (tow leads) must be less than
19.7 ft (6 m) long and have a minimum cross-section of 6 yd² (50 mm²).
Only operate the truck with battery current. Rectified AC current will damage the electronic components. Cable connections to the battery (tow leads) must be less than
19.7 ft (6 m) long and have a minimum cross-section of 6 yd² (50 mm²).
Procedure
• Check the equipment is complete.
• If necessary install the battery, see "Battery removal and installation" on page 34
• Charge the battery, see "Charging the battery" on page 33.
Procedure
• Check the equipment is complete.
• If necessary install the battery, see "Battery removal and installation" on page 34
• Charge the battery, see "Charging the battery" on page 33.
The truck can now be started, see "Starting up the truck" on page 43
The truck can now be started, see "Starting up the truck" on page 43
NOTE
NOTE
Cold store trucks
XTrucks designed for use in cold stores have a cold store hydraulic oil and a protective frame instead of a mast guard on the mast.
XIf a truck with cold store oil is used outside the cold store, the lowering speeds may
increase.
Cold store trucks
XTrucks designed for use in cold stores have a cold store hydraulic oil and a protective frame instead of a mast guard on the mast.
XIf a truck with cold store oil is used outside the cold store, the lowering speeds may
increase.
Removing the transport retainer to use the truck for the first time
Removing the transport retainer to use the truck for the first time
Procedure
• Fold down the operator platform.
• Open the front panel, see "Removing the front panel" on page 87.
• Undo the M12 nut (SW19) and remove the transport retainer (42).
• Leave the transport retainer (42) on the truck for later transportation without a battery.
Procedure
• Fold down the operator platform.
• Open the front panel, see "Removing the front panel" on page 87.
• Undo the M12 nut (SW19) and remove the transport retainer (42).
• Leave the transport retainer (42) on the truck for later transportation without a battery.
The truck can now be started, see "Starting up the truck" on page 43
The truck can now be started, see "Starting up the truck" on page 43
CAUTION!
CAUTION!
If the battery is included in the truck, the transport retainer must be removed. Otherwise the truck could tip over.
09.10 EN
09.10 EN
If the battery is included in the truck, the transport retainer must be removed. Otherwise the truck could tip over.
27
27
28
09.10 EN
09.10 EN
42
42
28
D Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement
1
1
Safety Regulations Governing the Handling of Lead-Acid
Batteries
Safety Regulations Governing the Handling of Lead-Acid
Batteries
Maintenance personnel
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This operator manual and the manufacturer’s instructions concerning batteries and charging
stations must be observed when carrying out the work.
Batteries may only be charged, serviced or replaced by trained personnel. This operator manual and the manufacturer’s instructions concerning batteries and charging
stations must be observed when carrying out the work.
Fire protection
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there shall be no inflammable material or lubricants
capable of creating sparks within 2 m around the truck. The room must be ventilated.
Fire protection equipment must be on hand.
Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there shall be no inflammable material or lubricants
capable of creating sparks within 2 m around the truck. The room must be ventilated.
Fire protection equipment must be on hand.
Battery maintenance
Battery maintenance
The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease.
The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease.
CAUTION!
CAUTION!
Battery disposal
Battery disposal
Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be
followed.
Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be
followed.
09.10 EN
Before closing the battery panel make sure that the battery cable cannot be damaged. There is a risk of short circuits with damaged cables.
09.10 EN
Before closing the battery panel make sure that the battery cable cannot be damaged. There is a risk of short circuits with damaged cables.
29
29
WARNING!
WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Above all avoid
any contact with battery acid.
XDispose of used battery acid in accordance with regulations.
XAlways wear protective clothing and goggles when working with batteries.
XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XCall for a doctor immediately in the event of physical damage (e.g. skin or eye contact with battery acid).
XNeutralise any spilled battery acid immediately with plenty of water.
XOnly batteries with a sealed battery container may be used.
XFollow national guidelines and legislation.
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Above all avoid
any contact with battery acid.
XDispose of used battery acid in accordance with regulations.
XAlways wear protective clothing and goggles when working with batteries.
XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XCall for a doctor immediately in the event of physical damage (e.g. skin or eye contact with battery acid).
XNeutralise any spilled battery acid immediately with plenty of water.
XOnly batteries with a sealed battery container may be used.
XFollow national guidelines and legislation.
30
Using unsuitable batteries can cause accidents
The weight and dimensions of the battery have a considerable effect on the operational safety and capacity of the industrial truck. Changing the battery features requires the manufacturer’s approval, as compensating weights are required if smaller
batteries are fitted. When replacing/installing the battery make sure the battery is securely located in the battery compartment of the truck.
Using unsuitable batteries can cause accidents
The weight and dimensions of the battery have a considerable effect on the operational safety and capacity of the industrial truck. Changing the battery features requires the manufacturer’s approval, as compensating weights are required if smaller
batteries are fitted. When replacing/installing the battery make sure the battery is securely located in the battery compartment of the truck.
Park the truck securely before carrying out any work on the batteries (see "Parking
the truck securely" on page 46).
Park the truck securely before carrying out any work on the batteries (see "Parking
the truck securely" on page 46).
Battery types
2
Battery types
Depending on the model, the truck will be supplied with different battery types. The
following table shows which combinations are included as standard:
Depending on the model, the truck will be supplied with different battery types. The
following table shows which combinations are included as standard:
Battery type
24 volt battery
621X209X627 mm (LxWxH)
24 volt battery
624x212x627 mm (Lxwxh)
24 volt battery
624x212x627 mm (Lxwxh)
24 volt battery
624x284x537 mm (Lxwxh)
24 volt battery
624x284x627 mm (Lxwxh)
24 volt battery
624x284x537 mm (Lxwxh)
Battery type
24 volt battery
621X209X627 mm (LxWxH)
24 volt battery
624x212x627 mm (Lxwxh)
24 volt battery
624x212x627 mm (Lxwxh)
24 volt battery
624x284x537 mm (Lxwxh)
24 volt battery
624x284x627 mm (Lxwxh)
24 volt battery
624x284x537 mm (Lxwxh)
Capacity
2 EPzS 250 Ah
Lib. Silver
2 EPzS 250 Ah
Weight
230 kg
220 kg
2 EPzV 200 Ah
Maintenance-free
220 kg
3 EPzS 270 Ah
245 kg
3 EPzS 375 Ah
288 kg
3 EPzV 240 Ah
maintenance-free
288 kg
09.10 EN
2
WARNING!
30
Capacity
2 EPzS 250 Ah
Lib. Silver
2 EPzS 250 Ah
Weight
230 kg
220 kg
2 EPzV 200 Ah
Maintenance-free
220 kg
3 EPzS 270 Ah
245 kg
3 EPzS 375 Ah
288 kg
3 EPzV 240 Ah
maintenance-free
288 kg
09.10 EN
WARNING!
The battery weights can be taken from the battery data plate. Batteries with non insulated terminals must be covered with a non slip insulating mat.
09.10 EN
09.10 EN
The battery weights can be taken from the battery data plate. Batteries with non insulated terminals must be covered with a non slip insulating mat.
31
31
3
Exposing the battery
3
Exposing the battery
CAUTION!
CAUTION!
Trapping hazard
XMake sure there is nothing between the battery cover and the truck when you fit the
battery cover.
Trapping hazard
XMake sure there is nothing between the battery cover and the truck when you fit the
battery cover.
WARNING!
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load / load handler is dangerous and
is strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
XAlways fully lower the mast and forks.
XSelect a place to park where no one is at risk of injury from lowering forks.
An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load / load handler is dangerous and
is strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
XAlways fully lower the mast and forks.
XSelect a place to park where no one is at risk of injury from lowering forks.
Requirements
– Park the truck on a level surface.
– Park the truck securely, see "Parking
the truck securely" on page 46.
Requirements
– Park the truck on a level surface.
– Park the truck securely, see "Parking
the truck securely" on page 46.
5
43
Procedure
• Pull out the Emergency Disconnect
(battery connector) (44).
• Open the battery panel (43).
CAUTION!
When you lift up the battery panel, make sure the panel lock engages.
The battery is exposed.
The battery is exposed.
Z
Remove the panel when replacing the battery. see "Battery removal and installation" on page 34.
09.10 EN
Remove the panel when replacing the battery. see "Battery removal and installation" on page 34.
09.10 EN
32
43
Procedure
• Pull out the Emergency Disconnect
(battery connector) (44).
• Open the battery panel (43).
CAUTION!
When you lift up the battery panel, make sure the panel lock engages.
Z
5
32
4
Charging the battery
4
WARNING!
Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge capacity.
XBefore charging, check all cables and plug connections for visible signs of damage.
XVentilate the room in which the truck is being charged.
XThe battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilation.
XDo not smoke and avoid naked flames when handling batteries.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station manufacturers.
The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge capacity.
XBefore charging, check all cables and plug connections for visible signs of damage.
XVentilate the room in which the truck is being charged.
XThe battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilation.
XDo not smoke and avoid naked flames when handling batteries.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station manufacturers.
Charging the battery
Charging the battery
Requirements
– Expose the battery, see "Exposing the
battery" on page 32.
Requirements
– Expose the battery, see "Exposing the
battery" on page 32.
Procedure
• Disconnect the battery connector (44)
from the truck connector.
• Connect the battery connector (44) to
the charging cable (45) of the stationary
charger and turn on the charger.
Procedure
• Disconnect the battery connector (44)
from the truck connector.
• Connect the battery connector (44) to
the charging cable (45) of the stationary
charger and turn on the charger.
44
45
45
09.10 EN
The battery is now charged.
09.10 EN
The battery is now charged.
44
33
33
Battery removal and installation
5
Battery removal and installation
WARNING!
WARNING!
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" section in this chapter.
XWear safety shoes when removing and installing the battery.
XUse only batteries with insulated cells and terminal connectors.
XPark the truck on a level surface to prevent the battery from sliding out.
XMake sure the crane slings have sufficient capacity to replace the battery.
XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" section in this chapter.
XWear safety shoes when removing and installing the battery.
XUse only batteries with insulated cells and terminal connectors.
XPark the truck on a level surface to prevent the battery from sliding out.
XMake sure the crane slings have sufficient capacity to replace the battery.
XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.
Removing the battery from the side
Removing the battery from the side
CAUTION!
34
Trapping hazard
Trapping hazard when removing and installing the battery.
XWhen removing and installing the battery door do not put your hands between the
door and the chassis.
Trapping hazard
Trapping hazard when removing and installing the battery.
XWhen removing and installing the battery door do not put your hands between the
door and the chassis.
Battery removal
Battery removal
Requirements
– Park the truck securely, see "Parking the truck securely" on page 46.
– Expose the battery, see "Exposing the battery" on page 32.
Requirements
– Park the truck securely, see "Parking the truck securely" on page 46.
– Expose the battery, see "Exposing the battery" on page 32.
Procedure
• Disconnect the battery connector (44) from the truck connector.
• Pull the lock (37) on the battery panel up. Hold on to the battery panel (49) while
doing so.
• Lift out the battery panel.
• Position the battery trolley by the truck.
• Push in the battery stop (46) and hold it tight.
The battery stop must not be disabled.
• Pull the battery (47) slightly towards you.
• Carefully push the battery from off the truck onto the trolley.
Procedure
• Disconnect the battery connector (44) from the truck connector.
• Pull the lock (37) on the battery panel up. Hold on to the battery panel (49) while
doing so.
• Lift out the battery panel.
• Position the battery trolley by the truck.
• Push in the battery stop (46) and hold it tight.
The battery stop must not be disabled.
• Pull the battery (47) slightly towards you.
• Carefully push the battery from off the truck onto the trolley.
Z
The battery is now removed.
The battery is now removed.
Battery installation
Battery installation
Requirements
– Park the truck securely, see "Parking the truck securely" on page 46.
– Expose the battery, see "Exposing the battery" on page 32.
Requirements
– Park the truck securely, see "Parking the truck securely" on page 46.
– Expose the battery, see "Exposing the battery" on page 32.
09.10 EN
Z
CAUTION!
34
09.10 EN
5
Procedure
Installation is the reverse order. When reinstalling the battery, note the proper installation position and make sure the battery is connected correctly.
Z
Procedure
Installation is the reverse order. When reinstalling the battery, note the proper installation position and make sure the battery is connected correctly.
46
47
47
48
48
49
49
09.10 EN
46
09.10 EN
Z
35
35
36
36
09.10 EN
09.10 EN
E Operation
E Operation
1
1
Safety Regulations for the Operation of the
Forklift Truck
Safety Regulations for the Operation of the
Forklift Truck
Driver authorisation
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities
Driver’s rights, obligations and responsibilities
The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. The driver
shall be afforded all due rights. Safety shoes must be worn for pedestrian operated
trucks.
The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. The driver
shall be afforded all due rights. Safety shoes must be worn for pedestrian operated
trucks.
Unauthorised use of truck
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.
The driver is responsible for the truck during the time it is in use. The driver must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.
