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Operating instructions G
51040407
11.14 EJE 110
EJE 116
EJE 118
EJE 120
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Foreword Foreword
Notes on the operating instructions Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is 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 provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously. numbered continuously.
The operator manual details different industrial truck models. When operating and The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your servicing the industrial truck, make sure that the particular section applies to your
truck model. truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to 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 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 particular features of the truck should therefore be assumed from the present
operating instructions. operating instructions.
Safety notices and text mark-ups Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following Safety instructions and important explanations are indicated by the following
graphics: graphics:
DANGER! DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death. result in severe irreparable injury and even death.
WARNING! WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death. may result in severe irreparable injury and even death.
CAUTION! CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury. slight to medium injury.
NOTE NOTE
Indicates a material hazard. Failure to comply with this instruction may result in Indicates a material hazard. Failure to comply with this instruction may result in
material damage. material damage.
Z Used before notices and explanations. Z Used before notices and explanations.
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Copyright of these operating instructions remains with JUNGHEINRICH AG. Copyright of these operating instructions remains with JUNGHEINRICH AG.
5 5
Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft
Am Stadtrand 35 Am Stadtrand 35
22047 Hamburg - Germany 22047 Hamburg - Germany
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Table of Contents Table of Contents
A Correct Use and Application ................................................... 9 A Correct Use and Application ................................................... 9
1 General.................................................................................................... 9 1 General.................................................................................................... 9
2 Correct application................................................................................... 9 2 Correct application................................................................................... 9
3 Approved application conditions .............................................................. 9 3 Approved application conditions .............................................................. 9
4 Proprietor responsibilities ........................................................................ 10 4 Proprietor responsibilities ........................................................................ 10
5 Adding attachments and/or accessories.................................................. 10 5 Adding attachments and/or accessories.................................................. 10
D Battery - Servicing, Recharging, Replacement ....................... 27 D Battery - Servicing, Recharging, Replacement ....................... 27
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 27 1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 27
2 Battery types............................................................................................ 29 2 Battery types............................................................................................ 29
3 Exposing the battery................................................................................ 30 3 Exposing the battery................................................................................ 30
4 Charging the battery ................................................................................ 31 4 Charging the battery ................................................................................ 31
4.1 Charging the battery with a stationary charger........................................ 32 4.1 Charging the battery with a stationary charger........................................ 32
4.2 Charging the battery with an on-board charger ....................................... 33 4.2 Charging the battery with an on-board charger ....................................... 33
5 Battery removal and installation .............................................................. 38 5 Battery removal and installation .............................................................. 38
5.1 Changing the battery from the top ........................................................... 39 5.1 Changing the battery from the top ........................................................... 39
5.2 Lateral battery removal............................................................................ 40 5.2 Lateral battery removal............................................................................ 40
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E Operation ................................................................................ 41 E Operation ................................................................................ 41
1 Safety Regulations for the Operation of the Forklift Truck....................... 41 1 Safety Regulations for the Operation of the Forklift Truck....................... 41
2 Displays and Controls.............................................................................. 42 2 Displays and Controls.............................................................................. 42
2.1 Battery discharge indicator ...................................................................... 45 2.1 Battery discharge indicator ...................................................................... 45
3 Starting up the truck ................................................................................ 46 3 Starting up the truck ................................................................................ 46
3.1 Checks and operations to be performed before starting daily operation . 46 3.1 Checks and operations to be performed before starting daily operation . 46
3.2 Preparing the truck for operation ............................................................. 47 3.2 Preparing the truck for operation ............................................................. 47
3.3 Parking the truck securely ....................................................................... 48 3.3 Parking the truck securely ....................................................................... 48
3.4 Battery discharge monitor........................................................................ 48 3.4 Battery discharge monitor........................................................................ 48
4 Industrial Truck Operation ....................................................................... 49 4 Industrial Truck Operation ....................................................................... 49
4.1 Safety regulations for truck operation...................................................... 49 4.1 Safety regulations for truck operation...................................................... 49
4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 51 4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 51
4.3 Lifting, transporting and depositing loads ................................................ 56 4.3 Lifting, transporting and depositing loads ................................................ 56
5 Troubleshooting....................................................................................... 59 5 Troubleshooting....................................................................................... 59
5.1 Truck does not start................................................................................. 59 5.1 Truck does not start................................................................................. 59
5.2 Load cannot be lifted ............................................................................... 59 5.2 Load cannot be lifted ............................................................................... 59
6 Operating the truck without its own drive system .................................... 60 6 Operating the truck without its own drive system .................................... 60
7 Optional equipment ................................................................................. 61 7 Optional equipment ................................................................................. 61
7.1 Emergency operation with service key GF60 .......................................... 61 7.1 Emergency operation with service key GF60 .......................................... 61
7.2 CanCode keypad..................................................................................... 63 7.2 CanCode keypad..................................................................................... 63
7.3 Setting the truck parameters with CanCode............................................ 68 7.3 Setting the truck parameters with CanCode............................................ 68
7.4 Parameters .............................................................................................. 70 7.4 Parameters .............................................................................................. 70
7.5 CANDIS display instrument ..................................................................... 72 7.5 CANDIS display instrument ..................................................................... 72
7.6 ISM access module (o)........................................................................... 73 7.6 ISM access module (o)........................................................................... 73
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9 Final de-commissioning, disposal............................................................ 95 9 Final de-commissioning, disposal............................................................ 95
8 8
Appendix Appendix
0506.GB
1 1
2
0506.GB
0506.GB
A Correct Use and Application A Correct Use and Application
1 General 1 General
The industrial truck described in the present operating instructions is designed for The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units. lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions. 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 Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property. personnel, the industrial truck or property.
NOTE NOTE
The maximum load and load distance are indicated on the load chart and must not be The maximum load and load distance are indicated on the load chart and must not be
exceeded. exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer. manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks. The load must rest on the back of the fork carriage and centrally between the forks.
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4 Proprietor responsibilities 4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as 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 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 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 the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties. 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 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 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 parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions. 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 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 same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer. parties without the permission of the manufacturer.
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B Truck Description B Truck Description
1 Application 1 Application
The EJE 110 / 116 / 118 / 120 is designed to transport goods on level surfaces. It can The EJE 110 / 116 / 118 / 120 is designed to transport goods on level surfaces. It can
lift open bottom or diagonal board pallets as well as roll cages beyond the area of the lift open bottom or diagonal board pallets as well as roll cages beyond the area of the
load wheels. The capacity is shown on the capacity plate, Qmax. load wheels. The capacity is shown on the capacity plate, Qmax.
1.1 Truck models and rated capacity 1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from The rated capacity depends on the model. The rated capacity can be derived from
the model description. the model description.
EJE110 EJE110
EJE Model name EJE Model name
1 Series 1 Series
10 Rated capacity x 100 kg 10 Rated capacity x 100 kg
The rated capacity does not generally match the permissible capacity. The capacity The rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack. can be found on the load chart attached to the rack.
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2 Assemblies and Functional Description 2 Assemblies and Functional Description
2.1 Assembly Overview 2.1 Assembly Overview
1 2 1 2
3 3
4 5 4 5
6 7 6 7
8 8
9 9
10 10
11 11
12 12
13 14 13 13 14 13
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t = Standard equipment o = Optional equipment t = Standard equipment o = Optional equipment
12 12
2.2 Functional Description 2.2 Functional Description
Safety Mechanisms Safety Mechanisms
– An enclosed, smooth truck geometry with rounded edges ensures safe handling of – An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck. the truck.
– The wheels are surrounded by a solid skirt. – The wheels are surrounded by a solid skirt.
– Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions – Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations. in hazardous situations.
Emergency Stop safety feature Emergency Stop safety feature
– The emergency stop is activated by the traction controller. – The emergency stop is activated by the traction controller.
– Each time the truck is switched on the system performed an automatic diagnosis. – 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. – All travel and lift operations can be performed sensitively without having to reach.
Hydraulic system Hydraulic system
– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil – When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder. from the oil reservoir to the lift cylinder.
– When the lift button is pressed the wheel arms are raised at an even speed; when – When the lift button is pressed the wheel arms are raised at an even speed; when
the lower button is pressed the wheel arms are lowered. the lower button is pressed the wheel arms are lowered.
Drive system Drive system
– A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox. – 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 – The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking with hence smooth travel, powerful acceleration and electrically controlled braking with
energy regeneration. energy regeneration.
– The driver can choose from 3 travel programs, depending on the load and the – The driver can choose from 3 travel programs, depending on the load and the
environment. from maximum performance to energy saving. environment. from maximum performance to energy saving.
Steering Steering
– The driver steers with an ergonomic control handle. – The driver steers with an ergonomic control handle.
– The drive system can be pivoted +/- 90°. – The drive system can be pivoted +/- 90°.
Electrical system Electrical system
– 24 volt system. – 24 volt system.
– Electronic traction control is standard. – Electronic traction control is standard.
Controls and Displays Controls and Displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of the – Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel operations. travel operations.
– The battery discharge indicator shows the available battery capacity. – The battery discharge indicator shows the available battery capacity.
– The optional CanDis displays show the key driver information and travel program, – The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and event messages. service hours, battery capacity and event messages.
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3 Technical Specifications 3 Technical Specifications
Z Technical data specified in accordance with VDI 2198. Z Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved. Technical modifications and additions reserved.