Damage and faults
Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
The supervisor must be immediately informed of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
Repairs
Repairs
The driver must not carry out any repairs or alterations to the truck without the necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches.
The driver must not carry out any repairs or alterations to the truck without the necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches.
Hazardous area
Hazardous area
WARNING!
WARNING!
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck immediately.
09.10 EN
09.10 EN
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck immediately.
37
37
Safety devices, warning signs (see "Identification points and data plates" on page 21)
and warning instructions in the present operating instructions must be strictly observed.
Safety devices, warning signs (see "Identification points and data plates" on page 21)
and warning instructions in the present operating instructions must be strictly observed.
38
09.10 EN
Safety devices and warning labels
09.10 EN
Safety devices and warning labels
38
2
Displays and Controls
50
50
51
52
53
2
54
Displays and Controls
50
55
50
51
52
53
1
54
55
1
2
5
2
5
6
7
6
7
4
9
4
9
11
11
15
15
09.10 EN
14
09.10 EN
14
39
39
Control / Display
Travel switch
Tiller
4
CanCode
5
Emergency Disconnect
switch
6
CanDis
7
Key switch
9
Folding side arm
11
Folding operator platform
Item
1
– travel speed restricted to max. 5.5 km/h.
t Pedestrian mode
40
Control / Display
Travel switch
2
Tiller
4
CanCode
5
Emergency Disconnect
switch
6
CanDis
7
Key switch
9
Folding side arm
11
Folding operator platform
Function
t – Controls the direction of travel as well as
the travel speed.
t Steering and braking
– Set to zone (B):
The truck brakes mechanically.
– Set to travel zone (F):
The mechanical brake is released and
the truck is ready for operation.
o Replaces the key switch
– The truck is activated when you enter the
appropriate code.
– Travel program selection
– Code setting
t Disconnects the battery supply
– All electric functions are cut out and the
truck decelerates
o Display instrument
– Battery charge status
– Service hours
– Warning messages
– Parameter settings
t – Activates the truck by switching on the
control voltage
– Removing the key prevents the truck
from being switched on by unauthorised
personnel
t When the side arms are not unfolded and
the operator platform is laden and unfolded:
– travel speed restricted to max. 5.5 km/h.
t Pedestrian mode
– Operator platform folded up:
Pedestrian speed restricted to max. 5.0
km/h.
– Operator platform folded up:
Pedestrian speed restricted to max. 5.0
km/h.
Rider mode, operator platform acts as a
deadman:
Rider mode, operator platform acts as a
deadman:
– Operator platform down and vacated:
travel inhibited.
– Operator platform folded down and laden
by operator (both arms must be folded
fully out or in):
travel enabled.
– Operator platform down and vacated:
travel inhibited.
– Operator platform folded down and laden
by operator (both arms must be folded
fully out or in):
travel enabled.
09.10 EN
2
Function
t – Controls the direction of travel as well as
the travel speed.
t Steering and braking
– Set to zone (B):
The truck brakes mechanically.
– Set to travel zone (F):
The mechanical brake is released and
the truck is ready for operation.
o Replaces the key switch
– The truck is activated when you enter the
appropriate code.
– Travel program selection
– Code setting
t Disconnects the battery supply
– All electric functions are cut out and the
truck decelerates
o Display instrument
– Battery charge status
– Service hours
– Warning messages
– Parameter settings
t – Activates the truck by switching on the
control voltage
– Removing the key prevents the truck
from being switched on by unauthorised
personnel
t When the side arms are not unfolded and
the operator platform is laden and unfolded:
09.10 EN
Item
1
40
15
50
Control / Display
Fixed operator platform
Deadman button
(function depends on the
tiller version)
51
Warning signal (horn)
button
Collision safety switch
52
Wheel arm lower button
53
54
55
Wheel arm lift button
Fork raise button
Fork lower button
Item
14
– Deadman laden:
Travel and all functions enabled.
– Deadman unladen:
The truck coasts.
o Trucks with moving tiller:
– Deadman button pressed:
Travel released.
– Deadman button released:
Truck coasts.
15
Trucks with rigid tiller:
– Deadman button pressed:
Truck ready for operation.
– Deadman button released:
The truck decelerates.
t – “Warning” button
50
t – Pedestrian mode:
Collision safety switch function which,
when activated, forces the truck to
reverse for approx. 3 seconds and then
cuts out until the controller is briefly
restored to neutral.
– Rider mode:
Void
t – Lowers the wheel arms at a constant
speed.
t – Lifts the wheel arms at a constant speed.
t – Raises the lift mechanism.
t – Lowers the lift mechanism.
o = Optional equipment
Control / Display
Fixed operator platform
Deadman button
(function depends on the
tiller version)
51
Warning signal (horn)
button
Collision safety switch
52
Wheel arm lower button
53
54
55
Wheel arm lift button
Fork raise button
Fork lower button
t = Standard equipment
09.10 EN
t = Standard equipment
Function
o rider mode only:
Function
o rider mode only:
– Deadman laden:
Travel and all functions enabled.
– Deadman unladen:
The truck coasts.
o Trucks with moving tiller:
– Deadman button pressed:
Travel released.
– Deadman button released:
Truck coasts.
Trucks with rigid tiller:
– Deadman button pressed:
Truck ready for operation.
– Deadman button released:
The truck decelerates.
t – “Warning” button
t – Pedestrian mode:
Collision safety switch function which,
when activated, forces the truck to
reverse for approx. 3 seconds and then
cuts out until the controller is briefly
restored to neutral.
– Rider mode:
Void
t – Lowers the wheel arms at a constant
speed.
t – Lifts the wheel arms at a constant speed.
t – Raises the lift mechanism.
t – Lowers the lift mechanism.
o = Optional equipment
09.10 EN
Item
14
41
41
2.1
Battery discharge indicator
When the truck has been released via the key
switch, code lock or ISM, the battery charge status
is displayed. The LED (56) colours represent the following conditions:
LED colour
Green
Orange
Flashing
green/orange 1Hz
Red
Z
2.1
When the truck has been released via the key
switch, code lock or ISM, the battery charge status
is displayed. The LED (56) colours represent the following conditions:
56
Residual capacity
40 - 100 %
30 - 40 %
LED colour
Green
Orange
Flashing
green/orange 1Hz
Red
20 - 30 %
0 - 20 %
Z
If the LED is red, load units can no longer be lifted. Lifting is only enabled again
when the battery connected is at least 70% charged.
56
Residual capacity
40 - 100 %
30 - 40 %
20 - 30 %
0 - 20 %
If the LED is red, load units can no longer be lifted. Lifting is only enabled again
when the battery connected is at least 70% charged.
09.10 EN
If the LED flashes red and the truck is not ready for operation, inform the manufacturer's service department. Red flashing is a truck controller code. The flashing sequence indicates the type of fault.
09.10 EN
If the LED flashes red and the truck is not ready for operation, inform the manufacturer's service department. Red flashing is a truck controller code. The flashing sequence indicates the type of fault.
42
Battery discharge indicator
42
3
Starting up the truck
3
Starting up the truck
3.1
Checks and operations to be performed before starting daily operation
3.1
Checks and operations to be performed before starting daily operation
WARNING!
WARNING!
Pre-start inspections
Pre-start inspections
Procedure
• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.
• Check the battery attachment and wire connections for damage and make sure
they are secure.
• Check the battery connector is secure.
• Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks.
• Check the drive wheel and load wheels for damage.
• Check that the markings and labels are present, clean and legible, see "Identification points and data plates" on page 21.
• Test the Emergency Disconnect switch.
• Check the control handle (damper) is restored to its normal position.
• Check the controls are automatically restored to zero after being applied.
• Test the warning signal.
• Test the brakes.
• Test the collision safety switch.
• Check the steering play.
• Safety cutout height switch (56), visually inspect cable connections and magnet attachment.
Procedure
• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.
• Check the battery attachment and wire connections for damage and make sure
they are secure.
• Check the battery connector is secure.
• Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks.
• Check the drive wheel and load wheels for damage.
• Check that the markings and labels are present, clean and legible, see "Identification points and data plates" on page 21.
• Test the Emergency Disconnect switch.
• Check the control handle (damper) is restored to its normal position.
• Check the controls are automatically restored to zero after being applied.
• Test the warning signal.
• Test the brakes.
• Test the collision safety switch.
• Check the steering play.
• Safety cutout height switch (56), visually inspect cable connections and magnet attachment.
09.10 EN
Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
09.10 EN
Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
43
43
44
09.10 EN
09.10 EN
56
56
56
56
44
3.2
Preparing the truck for operation
3.2
Switching on the Industrial Truck
Switching on the Industrial Truck
Requirements
– For checks and operations to be performed before starting daily operation, see
"Checks and operations to be performed before starting daily operation" on
page 43.
Requirements
– For checks and operations to be performed before starting daily operation, see
"Checks and operations to be performed before starting daily operation" on
page 43.
Procedure
• Step onto the operator platform (11).
• Pull out the Emergency Disconnect switch (5).
• Switch on the truck, to do this:
• Insert the key in the key switch (7) and turn it to the right as far as it will go (position “I”) or for CANCODE (4,o) enter the activation code, see "CanCode keypad" on page 67.
• Test the warning signal button (50).
• Test the travel switch (1).
• Test the steering.
Procedure
• Step onto the operator platform (11).
• Pull out the Emergency Disconnect switch (5).
• Switch on the truck, to do this:
• Insert the key in the key switch (7) and turn it to the right as far as it will go (position “I”) or for CANCODE (4,o) enter the activation code, see "CanCode keypad" on page 67.
• Test the warning signal button (50).
• Test the travel switch (1).
• Test the steering.
The truck is operational.
The truck is operational.
WARNING!
WARNING!
Do not press the travel switch or the "pedestrian" button (o) when entering and exiting the truck.
Z
Preparing the truck for operation
Do not press the travel switch or the "pedestrian" button (o) when entering and exiting the truck.
Z
The CanDis display instrument (6(o)) indicates the available battery capacity.
1
50
6, 4
The CanDis display instrument (6(o)) indicates the available battery capacity.
7
1
50
5
7
5
09.10 EN
11
09.10 EN
11
6, 4
45
45
3.3
Parking the truck securely
3.3
WARNING!
Z
WARNING!
An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
XAlways fully lower the mast and forks.
XSelect a place to park where no other people are at risk of injury from lowering
forks.
An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
XAlways fully lower the mast and forks.
XSelect a place to park where no other people are at risk of injury from lowering
forks.
Parking the truck securely
Parking the truck securely
Procedure
• Fully lower the load handler.
• Set the drive wheel to “Straight ahead”.
Set tiller to the forward position.
• Switch off the truck (7) and remove the
key.
• For CanCode, press the O key.
• For ISM, press the red button.
• Press the Emergency Disconnect (5).
• Fold in the side arm.
• Fold up the operator platform.
Procedure
• Fully lower the load handler.
• Set the drive wheel to “Straight ahead”.
Set tiller to the forward position.
• Switch off the truck (7) and remove the
key.
• For CanCode, press the O key.
• For ISM, press the red button.
• Press the Emergency Disconnect (5).
• Fold in the side arm.
• Fold up the operator platform.
7
Z
5
7
5
09.10 EN
The truck is parked.
09.10 EN
The truck is parked.
46
Parking the truck securely
46
3.4
Z
Battery discharge monitor
3.4
Z
The standard setting for the battery discharge indicator / discharge monitor is
based on standard batteries. When using maintenance-free or special batteries the
display and cutout points of the battery discharge monitor must be set by authorised specialist personnel. If this adjustment is not made the battery may become
damaged through excessive depletion.
CAUTION!
Battery discharge monitor
The standard setting for the battery discharge indicator / discharge monitor is
based on standard batteries. When using maintenance-free or special batteries the
display and cutout points of the battery discharge monitor must be set by authorised specialist personnel. If this adjustment is not made the battery may become
damaged through excessive depletion.
CAUTION!
If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (56) appears. Lifting is only released when the battery connected is at least
70% charged.
If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (56) appears. Lifting is only released when the battery connected is at least
70% charged.
09.10 EN
Excessive depletion shortens the useful life of the battery.
XCharge the battery in good time, see "Charging the battery" on page 33.
09.10 EN
Excessive depletion shortens the useful life of the battery.
XCharge the battery in good time, see "Charging the battery" on page 33.
47
47
4
Industrial Truck Operation
4
Industrial Truck Operation
4.1
Safety regulations for truck operation
4.1
Safety regulations for truck operation
Travel routes and work areas
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
DANGER!
Travel conduct
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
Travel visibility
Travel visibility
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye contact.
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye contact.
Negotiating slopes and inclines
Negotiating slopes and inclines
Negotiating slopes or inclines is only permitted if they are specifically designed as
travel routes, are clean and have a non-slip surface and providing they can be safely
travelled along in accordance with the truck's technical specifications. The truck must
always be driven with the load unit facing uphill. The industrial truck must not be
turned, operated at an angle or parked on inclines or slopes. Inclines must only be
negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating slopes or inclines is only permitted if they are specifically designed as
travel routes, are clean and have a non-slip surface and providing they can be safely
travelled along in accordance with the truck's technical specifications. The truck must
always be driven with the load unit facing uphill. The industrial truck must not be
turned, operated at an angle or parked on inclines or slopes. Inclines must only be
negotiated at slow speed, with the driver ready to brake at any moment.
48
09.10 EN
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading ramp / bridge cannot move or come loose
during loading / unloading.
09.10 EN
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading ramp / bridge cannot move or come loose
during loading / unloading.
48
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. 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. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
Negotiating lifts and docks
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. 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. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. 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. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
09.10 EN
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. 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. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
09.10 EN
Negotiating lifts and docks
49
49
Emergency Disconnect, Travel, Steering, Braking
4.2
4.2.1 Emergency Disconnect
Z
4.2.1 Emergency Disconnect
Applying the Emergency Disconnect
Applying the Emergency Disconnect
Procedure
Procedure
CAUTION!
Accident risk
The operation of the Emergency Disconnect switch must not be affected by any objects placed in its way.
CAUTION!
Accident risk
The operation of the Emergency Disconnect switch must not be affected by any objects placed in its way.
Z
Do not use the Emergency Disconnect (5) as a service brake.
• Press the Emergency Disconnect (5).
Do not use the Emergency Disconnect (5) as a service brake.
• Press the Emergency Disconnect (5).
All electrical functions are deactivated. The truck brakes to a halt.
All electrical functions are deactivated. The truck brakes to a halt.
Release the Emergency Disconnect
Release the Emergency Disconnect
Procedure
• Pull the Emergency Disconnect (5) to unlock it.
Procedure
• Pull the Emergency Disconnect (5) to unlock it.
All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed).
For CanCode and ISM the truck remains switched off.
All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed).
For CanCode and ISM the truck remains switched off.
1
5
09.10 EN
5
50
Emergency Disconnect, Travel, Steering, Braking
1
09.10 EN
4.2
50
4.2.2 Travel
4.2.2 Travel
CAUTION!
CAUTION!
XDo not drive the truck unless the panels are closed and properly locked.
XWhen travelling through swing doors etc. make sure that the doors do not activate
the collision safety button.
XDo not drive the truck unless the panels are closed and properly locked.
XWhen travelling through swing doors etc. make sure that the doors do not activate
the collision safety button.
WARNING!
WARNING!
Trapping hazard
Be extremely careful when driving and steering, especially if parts of your body
extend outside the border of the truck.
XDo not reach between the standing platform and the truck frame when you fold up
the platform.
XIn pedestrian mode make sure you have sufficient distance from the industrial
truck.
Trapping hazard
Be extremely careful when driving and steering, especially if parts of your body
extend outside the border of the truck.
XDo not reach between the standing platform and the truck frame when you fold up
the platform.
XIn pedestrian mode make sure you have sufficient distance from the industrial
truck.
NOTE
Z
NOTE
XTravelling is inhibited when the operator platform is unladen and the side arms are
not folded out.
XIf the standing platform is occupied and the gates are not folded out, the industrial
truck can only be operated at reduced speed.
XIf the operator platform is occupied and only one gate is folded out, travelling is inhibited.
XTravelling is inhibited when the operator platform is unladen and the side arms are
not folded out.
XIf the standing platform is occupied and the gates are not folded out, the industrial
truck can only be operated at reduced speed.
XIf the operator platform is occupied and only one gate is folded out, travelling is inhibited.
Industrial trucks with a folding standing platform and moving tiller
Industrial trucks with a folding standing platform and moving tiller
We distinguish between two travel modes:
We distinguish between two travel modes:
– Travel in pedestrian mode
– Travel in rider mode
– Travel in pedestrian mode
– Travel in rider mode
Travel in pedestrian mode
Travel in pedestrian mode
Requirements
– Start up the truck, see "Starting up the truck" on page 43
Requirements
– Start up the truck, see "Starting up the truck" on page 43
Procedure
• Move the folding side arms (9) towards the inside.
• Fold up the standing platform (11).
• Set the tiller (2) to travel zone (F).
• Control the travel speed with the travel switch (1).
• Set the travel switch (1) to the desired travel direction: forward (V) or reverse (R).
When the travel switch is release it automatically returns to its original position.
Procedure
• Move the folding side arms (9) towards the inside.
• Fold up the standing platform (11).
• Set the tiller (2) to travel zone (F).
• Control the travel speed with the travel switch (1).
• Set the travel switch (1) to the desired travel direction: forward (V) or reverse (R).
When the travel switch is release it automatically returns to its original position.
Z
Z
The brakes are released and the truck moves in the selected direction.
In pedestrian mode the truck can only be operated at reduced speed.
09.10 EN
09.10 EN
The brakes are released and the truck moves in the selected direction.
51
Z
In pedestrian mode the truck can only be operated at reduced speed.
51
Z
Travel in rider mode
Travel in rider mode
Requirements
– Start up the truck, see "Starting up the truck" on page 43
Requirements
– Start up the truck, see "Starting up the truck" on page 43
Procedure
• Move the folding side arms (9) towards the outside.
• Fold down the standing platform (11).
• Set the tiller (2) to travel zone (F).
• Control the travel speed with the travel switch (1).
• Set the travel switch (1) to the desired travel direction: forward (V) or reverse (R).
When the travel switch is release it automatically returns to its original position.
Procedure
• Move the folding side arms (9) towards the outside.
• Fold down the standing platform (11).
• Set the tiller (2) to travel zone (F).
• Control the travel speed with the travel switch (1).
• Set the travel switch (1) to the desired travel direction: forward (V) or reverse (R).
When the travel switch is release it automatically returns to its original position.
Z
The brakes are released and the truck moves in the selected direction.
Z
The brakes are released and the truck moves in the selected direction.
Z
Preventing the truck from “rolling downhill”:
If the truck rolls backwards on an incline the controller detects the situation and the
travel switch brake applies automatically after a short jerk.
B
F
2
V1
Preventing the truck from “rolling downhill”:
If the truck rolls backwards on an incline the controller detects the situation and the
travel switch brake applies automatically after a short jerk.
B
R
F
B
R
9
9
11
V
09.10 EN
V
09.10 EN
52
R
B
R
11
2
V1
52
4.2.3 Steering
4.2.3 Steering
The truck is steered in the required direction.
The truck is steered in the required direction.
09.10 EN
Procedure
• Move the tiller (2) to the left or right.
09.10 EN
Procedure
• Move the tiller (2) to the left or right.
53
53
4.2.4 Brakes
4.2.4 Brakes
The brake pattern of the truck depends largely on the travel route conditions. The driver must take this into account when travelling.
The brake pattern of the truck depends largely on the travel route conditions. The driver must take this into account when travelling.
The truck can brake in three different ways:
The truck can brake in three different ways:
– Using the service brake
– By inversion braking (controller)
– Using the regenerative brake (coasting)
– Using the service brake
– By inversion braking (controller)
– Using the regenerative brake (coasting)
CAUTION!
Z
Z
XUse the service brake in emergencies
XUse the service brake in emergencies
Braking with the service brake:
Braking with the service brake:
Procedure
• Press the Stop button (6).
Procedure
• Press the Stop button (6).
The truck will decelerate at the maximum rate and the service brake will apply.
The truck will decelerate at the maximum rate and the service brake will apply.
Z
The truck can only start again when the travel switch has been set to neutral.
Regenerative braking
Regenerative braking
Procedure
• Release the travel switch (1) - the travel switch (1) reverts to neutral.
Procedure
• Release the travel switch (1) - the travel switch (1) reverts to neutral.
The truck brakes to a halt regeneratively via the coasting brake. The service brake
then applies.
The truck brakes to a halt regeneratively via the coasting brake. The service brake
then applies.
Z
With regenerative braking energy is recuperated to the battery, ensuring a longer
service time.
With regenerative braking energy is recuperated to the battery, ensuring a longer
service time.
Inversion braking
Inversion braking
Procedure
• When travelling, set the travel switch (1) to the opposite direction.
Procedure
• When travelling, set the travel switch (1) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z
The braking intensity can be set by the manufacturer’s service department.
1
The braking intensity can be set by the manufacturer’s service department.
1
1
6
1
6
09.10 EN
6
54
The truck can only start again when the travel switch has been set to neutral.
54
1
6
1
09.10 EN
Z
CAUTION!
4.3
Lifting, transporting and depositing loads
4.3
WARNING!
WARNING!
Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XOnly carry loads that have been correctly secured and positioned. Use suitable precautions to prevent parts of the load from tipping or falling down.
XDamaged loads must not be transported.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XInsert the forks as far as possible underneath the load.
Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XOnly carry loads that have been correctly secured and positioned. Use suitable precautions to prevent parts of the load from tipping or falling down.
XDamaged loads must not be transported.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XInsert the forks as far as possible underneath the load.
NOTE
NOTE
The pressure sensitive mat (10) must be occupied by the operator for lifting/lowering
to be enabled.
The pressure sensitive mat (10) must be occupied by the operator for lifting/lowering
to be enabled.
4.3.1 Lifting and lowering
4.3.1 Lifting and lowering
Lift a load unit
Lift a load unit
Requirements
– Load unit correctly palletised.
– Load unit weight matches the truck's capacity.
– Forks evenly loaded for heavy loads.
Requirements
– Load unit correctly palletised.
– Load unit weight matches the truck's capacity.
– Forks evenly loaded for heavy loads.
Procedure
• Drive the truck carefully up to the pallet.
• Slowly insert the forks into the pallet until the fork shank touches the pallet.
The load unit must not extend by more than 50 mm beyond the fork tips.
• Press the “Lift” button (54) button until you reach the desired lift height.
Procedure
• Drive the truck carefully up to the pallet.
• Slowly insert the forks into the pallet until the fork shank touches the pallet.
The load unit must not extend by more than 50 mm beyond the fork tips.
• Press the “Lift” button (54) button until you reach the desired lift height.
Z
Z
The load unit is raised.
Z
The load unit is raised.
Z
The lift/lower speed can be infinitely controlled via the movement of the button (approx. 8 mm).
The lift/lower speed can be infinitely controlled via the movement of the button (approx. 8 mm).
Short stroke = slow lift / lower
Short stroke = slow lift / lower
Long stroke = fast lift / lower
Long stroke = fast lift / lower
Trucks with a lift height greater than 2010 mm:
when the wheel arms are raised, lifting is disabled beyond 1800 mm lift height. The
wheel arms will lower automatically. The forks can only be lifted up to the maximum
height when the wheel arms have been completely lowered.
55
Z
09.10 EN
Z
09.10 EN
Lifting, transporting and depositing loads
Trucks with a lift height greater than 2010 mm:
when the wheel arms are raised, lifting is disabled beyond 1800 mm lift height. The
wheel arms will lower automatically. The forks can only be lifted up to the maximum
height when the wheel arms have been completely lowered.
55
CAUTION!
XRelease the button as soon as you reach the limit position of the load handler.
XRelease the button as soon as you reach the limit position of the load handler.
Depositing load units
Depositing load units
Requirements
– Warehouse location suitable for storing the load.
Requirements
– Warehouse location suitable for storing the load.
Procedure
• Set the mast vertical.
• Drive carefully up to the storage location.
• Press the "Lower load handler" button until the forks are clear of the load.
Avoid depositing the load to avoid damaging the load and the load handler.
• Lower the load handler.
• Carefully remove the forks from the pallet.
Procedure
• Set the mast vertical.
• Drive carefully up to the storage location.
• Press the "Lower load handler" button until the forks are clear of the load.
Avoid depositing the load to avoid damaging the load and the load handler.
• Lower the load handler.
• Carefully remove the forks from the pallet.
Z
The load unit is lowered.
The load unit is lowered.
Transporting load units
Transporting load units
Requirements
– Load unit correctly lifted.
– Mast lowered for transport (approx. 150 - 200 mm above the ground).
– Good ground conditions.
Requirements
– Load unit correctly lifted.
– Mast lowered for transport (approx. 150 - 200 mm above the ground).
– Good ground conditions.
Procedure
• Accelerate and decelerate gradually.
• Adapt your travel speed to the conditions of the route and the load you are transporting.
• Travel at a constant speed.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.
• On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn.
Procedure
• Accelerate and decelerate gradually.
• Adapt your travel speed to the conditions of the route and the load you are transporting.
• Travel at a constant speed.
• Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots.
• On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn.
Transporting 2 pallets on top of each other
Transporting 2 pallets on top of each other
Procedure
• Insert the forks under the first pallet. see "Lifting and lowering" on page 55
• Insert the wheel arms under the second pallet and raise it.see "Lifting and lowering"
on page 55
• Transport the pallet.see "Lifting, transporting and depositing loads" on page 55
Procedure
• Insert the forks under the first pallet. see "Lifting and lowering" on page 55
• Insert the wheel arms under the second pallet and raise it.see "Lifting and lowering"
on page 55
• Transport the pallet.see "Lifting, transporting and depositing loads" on page 55
CAUTION!