Description EJE 110 EJE 116 EJE 118 EJE 120 Description EJE 110 EJE 116 EJE 118 EJE 120
Q Rated capacity 1000 1600 1800 2000 kg Q Rated capacity 1000 1600 1800 2000 kg
C Load centre distance for C Load centre distance for
600 600 600 600 mm 600 600 600 600 mm
standard fork length *) standard fork length *)
Travel speed Travel speed
5,0 / 5,0 6,0 / 6,0 6,0 / 6,0 6,0 / 6,0 km/h 5,0 / 5,0 6,0 / 6,0 6,0 / 6,0 6,0 / 6,0 km/h
with / without rated load with / without rated load
Lift speed Lift speed
0,04/0,05 0,04/0,05 0,04/0,05 0,04/0,05 m/s 0,04/0,05 0,04/0,05 0,04/0,05 0,04/0,05 m/s
with / without rated load with / without rated load
Lowering speed Lowering speed
0,05/0,04 0,05/0,04 0,05/0,04 0,05/0,04 m/s 0,05/0,04 0,05/0,04 0,05/0,04 0,05/0,04 m/s
with / without rated load with / without rated load
Max. gradeability (5 min Max. gradeability (5 min
rating) 10 / 20 10 / 20 9 / 20 8 / 20 % rating) 10 / 20 10 / 20 9 / 20 8 / 20 %
with / without rated load with / without rated load
*) For longer fork lengths the load centre of gravity is in the centre of the forks *) For longer fork lengths the load centre of gravity is in the centre of the forks
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3.2 Dimensions 3.2 Dimensions
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Description EJE 110 / 116 Description EJE 110 / 116
/ 118 / 120 / 118 / 120
Short Short
version version
h3 Lift 122 mm h3 Lift 122 mm
h13 Load handler lowered 85 mm h13 Load handler lowered 85 mm
h14 Tiller height in min./max. travel position 797 / 1313 mm h14 Tiller height in min./max. travel position 797 / 1313 mm
Y* Wheel base (short / long) 1255 / 1326 mm Y* Wheel base (short / long) 1255 / 1326 mm
l1 Overall length (short / long) 1644 / 1715 mm l1 Overall length (short / long) 1644 / 1715 mm
l2 Length including fork shank (short, long) 494 / 565 mm l2 Length including fork shank (short, long) 494 / 565 mm
l Standard fork length 1150 mm l Standard fork length 1150 mm
b1 Truck width 720 mm b1 Truck width 720 mm
b5 Outside straddle 540 mm b5 Outside straddle 540 mm
b10 Track width, front 508 mm b10 Track width, front 508 mm
b11 Track width, rear 368 mm b11 Track width, rear 368 mm
e Fork width 172 mm e Fork width 172 mm
s Fork thickness 55 mm s Fork thickness 55 mm
m2 Ground clearance centre wheelbase 30 mm m2 Ground clearance centre wheelbase 30 mm
x Load distance 911 mm x Load distance 911 mm
Wa* Turning radius 1440 / 1511 mm Wa* Turning radius 1440 / 1511 mm
Ast* Aisle width, pallet 800x1200 longitudinal (short/long) 1929**/2000** mm Ast* Aisle width, pallet 800x1200 longitudinal (short/long) 1929**/2000** mm
Ast* Aisle width, pallet 1000x1200 longitudinal (short/long) 1879 / 1950 mm Ast* Aisle width, pallet 1000x1200 longitudinal (short/long) 1879 / 1950 mm
a Safety distance 200 mm a Safety distance 200 mm
* Load section raised / lowered +53 mm * Load section raised / lowered +53 mm
** Diagonal in accordance with VDI +204 mm ** Diagonal in accordance with VDI +204 mm
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3.3 Weights 3.3 Weights
Description EJE 110 EJE 116 EJE 118 EJE 120 Description EJE 110 EJE 116 EJE 118 EJE 120
Net weight; s / m 439 / 508 439 / 508 441 / 510 445 / 514 kg Net weight; s / m 439 / 508 439 / 508 441 / 510 445 / 514 kg
Axle load with load Axle load with load
737 / 1302 737 / 1302 787 / 1454 836 / 1609 kg 737 / 1302 737 / 1302 787 / 1454 836 / 1609 kg
front / rear front / rear
Axle load without load Axle load without load
346 / 93 346 / 93 347 / 94 351 / 94 kg 346 / 93 346 / 93 347 / 94 351 / 94 kg
front / rear front / rear
Description EJE 110 EJE 116 EJE 118 EJE 120 Description EJE 110 EJE 116 EJE 118 EJE 120
Tyre size, front 230 x 65 230 x 70 230 x 70 230 x 70 mm Tyre size, front 230 x 65 230 x 70 230 x 70 230 x 70 mm
Tyre size, rear; single / ø85x110 / ø85x110 / ø85x110 / Tyre size, rear; single / ø85x110 / ø85x110 / ø85x110 /
mm mm
tandem ø85x85 ø85x85 ø85x85 tandem ø85x85 ø85x85 ø85x85
Additional wheels Additional wheels
ø100x40 ø100x40 ø100x40 ø100x40 mm ø100x40 ø100x40 ø100x40 ø100x40 mm
(dimensions) (dimensions)
Wheels, number front / Wheels, number front /
1x +2 /2 or 4 1x +2 /2 or 4
rear (x = driven) rear (x = driven)
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3.5 EN norms 3.5 EN norms
Noise emission level Noise emission level
– EJE 110 / 116 / 118 / 120: 70 dB(A) – EJE 110 / 116 / 118 / 120: 70 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871. in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and 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 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. level is measured at the level of the driver's ear.
Z No changes to electric or electronic components or their arrangement may be Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer. made without the written agreement of the manufacturer.
WARNING! WARNING!
Medical equipment can be damaged by non-ionised radiation Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the medical equipment etc.) and result in malfunctions. Consult with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck. manufacturer to clarify whether it can be used near the industrial truck.
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3.6 Conditions of use 3.6 Conditions of use
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 Z Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations. used in conditions of extreme temperature or air humidity fluctuations.
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4 Identification points and data plates 4 Identification points and data plates
15 16 15 16
17 17
18 18
19 19
20 20
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20 Model description 20 Model description
20 20
4.1 Data plate 4.1 Data plate
21 22 23 24 25 26 27 21 22 23 24 25 26 27
28 28
29 29
30 30
31 31
32 32
Z For queries regarding the truck or ordering spare parts always quote the truck serial Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (22). number (22).
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22
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22
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C Transport and Commissioning C Transport and Commissioning
1 Lifting by crane 1 Lifting by crane
WARNING! WARNING!
Improper lifting by crane can result in accidents Improper lifting by crane can result in accidents
The use of unsuitable lifting gear can cause the truck to crash when being lifted by The use of unsuitable lifting gear can cause the truck to crash when being lifted by
crane. crane.
Prevent the truck from striking other objects when it is being raised, and avoid any 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. involuntary movements. If necessary secure the truck with guide ropes.
The truck should only be handled by people who are trained in using lifting slings The truck should only be handled by people who are trained in using lifting slings
and tools. and tools.
Wear safety shoes when lifting the truck by crane. Wear safety shoes when lifting the truck by crane.
Do not stand under a swaying load. Do not stand under a swaying load.
Do not walk into or stand in a hazardous area. Do not walk into or stand in a hazardous area.
Always use lifting gear with sufficient capacity (for truck weight see truck data Always use lifting gear with sufficient capacity (for truck weight see truck data
plate). plate).
Always attach the crane slings to the prescribed strap points and prevent them from Always attach the crane slings to the prescribed strap points and prevent them from
slipping. slipping.
Use the lifting gear only in the prescribed load direction. Use the lifting gear only in the prescribed load direction.
Crane slings should be fastened in such a way that they do not come into contact Crane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting. with any attachments when lifting.
Z Strap points (18) on the chassis are provided for transporting the truck with crane Z Strap points (18) on the chassis are provided for transporting the truck with crane
lifting gear. lifting gear.
Requirements Requirements
– Park the truck securely, (see "Parking the truck – Park the truck securely, (see "Parking the truck
securely" on page 48). securely" on page 48).
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2 Transport 2 Transport
WARNING! WARNING!
33 33
33 33
Securing the truck for transport Securing the truck for transport
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3 Using the Truck for the First Time 3 Using the Truck for the First Time
CAUTION! CAUTION!
Only operate the truck with battery current. Rectified AC current will damage the 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 electronic components. Cable connections to the battery (tow leads) must be less
than 6 m long and have a minimum cross-section of 50 mm². than 6 m long and have a minimum cross-section of 50 mm².
NOTE NOTE
Do not lift loads if the truck is operated via a tow lead with an external battery. Do not lift loads if the truck is operated via a tow lead with an external battery.
Procedure Procedure
• Check the equipment is complete. • Check the equipment is complete.
• Install battery (where required), (see "Battery removal and installation" on • Install battery (where required), (see "Battery removal and installation" on
page 38), do not damage battery cable. page 38), do not damage battery cable.
• Charge the battery, (see "Charging the battery" on page 31). • Charge the battery, (see "Charging the battery" on page 31).
• The truck settings must match the battery model (if the customer is charging the • The truck settings must match the battery model (if the customer is charging the
battery). battery).
The truck can now be started, (see "Starting up the truck" on page 46). The truck can now be started, (see "Starting up the truck" on page 46).
Z When the truck is parked the surface of the tyres will flatten. The flattening will Z When the truck is parked the surface of the tyres will flatten. The flattening will
disappear after a short period of operation. disappear after a short period of operation.
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26
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D Battery - Servicing, Recharging, D Battery - Servicing, Recharging,
Replacement Replacement
1 Safety Regulations Governing the Handling of Lead-Acid 1 Safety Regulations Governing the Handling of Lead-Acid
Batteries Batteries
Maintenance personnel Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This Batteries may only be charged, serviced or replaced by trained personnel. This
operator manual and the manufacturer’s instructions concerning batteries and operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work. 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 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 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 lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand. ventilated. Fire protection equipment must be on hand.
CAUTION! CAUTION!
Before closing the battery panel make sure that the battery cable cannot be Before closing the battery panel make sure that the battery cable cannot be
damaged. There is a risk of short circuits with damaged cables. damaged. There is a risk of short circuits with damaged cables.
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WARNING! WARNING!
Batteries can be hazardous Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Above all avoid Batteries contain an acid solution which is poisonous and corrosive. Above all avoid
any contact with battery acid. any contact with battery acid.
Dispose of used battery acid in accordance with regulations. Dispose of used battery acid in accordance with regulations.