CAUTION!
The heavier pallet should always be transported below for safety reasons.
56
When transporting, the forks with the load must be lowered as near as possible to
the lower load, however NOT on top of the lower load.
Z
09.10 EN
Z
The heavier pallet should always be transported below for safety reasons.
56
When transporting, the forks with the load must be lowered as near as possible to
the lower load, however NOT on top of the lower load.
09.10 EN
Z
CAUTION!
Switch Matrix / Safety Switch Height
09.10 EN
Operator platform
Side arm
4.4
Safety height Initial lift With load
reached
in mast lift
> 250 kg
Collision safety
switch active
Switch Matrix / Safety Switch Height
Operator platform
Side arm
Safety height Initial lift With load
reached
in mast lift
> 250 kg
Collision safety
switch active
Folded out
Folded out
No
No
No
Folded out
Folded out
No
No
No
Folded out
Folded in
No
No
No
Folded out
Folded in
No
No
No
Folded up
Folded in
No
No
Yes
Folded up
Folded in
No
No
Yes
Folded out
Folded out
Yes
No
No
Folded out
Folded out
Yes
No
No
Folded out
Folded in
Yes
No
No
Folded out
Folded in
Yes
No
No
Folded up
Folded in
Yes
No
Yes
Folded up
Folded in
Yes
No
Yes
Folded up
Folded in
Yes
No
No
Folded up
Folded in
Yes
No
No
Folded out
Folded out
No
No
No
Folded out
Folded out
No
No
No
Folded out
Folded out
No
Yes
No
Folded out
Folded out
No
Yes
No
Folded out
Folded in
No
Yes
No
Folded out
Folded in
No
Yes
No
Folded up
Folded in
No
Yes
Yes
Folded up
Folded in
No
Yes
Yes
Folded out
Folded out
Yes
Yes
No
Folded out
Folded out
Yes
Yes
No
Folded out
Folded in
Yes
Yes
No
Folded out
Folded in
Yes
Yes
No
Folded up
Folded in
Yes
Yes
Yes
Folded up
Folded in
Yes
Yes
Yes
Folded out
Folded out
Yes
Yes
No
Folded out
Folded out
Yes
Yes
No
none
Fixed opera- No
tor platform
No
with deadman
No
switch
Yes
No
No
none
No
No
No
No
No
No
Yes
No
Yes
No
Yes
No
Fixed opera- No
tor platform
No
with deadman
No
switch
Yes
Yes
No
Mast lift raise
active
Side arm
Yes
Yes
Yes
Yes
No**)
Note
Mast lift raise
active
Side arm
Unladen, rider fast
Yes
Yes
Unladen, rider fast
Yes
Unladen, rider slow
Yes
Yes
Unladen, rider slow
Yes
Unladen, pedestrian
Yes
Yes
Unladen, pedestrian
No
Unladen, rider slow
No**)
No
Unladen, rider slow
Note
STOP
No
No
STOP
No
No
Yes
No
Unladen, pedestrian
Yes
No
Unladen, pedestrian
No
No
STOP
No
No
STOP
Yes
Yes
Laden, initial lift, rider fast
Yes
Yes
Laden, initial lift, rider fast
Yes***)
Yes
Double deck laden, rider slow
Yes***)
Yes
Double deck laden, rider slow
Yes
Yes
Double deck laden, rider slow
Yes
Yes
Double deck laden, rider slow
Yes
Yes
Double deck laden, pedestrian
Yes
Yes
Double deck laden, pedestrian
No**)
No
Double deck laden, rider slow
No**)
No
Double deck laden, rider slow
09.10 EN
4.4
57
57
Yes*)
*)
No
Yes*)
Double deck laden, rider slow
*
Yes )
No
Double deck laden, pedestrian
No
No
Yes
Yes
Yes
Yes
No**)
Yes )
No
Double deck laden, pedestrian
No
No
STOP
Unladen, rider fast
Yes
Yes
Unladen, rider fast
Yes
Laden, initial lift, rider fast
Yes
Yes
Laden, initial lift, rider fast
Yes
Double deck laden, rider slow
Yes
Yes
Double deck laden, rider slow
No
Double deck laden, rider slow
No**)
No
Double deck laden, rider slow
*)
only with side arms folded in, otherwise mast lift is inhibited.
only with side arms folded in, otherwise mast lift is inhibited.
**)optional travel (rider slow) and lifting above 1800 mm with side restraints folded out
**)optional travel (rider slow) and lifting above 1800 mm with side restraints folded out
is available in conjunction with a load backrest.
is available in conjunction with a load backrest.
***) optional with load chart mast lift / wheel arm lift 600 kg/ 1400 kg ==> travel speed
increased to 7.2 km/h with load.
*** optional with load chart mast lift / wheel arm lift 600 kg/ 1400 kg ==> travel speed
increased to 7.2 km/h with load.
Z
"Mast lift lower" and "Initial lift lower" are always active.
09.10 EN
"Mast lift lower" and "Initial lift lower" are always active.
09.10 EN
58
Double deck laden, rider slow
STOP
)
Z
No
*
58
5
Troubleshooting
5
Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table.
Z
5.1
Z
If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially
trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the following information is essential:
- Truck serial number
- Error number on the display unit (if applicable)
- Error description
- Current location of truck
Truck does not start
Possible Cause
– Battery connector not plugged in.
– Emergency Disconnect switch
pressed.
– Key switch set to O.
– Battery charge too low.
– Faulty fuse.
5.2
This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table.
5.1
Action
– Check the battery connector and
plug it in if necessary.
– Unlock the Emergency Disconnect button.
– Set the key switch to “I”.
– Check the battery charge
and charge battery if necessary.
– Check the fuses.
Truck does not start
Possible Cause
– Battery connector not plugged in.
– Emergency Disconnect switch
pressed.
– Key switch set to O.
– Battery charge too low.
– Faulty fuse.
Load cannot be lifted
Possible Cause
– Truck not operational.
If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially
trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the following information is essential:
- Truck serial number
- Error number on the display unit (if applicable)
- Error description
- Current location of truck
5.2
Action
– Carry out all measures listed under
“Truck does not start”.
– Check hydraulic oil level.
– Charge the battery.
Load cannot be lifted
Possible Cause
– Truck not operational.
Action
– Carry out all measures listed under
“Truck does not start”.
– Check hydraulic oil level.
– Charge the battery.
09.10 EN
– Hydraulic oil level too low.
– Battery discharge monitor has switched
off.
– Check the fuses.
– Faulty fuse.
– Note maximum capacity (see data
– Load is too heavy.
plate).
09.10 EN
– Hydraulic oil level too low.
– Battery discharge monitor has switched
off.
– Check the fuses.
– Faulty fuse.
– Note maximum capacity (see data
– Load is too heavy.
plate).
Action
– Check the battery connector and
plug it in if necessary.
– Unlock the Emergency Disconnect button.
– Set the key switch to “I”.
– Check the battery charge
and charge battery if necessary.
– Check the fuses.
59
59
6
Operating the truck without its own drive system
6
WARNING!
WARNING!
Uncontrolled truck movement
When the brakes are de-activated the truck must be parked on a level surface, since
the brakes are no longer effective.
XDo not release the brake on slopes or inclines.
XApply the brake again when you reach your destination.
XDo not park the truck with the brake released.
Uncontrolled truck movement
When the brakes are de-activated the truck must be parked on a level surface, since
the brakes are no longer effective.
XDo not release the brake on slopes or inclines.
XApply the brake again when you reach your destination.
XDo not park the truck with the brake released.
Releasing the brake
Releasing the brake
Procedure
• Switch off the Emergency Disconnect button.
• Turn of the key switch, CanCode (o).
• Disconnect the battery.
• Prevent the truck from rolling away.
• Open the front panel and put it to one side,
see "Removing the front panel" on
page 87.
• Slacken the lock nuts (58) and tighten the
screws (57).
57
Procedure
• Switch off the Emergency Disconnect button.
• Turn of the key switch, CanCode (o).
• Disconnect the battery.
• Prevent the truck from rolling away.
• Open the front panel and put it to one side,
see "Removing the front panel" on
page 87.
• Slacken the lock nuts (58) and tighten the
screws (57).
58
57
58
The brake is now released and the truck can be moved.
Applying the brake
Applying the brake
Procedure
• Loosen the screws (57) by approx. 5mm and secure them with lock nuts (58).
• Refit the front panel.
Procedure
• Loosen the screws (57) by approx. 5mm and secure them with lock nuts (58).
• Refit the front panel.
Braking is now restored again.
Braking is now restored again.
09.10 EN
The brake is now released and the truck can be moved.
09.10 EN
60
Operating the truck without its own drive system
60
7
Load handler emergency lowering
7
Load handler emergency lowering
Load handler emergency lowering
Requirements
– Load handler is not in the rack.
Requirements
– Load handler is not in the rack.
59
59
Tools and Material Required
– Allen key (2.5 mm)
Tools and Material Required
– Allen key (2.5 mm)
Procedure
• Set key switch (7) to “0”.
• Depress the Emergency Disconnect (5). see
"Emergency Disconnect" on page 50.
• Open the front panel. see "Removing the front panel" on page 87.
• Undo the screw on the valve manifold (59).
Procedure
• Set key switch (7) to “0”.
• Depress the Emergency Disconnect (5). see
"Emergency Disconnect" on page 50.
• Open the front panel. see "Removing the front panel" on page 87.
• Undo the screw on the valve manifold (59).
The load handler is lowered.
The load handler is lowered.
Z
After carrying out the emergency lowering, turn in the screw (59) as far as the stop.
09.10 EN
After carrying out the emergency lowering, turn in the screw (59) as far as the stop.
09.10 EN
Z
Load handler emergency lowering
61
61
8
62
Optional equipment
09.10 EN
Optional equipment
09.10 EN
8
62
8.1
CANDIS display instrument
8.1
The instrument indicates:
82
83
84
85
86
87
Battery charge display (on board charger
only)
Capacity display bars
Battery residual charge status
Warning - pre-warning symbol,
Battery charge recommended
Stop symbol; lift cutout,
Battery charge required
T symbol appears during operation when
the discharge indicator is set to maintenance-free battery
6 digit LCD display;
hourmeter, input display;
error display
CANDIS display instrument
The instrument indicates:
82
82
83
84
85
86
83
84
87
85
86
87
Battery charge display (on board charger
only)
Capacity display bars
Battery residual charge status
Warning - pre-warning symbol,
Battery charge recommended
Stop symbol; lift cutout,
Battery charge required
T symbol appears during operation when
the discharge indicator is set to maintenance-free battery
6 digit LCD display;
hourmeter, input display;
error display
82
83
84
85
86
87
In addition, service messages for the electronic components and parameter changes
are displayed.
In addition, service messages for the electronic components and parameter changes
are displayed.
Discharge status display
Discharge status display
Setting limits for the additional “Warning” (84) and “Stop” (85) displays will depend on
the battery type.
Setting limits for the additional “Warning” (84) and “Stop” (85) displays will depend on
the battery type.
The available capacity is shown via 8 LED bars.
The available capacity is shown via 8 LED bars.
The current battery capacity is shown by the illuminated LED bars. 8 bars correspond
to full battery capacity, 1 bar corresponds to the minimum available capacity.
The current battery capacity is shown by the illuminated LED bars. 8 bars correspond
to full battery capacity, 1 bar corresponds to the minimum available capacity.
If only one LED bar is lit, the battery capacity is almost depleted and the “Warning”
indicator (84) is lit. The battery must be charged immediately.
If only one LED bar is lit, the battery capacity is almost depleted and the “Warning”
indicator (84) is lit. The battery must be charged immediately.
If no more LED bars are illuminated, the “Stop” indicator (85) lights up. Lifting is now
inhibited. The battery must be charged.
If no more LED bars are illuminated, the “Stop” indicator (85) lights up. Lifting is now
inhibited. The battery must be charged.
8.1.1 Discharge monitor function
8.1.1 Discharge monitor function
When the discharge monitor function is enabled, lifting is cut out when reaching the
discharge limit is reached (the Stop LED goes on). Travel and lowering are still possible.
09.10 EN
09.10 EN
When the discharge monitor function is enabled, lifting is cut out when reaching the
discharge limit is reached (the Stop LED goes on). Travel and lowering are still possible.
63
63
8.1.2 Service hours display
8.1.2 Service hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are
logged. This is a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the hourmeter
display (86).
8.1.3 Event messages
Z
8.1.3 Event messages
The service hours display is also used to display event messages. The error display
starts with an ”E” for Event and a four-digit error number.
If several events occur simultaneously, they are displayed one after the other. The
events are displayed until they are rectified. Event messages overwrite the service
hour display. Most events cause the Emergency Stop to be activated. Events remain
displayed until the control circuit is switched off (key switch).