Always wear protective clothing and goggles when working with batteries. Always wear protective clothing and goggles when working with batteries.
Do not let battery acid come into contact with skin, clothing or eyes. If necessary, Do not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water. rinse with plenty of clean water.
Call for a doctor immediately in the event of physical damage (e.g. skin or eye Call for a doctor immediately in the event of physical damage (e.g. skin or eye
contact with battery acid). contact with battery acid).
Neutralise any spilled battery acid immediately with plenty of water. Neutralise any spilled battery acid immediately with plenty of water.
Only batteries with a sealed battery container may be used. Only batteries with a sealed battery container may be used.
Follow national guidelines and legislation. Follow national guidelines and legislation.
WARNING! WARNING!
Using unsuitable batteries can cause accidents Using unsuitable batteries can cause accidents
The weight and dimensions of the battery have a considerable effect on the 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 operational safety and capacity of the industrial truck. Changing the battery features
requires the manufacturer’s approval, as compensating weights are required if requires the manufacturer’s approval, as compensating weights are required if
smaller batteries are fitted. When replacing/installing the battery make sure the smaller batteries are fitted. When replacing/installing the battery make sure the
battery is securely located in the battery compartment of the truck. 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 Park the truck securely before carrying out any work on the batteries ((see "Parking
the truck securely" on page 48)). the truck securely" on page 48)).
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2 Battery types 2 Battery types
Depending on the model, the truck will be supplied with different battery types. The Depending on the model, the truck will be supplied with different battery types. The
following table shows which combinations are included as standard: following table shows which combinations are included as standard:
The battery weights can be taken from the battery data plate. Batteries with non 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. insulated terminals must be covered with a non slip insulating mat.
Z The abbreviations “S” (short version) and “L” (long version) on the data plate Z The abbreviations “S” (short version) and “L” (long version) on the data plate
indicate the actual version of the truck. indicate the actual version of the truck.
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3 Exposing the battery 3 Exposing the battery
CAUTION! CAUTION!
WARNING! WARNING!
An unsecured truck can cause accidents An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load handler is dangerous and is Parking the truck on an incline or with a raised load handler is dangerous and is
strictly prohibited. strictly prohibited.
Always park the truck on a level surface. In special cases the truck may need to be Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges. secured with wedges.
Always fully lower the mast and forks. Always fully lower the mast and forks.
Select a place to park where no other people are at risk of injury from lowering Select a place to park where no other people are at risk of injury from lowering
forks. forks.
Requirements Requirements
– Park the truck on a level surface. – Park the truck on a level surface.
– Park the truck securely, (see "Parking the truck securely" on page 48). – Park the truck securely, (see "Parking the truck securely" on page 48).
Procedure Procedure
• Open the battery panel (5). • Open the battery panel (5).
• Where necessary remove the insulating mat from the battery. • Where necessary remove the insulating mat from the battery.
The battery is now exposed. The battery is now exposed.
5 5
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4 Charging the battery 4 Charging the battery
WARNING! WARNING!
The gases produced during charging can cause explosions The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during 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 charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited. must not be ignited.
Switch the charging station and truck off first before connecting/disconnecting the Switch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector. charging cable of the battery charging station to/from the battery connector.
The charger must be adapted to the battery in terms of voltage and charge The charger must be adapted to the battery in terms of voltage and charge
capacity. capacity.
Before charging, check all cables and plug connections for visible signs of damage. Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged. Ventilate the room in which the truck is being charged.
The battery cover must be open and the battery cell surfaces must be exposed The battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation. during charging to ensure adequate ventilation.
Do not smoke and avoid naked flames when handling batteries. Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there shall be no inflammable 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. material or lubricants capable of creating sparks within 2 m around the truck.
Fire protection equipment must be on hand. Fire protection equipment must be on hand.
Do not lay any metallic objects on battery. Do not lay any metallic objects on battery.
It is essential to follow the safety regulations of the battery and charger station It is essential to follow the safety regulations of the battery and charger station
manufacturers. manufacturers.
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4.1 Charging the battery with a stationary charger 4.1 Charging the battery with a stationary charger
34 34
35 35
Requirements Requirements
– Expose the battery, (see "Exposing the battery" on page 30). – Expose the battery, (see "Exposing the battery" on page 30).
Procedure Procedure
• Disconnect the battery connector (34) from the truck connector. • Disconnect the battery connector (34) from the truck connector.
• Connect the battery connector (34) to the charging cable (35) of the stationary • Connect the battery connector (34) to the charging cable (35) of the stationary
charger. charger.
• Start charging in accordance with the charger operating instructions. • Start charging in accordance with the charger operating instructions.
The battery is now charged. The battery is now charged.
Completing the battery charge, restoring the truck to operation Completing the battery charge, restoring the truck to operation
NOTE NOTE
If charging has been interrupted, the full battery capacity will not be available If charging has been interrupted, the full battery capacity will not be available
Requirements Requirements
– Battery charging is complete. – Battery charging is complete.
Procedure Procedure
• Complete charging in accordance with the charger operating instructions. • Complete charging in accordance with the charger operating instructions.
• Disconnect the battery from the charger. • Disconnect the battery from the charger.
• Connect the battery to the truck. • Connect the battery to the truck.
The truck is operational again The truck is operational again
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4.2 Charging the battery with an on-board charger 4.2 Charging the battery with an on-board charger
DANGER! DANGER!
Risk of electric shock and burning Risk of electric shock and burning
Damaged and unsuitable wires can cause electric shocks and can overheat, resulting Damaged and unsuitable wires can cause electric shocks and can overheat, resulting
in fires. in fires.
Only use mains cables with a maximum length of 30 m. Only use mains cables with a maximum length of 30 m.
Local regulations must be observed. Local regulations must be observed.
Fully unreel the cable reel when using it. Fully unreel the cable reel when using it.
Always use original manufacturer’s mains cables. Always use original manufacturer’s mains cables.
Insulation safety, acid and caustic ratings must comply with the manufacturer's Insulation safety, acid and caustic ratings must comply with the manufacturer's
mains cable. mains cable.
NOTE NOTE
Improper use of the on-board charger can cause material damage. Improper use of the on-board charger can cause material damage.
The on-board charger consisting of a battery charger and battery controller must not The on-board charger consisting of a battery charger and battery controller must not
be opened. For faults, contact the manufacturer’s service department. be opened. For faults, contact the manufacturer’s service department.
The charger must only be used for batteries supplied by Jungheinrich or other The charger must only be used for batteries supplied by Jungheinrich or other
approved batteries provided it has been adapted by the manufacturer's service approved batteries provided it has been adapted by the manufacturer's service
department. department.
Batteries must never be swapped from truck to truck. Batteries must never be swapped from truck to truck.
Do not connect the battery to two chargers simultaneously. Do not connect the battery to two chargers simultaneously.
Z The factory setting for trucks without a battery is the 0 position. A battery discharge Z The factory setting for trucks without a battery is the 0 position. A battery discharge
indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached
to the connector (37). to the connector (37).
36 37 36 37
CAUTION! CAUTION!
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Remove the mains connector before setting the respective charging curve. Remove the mains connector before setting the respective charging curve.
33 33
Set the charging characteristic Set the charging characteristic
Requirements Requirements
– Battery connected. – Battery connected.
Procedure Procedure
• Turn the setting switch (36) on the charger right to adapt the charging curve to the • Turn the setting switch (36) on the charger right to adapt the charging curve to the
battery being used. battery being used.
• The validity of the new setting is acknowledged by the flashing of the green LED • The validity of the new setting is acknowledged by the flashing of the green LED
and the setting takes immediate effect. and the setting takes immediate effect.
The charging characteristic is now set. The charging characteristic is now set.
Switch setting / charging curve assignment Switch setting / charging curve assignment
Switch position (36) Selected charging curves (characteristics) Switch position (36) Selected charging curves (characteristics)
0 Truck without battery 0 Truck without battery
Wet cell battery: PzS with 100 - 300 Ah Wet cell battery: PzS with 100 - 300 Ah
1 1
Wet cell battery: PzM with 100 - 180 Ah Wet cell battery: PzM with 100 - 180 Ah
2 Maintenance-free: PzV with 100 - 149 Ah 2 Maintenance-free: PzV with 100 - 149 Ah
3 Maintenance-free: PzV with 150 - 199 Ah 3 Maintenance-free: PzV with 150 - 199 Ah
4 Maintenance-free: PzV with 200 - 300 Ah 4 Maintenance-free: PzV with 200 - 300 Ah
Wet cell battery: PzS with pulse characteristic 200 - Wet cell battery: PzS with pulse characteristic 200 -
400 Ah 400 Ah
5 5
Wet cell battery: PzM with pulse characteristic 180 - Wet cell battery: PzM with pulse characteristic 180 -
400 Ah 400 Ah
6 Jungheinrich 100 - 300 Ah 6 Jungheinrich 100 - 300 Ah
NOTE NOTE
All other switch positions (36) block the charger, and the battery is not charged. All other switch positions (36) block the charger, and the battery is not charged.
For PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond For PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond
180 Ah set characteristic 5. 180 Ah set characteristic 5.
With PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be With PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be
used. Characteristic 5 achieves a faster charge. used. Characteristic 5 achieves a faster charge.
When the battery is connected this allows you to adjust via the charger: If the switch When the battery is connected this allows you to adjust via the charger: If the switch
position is valid the green LED flashes according to the position set; if the switch position is valid the green LED flashes according to the position set; if the switch
position is invalid the red LED flashes. position is invalid the red LED flashes.
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Starting to charge with the onboard charger Starting to charge with the onboard charger
Mains connection Mains connection
Mains voltage: 230 V / 110 V (+10/-15%) Mains voltage: 230 V / 110 V (+10/-15%)
Mains frequency: 50 Hz / 60 Hz Mains frequency: 50 Hz / 60 Hz
The mains cable of the charger (38) is contained in the front panel or the battery The mains cable of the charger (38) is contained in the front panel or the battery
compartment. compartment.
Requirements Requirements
– Park the truck securely, (see "Parking the truck – Park the truck securely, (see "Parking the truck
securely" on page 48). 38 securely" on page 48). 38
– Expose the battery, (see "Exposing the battery" on – Expose the battery, (see "Exposing the battery" on
page 30). page 30).
– Correct charging program set on charger. – Correct charging program set on charger.
Procedure Procedure
• Remove any insulating mats from the battery. • Remove any insulating mats from the battery.
• The battery connector must remain plugged. • The battery connector must remain plugged.
• Attach the mains connector (38) to a mains socket. • Attach the mains connector (38) to a mains socket.
• Pull Emergency Disconnect switch up. • Pull Emergency Disconnect switch up.
The flashing LED indicates the charge status or a fault (for flashing codes see “LED The flashing LED indicates the charge status or a fault (for flashing codes see “LED
Display” table). Display” table).
The battery is now charged. The battery is now charged.
Z When the mains connector (38) is connected to the mains, all the truck’s electrical Z When the mains connector (38) is connected to the mains, all the truck’s electrical
functions are disconnected (electric immobilizer). The truck cannot be operated. functions are disconnected (electric immobilizer). The truck cannot be operated.
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Completing the battery charge, restoring the truck to operation Completing the battery charge, restoring the truck to operation
NOTE NOTE
If charging has been interrupted, the full battery capacity will not be available If charging has been interrupted, the full battery capacity will not be available
Requirements Requirements
– Battery charging is complete. – Battery charging is complete.
Procedure Procedure
• Remove the mains connector (38) from the socket and store it in the battery • Remove the mains connector (38) from the socket and store it in the battery
compartment with the cable. compartment with the cable.
• If applicable, place the existing insulating mats back over the battery. • If applicable, place the existing insulating mats back over the battery.
• Close the battery cover securely. • Close the battery cover securely.
The truck is now ready for operation. The truck is now ready for operation.
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LED display (39) LED display (39)
39 39
Green LED (charge status) Green LED (charge status)
Lit Charging complete, battery full. Lit Charging complete, battery full.
(Charge interval, float or (Charge interval, float or
compensation charge). compensation charge).
Flashes slowly Charging. Flashes slowly Charging.
Rapid flash Display at beginning of charge or Rapid flash Display at beginning of charge or
after setting a new characteristic after setting a new characteristic
curve. Number of flash pulses curve. Number of flash pulses
corresponds to the characteristic corresponds to the characteristic
curve set. curve set.
The compensation charge starts automatically when charging is complete. The compensation charge starts automatically when charging is complete.
The charger is designed to automatically adapt to partially charged batteries. This The charger is designed to automatically adapt to partially charged batteries. This
keeps battery wear to a minimum. keeps battery wear to a minimum.
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5 Battery removal and installation 5 Battery removal and installation
WARNING! WARNING!
Accident risk during battery removal and installation Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the Due to the battery weight and acid there is a risk of trapping or scalding when the
battery is removed and installed. battery is removed and installed.
Note the "Safety regulations for handling acid batteries" section in this chapter. Note the "Safety regulations for handling acid batteries" section in this chapter.
Wear safety shoes when removing and installing the battery. Wear safety shoes when removing and installing the battery.
Use only batteries with insulated cells and terminal connectors. If necessary cover Use only batteries with insulated cells and terminal connectors. If necessary cover
them with a rubber mat. them with a rubber mat.
Park the truck on a level surface. Park the truck on a level surface.
Make sure the crane lifting gear has sufficient capacity to replace the battery. Make sure the crane lifting gear has sufficient capacity to replace the battery.
Use only approved battery replacement devices (battery roller stand, replacement Use only approved battery replacement devices (battery roller stand, replacement
trolley etc.). trolley etc.).
Make sure the battery is securely located in the truck's battery compartment. Make sure the battery is securely located in the truck's battery compartment.
CAUTION! CAUTION!
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5.1 Changing the battery from the top 5.1 Changing the battery from the top
Requirements Requirements
– Park the truck securely, (see "Parking the – Park the truck securely, (see "Parking the
truck securely" on page 48). truck securely" on page 48).
– Expose the battery, (see "Exposing the – Expose the battery, (see "Exposing the
battery" on page 30). battery" on page 30).
Procedure Procedure
• Disconnect the battery connector from the • Disconnect the battery connector from the
truck connector. truck connector.
Z Place the battery cable on the tray so that it Z Place the battery cable on the tray so that it
cannot be severed when the battery is pulled out. cannot be severed when the battery is pulled out.
• Strap the crane lifting gear to the eyes (40). • Strap the crane lifting gear to the eyes (40).
Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must
never fall into the battery cells. never fall into the battery cells.
• Pull the battery up out of the container. • Pull the battery up out of the container.
Z Installation is the reverse order. When reinstalling the battery, note the proper Z Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. Place the installation position and make sure the battery is connected correctly. Place the
battery cable on the tray so that it cannot be severed when the battery is inserted. battery cable on the tray so that it cannot be severed when the battery is inserted.
– After installing the battery, check all cables and plug connections for visible signs – After installing the battery, check all cables and plug connections for visible signs
of damage. of damage.
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5.2 Lateral battery removal 5.2 Lateral battery removal
Z Installation is the reverse order. When reinstalling the battery, note the proper Z Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. Place the installation position and make sure the battery is connected correctly. Place the
battery cable on the tray so that it cannot be severed when the battery is inserted. battery cable on the tray so that it cannot be severed when the battery is inserted.
– After installing the battery, check all cables and plug connections for visible signs – After installing the battery, check all cables and plug connections for visible signs
of damage. of damage.
41 41
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E Operation E Operation
1 Safety Regulations for the Operation of the 1 Safety Regulations for the Operation of the
Forklift Truck Forklift Truck
Driver authorisation Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to 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 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. 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 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 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 shall be afforded all due rights. Safety shoes must be worn for pedestrian operated
trucks. 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 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 prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people. passengers or lift other people.
Repairs Repairs
The driver must not carry out any repairs or alterations to the truck without the 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 necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches. safety mechanisms or switches.
Hazardous area Hazardous area
WARNING! WARNING!
Risk of accidents / injury in the hazardous area of the truck 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 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 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 itself. This also includes areas which can be reached by falling loads or lowering
operating equipment. operating equipment.
Instruct unauthorised people to leave the hazardous area. Instruct unauthorised people to leave the hazardous area.
Give a warning signal with plenty of time for people to leave. Give a warning signal with plenty of time for people to leave.
If unauthorised personnel are still within the hazardous area stop the truck If unauthorised personnel are still within the hazardous area stop the truck
immediately. immediately.
Safety devices and warning labels Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" on Safety devices, warning signs ((see "Identification points and data plates" on
page 20)) and warning instructions in the present operating instructions must be page 20)) and warning instructions in the present operating instructions must be
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2 Displays and Controls 2 Displays and Controls
42 42 42 42
43 43 43 43
2 1 44 2 2 1 44 2
3 3
8 6 8 6
4 4
9, 45 9, 45
10, 46 10, 46
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Ite Control / Display EJE 110 Function Ite Control / Display EJE 110 Function
m EJE 116 m EJE 116
EJE 118 EJE 118
EJE120 EJE120
42 Load handler lower button t Lower the load handler. 42 Load handler lower button t Lower the load handler.
43 Load handler raise button t Raises the load handler. 43 Load handler raise button t Raises the load handler.
2 Travel switch t Controls travel direction and speed. 2 Travel switch t Controls travel direction and speed.
1 Safety collision switch t Collision safety switch function 1 Safety collision switch t Collision safety switch function
which, when activated, forces the which, when activated, forces the
truck to reverse for approx. truck to reverse for approx.
3 seconds and then cuts out until 3 seconds and then cuts out until
the controller is briefly restored to the controller is briefly restored to
neutral. neutral.
44 Warning button t Activates an audible signal 44 Warning button t Activates an audible signal
3 Slow travel button t Pressing the slow travel button 3 Slow travel button t Pressing the slow travel button
reduces the travel speed and reduces the travel speed and
acceleration. If the control handle is acceleration. If the control handle is
set to the brake zone, you can set to the brake zone, you can
press this button to override press this button to override
braking; the truck will travel at slow braking; the truck will travel at slow
speed. speed.
8 On-board charger (with o Charges the battery by inserting the 8 On-board charger (with o Charges the battery by inserting the
safety switch) mains connector into a mains safety switch) mains connector into a mains
socket. socket.
6 Emergency Disconnect t Interrupts the battery connection 6 Emergency Disconnect t Interrupts the battery connection
switch – All electric functions are cut out switch – All electric functions are cut out
and the truck decelerates and the truck decelerates
4 Tiller t Used for steering and braking. 4 Tiller t Used for steering and braking.
9 Charge / discharge indicator t Shows the charge/discharge status 9 Charge / discharge indicator t Shows the charge/discharge status
of the battery. of the battery.
45 CanDis o Display instrument for 45 CanDis o Display instrument for
– Battery charge status – Battery charge status
– Service hours – Service hours
– Warning messages – Warning messages
– Parameter setting – Parameter setting
10 Key switch t – Activates the truck by switching 10 Key switch t – Activates the truck by switching
on the control voltage on the control voltage
– Removing the key prevents the – Removing the key prevents the
truck from being switched on by truck from being switched on by
unauthorised personnel unauthorised personnel
Key switch with second o Brake release to move the truck Key switch with second o Brake release to move the truck
switch level when non-operational. switch level when non-operational.