The service hours display is also used to display event messages. The error display
starts with an ”E” for Event and a four-digit error number.
If several events occur simultaneously, they are displayed one after the other. The
events are displayed until they are rectified. Event messages overwrite the service
hour display. Most events cause the Emergency Stop to be activated. Events remain
displayed until the control circuit is switched off (key switch).
If no CanDis is present, the event code is displayed by the flashing of the discharge
monitor LED.
If no CanDis is present, the event code is displayed by the flashing of the discharge
monitor LED.
Z
The manufacturer’s service department has detailed component descriptions with
event codes.
8.1.4 Power up test
The manufacturer’s service department has detailed component descriptions with
event codes.
8.1.4 Power up test
On power up the display shows:
On power up the display shows:
– the software version of the display instrument (briefly),
– the service hours,
– the battery charge status.
– the software version of the display instrument (briefly),
– the service hours,
– the battery charge status.
09.10 EN
64
For maintenance-free batteries a “T” symbol is shown in the hourmeter
display (86).
09.10 EN
Z
Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are
logged. This is a backlit display.
64
8.2
ISM access module
8.2
The ISM module enables you to switch on the truck with the transponder or card.
ISM access module
The ISM module enables you to switch on the truck with the transponder or card.
85
86
Item Control or
Display
84 Display
87
Information System
for truck Management
84
Information System
for truck Management
84
88
85
Function
87
88
Access card
Transponder
Switch off the truck.
Data card to activate the truck
Data transponder to activate the truck
Item Control or
Display
84 Display
87
88
Function
85
86
Green switch (+)
Red switch (mode)
Displays important information, requests, impacts on
the truck and error messages
Start the truck.
Starts the truck if damage has been detected.
87
88
Access card
Transponder
Switch off the truck.
Data card to activate the truck
Data transponder to activate the truck
09.10 EN
Green switch (+)
Red switch (mode)
09.10 EN
85
86
Displays important information, requests, impacts on
the truck and error messages
Start the truck.
Starts the truck if damage has been detected.
86
65
65
NOTE
Z
To start a truck via the access module, you need a valid driver’s card or a valid transponder.
Card and transponder
Card and transponder
The card and transponder have the following functions:
– Assigning a card to a driver
– Access rights for selected trucks
– Storing the driver’s operating data (level 2 only)
The card and transponder have the following functions:
– Assigning a card to a driver
– Access rights for selected trucks
– Storing the driver’s operating data (level 2 only)
Switching on the truck
Switching on the truck
Tools and Material Required
– Valid card or valid transponder
Tools and Material Required
– Valid card or valid transponder
Procedure
• Unlock the Emergency Disconnect button.
“Card?” is shown on the display.
Procedure
• Unlock the Emergency Disconnect button.
“Card?” is shown on the display.
• Place the card / transponder on the access module.
If the card/transponder is valid, a beep sounds.
"ok?" is shown on the display.
• Place the card / transponder on the access module.
If the card/transponder is valid, a beep sounds.
"ok?" is shown on the display.
• If the truck is ok, press the green button (85).
If the truck is damaged press the red button (86).
• If the truck is ok, press the green button (85).
If the truck is damaged press the red button (86).
“go?” is shown on the display.
The truck is now operational.
“go?” is shown on the display.
The truck is now operational.
Z
If the card / transponder is invalid "XXcardXx" is displayed and the truck will not
switch on.
66
If the card / transponder is invalid "XXcardXx" is displayed and the truck will not
switch on.
Switching off the truck
Switching off the truck
Procedure
• Press the red button (86).
Procedure
• Press the red button (86).
“card?” is now displayed. The truck is switched off.
“card?” is now displayed. The truck is switched off.
Z
If you forget to switch the truck off, the access module automatically switches the
truck off after a set timeout period.
Z
For more information on ISM refer to the ISM operating instructions.
09.10 EN
Z
To start a truck via the access module, you need a valid driver’s card or a valid transponder.
If you forget to switch the truck off, the access module automatically switches the
truck off after a set timeout period.
For more information on ISM refer to the ISM operating instructions.
09.10 EN
Z
NOTE
66
8.3
CanCode keypad
8.3
CanCode keypad
CanCode keypad
The keypad consists of 10 digit keys, a Set key and a o
key.
The keypad consists of 10 digit keys, a Set key and a o
key.
The O key indicates the follow operating statuses via a
red / green LED:
– Code lock function (starting up the truck).
– Adjusting the travel program depending on the setting
and truck.
– Setting and changing parameters.
1
2
3
4
5
6
7
8
9
Set
0
The O key indicates the follow operating statuses via a
red / green LED:
– Code lock function (starting up the truck).
– Adjusting the travel program depending on the setting
and truck.
– Setting and changing parameters.
8.3.1 Keypad
Procedure
• Insert the battery connector.
LED (83) lights up red.
82
The truck is switched on
Z
Z
78
Starting the truck
Z
79
80
3
4
5
6
7
8
9
Set
0
1
2
3
4
5
6
7
8
9
Set
Set different codes for rider and pedestrian trucks.
78
Starting the truck
0
Procedure
• Insert the battery connector.
LED (83) lights up red.
• Enter the code.
When you enter the correct operator
code the LED (83) turns green. If the
LED (83) flashes red this means the
wrong code has been entered. Try
again.
81
83
82
The truck is switched on
Z
The Set key (82) has no function in operating mode.
Switching the truck off
Procedure
• Press the O key.
Procedure
• Press the O key.
The truck is switched off.
The truck is switched off.
Z
The truck can switch off automatically after a set time. To do this the relevant code
lock parameters must be entered, see "Parameter Settings" on page 68.
79
80
1
2
3
4
5
6
7
8
9
Set
0
81
83
The Set key (82) has no function in operating mode.
Switching the truck off
8.3.2 Parameters
The truck can switch off automatically after a set time. To do this the relevant code
lock parameters must be entered, see "Parameter Settings" on page 68.
8.3.2 Parameters
The keypad enables parameters to be adjusted in programming mode.
09.10 EN
09.10 EN
2
When the correct code is entered, the truck is ready for use. You can allocate an individual code to each truck, operator or group of operators. When the truck is supplied
from the factory, the code is indicated on a sticker. Change the master and operator
codes when you use the truck for the first time.
Set different codes for rider and pedestrian trucks.
• Enter the code.
When you enter the correct operator
code the LED (83) turns green. If the
LED (83) flashes red this means the
wrong code has been entered. Try
again.
1
8.3.1 Keypad
When the correct code is entered, the truck is ready for use. You can allocate an individual code to each truck, operator or group of operators. When the truck is supplied
from the factory, the code is indicated on a sticker. Change the master and operator
codes when you use the truck for the first time.
Z
CanCode keypad
67
The keypad enables parameters to be adjusted in programming mode.
67
Parameter Groups
Parameter Groups
The parameter number is composed of three digits. The first digit refers to the parameter group as shown in Table 1. The second and third digits are numbered in sequence from 00 to 99.
The parameter number is composed of three digits. The first digit refers to the parameter group as shown in Table 1. The second and third digits are numbered in sequence from 00 to 99.
No.
0XX
No.
0XX
Parameter Groups
Code lock settings (codes, travel program release, automatic cutout, etc.)
8.3.3 Parameter Settings
8.3.3 Parameter Settings
To change the truck settings you must enter the master code.
Z
Z
Z
To change the truck settings you must enter the master code.
Z
The master code factory setting is 7-2-9-5. Change the master code the first time
you use the truck.
Z
Set different codes for rider and pedestrian trucks.
The master code factory setting is 7-2-9-5. Change the master code the first time
you use the truck.
Set different codes for rider and pedestrian trucks.
Changing the truck settings
Changing the truck settings
Procedure
• Press the O key (81).
• Enter the master code.
• Enter the three-digit parameter number.
• Confirm with the SET key (82).
• Enter the setting as per parameter list.
If the entry is incorrect, the LED (83) of the O key (81) turns red.
• Enter the parameter number again.
• Enter the setting again or change it.
• Confirm with the SET key (82).
• Repeat the procedure for other parameters.
• Then press the O key (81).
Procedure
• Press the O key (81).
• Enter the master code.
• Enter the three-digit parameter number.
• Confirm with the SET key (82).
• Enter the setting as per parameter list.
If the entry is incorrect, the LED (83) of the O key (81) turns red.
• Enter the parameter number again.
• Enter the setting again or change it.
• Confirm with the SET key (82).
• Repeat the procedure for other parameters.
• Then press the O key (81).
Z
09.10 EN
The settings are now saved.
09.10 EN
The settings are now saved.
68
Parameter Groups
Code lock settings (codes, travel program release, automatic cutout, etc.)
68
Parameter list
Parameter list
No.
Function
Setting range
000
Change master code:
The length (4-6 digits) of
the master code also
determines the length of
the operator code (4-6
digits). Provided the
operator codes are programmed, only new
codes of the same
length can be entered. If
you wish to change the
code length, you must
first delete all the operator codes.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
001
Add code (max. 250)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
002
Change code
0000 - 9999
or
00000 - 99999
or
000000 - 999999
Standard set- Procedure
ting
7295
– (LED 78 flashes)
Confirm current
code entry
–
(Set 82)
– (LED 79 flashes)
Confirm new code
entry
–
(Set 82)
– (LED 80 flashes)
repeat new code
–
(Set 82)
2580
– (LED 79 flashes)
Confirm code
entry
–
(Set 82)
– (LED 80 flashes)
repeat code entry
–
(Set 82)
– (LED 78 flashes)
Confirm current
code entry
–
(Set 82)
– (LED 79 flashes)
Confirm new code
entry
–
(Set 82)
– (LED 80 flashes)
Confirm code reentry
–
(Set 82)
Function
Setting range
000
Change master code:
The length (4-6 digits) of
the master code also
determines the length of
the operator code (4-6
digits). Provided the
operator codes are programmed, only new
codes of the same
length can be entered. If
you wish to change the
code length, you must
first delete all the operator codes.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
001
Add code (max. 250)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
002
Change code
0000 - 9999
or
00000 - 99999
or
000000 - 999999
Standard set- Procedure
ting
7295
– (LED 78 flashes)
Confirm current
code entry
–
(Set 82)
– (LED 79 flashes)
Confirm new code
entry
–
(Set 82)
– (LED 80 flashes)
repeat new code
–
(Set 82)
2580
– (LED 79 flashes)
Confirm code
entry
–
(Set 82)
– (LED 80 flashes)
repeat code entry
–
(Set 82)
– (LED 78 flashes)
Confirm current
code entry
–
(Set 82)
– (LED 79 flashes)
Confirm new code
entry
–
(Set 82)
– (LED 80 flashes)
Confirm code reentry
–
(Set 82)
09.10 EN
LEDs 78-80 are located in keypads 1-3.
09.10 EN
LEDs 78-80 are located in keypads 1-3.
No.
69
69
No.
Function
Setting range
003
Delete code
004
Delete code log (deletes
all codes)
3265
010
Automatic timeout
00-31
0000 - 9999
or
00000 - 99999
or
000000 - 999999
Standard set- Procedure
ting
– (LED 79 flashes)
Confirm new code
entry
–
(Set 82)
– (LED 80 flashes)
repeat code entry
–
(Set 82)
– 3265 = delete
– other inputs = do
not delete
00
– 00 = No timeout
– 01 - 30 = Timeout
in minutes
– 31 = Timeout after
10 seconds
LEDs 78-80 are located in keypads 1-3.
No.
Function
003
Delete code
004
Delete code log (deletes
all codes)
3265
010
Automatic timeout
00-31
0000 - 9999
or
00000 - 99999
or
000000 - 999999
Standard set- Procedure
ting
– (LED 79 flashes)
Confirm new code
entry
–
(Set 82)
– (LED 80 flashes)
repeat code entry
–
(Set 82)
– 3265 = delete
– other inputs = do
not delete
00
– 00 = No timeout
– 01 - 30 = Timeout
in minutes
– 31 = Timeout after
10 seconds
LEDs 78-80 are located in keypads 1-3.
Assigning the starting travel program (depending on the truck)
Assigning the starting travel program (depending on the truck)
The travel programs are connected to the code. The travel programs can be individually released or blocked for each code. A starting travel program can be assigned to
each code.
The travel programs are connected to the code. The travel programs can be individually released or blocked for each code. A starting travel program can be assigned to
each code.
Once a user code has been set up, all travel programs are globally released, the valid
start travel program is travel program 2.
The code configuration can then be changed with program number 024.
Once a user code has been set up, all travel programs are globally released, the valid
start travel program is travel program 2.
The code configuration can then be changed with program number 024.
No.
Function
024
Code configuration
Setting range
Standard set- Procedure
ting
1112
No.
Function
024
Code configuration
Setting range
Standard set- Procedure
ting
1112
09.10 EN
1. digit: travel program 1 release (0 = blocked or 1 = released)
2nd digit: travel program 2 release (0 = blocked or 1 = released)
3rd digit: travel program 3 release (0 = blocked or 1 = released)
4th digit: start travel program (0, 1, 2 or 3)
09.10 EN
1. digit: travel program 1 release (0 = blocked or 1 = released)
2nd digit: travel program 2 release (0 = blocked or 1 = released)
3rd digit: travel program 3 release (0 = blocked or 1 = released)
4th digit: start travel program (0, 1, 2 or 3)
70
Setting range
70
Procedure
• Press the O key (81).
• Enter the master code.
• Enter the three-digit parameter number 024.
• Confirm with the SET key (82).
• Enter the code to be changed and confirm with SET.
• Enter the configuration (4 digit) and confirm with SET.
• Enter the configuration (4 digit) again and confirm with SET.
• Repeat the procedure for other codes.
• Then press the O key.
Procedure
• Press the O key (81).
• Enter the master code.
• Enter the three-digit parameter number 024.
• Confirm with the SET key (82).
• Enter the code to be changed and confirm with SET.
• Enter the configuration (4 digit) and confirm with SET.
• Enter the configuration (4 digit) again and confirm with SET.
• Repeat the procedure for other codes.
• Then press the O key.
The travel programs are assigned to the codes
The travel programs are assigned to the codes
Keypad event messages
Keypad event messages
The LED (83) flashes red to indicate the following events:
– New master code is already in use.
– New code is already the master code
– Code to be changed does not exist
– Attempt to change the code to one that already exists.
– Attempt to delete a code that does not exist
– Code memory full.
The LED (83) flashes red to indicate the following events:
– New master code is already in use.
– New code is already the master code
– Code to be changed does not exist
– Attempt to change the code to one that already exists.
– Attempt to delete a code that does not exist
– Code memory full.
09.10 EN
Setting the travel program configuration to a code
09.10 EN
Setting the travel program configuration to a code
71
71
72
72
09.10 EN
09.10 EN
F Industrial Truck Maintenance
F Industrial Truck Maintenance
1
1
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.
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
WARNING!
WARNING!
Risk of accidents and damage to components
All modifications to the forklift truck assemblies, in particular the safety mechanisms,
are prohibited. The operating speeds of the truck must not be increased under any
circumstances.
Risk of accidents and damage to components
All modifications to the forklift truck assemblies, in particular the safety mechanisms,
are prohibited. The operating speeds of the truck must not be increased under any
circumstances.
NOTE
NOTE
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the manufacturer for this truck may be installed near the computer, controllers and wire guidance sensors (antennae). These components (computers, controllers, wire guidance
sensors (antennae)) must therefore not be replaced either by similar components
from other trucks of the same series.
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the manufacturer for this truck may be installed near the computer, controllers and wire guidance sensors (antennae). These components (computers, controllers, wire guidance
sensors (antennae)) must therefore not be replaced either by similar components
from other trucks of the same series.
Maintenance Safety Regulations
2
Maintenance Safety Regulations
Maintenance personnel
The truck should only be serviced and repaired by the manufacturer's specialist customer service personnel who have been trained to do this. We therefore recommend
that you enter into a maintenance contract with the manufacturer’s local sales office.
The truck should only be serviced and repaired by the manufacturer's specialist customer service personnel who have been trained to do this. We therefore recommend
that you enter into a maintenance contract with the manufacturer’s local sales office.
09.10 EN
Maintenance personnel
09.10 EN
2
Operational Safety and Environmental Protection
73
73
Lifting and jacking up
Lifting and jacking up
WARNING!
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take appropriate measures to prevent it from slipping or tipping over (e.g. wedges, wooden
blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose, see "Transport and Commissioning" on page 25.
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take appropriate measures to prevent it from slipping or tipping over (e.g. wedges, wooden
blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose, see "Transport and Commissioning" on page 25.
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
Cleaning
Cleaning
CAUTION!
CAUTION!
Fire hazard
Do not use flammable liquids to clean the industrial truck.
XAlways disconnect the battery before starting cleaning work.
XCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
Fire hazard
Do not use flammable liquids to clean the industrial truck.
XAlways disconnect the battery before starting cleaning work.
XCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
CAUTION!
CAUTION!
Risk of electrical system damage
The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
Risk of electrical system damage
The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
CAUTION!
CAUTION!
74
After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” (see "Restoring the truck to service after maintenance and repairs" on page 90).
Z
09.10 EN
Z
Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water.
74
After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” (see "Restoring the truck to service after maintenance and repairs" on page 90).
09.10 EN
Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water.
Electrical system
Electrical system
WARNING!
WARNING!
Accident risk
XOnly suitably trained electricians may operate on the truck's electrical system.
XBefore working on the electrical system, take all precautionary measures to avoid
electric shocks.
XAlways disconnect the battery before starting cleaning operations.
Accident risk
XOnly suitably trained electricians may operate on the truck's electrical system.
XBefore working on the electrical system, take all precautionary measures to avoid
electric shocks.
XAlways disconnect the battery before starting cleaning operations.
WARNING!
WARNING!
Electric currents can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before starting maintenance on the electrical system:
XPark the truck securely (see "Parking the truck securely" on page 46).
XPress the Emergency Disconnect.
X Disconnect the battery.
XRemove any rings or metal bracelets etc. before working on electrical components.
Electric currents can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before starting maintenance on the electrical system:
XPark the truck securely (see "Parking the truck securely" on page 46).
XPress the Emergency Disconnect.
X Disconnect the battery.
XRemove any rings or metal bracelets etc. before working on electrical components.
Consumables and used parts
Consumables and used parts
CAUTION!
CAUTION!
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
Welding
Welding
Remove electrical and electronic components from the truck before performing welding operations, to avoid damage.
Remove electrical and electronic components from the truck before performing welding operations, to avoid damage.
Settings
Settings
When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.
When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.
Wheels
Wheels
WARNING!
WARNING!
The use of wheels that do not match the manufacturer's specifications can result in accidents.
The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
XWhen replacing wheels make sure the truck is not skewed.
XAlways replace wheels in pairs, i.e. left and right at the same time.
09.10 EN
09.10 EN
The use of wheels that do not match the manufacturer's specifications can result in accidents.
The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
XWhen replacing wheels make sure the truck is not skewed.
XAlways replace wheels in pairs, i.e. left and right at the same time.
75
75
Z
Z
When replacing wheels fitted at the factory, only use the manufacturer’s original
spare parts. Otherwise the truck's rated performance cannot be ensured.
Hydraulic hoses
Hydraulic hoses
WARNING!
WARNING!
Brittle hydraulic hose lines can cause accidents
The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations.
XComply with the safety regulations for hydraulic hose lines in accordance with BGR
237.
Brittle hydraulic hose lines can cause accidents
The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations.
XComply with the safety regulations for hydraulic hose lines in accordance with BGR
237.
WARNING!
WARNING!
Hydraulic line leaks can cause accidents
Hydraulic oil can escape from leaky and faulty hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with regulations.
Hydraulic line leaks can cause accidents
Hydraulic oil can escape from leaky and faulty hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with regulations.
WARNING!
WARNING!
09.10 EN
Hairline cracks in the hydraulic lines can cause injury and infection
Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury.
XCall for a doctor immediately if you are injured.
XDo not touch pressurised hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with regulations.
09.10 EN
Hairline cracks in the hydraulic lines can cause injury and infection
Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury.
XCall for a doctor immediately if you are injured.
XDo not touch pressurised hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with regulations.
76
When replacing wheels fitted at the factory, only use the manufacturer’s original
spare parts. Otherwise the truck's rated performance cannot be ensured.
76
3
Servicing and Inspection
3
Servicing and Inspection
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 truck
failure and poses a potential hazard to personnel and equipment.
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 truck
failure and poses a potential hazard to personnel and equipment.
WARNING!
Z
WARNING!
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an application analysis on site to work out specific service intervals to prevent damage due to
wear.
The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an application analysis on site to work out specific service intervals to prevent damage due to
wear.
The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. Maintenance intervals are defined as:
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. Maintenance intervals are defined as:
W
A
B
= Every 50 service hours, at least weekly
= Every 500 service hours
= Every 1000 service hours, or at least annually
W
A
B
= Every 50 service hours, at least weekly
= Every 500 service hours
= Every 1000 service hours, or at least annually
C
= Every 2000 service hours, or at least annually
C
= Every 2000 service hours, or at least annually
Z
W maintenance interval operations are performed by the proprietor.
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary.
09.10 EN
09.10 EN
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary.
W maintenance interval operations are performed by the proprietor.
77
77
4
Maintenance Intervals
Standard = t
Brakes
1.1 Test the brakes and adjust if necessary.
1.2 Check magnetic brake air gap, adjust if necessary.
Maintenance Intervals
Standard = t
Electrical System
Test warning and safety devices in accordance with operating
2.1
instructions.
2.2 Test cable and motor attachments.
2.3 Test instruments, displays and control switches.
2.4 Check micro switch setting.
2.5 Test the Emergency Disconnect button.
2.6 Check contactors and relays.
2.7 Check fuse ratings.
2.8 Carry out a frame leakage test.
2.9 Check carbon brush wear, replace if necessary.
2.10 Make sure wire connections are secure and check for damage.
Maintenance Intervals
Standard = t
Power supply
3.1 Visually inspect battery and battery components.
Check battery cable connections are secure, grease terminals if nec3.2
essary.
3.3 Check acid density, acid level and battery voltage.
Check the battery connector for damage, test it and make sure it is
3.4
secure.
Maintenance Intervals
Standard = t
Travel
4.1 Test the deadman switch.
4.2 Check the transmission for noise and leakage.
4.3 Replace gear oil if service life exceeded (10,000 hours).
4.4 Check wheel suspension and attachment.
4.5 Check wheels for wear and damage.
78
Maintenance Intervals
Standard = t
W A B C
Brakes
1.1 Test the brakes and adjust if necessary.
1.2 Check magnetic brake air gap, adjust if necessary.
t
t
Maintenance Intervals
Standard = t
W A B C
Electrical System
Test warning and safety devices in accordance with operating
2.1
instructions.
2.2 Test cable and motor attachments.
2.3 Test instruments, displays and control switches.
2.4 Check micro switch setting.
2.5 Test the Emergency Disconnect button.
2.6 Check contactors and relays.
2.7 Check fuse ratings.
2.8 Carry out a frame leakage test.
2.9 Check carbon brush wear, replace if necessary.
2.10 Make sure wire connections are secure and check for damage.
t
t
t
t
t
t
t
t
t
t
Maintenance Intervals
Standard = t
W A B C
Power supply
3.1 Visually inspect battery and battery components.
Check battery cable connections are secure, grease terminals if nec3.2
essary.
3.3 Check acid density, acid level and battery voltage.
Check the battery connector for damage, test it and make sure it is
3.4
secure.
t
t
t
t
Maintenance Intervals
Standard = t
W A B C
t
t
t
t
t
Maintenance checklist
Travel
4.1 Test the deadman switch.
4.2 Check the transmission for noise and leakage.
4.3 Replace gear oil if service life exceeded (10,000 hours).
4.4 Check wheel suspension and attachment.
4.5 Check wheels for wear and damage.
78
W A B C
t
t
W A B C
t
t
t
t
t
t
t
t
t
t
W A B C
t
t
t
t
W A B C
t
t
t
t
t
09.10 EN
Maintenance checklist
09.10 EN
4
Chassis and superstructure
5.1 Check doors and covers.
5.2 Check labels are present and complete.
5.3 Check chassis and screw connections for damage.
5.4 Check operator position mounting bolts.
5.5 Check driver’s seat.
Check overhead guard and / or cab are secure and check for dam5.6
age.
5.7 Check mast attachment / suspension.
5.8 Test adjustable floor plate and make sure it is secure.
Maintenance Intervals
Standard = t
t
t
t
Maintenance Intervals
Standard = t
W A B C
t
t
t
t
t
t
t
t
t
t
t
Maintenance Intervals
Standard = t
W A B C
k
k
t
t
t
t
t
t
t
t
W A B C
Hydraulic operation
Test the "hydraulic function" controls and make sure the labels are
6.1
present and complete.
Check cylinders and piston rods for damage and leaks, and make
6.2
sure they are secure.
Check settings and wear levels of slide pieces and stops, and adjust
6.3
if necessary.
Visually inspect the mast rollers and check contact surface wear
6.4
level.
Check that hose and pipe lines and their connections are secure,
6.5
check for leaks and damage.