46 CanCode o Replaces the key switch 46 CanCode o Replaces the key switch
– Activates the truck by entering – Activates the truck by entering
the relevant code the relevant code
– Travel program selection – Travel program selection
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Ite Control / Display EJE 110 Function Ite Control / Display EJE 110 Function
m EJE 116 m EJE 116
EJE 118 EJE 118
EJE120 EJE120
ISM o Replaces the key switch ISM o Replaces the key switch
– Activates the truck via a card / – Activates the truck via a card /
transponder transponder
– Displays readiness for operation – Displays readiness for operation
– Operational data acquisition – Operational data acquisition
– Data exchange with card / – Data exchange with card /
transponder transponder
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2.1 Battery discharge indicator 2.1 Battery discharge indicator
When the truck has been released via the key When the truck has been released via the key
switch, code lock or ISM, the battery charge status 47 switch, code lock or ISM, the battery charge status 47
is displayed. The LED (47) colours represent the is displayed. The LED (47) colours represent the
following conditions: following conditions:
Z If the LED is red, load units can no longer be lifted. Lifting is only enabled again 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. when the battery connected is at least 70% charged.
If the LED flashes red and the truck is not ready for operation, inform the 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 manufacturer's service department. Red flashing is a truck controller code. The
flashing sequence indicates the type of fault. flashing sequence indicates the type of fault.
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3 Starting up the truck 3 Starting up the truck
3.1 Checks and operations to be performed before starting daily 3.1 Checks and operations to be performed before starting daily
operation operation
WARNING! WARNING!
Damage and other truck or attachment (special equipment) defects can result Damage and other truck or attachment (special equipment) defects can result
in accidents. in accidents.
If damage or other truck or attachment (special equipment) defects are discovered 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 during the following checks, the truck must be taken out of service until it has been
repaired. repaired.
Report any defects immediately to your supervisor. Report any defects immediately to your supervisor.
Tag out and decommission a faulty lift truck. Tag out and decommission a faulty lift truck.
Only return the truck to service when you have identified and rectified the fault. Only return the truck to service when you have identified and rectified the fault.
Procedure Procedure
• Check the whole of the outside of the truck for signs of damage and leaks. • Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately. Damaged hoses must be replaced immediately.
• Check the battery attachment and wire connections for damage and make sure • Check the battery attachment and wire connections for damage and make sure
they are secure. they are secure.
• Check the battery connector is secure. • Check the battery connector is secure.
• Check the load handler for visible signs of damage such as cracks, bent or severely • Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks. worn forks.
• Check the drive wheel and load wheels for damage. • Check the drive wheel and load wheels for damage.
• Check that the markings and labels are present, clean and legible, (see • Check that the markings and labels are present, clean and legible, (see
"Identification points and data plates" on page 20). "Identification points and data plates" on page 20).
• Test the Emergency Disconnect switch. • Test the Emergency Disconnect switch.
• Check the control handle (damper) is restored to its normal position. • Check the control handle (damper) is restored to its normal position.
• Check the controls are automatically restored to zero after being applied. • Check the controls are automatically restored to zero after being applied.
• Test the warning signal. • Test the warning signal.
• Test brakes. • Test brakes.
• Test the collision safety switch. • Test the collision safety switch.
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3.2 Preparing the truck for operation 3.2 Preparing the truck for operation
Switching on the truck Switching on the truck
Requirements Requirements
– For checks and operations to be performed before starting daily operation, (see – For checks and operations to be performed before starting daily operation, (see
"Checks and operations to be performed before starting daily operation" on "Checks and operations to be performed before starting daily operation" on
page 46). page 46).
Procedure Procedure
• Pull the Emergency Disconnect (6) to switch it on. • Pull the Emergency Disconnect (6) to switch it on.
• Switch on the truck, to do this • Switch on the truck, to do this
• Insert the key in the key switch (10) and turn it as far right as it will go. • Insert the key in the key switch (10) and turn it as far right as it will go.
• Enter the code in the code lock (o). • Enter the code in the code lock (o).
• Hold the card or transponder in front of the ISM access module and depending • Hold the card or transponder in front of the ISM access module and depending
on the setting press the green button on the ISM access module (o). on the setting press the green button on the ISM access module (o).
• Test the warning signal button (44). • Test the warning signal button (44).
• Test the lifting operation. • Test the lifting operation.
• Test the steering. • Test the steering.
• Test the brake function of the tiller (4). • Test the brake function of the tiller (4).
The truck is now ready for operation. The truck is now ready for operation.
tThe battery discharge indicator (9) shows the current battery charge status. tThe battery discharge indicator (9) shows the current battery charge status.
o The CanDis display instrument (45) indicates the available battery capacity and o The CanDis display instrument (45) indicates the available battery capacity and
the service hours. the service hours.
6 6
4 4
44 44
9, 45 9, 45
10, 46 10, 46
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3.3 Parking the truck securely 3.3 Parking the truck securely
WARNING! WARNING!
An unsecured truck can cause accidents An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load / load Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited. handler is dangerous and is strictly prohibited.
Always park the truck on a level surface. In special cases the truck may need to be Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges. secured with wedges.
Always fully lower the mast and forks. Always fully lower the mast and forks.
Select a place to park where no other people are at risk of injury from lowering Select a place to park where no other people are at risk of injury from lowering
forks. forks.
Procedure Procedure
• Fully lower the load handler. • Fully lower the load handler.
• Turn off the key switch and remove the key. • Turn off the key switch and remove the key.
• For CANCODE, press the O key. • For CANCODE, press the O key.
• For ISM, press the red button. • For ISM, press the red button.
• Press the Emergency Disconnect. • Press the Emergency Disconnect.
The truck is parked. The truck is parked.
If the residual capacity falls below the required level, lifting is inhibited. An alternating If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (47) appears. Lifting is only released when the battery connected is at least display (47) appears. Lifting is only released when the battery connected is at least
70% charged. 70% charged.
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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 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 parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose. specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger 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 to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting. areas of insufficient lighting.
DANGER! DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes. Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist. At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading. during loading / unloading.
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Negotiating lifts and docks Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on 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 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 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 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 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 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 must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading. / unloading.
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4.2 Emergency Disconnect, Travel, Steering, Braking 4.2 Emergency Disconnect, Travel, Steering, Braking
Procedure Procedure
CAUTION! CAUTION!
Accident risk Accident risk
The operation of the Emergency Disconnect switch must not be affected by any The operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way. objects placed in its way.
Z Do not use the Emergency Disconnect (6) as a service brake. Z Do not use the Emergency Disconnect (6) as a service brake.
• Press the Emergency Disconnect (6). • Press the Emergency Disconnect (6).
All electrical functions are deactivated. The truck brakes to a halt. All electrical functions are deactivated. The truck brakes to a halt.
Procedure Procedure
• Pull the Emergency Disconnect (6) to unlock it. • Pull the Emergency Disconnect (6) to unlock it.
All electrical functions are enabled and the truck is operational again (assuming the All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed). truck was not operational before the Emergency Disconnect was pressed).
For CanCode and ISM the truck remains switched off. For CanCode and ISM the truck remains switched off.
WARNING! WARNING!
If the tiller moves slowly or not at all to the upper brake zone, the truck must be If the tiller moves slowly or not at all to the upper brake zone, the truck must be
taken out of service until the cause of this fault is be rectified. Replace the gas taken out of service until the cause of this fault is be rectified. Replace the gas
pressure spring if necessary. pressure spring if necessary.
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4.2.3 Travel 4.2.3 Travel
CAUTION! CAUTION!
Do not drive the truck unless the panels are closed and properly locked. Do not drive the truck unless the panels are closed and properly locked.
When travelling through swing doors etc. make sure that the doors do not activate When travelling through swing doors etc. make sure that the doors do not activate
the collision safety button. the collision safety button.
Requirements Requirements
– Start up the truck, (see "Starting up the truck" on page 46) – Start up the truck, (see "Starting up the truck" on page 46)
Procedure Procedure
• Set the tiller (4) to the travel range (F) and press the travel switch (2) in the desired • Set the tiller (4) to the travel range (F) and press the travel switch (2) in the desired
direction (fwd. or rev.). direction (fwd. or rev.).
• Control the travel speed with the travel switch (2). • Control the travel speed with the travel switch (2).
Z When the travel switch is release it automatically returns to its original position. Z When the travel switch is release it automatically returns to its original position.
The brakes are released and the truck moves in the selected direction. The brakes are released and the truck moves in the selected direction.
Z Preventing the truck from “rolling downhill”: Z Preventing the truck from “rolling downhill”:
If the truck rolls backwards on an incline the controller detects the situation and the If the truck rolls backwards on an incline the controller detects the situation and the
brake applies automatically after a short jerk. brake applies automatically after a short jerk.
oReduced speed when forks are fully lowered oReduced speed when forks are fully lowered
When the forks are fully lowered the truck will only travel at reduced speed. The forks When the forks are fully lowered the truck will only travel at reduced speed. The forks
must be raised in order to use the maximum available speed. must be raised in order to use the maximum available speed.
R R
2 2
0 0
4 4
V V
3 3
B
6 B
6
R R
F F
B B
V V
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4.2.4 Slow travel 4.2.4 Slow travel
CAUTION! CAUTION!
The driver must be particularly careful when applying the “slow travel speed” The driver must be particularly careful when applying the “slow travel speed”
button (3). button (3).
The brake is only activated when the "slow travel" button is released. The brake is only activated when the "slow travel" button is released.
In hazardous situations brake by immediately releasing the slow travel button (3) In hazardous situations brake by immediately releasing the slow travel button (3)
and the travel switch (2). and the travel switch (2).
In "slow travel" you can only brake by inversion braking (travel switch (2)). In "slow travel" you can only brake by inversion braking (travel switch (2)).
The truck can be operated with a vertical tiller (4) (e.g. in congested areas / travel The truck can be operated with a vertical tiller (4) (e.g. in congested areas / travel
seat). seat).
Procedure Procedure
• Press the slow travel button (3). • Press the slow travel button (3).
• Set the controller (2) to the required direction (fwd. or rev.). • Set the controller (2) to the required direction (fwd. or rev.).
The brake is released. The truck travels at slow speed. The brake is released. The truck travels at slow speed.
Procedure Procedure
• Release the slow travel button (3). • Release the slow travel button (3).
In zone "B" the brake applies and the truck stops. In zone "B" the brake applies and the truck stops.
In zone "F" the truck continues at slow travel. In zone "F" the truck continues at slow travel.