6.6 Check load chain setting and tension if necessary.
6.7 Check lateral clearance of mast connections and of load handler.
6.8 Test the hydraulic system.
6.9 Test the emergency lowering.
6.10 Check hydraulic oil level and top up if necessary.
6.11 Replace the hydraulic oil after 2000 service hours / bi-annually.
6.12 Check tie / plunger rods.
t
Agreed performance levels
7.1 Carry out a test run with rated load.
7.2 Demonstration after servicing.
7.3 Lubricate the truck according to the lubrication schedule.
t
t
t
09.10 EN
Agreed performance levels
7.1 Carry out a test run with rated load.
7.2 Demonstration after servicing.
7.3 Lubricate the truck according to the lubrication schedule.
W A B C
Chassis and superstructure
5.1 Check doors and covers.
5.2 Check labels are present and complete.
5.3 Check chassis and screw connections for damage.
5.4 Check operator position mounting bolts.
5.5 Check driver’s seat.
Check overhead guard and / or cab are secure and check for dam5.6
age.
5.7 Check mast attachment / suspension.
5.8 Test adjustable floor plate and make sure it is secure.
t
t
t
t
t
Hydraulic operation
Test the "hydraulic function" controls and make sure the labels are
6.1
present and complete.
Check cylinders and piston rods for damage and leaks, and make
6.2
sure they are secure.
Check settings and wear levels of slide pieces and stops, and adjust
6.3
if necessary.
Visually inspect the mast rollers and check contact surface wear
6.4
level.
Check that hose and pipe lines and their connections are secure,
6.5
check for leaks and damage.
6.6 Check load chain setting and tension if necessary.
6.7 Check lateral clearance of mast connections and of load handler.
6.8 Test the hydraulic system.
6.9 Test the emergency lowering.
6.10 Check hydraulic oil level and top up if necessary.
6.11 Replace the hydraulic oil after 2000 service hours / bi-annually.
6.12 Check tie / plunger rods.
Maintenance Intervals
Standard = t
Maintenance Intervals
Standard = t
W A B C
t
t
t
t
t
t
t
t
t
t
t
t
W A B C
k
k
t
t
t
09.10 EN
Maintenance Intervals
Standard = t
79
79
Steering
8.1 Test the electric steering and its components.
Check the steering head bearings, steering play and steering tooth8.2 ing and/or steering chain. Lubricate the steering toothing and/or
steering chain.
t
t
09.10 EN
Steering
8.1 Test the electric steering and its components.
Check the steering head bearings, steering play and steering tooth8.2 ing and/or steering chain. Lubricate the steering toothing and/or
steering chain.
Maintenance Intervals
Standard = t
W A B C
80
W A B C
t
t
09.10 EN
Maintenance Intervals
Standard = t
80
5
Lubricants and Lubrication Schedule
5
Lubricants and Lubrication Schedule
5.1
Handling consumables safely
5.1
Handling consumables safely
Handling consumables
Handling consumables
Consumables must always be handled correctly. Follow the manufacturer’s instructions.
Consumables must always be handled correctly. Follow the manufacturer’s instructions.
WARNING!
WARNING!
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
CAUTION!
CAUTION!
Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous.
XDispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill oil.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
XObserve national regulations when handling oils.
XWear safety gloves when handling oils.
XPrevent oil from coming into contact with hot motor parts.
XDo not smoke when handling oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a doctor immediately.
XReplace oil-soaked clothing and shoes immediately.
81
09.10 EN
09.10 EN
WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous.
XDispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.
XDo not spill oil.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
XObserve national regulations when handling oils.
XWear safety gloves when handling oils.
XPrevent oil from coming into contact with hot motor parts.
XDo not smoke when handling oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a doctor immediately.
XReplace oil-soaked clothing and shoes immediately.
81
Consumables and used parts
Consumables and used parts
CAUTION!
CAUTION!
82
09.10 EN
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
09.10 EN
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
82
5.2
Lubrication Schedule
5.2
E
Lubrication Schedule
F
E
G
E
G
F
E
F
E
F
E
F
E
F
E
F
E
F
G
E
F
G
G
G
B
A
A+C
3l
B+C
0,7l
1)
B
1)
A
a
g Contact surfaces
s
F
Grease nipple
A+C
3l
B+C
0,7l
1)
1)
a
g Contact surfaces
Cold Store Application
b Transmission oil filler neck
s
Hydraulic oil filler neck
Grease nipple
Cold Store Application
b Transmission oil filler neck
Hydraulic oil filler neck
2 Transmission oil is a guideline. The spur wheel should be dipped approx. 2mm in
the oil.
09.10 EN
1 Compound ratio for cold store usage 1:1
2 Transmission oil is a guideline. The spur wheel should be dipped approx. 2mm in
the oil.
09.10 EN
1 Compound ratio for cold store usage 1:1
83
83
Consumables
Code Order no.
5.3
A
50 449 669
Package
quantity
5.0 l
B
50 380 904
5.0 l
C
29 200 810
5.0 l
D
E
F
G
29 200 150
29 201 430
29 200 100
29 201 280
1.0 l
1.0 kg
1.0 kg
0.4 l
Model
Used for
H-LPD 46, DIN
51524
Fuchs Titan Cytrac
HSY 75W-90 *)
H-LP 10,
DIN 51524
Brake fluid
Grease, DIN 51825
Grease, TTF52
Chain spray
Hydraulic system
A
50 449 669
Package
quantity
5.0 l
Transmission
B
50 380 904
5.0 l
Hydraulic system
C
29 200 810
5.0 l
Brake System
Lubrication
Lubrication
Chains
D
E
F
G
29 200 150
29 201 430
29 200 100
29 201 280
1.0 l
1.0 kg
1.0 kg
0.4 l
Code Order no.
Model
Used for
H-LPD 46, DIN
51524
Fuchs Titan Cytrac
HSY 75W-90 *)
H-LP 10,
DIN 51524
Brake fluid
Grease, DIN 51825
Grease, TTF52
Chain spray
Hydraulic system
*) also for cold store applications
*) also for cold store applications
Grease guidelines
Grease guidelines
Code Saponification Dew point
°C
Worked pen- NLG1 class
etration at
25 °C
Application
temperature
°C
Code Saponification Dew point
°C
Transmission
Hydraulic system
Brake System
Lubrication
Lubrication
Chains
Worked pen- NLG1 class
etration at
25 °C
Application
temperature
°C
E
Lithium
185
265 - 295
2
-35/+120
E
Lithium
185
265 - 295
2
-35/+120
F
--
--
310 - 340
1
-52/+100
F
--
--
310 - 340
1
-52/+100
09.10 EN
84
Consumables
09.10 EN
5.3
84
6
Maintenance and repairs
6
Maintenance and repairs
6.1
Preparing the truck for maintenance and repairs
6.1
Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
Procedure
• Park the truck on a level surface.
• Fully lower the main and auxiliary lift.
• Park the truck securely, see "Parking the truck securely" on page 46.
• Disconnect the battery to prevent the truck from being switched on accidentally.
• When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
Procedure
• Park the truck on a level surface.
• Fully lower the main and auxiliary lift.
• Park the truck securely, see "Parking the truck securely" on page 46.
• Disconnect the battery to prevent the truck from being switched on accidentally.
• When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
WARNING!
WARNING!
Risk of accidents when working under the load handler, driver's cab and lift
truck
XWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.
XWhen raising the truck, follow the instructions, see "Transport and Commissioning"
on page 25. When working on the parking brake, prevent the truck from accidentally rolling away (e.g. with wedges).
09.10 EN
09.10 EN
Risk of accidents when working under the load handler, driver's cab and lift
truck
XWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.
XWhen raising the truck, follow the instructions, see "Transport and Commissioning"
on page 25. When working on the parking brake, prevent the truck from accidentally rolling away (e.g. with wedges).
85
85
Checking the drive wheel bearing and attachment
Requirements
– Prepare the truck for maintenance
and repairs, see "Preparing the truck
for maintenance and repairs" on
page 85.
– Remove the front panel, see "Removing the front panel" on page 87.
89
86
Checking the drive wheel bearing and attachment
Requirements
– Prepare the truck for maintenance
and repairs, see "Preparing the truck
for maintenance and repairs" on
page 85.
– Remove the front panel, see "Removing the front panel" on page 87.
90
Procedure
• Remove the control line connections
13 91
(90) from the operator platform.
• Undo the mounting screws (89) of the
operator platform and remove the operator platform.
• Raise the truck so that the drive
wheel (13) turns freely.
• Manually turn the drive wheel (13)
and make sure there is no noise.
• Put the truck down.
• Turn the tiller to the left as far as it will go.
• Tighten the wheel bolts (91) crosswise with a torque wrench.
1. MA = 10 Nm
2. MA = 150 Nm
• Set the operator platform (11) in position and secure with the mounting screws.
• Restore the control line connections to the operator platform.
Z
09.10 EN
Z
89
6.2
89
89
90
Procedure
• Remove the control line connections
13 91
(90) from the operator platform.
• Undo the mounting screws (89) of the
operator platform and remove the operator platform.
• Raise the truck so that the drive
wheel (13) turns freely.
• Manually turn the drive wheel (13)
and make sure there is no noise.
• Put the truck down.
• Turn the tiller to the left as far as it will go.
• Tighten the wheel bolts (91) crosswise with a torque wrench.
1. MA = 10 Nm
2. MA = 150 Nm
• Set the operator platform (11) in position and secure with the mounting screws.
• Restore the control line connections to the operator platform.
09.10 EN
6.2
86
6.3
Z
Removing the front panel
6.3
Removing the front panel
Disassemble the front panel (trucks with folding operator platform)
Disassemble the front panel (trucks with folding operator platform)
Tools and Material Required
– Allen key (width 8)
Tools and Material Required
– Allen key (width 8)
Procedure
• Fold down the operator platform (11).
• Remove the screws (92) with an Allen key.
• Lift the front panel (93) and remove it from the truck.
Procedure
• Fold down the operator platform (11).
• Remove the screws (92) with an Allen key.
• Lift the front panel (93) and remove it from the truck.
The front panel is now disassembled.
The front panel is now disassembled.
Z
Assembly is the reverse order.
Assembly is the reverse order.
92
92
11
11
09.10 EN
93
09.10 EN
93
87
87
6.4
Checking electrical fuses
6.4
Checking electrical fuses
Checking fuses
Checking fuses
Requirements
– Truck prepared for maintenance and repairs, see "Preparing the truck for maintenance and repairs" on page 85.
– Front panel removed, see "Removing the front panel" on page 87.
Requirements
– Truck prepared for maintenance and repairs, see "Preparing the truck for maintenance and repairs" on page 85.
– Front panel removed, see "Removing the front panel" on page 87.
Procedure
• Check the fuse ratings against the table and replace if necessary.
Procedure
• Check the fuse ratings against the table and replace if necessary.
The fuses are now checked.
The fuses are now checked.
94
94
95
96
96
97
97
To protect
Rating (A)
Battery discharge indicator / battery hour meter
2
Overall fuse
10
Drive motor (parallel to 1F1)
30
Lift motor
150
Drive motor (parallel to 1F10)
300
Item
94
95
96
97
98
88
Model
6F1
F1
1F10
2F1
1F1
98
To protect
Rating (A)
Battery discharge indicator / battery hour meter
2
Overall fuse
10
Drive motor (parallel to 1F1)
30
Lift motor
150
Drive motor (parallel to 1F10)
300
09.10 EN
Model
6F1
F1
1F10
2F1
1F1
98
09.10 EN
Item
94
95
96
97
98
95
88
6.5
Z
Checking the hydraulic oil level
6.5
Checking the hydraulic oil level
Check oil level
Check oil level
Requirements
– Lower the load handler.
– Prepare the truck for maintenance and repairs, see "Preparing the truck for maintenance and repairs" on page 85.
– Open the battery panel, see "Exposing the battery" on page 32.
– Remove the front panel, see "Removing the front panel" on page 87.
Requirements
– Lower the load handler.
– Prepare the truck for maintenance and repairs, see "Preparing the truck for maintenance and repairs" on page 85.
– Open the battery panel, see "Exposing the battery" on page 32.
– Remove the front panel, see "Removing the front panel" on page 87.
Procedure
• Check the oil level in the hydraulic reservoir.
With the load handler lowered the hydraulic oil level in the reservoir should lie between the min. and max. markings.
• If necessary add transmission oil of the correct grade, see "Consumables" on
page 84, (see also table).
Procedure
• Check the oil level in the hydraulic reservoir.
With the load handler lowered the hydraulic oil level in the reservoir should lie between the min. and max. markings.
• If necessary add transmission oil of the correct grade, see "Consumables" on
page 84, (see also table).
Z
09.10 EN
The oil level is now checked.
09.10 EN
The oil level is now checked.
89
89
6.6
Z
Restoring the truck to service after maintenance and repairs
6.6
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 83.
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, see "Charging the battery" on page 33.
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
The manufacturer's customer service department is specially trained to carry out
these operations.
Z
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
90
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 83.
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, see "Charging the battery" on page 33.
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, see "Starting up the truck" on page 43.
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
• Start up the truck, see "Starting up the truck" on page 43.
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
09.10 EN
Z
09.10 EN
Z
Restoring the truck to service after maintenance and repairs
90
Safety tests to be performed at intervals and after unusual
incidents
Z
Safety tests to be performed at intervals and after unusual
incidents
Z
Perform a safety check in accordance with national regulations. Jungheinrich recommends the truck be checked to FEM guideline 4.004. The Jungheinrich safety
department has trained personnel who are able to carry out inspections.