• Release the travel switch (2). • Release the travel switch (2).
Slow travel ends and the truck can now travel again at normal speed. Slow travel ends and the truck can now travel again at normal speed.
R R
2 2
0 0
4 4
V V
3 3
B
6 B
6
R R
F F
B B
V V
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4.2.5 Steering 4.2.5 Steering
Procedure Procedure
• Move the tiller (4) to the left or right. • Move the tiller (4) to the left or right.
The truck is steered in the required direction. The truck is steered in the required direction.
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4.2.6 Brakes 4.2.6 Brakes
The brake pattern of the truck depends largely on the travel route conditions. The The brake pattern of the truck depends largely on the travel route conditions. The
driver must take this into account. driver must take this into account.
The truck can brake in the following ways: The truck can brake in the following ways:
– By inversion braking (travel switch) – By inversion braking (travel switch)
– Using the regenerative brake (coasting) – Using the regenerative brake (coasting)
– Emergency Disconnect switch – Emergency Disconnect switch
– By setting the tiller to the "B" zone. – By setting the tiller to the "B" zone.
CAUTION! CAUTION!
In hazardous situations set the tiller to the brake position or press the Emergency In hazardous situations set the tiller to the brake position or press the Emergency
Disconnect switch. Disconnect switch.
Brakes Brakes
Procedure Procedure
• Move the tiller (4) up or down to one of the brake • Move the tiller (4) up or down to one of the brake
zones (B). zones (B).
Z Initially the truck brakes regeneratively. The Z Initially the truck brakes regeneratively. The
mechanical brake is only applied when this brake mechanical brake is only applied when this brake
2 2 2 2
fails to achieve the necessary braking force. fails to achieve the necessary braking force.
The truck will decelerate at the maximum rate and the The truck will decelerate at the maximum rate and the
brake will apply. brake will apply.
Procedure Procedure
• You can set the travel switch (2) to the opposite direction when travelling. • You can set the travel switch (2) to the opposite direction when travelling.
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.
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Regenerative braking Regenerative braking
Procedure Procedure
• If the travel switch is set to 0, the truck automatically brakes regeneratively. • If the travel switch is set to 0, the truck automatically brakes regeneratively.
The truck brakes to a halt regeneratively via the coasting brake. The brake then The truck brakes to a halt regeneratively via the coasting brake. The brake then
applies. applies.
Z With regenerative braking energy is recuperated to the battery, ensuring a longer Z With regenerative braking energy is recuperated to the battery, ensuring a longer
service time. service time.
4.3 Lifting, transporting and depositing loads 4.3 Lifting, transporting and depositing loads
WARNING! WARNING!
Unsecured and incorrectly positioned loads can cause accidents Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must make sure that it has been correctly palletised Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity. and does not exceed the truck’s capacity.
Instruct other people to move out of the hazardous area of the truck. Stop working Instruct 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. with the truck if people do not leave the hazardous area.
Only carry loads that have been correctly secured and positioned. Use suitable Only carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down. precautions to prevent parts of the load from tipping or falling down.
Damaged loads must not be transported. Damaged loads must not be transported.
Never exceed the maximum loads specified in the capacity chart. Never exceed the maximum loads specified in the capacity chart.
Never stand underneath a raised load handler. Never stand underneath a raised load handler.
Do not stand on the load handler. Do not stand on the load handler.
Do not lift other people on the load handler. Do not lift other people on the load handler.
Insert the forks as far as possible underneath the load. Insert the forks as far as possible underneath the load.
CAUTION! CAUTION!
Do not lift long loads at an angle. Do not lift long loads at an angle.
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Lifting load units Lifting load units
Requirements Requirements
– Load unit correctly palletised. – Load unit correctly palletised.
– Load unit weight matches the truck's – Load unit weight matches the truck's
capacity. capacity.
– Forks evenly loaded for heavy loads. – Forks evenly loaded for heavy loads.
Procedure Procedure
• Drive the truck carefully up to the pallet. 48 49 49 48 • Drive the truck carefully up to the pallet. 48 49 49 48
• Slowly insert the forks into the pallet until the • Slowly insert the forks into the pallet until the
fork shank touches the pallet. fork shank touches the pallet.
Z The load unit must not extend by more than Z The load unit must not extend by more than
50 mm beyond the fork tips. 49 48 48 49 50 mm beyond the fork tips. 49 48 48 49
• Press the “Lift” button (49) button until you • Press the “Lift” button (49) button until you
reach the desired lift height. reach the desired lift height.
The load unit is raised. The load unit is raised.
CAUTION! CAUTION!
Release the button as soon as you reach the limit position of the load handler. Release the button as soon as you reach the limit position of the load handler.
Procedure Procedure
• Accelerate and decelerate gradually. • Accelerate and decelerate gradually.
• Adapt your travel speed to the conditions of the route and the load you are • Adapt your travel speed to the conditions of the route and the load you are
transporting. transporting.
• Travel at a constant speed. • Travel at a constant speed.
• Watch out for other traffic at crossings and passageways. • Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots. • Always travel with a lookout at blind spots.
• On slopes and inclines always carry the load facing uphill, never approach at an • On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn. angle or turn.
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Depositing load units Depositing load units
NOTE NOTE
Loads must not be deposited on travel or escape routes, in front of safety Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times. mechanisms or operating equipment that must be accessible at all times.
Requirements Requirements
– Warehouse location suitable for storing the load. – Warehouse location suitable for storing the load.
Procedure Procedure
• Drive carefully up to the storage location. • Drive carefully up to the storage location.
• Press the “Lower load handler” button (48). • Press the “Lower load handler” button (48).
• Carefully lower the load handler so that the forks are clear of the load. • Carefully lower the load handler so that the forks are clear of the load.
• Carefully remove the forks from the pallet. • Carefully remove the forks from the pallet.
The load unit is lowered. The load unit is lowered.
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5 Troubleshooting 5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of 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 incorrect operation. When trying to locate a fault, proceed in the order shown in the
table. table.
Z If, after carrying out the following remedial action, the truck cannot be restored to 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 operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department. error code, contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially service engineers. The manufacturer's customer service department is specially
trained to carry out these operations. trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the In order for customer services to react quickly and specifically to the fault, the
following information is essential: following information is essential:
- Truck serial number - Truck serial number
- Error number on the display unit (if applicable) - Error number on the display unit (if applicable)
- Error description - Error description
- Current location of truck - Current location of truck
5.1 Truck does not start 5.1 Truck does not start
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6 Operating the truck without its own drive system 6 Operating the truck without its own drive system
WARNING! WARNING!
Procedure Procedure
• Turn of the key switch, CanCode or ISM. • Turn of the key switch, CanCode or ISM.
• Switch off the Emergency Disconnect button. • Switch off the Emergency Disconnect button.
• Prevent the truck from rolling away. • Prevent the truck from rolling away.
• Remove the front panel (11) and right-hand drive panel (50). (see "Industrial Truck • Remove the front panel (11) and right-hand drive panel (50). (see "Industrial Truck
Maintenance" on page 75). Maintenance" on page 75).
• Pull up the anchor plate by screwing in two M5x45 screws (51) as far as the stop. • Pull up the anchor plate by screwing in two M5x45 screws (51) as far as the stop.
The brake is now released and the truck can be moved. The brake is now released and the truck can be moved.
Procedure Procedure
• Unscrew the two M5x45 (51) screws again. • Unscrew the two M5x45 (51) screws again.
• Refit the right hand drive panel (50). • Refit the right hand drive panel (50).
• Refit front panel (11). • Refit front panel (11).
Braking is now restored again. Braking is now restored again.
11 11
50 50
51 51
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7 Optional equipment 7 Optional equipment
7.1 Emergency operation with service key GF60 7.1 Emergency operation with service key GF60
WARNING! WARNING!
The truck can move accidentally when the brake is released The truck can move accidentally when the brake is released
The GF60 service key must not remain on the truck during normal operation. The GF60 service key must not remain on the truck during normal operation.
The service key should only be used by an authorised person (e.g. warehouse The service key should only be used by an authorised person (e.g. warehouse
manager). manager).
Extreme caution is required on a ramp or incline as the truck could roll away when Extreme caution is required on a ramp or incline as the truck could roll away when
the brake is released. the brake is released.
When the key switch is set to position 2 (brake released), the truck cannot brake When the key switch is set to position 2 (brake released), the truck cannot brake
through inversion braking or the tiller switch. through inversion braking or the tiller switch.
GF 60 GF 60
Operating the truck without its own drive system. Operating the truck without its own drive system.
Requirements Requirements
– Truck prevented from rolling away. – Truck prevented from rolling away.
– Charged battery in truck. – Charged battery in truck.
Procedure Procedure
• Insert the GF60 service key in the key switch. • Insert the GF60 service key in the key switch.
Z The service key GF60 with a lock bar can only be inserted and turned on one side. Z The service key GF60 with a lock bar can only be inserted and turned on one side.
If inserted in the wrong direction the key will not turn. If inserted in the wrong direction the key will not turn.
• Turn service key to position 1. • Turn service key to position 1.
• Move the lock bar on the head of the key. • Move the lock bar on the head of the key.
• Turn service key to position 2. • Turn service key to position 2.
CAUTION! CAUTION!
The brake is now released The brake is now released
The truck can only brake by turning the service key to position 1 or pressing the The truck can only brake by turning the service key to position 1 or pressing the
Emergency Disconnect. Emergency Disconnect.
The truck can be operated without its own drive system. The truck can be operated without its own drive system.
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Parking the truck securely Parking the truck securely
Procedure Procedure
• Set the key switch to the “0” position and remove the key. • Set the key switch to the “0” position and remove the key.
Z When you switch back from level 2 to level 1 the bar returns to its original position. Z When you switch back from level 2 to level 1 the bar returns to its original position.
The brake is now activated again. The brake is now activated again.
Z The GF30 key without a bar is designed for normal truck operation.
GF 30
Z The GF30 key without a bar is designed for normal truck operation.
GF 30
It can be inserted on either side and can only be turned to position 1 It can be inserted on either side and can only be turned to position 1
of the key switch. of the key switch.
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7.2 CanCode keypad 7.2 CanCode keypad
CanCode keypad CanCode keypad
The keypad consists of 10 digit keys, a Set key and a o The keypad consists of 10 digit keys, a Set key and a o
key. key.
1 2 3 1 2 3
The O key indicates the follow operating statuses via a The O key indicates the follow operating statuses via a
red / green LED: 4 5 6 red / green LED: 4 5 6
– Code lock function (starting up the truck). – Code lock function (starting up the truck).
7 8 9 7 8 9
– Adjusting the travel program depending on the setting – Adjusting the travel program depending on the setting
and truck. Set 0 and truck. Set 0
– Setting and changing parameters. – Setting and changing parameters.
Z Set different codes for rider and pedestrian trucks. Z Set different codes for rider and pedestrian trucks.
52 53 54 52 53 54
Starting the truck Starting the truck
Procedure Procedure
• Switching on the Emergency • Switching on the Emergency
Disconnect. 1 2 3 Disconnect. 1 2 3
LED (57) lights up red. LED (57) lights up red.
4 5 6 4 5 6
• Enter the code. • Enter the code.
7 8 9 7 8 9
When you enter the correct operator When you enter the correct operator
code the LED (57) turns green. If the Set 0 55 code the LED (57) turns green. If the Set 0 55
LED (57) flashes red this means the 56 LED (57) flashes red this means the 56
wrong code has been entered. Try wrong code has been entered. Try
again. again.
57 57
The truck is switched on The truck is switched on
Z The Set key (56) has no function in operating mode. Z The Set key (56) has no function in operating mode.
Switching the truck off Switching the truck off
Procedure Procedure
• Press the O key. • 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 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 64). lock parameters must be entered, (see "Parameter Settings" on page 64).
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The keypad enables parameters to be adjusted in programming mode. The keypad enables parameters to be adjusted in programming mode.
63 63
Parameter Groups Parameter Groups
The parameter number is composed of three digits. The first digit refers to the 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 parameter group as shown in Table 1. The second and third digits are numbered in
sequence from 00 to 99. sequence from 00 to 99.
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Parameter list Parameter list
No. Function Setting range Standard Procedure No. Function Setting range Standard Procedure
setting setting
000 Change master code: 0000 - 9999 7295 – (LED 52 flashes) 000 Change master code: 0000 - 9999 7295 – (LED 52 flashes)
The length (4-6 digits) of or Confirm current The length (4-6 digits) of or Confirm current
the master code also 00000 - 99999 code entry the master code also 00000 - 99999 code entry
determines the length of or – determines the length of or –
the operator code (4-6 000000 - 999999 (Set 56) the operator code (4-6 000000 - 999999 (Set 56)
digits). Provided the – (LED 53 flashes) digits). Provided the – (LED 53 flashes)
operator codes are Enter a new code operator codes are Enter a new code
programmed, only new – programmed, only new –
codes of the same (Set 56) codes of the same (Set 56)
length can be entered. If length can be entered. If
– (LED 54 flashes) – (LED 54 flashes)
you wish to change the you wish to change the
repeat new code repeat new code
code length, you must code length, you must
first delete all the – first delete all the –
operator codes. (Set 56) operator codes. (Set 56)
001 Add code (max. 250) 0000 - 9999 2580 – (LED 53 flashes) 001 Add code (max. 250) 0000 - 9999 2580 – (LED 53 flashes)
or Confirm code or Confirm code
00000 - 99999 entry 00000 - 99999 entry
or – or –
000000 - 999999 (Set 56) 000000 - 999999 (Set 56)
– (LED 54 flashes) – (LED 54 flashes)
repeat code entry repeat code entry
– –
(Set 56) (Set 56)
002 Change code 0000 - 9999 – (LED 52 flashes) 002 Change code 0000 - 9999 – (LED 52 flashes)
or Confirm current or Confirm current
00000 - 99999 code entry 00000 - 99999 code entry
or – or –
000000 - 999999 (Set 56) 000000 - 999999 (Set 56)
– (LED 53 flashes) – (LED 53 flashes)
Confirm new code Confirm new code
entry entry
– –
(Set 56) (Set 56)
– (LED 54 flashes) – (LED 54 flashes)
Confirm code re- Confirm code re-
entry entry
– –
(Set 56) (Set 56)
LEDs 52-54 are located in keypads 1-3. LEDs 52-54 are located in keypads 1-3.
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No. Function Setting range Standard Procedure No. Function Setting range Standard Procedure
setting setting
003 Delete code 0000 - 9999 – (LED 53 flashes) 003 Delete code 0000 - 9999 – (LED 53 flashes)
or Confirm new code or Confirm new code
00000 - 99999 entry 00000 - 99999 entry
or – or –
000000 - 999999 (Set 56) 000000 - 999999 (Set 56)
– (LED 54 flashes) – (LED 54 flashes)
repeat code entry repeat code entry
– –
(Set 56) (Set 56)
004 Delete code log (deletes 3265 – 3265 = delete 004 Delete code log (deletes 3265 – 3265 = delete
all codes) – other inputs = do all codes) – other inputs = do
not delete not delete
010 Automatic timeout 00-31 00 – 00 = No timeout 010 Automatic timeout 00-31 00 – 00 = No timeout
– 01 - 30 = Timeout – 01 - 30 = Timeout
in minutes in minutes
– 31 = Timeout after – 31 = Timeout after
10 seconds 10 seconds
LEDs 52-54 are located in keypads 1-3. LEDs 52-54 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 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 individually released or blocked for each code. A starting travel program can be
assigned to each code. assigned to each code.
Once a user code has been set up, all travel programs are globally released, the valid Once a user code has been set up, all travel programs are globally released, the valid
start travel program is travel program 2. start travel program is travel program 2.
The code configuration can then be changed with program number 024. The code configuration can then be changed with program number 024.
No. Function Setting range Standard Procedure No. Function Setting range Standard Procedure
setting setting
024 Code configuration 1112 024 Code configuration 1112
1. digit: travel program 1 release (0 = blocked or 1 = released) 1. digit: travel program 1 release (0 = blocked or 1 = released)
2nd digit: travel program 2 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) 3rd digit: travel program 3 release (0 = blocked or 1 = released)
4th digit: start travel program (0, 1, 2 or 3) 4th digit: start travel program (0, 1, 2 or 3)
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Setting the travel program configuration to a code Setting the travel program configuration to a code
Procedure Procedure
• Press the O key (55). • Press the O key (55).
• Enter the master code. • Enter the master code.
• Enter the three-digit parameter number 024. • Enter the three-digit parameter number 024.
• Confirm with the SET key (56). • Confirm with the SET key (56).
• Enter the code to be changed and confirm with SET. • Enter the code to be changed and confirm with SET.
• Enter the configuration (4 digit) and confirm with SET. • Enter the configuration (4 digit) and confirm with SET.
• Enter the configuration (4 digit) again and confirm with SET. • Enter the configuration (4 digit) again and confirm with SET.
• Repeat the procedure for other codes. • Repeat the procedure for other codes.
• Then press the O key. • Then press the O key.
The travel programs are assigned to the codes The travel programs are assigned to the codes
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7.3 Setting the truck parameters with CanCode 7.3 Setting the truck parameters with CanCode
CAUTION! CAUTION!
Faulty entry Faulty entry
Without CanDis only CanCode internal parameters can be changed. Traction Without CanDis only CanCode internal parameters can be changed. Traction
controller parameters can only be changed with CanDis, without CanDis the settings controller parameters can only be changed with CanDis, without CanDis the settings
must be performed by the manufacturer's service department. must be performed by the manufacturer's service department.
CAUTION! CAUTION!
Altering travel parameters can cause accidents Altering travel parameters can cause accidents
Increasing the settings for acceleration, steering, travel, lifting and lowering can result Increasing the settings for acceleration, steering, travel, lifting and lowering can result
in accidents. in accidents.
Carry out a test run in a secure environment. Carry out a test run in a secure environment.
This requires greater attention on the part of the operator. This requires greater attention on the part of the operator.
Procedure Procedure
• Enter four-digit parameter number "0256" and confirm with the SET key (56). • Enter four-digit parameter number "0256" and confirm with the SET key (56).
• Enter sub-index (enter "2") and confirm with the SET key (56). • Enter sub-index (enter "2") and confirm with the SET key (56).
Z The parameter and sub index are displayed alternately with the current reading Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-3). (0256-2<->0000-3).
• Enter the parameter according to the parameter list and confirm with the Set key • Enter the parameter according to the parameter list and confirm with the Set key
(56). (56).
Z The LED (57) of the O key (55) switches briefly to steady light and start flashing Z The LED (57) of the O key (55) switches briefly to steady light and start flashing
again after approx. 2 seconds. again after approx. 2 seconds.
Z If the entry is incorrect, the LED (57) of the O key (55) turns red. Enter the Z If the entry is incorrect, the LED (57) of the O key (55) turns red. Enter the
parameter number again to repeat the setting. parameter number again to repeat the setting.
Z The parameter and sub index are displayed alternately with the current reading Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-5). (0256-2<->0000-5).
The travel parameter is now set. The travel parameter is now set.
Repeat the procedure to enter further parameters as soon as the LED (57) of the O Repeat the procedure to enter further parameters as soon as the LED (57) of the O
key (55) flashes. key (55) flashes.
Z Travel is disabled while the parameters are being entered. Z Travel is disabled while the parameters are being entered.
Checking the settings in programming mode Checking the settings in programming mode
Procedure Procedure
• Select the travel program to be worked on after changing the parameter value, and • Select the travel program to be worked on after changing the parameter value, and
confirm with the Set key (56). confirm with the Set key (56).
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The truck is now in travel mode and can be checked. The truck is now in travel mode and can be checked.
68 68
Z To continue setting, confirm with the Set key (56) again. Z To continue setting, confirm with the Set key (56) again.