Perform a safety check in accordance with national regulations. Jungheinrich recommends the truck be checked to FEM guideline 4.004. The Jungheinrich safety
department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at
least the next 2 inspections.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at
least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
The owner is responsible for ensuring that faults are rectified immediately.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
09.10 EN
Z
7
A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
09.10 EN
7
91
91
8
Decommissioning the industrial truck
Z
8
Z
If the truck is to be out of service for more than a month, e.g. for commercial reasons, it must be stored in a frost-free and dry room. All necessary measures must
be taken before, during and after decommissioning as described hereafter.
WARNING!
If the truck is to be out of service for more than a month, e.g. for commercial reasons, it must be stored in a frost-free and dry room. All necessary measures must
be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XOnly use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose. see "Identification points and data plates" on
page 21.
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
09.10 EN
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XOnly use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points specially provided for this purpose. see "Identification points and data plates" on
page 21.
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
09.10 EN
92
Decommissioning the industrial truck
92
8.1
Procedure
• Thoroughly clean the truck.
• Test the brakes.
• Check the hydraulic oil level and replenish if necessary, see "Consumables" on
page 84.
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 83.
• Charge the battery, see "Charging the battery" on page 33.
• Disconnect the battery, clean it and grease the terminals.
In addition, follow the battery manufacturer’s instructions.
• Spray all exposed electrical contacts with a suitable contact spray.
09.10 EN
Z
Before taking the truck out of service
Z
Before taking the truck out of service
Procedure
• Thoroughly clean the truck.
• Test the brakes.
• Check the hydraulic oil level and replenish if necessary, see "Consumables" on
page 84.
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 83.
• Charge the battery, see "Charging the battery" on page 33.
• Disconnect the battery, clean it and grease the terminals.
In addition, follow the battery manufacturer’s instructions.
• Spray all exposed electrical contacts with a suitable contact spray.
09.10 EN
8.1
93
93
Action to be taken during decommissioning:
8.2
94
Action to be taken during decommissioning:
Every 2 months:
Procedure
• Charge the battery, see "Charging the battery" on page 33.
Procedure
• Charge the battery, see "Charging the battery" on page 33.
CAUTION!
Risk of battery damage
It is important to charge the battery regularly as otherwise automatic discharge will
result in battery depletion. The ensuing sulphating will damage the battery.
CAUTION!
Risk of battery damage
It is important to charge the battery regularly as otherwise automatic discharge will
result in battery depletion. The ensuing sulphating will damage the battery.
09.10 EN
Every 2 months:
09.10 EN
8.2
94
8.3
Z
Restoring the truck to service after decommissioning
8.3
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 83.
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, see "Charging the battery" on page 33.
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
The manufacturer's customer service department is specially trained to carry out
these operations.
Z
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 83.
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, see "Charging the battery" on page 33.
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, see "Starting up the truck" on page 43.
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
Z
• Start up the truck, see "Starting up the truck" on page 43.
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
09.10 EN
09.10 EN
Z
Restoring the truck to service after decommissioning
95
95
9
Final de-commissioning, disposal
Z
9
Final de-commissioning, disposal
Z
Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing
the disposal of batteries, fuels and electronic and electrical systems must be observed.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety instructions as specified in the service documentation.
Human vibration measurement
10
Z
Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a service of measuring these human vibrations.
09.10 EN
Z
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety instructions as specified in the service documentation.
96
Human vibration measurement
Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a service of measuring these human vibrations.
09.10 EN
10
Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing
the disposal of batteries, fuels and electronic and electrical systems must be observed.
96
Instructions for use
Instructions for use
Jungheinrich traction battery
Jungheinrich traction battery
Table of contents
Table of contents
1
1
Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB ..........................................2-6
with positive tubular plates type EPzS and EPzB ..........................................2-6
Type plate Jungheinrich traction battery............................................7
Type plate Jungheinrich traction battery............................................7
Instruction for use
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
Aquamatic/BFS III water refilling system ......................................................8-12
Jungheinrich traction battery
2
Jungheinrich traction battery
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS ............................................................................................13-17
Type plate Jungheinrich traction battery............................................17
Type plate Jungheinrich traction battery............................................17
0506.GB
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS ............................................................................................13-17
0506.GB
2
Jungheinrich traction battery
1
1
Jungheinrich traction battery
1
with positive tubular plates type EPzS and EPzB
with positive tubular plates type EPzS and EPzB
Rating Data
Rating Data
1.
2.
3.
4.
Nominal capacity C5:
Nominal voltage:
Discharge current::
Nominal S.G. of electrolyte*
Type EPzS:
Type EPzB:
5. Rated temperature:
6. Nominal electrolyte level:
See type plate
2,0 V x No of cells
C5/5h
1.
2.
3.
4.
Nominal capacity C5:
Nominal voltage:
Discharge current::
Nominal S.G. of electrolyte*
Type EPzS:
Type EPzB:
5. Rated temperature:
6. Nominal electrolyte level:
1,29 kg/l
1,29 kg/l
30° C
up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
See type plate
2,0 V x No of cells
C5/5h
1,29 kg/l
1,29 kg/l
30° C
up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
0506.GB
2
Jungheinrich traction battery
0506.GB
1
2
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes
I and
II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
For batteries in classes
I and
II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
The specified torque loading for the polscrews of the charger cables and connectors
are:
steel
23 ± 1 Nm
M 10
steel
23 ± 1 Nm
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
3
0506.GB
0506.GB
M 10
3
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Watch the temperature!
Watch the temperature!
2.4 Temperature
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
4
0506.GB
Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
0506.GB
Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
4
3.1 Daily
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and recorded.
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and recorded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
0506.GB
3. Maintenance
0506.GB
3. Maintenance
5
5
5. Storage
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
6. Malfunctions
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
6
0506.GB
We reserve the right make technical modification.
0506.GB
We reserve the right make technical modification.
6
7. Type plate, Jungheinrich traction battery
2/3
4
10
12
7
8
1
2
Typ
Type
6
5
11
13
Baujahr
Year of manufacture
Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
2/3
4
10
12
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
7
1
Pb
9
Item
1
2
3
4
5
6
7
7. Type plate, Jungheinrich traction battery
8
2
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
Item
1
2
3
4
5
6
7
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
1
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
14
Item
8
9
10
11
12
13
14
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
6
5
11
13
Baujahr
Year of manufacture
3
9
14
Item
8
9
10
11
12
13
14
1
Typ
Type
Serien-Nr.
Serial-Nr.
7
7
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
Aquamatic plug arrangement for the Operating Instructions
Cell series*
EPzS
EPzB
2/120 – 10/ 600
2/ 42 – 12/ 252
2/160 – 10/ 800
2/ 64 – 12/ 384
–
2/ 84 – 12/ 504
–
2/110 – 12/ 660
–
2/130 – 12/ 780
–
2/150 – 12/ 900
–
2/172 – 12/1032
–
2/200 – 12/1200
–
2/216 – 12/1296
2/180 – 10/900
–
2/210 – 10/1050
–
2/230 – 10/1150
–
2/250 – 10/1250
–
2/280 – 10/1400
–
2/310 – 10/1550
–
Aquamatic plug type (length)
Frötek (yellow)
BFS (black)
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
56,0 mm
56,0 mm
56,0 mm
56,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
72,0 mm
66,0 mm
72,0 mm
66,0 mm
Cell series*
EPzS
EPzB
2/120 – 10/ 600
2/ 42 – 12/ 252
2/160 – 10/ 800
2/ 64 – 12/ 384
–
2/ 84 – 12/ 504
–
2/110 – 12/ 660
–
2/130 – 12/ 780
–
2/150 – 12/ 900
–
2/172 – 12/1032
–
2/200 – 12/1200
–
2/216 – 12/1296
2/180 – 10/900
–
2/210 – 10/1050
–
2/230 – 10/1150
–
2/250 – 10/1250
–
2/280 – 10/1400
–
2/310 – 10/1550
–
Aquamatic plug BFS III with
diagnostics hole
Aquamatic plug with
diagnostics hole
length
stroke
length
stroke
length
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
stroke
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
length
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
stroke
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
0506.GB
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
0506.GB
8
Aquamatic plug type (length)
Frötek (yellow)
BFS (black)
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
56,0 mm
56,0 mm
56,0 mm
56,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
72,0 mm
66,0 mm
72,0 mm
66,0 mm
8
Equipment for the
water refilling system
Equipment for the
water refilling system
1. Water tank
1. Water tank
2. Level switch
2. Level switch
3. Discharge point with ball
valve
3. Discharge point with ball
valve
4. Discharge point with solenoid valve
4. Discharge point with solenoid valve
5. Charger
6. Sealing coupler
6. Sealing coupler
7. Closing nipple
7. Closing nipple
8. Ion exchange cartridge with
conductance meter and
solenoid valve
8. Ion exchange cartridge with
conductance meter and
solenoid valve
9. Connection for untreated
water
9. Connection for untreated
water
10. Charging lead
10. Charging lead
1. Design
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
3. Function
3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
9
0506.GB
0506.GB
5. Charger
at least 3 m
Diagrammatic view
at least 3 m
Diagrammatic view
9
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of filling.
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of filling.
5.1 Falling water
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
7. Water quality
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
10
0506.GB
4. Filling (manual/automatic)
0506.GB
4. Filling (manual/automatic)
10
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
9. Operating temperature
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
9.1 Diagnostics hole
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
9.2 Float
Different floats are used depending on the cell design and type.
Different floats are used depending on the cell design and type.
9.3 Cleaning
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
10. Accessories
10. Accessories
10.1 Flow indicator
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
10.2 Plug lifter
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
0506.GB
8. Battery hose connections
0506.GB
8. Battery hose connections
11
11
10.2.1 Clamping ring tool
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D
BFS system none
- rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T
T
- permissible temperature range: 0° C to a maximum of 65° C
- permissible temperature range: 0° C to a maximum of 65° C
0506.GB
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
0506.GB
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
12
- rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
12
Jungheinrich traction batterie
2
Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Rating Data
Rating Data
1. Nominal capacity C5:
See type plate
1. Nominal capacity C5:
See type plate
2. Nominal voltage:
2,0 Volt x No of cells
2. Nominal voltage:
2,0 Volt x No of cells
3. Discharge current:
C5/5h
3. Discharge current:
C5/5h
4. Rated temperature:
30° C
4. Rated temperature:
30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire, avoid short circuits!
• Risk of explosion and fire, avoid short circuits!
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
0506.GB
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
0506.GB
2
13
13
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning
1. Commissioning
The battery should be inspected to ensure it is in perfect physical condition.
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
Otherwise battery, vehicle or charger could be destroyed.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors
are:
The specified torque loading for the pole screws of the end cables and connectors
are:
14
steel
23 ± 1 Nm
M 10
steel
23 ± 1 Nm
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
2.1 Discharging
Ventilation openings must not be sealed or covered.
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left discharged.
Discharged batteries must be recharged immediately and must not be left discharged.
This also applies to partially discharged batteries.
This also applies to partially discharged batteries.
2.2 Charging
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or removed.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or removed.
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2. Operation
14
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M 10
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
2.3 Equalising charge
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed chargers.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed chargers.
Watch the temperature!
Watch the temperature!
2.4 Temperature
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating temperature.
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
3. Maintenance
Don’t refill water!
Don’t refill water!
3.1 Daily
3.1 Daily
Charge the battery immediately after every discharge.
Charge the battery immediately after every discharge.
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With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
0506.GB
With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
15
15
16
Visual inspection after recharging for signs of dirt and mechanical damage.
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
• the voltages of the battery
• the voltages of the battery
• the voltages of every cells
• the voltages of every cells
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
3.4 Annually
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
5. Storage
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
To ensure the battery is always ready for use a choice of charging methods can be
made:
To ensure the battery is always ready for use a choice of charging methods can be
made:
1. a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
1. a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
2. float charging at a charging voltage of 2.25 V x the number of cells.
2. float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the battery.
The storage time should be taken into account when considering the life of the battery.
16
0506.GB
3.2 Weekly
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3.2 Weekly
6. Malfunctions
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
We reserve the right make technical modification.
7. Type plate, Jungheinrich traction battery
2/3
4
10
12
7
8
1
2
6
5
11
13
Baujahr
Year of manufacture
Typ
Type
Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
2/3
4
10
12
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
7
1
Pb
9
Item
1
2
3
4
5
6
7
7. Type plate, Jungheinrich traction battery
8
2
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
Item
1
2
3
4
5
6
7
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
1
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
14
Item
8
9
10
11
12
13
14
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
6
5
11
13
Baujahr
Year of manufacture
3
9
14
Item
8
9
10
11
12
13
14
1
Typ
Type
Serien-Nr.
Serial-Nr.
17
17
18
18
0506.GB
0506.GB
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