Requirements Requirements
– Enter all parameters. – Enter all parameters.
Procedure Procedure
• Run "SaveParameters" by pressing 1-2-3-Set. • Run "SaveParameters" by pressing 1-2-3-Set.
• Confirm with the O key (55). • Confirm with the O key (55).
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7.4 Parameters 7.4 Parameters
Travel program 1 Travel program 1
No. Function Setting range Standard Comments No. Function Setting range Standard Comments
setting setting
0256 Acceleration 0-9 2 0256 Acceleration 0-9 2
(0.2 – 2.0 m/s2) (0.6 m/s2) (0.2 – 2.0 m/s2) (0.6 m/s2)
0260 Coasting brake 0-9 6 0260 Coasting brake 0-9 6
(0.2 – 1.1 m/s2) (0.8 m/s2) (0.2 – 1.1 m/s2) (0.8 m/s2)
0264 Maximum speed in drive 0-9 6 depending on travel 0264 Maximum speed in drive 0-9 6 depending on travel
direction via controller (0.5 - 6.0 km/h) (4.8 km/h) switch direction via controller (0.5 - 6.0 km/h) (4.8 km/h) switch
0268 Maximum speed in fork 0-9 6 depending on travel 0268 Maximum speed in fork 0-9 6 depending on travel
direction via controller (0.5 - 6.0 km/h) (4.8 km/h) switch direction via controller (0.5 - 6.0 km/h) (4.8 km/h) switch
No. Function Setting range Standard Comments No. Function Setting range Standard Comments
setting setting
0272 Acceleration 0-9 5 0272 Acceleration 0-9 5
(0.2 – 2.0 m/s2) (1.2 m/s2) (0.2 – 2.0 m/s2) (1.2 m/s2)
0276 Coasting brake 0-9 6 0276 Coasting brake 0-9 6
(0.2 – 1.1 m/s2) (0.8 m/s2) (0.2 – 1.1 m/s2) (0.8 m/s2)
0280 Maximum speed in tiller 0-9 9 depending on travel 0280 Maximum speed in tiller 0-9 9 depending on travel
direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch
0284 Maximum speed in fork 0-9 9 depending on travel 0284 Maximum speed in fork 0-9 9 depending on travel
direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch
No. Function Setting range Standard Comments No. Function Setting range Standard Comments
setting setting
0288 Acceleration 0-9 9 0288 Acceleration 0-9 9
(0.2 – 2.0 m/s2) (2.0 m/s2) (0.2 – 2.0 m/s2) (2.0 m/s2)
0292 Coasting brake 0-9 9 0292 Coasting brake 0-9 9
(0.2 – 1.1 m/s2) (1.1 m/s2) (0.2 – 1.1 m/s2) (1.1 m/s2)
0296 Maximum speed in tiller 0-9 9 depending on travel 0296 Maximum speed in tiller 0-9 9 depending on travel
direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch
0300 Maximum speed in fork 0-9 9 depending on travel 0300 Maximum speed in fork 0-9 9 depending on travel
direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch direction via controller (0.5 - 6.0 km/h) (6.0 km/h) switch
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Battery parameters Battery parameters
No. Function Setting Standard Comments No. Function Setting Standard Comments
range setting range setting
1377 Battery type 0-2 1 0 = Normal (wet) 1377 Battery type 0-2 1 0 = Normal (wet)
(normal / high (normal / high
performance / dry) 1 = High performance performance / dry) 1 = High performance
(wet) (wet)
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7.5 CANDIS display instrument 7.5 CANDIS display instrument
The instrument indicates: The instrument indicates:
Battery charge display (on board charger Battery charge display (on board charger
58 58
only) only)
Capacity display bars 58 59 Capacity display bars 58 59
59 59
Battery residual charge status Battery residual charge status
60 61 60 61
Warning - pre-warning symbol, Warning - pre-warning symbol,
60 60
Battery charge recommended 62 63 Battery charge recommended 62 63
Stop symbol; lift cutout, Stop symbol; lift cutout,
61 61
Battery charge required Battery charge required
T symbol appears during operation when T symbol appears during operation when
62 the discharge indicator is set to 62 the discharge indicator is set to
maintenance-free battery maintenance-free battery
6 digit LCD display; 6 digit LCD display;
63 hourmeter, input display; 63 hourmeter, input display;
error display error display
In addition, service messages for the electronic components and parameter changes In addition, service messages for the electronic components and parameter changes
are displayed. are displayed.
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 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. 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” If only one LED bar is lit, the battery capacity is almost depleted and the “Warning”
indicator (60) is lit. The battery must be charged immediately. indicator (60) is lit. The battery must be charged immediately.
If no more LED bars are illuminated, the “Stop” indicator (61) lights up. Lifting is now If no more LED bars are illuminated, the “Stop” indicator (61) lights up. Lifting is now
inhibited. The battery must be charged. inhibited. The battery must be charged.
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7.5.2 Service hours display 7.5.2 Service hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are
logged. This is a backlit display. logged. This is a backlit display.
Z For maintenance-free batteries a “T” symbol is shown in the hourmeter Z For maintenance-free batteries a “T” symbol is shown in the hourmeter
display (62). display (62).
– the software version of the display instrument (briefly), – the software version of the display instrument (briefly),
– the service hours, – the service hours,
– the battery charge status. – the battery charge status.
7.6 ISM access module (o) 7.6 ISM access module (o)
Z If the truck is equipped with an ISM access module or Can Code refer to the “ISM Z If the truck is equipped with an ISM access module or Can Code refer to the “ISM
Access Module” operator manual. Access Module” operator manual.
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74
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F Industrial Truck Maintenance F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection 1 Operational Safety and Environmental Protection
The checks and servicing operations contained in this chapter must be performed in The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists. accordance with the intervals as indicated in the servicing checklists.
WARNING! WARNING!
Risk of accidents and damage to components Risk of accidents and damage to components
All modifications to the forklift truck assemblies, in particular the safety mechanisms, 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 are prohibited. The operating speeds of the truck must not be increased under any
circumstances. circumstances.
NOTE NOTE
Only original spare parts have been certified by our quality assurance department. To 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 ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts. parts.
For safety reasons, only components which have been specially agreed by the 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 manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series. components from other trucks of the same series.
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Lifting and jacking up Lifting and jacking up
WARNING! WARNING!
Lifting and jacking up the truck safely Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose. provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured 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. with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows: In order to raise and jack up the truck safely, proceed as follows:
Jack up the truck only on a level surface and prevent it from moving accidentally. Jack up the truck only on a level surface and prevent it from moving accidentally.
Always use a jack with sufficient capacity. When jacking up the truck, take Always 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, appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks). wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the points In 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 specially provided for this purpose, (see "Transport and Commissioning" on
page 23). page 23).
When jacking up the truck, take appropriate measures to prevent it from slipping or When jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks). tipping over (e.g. wedges, wooden blocks).
Cleaning Cleaning
CAUTION! CAUTION!
CAUTION! CAUTION!
CAUTION! CAUTION!
Risk of component damage when cleaning the truck 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 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 and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water. cause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck after Z After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” ((see "Restoring the truck to service after cleaning or maintenance work” ((see "Restoring the truck to service after
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maintenance and repairs" on page 91)). maintenance and repairs" on page 91)).
76 76
Electrical system Electrical system
WARNING! WARNING!
Accident risk Accident risk
Only suitably trained electricians may operate on the truck's electrical system. Only suitably trained electricians may operate on the truck's electrical system.
Before working on the electrical system, take all precautionary measures to avoid Before working on the electrical system, take all precautionary measures to avoid
electric shocks. electric shocks.
Always disconnect the battery before starting cleaning operations. Always disconnect the battery before starting cleaning operations.
WARNING! WARNING!
Electric currents can cause accidents Electric currents can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before Make sure the electrical system is voltage-free before starting work on it. Before
starting maintenance on the electrical system: starting maintenance on the electrical system:
Park the truck securely ((see "Parking the truck securely" on page 48)). Park the truck securely ((see "Parking the truck securely" on page 48)).
Press the Emergency Disconnect. Press the Emergency Disconnect.
Disconnect the battery. Disconnect the battery.
Remove any rings or metal bracelets etc. before working on electrical components. Remove any rings or metal bracelets etc. before working on electrical components.
CAUTION! CAUTION!
Consumables and used parts are an environmental hazard Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant 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 environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task. customer service department, who have been specially trained for this task.
Note the safety regulations when handling these materials. Note the safety regulations when handling these materials.
Welding Welding
Remove electrical and electronic components from the truck before performing Remove electrical and electronic components from the truck before performing
welding operations, to avoid damage. welding operations, to avoid damage.
Settings Settings
When repairing or replacing hydraulic, electric or electronic components or When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings. assemblies, always note the truck-specific settings.
Wheels Wheels
WARNING! WARNING!
The use of wheels that do not match the manufacturer's specifications can The use of wheels that do not match the manufacturer's specifications can
result in accidents. result in accidents.
The quality of wheels affects the stability and performance of the truck. The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance. Uneven wear affects the truck's stability and increases the stopping distance.
When replacing wheels make sure the truck is not skewed. When replacing wheels make sure the truck is not skewed.
Always replace wheels in pairs, i.e. left and right at the same time. Always replace wheels in pairs, i.e. left and right at the same time.
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Z When replacing wheels fitted at the factory, only use the manufacturer’s original 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. spare parts. Otherwise the truck's rated performance cannot be ensured.
WARNING! WARNING!
Leaky hydraulic systems can result in accidents Leaky hydraulic systems can result in accidents
Hydraulic oil can escape from leaky and faulty hydraulic systems. Hydraulic oil can escape from leaky and faulty hydraulic systems.
Report any defects immediately to your supervisor. Report any defects immediately to your supervisor.
Mark defective truck and take out of service. Mark defective truck and take out of service.
Do not return the industrial truck to service until you have identified and rectified the Do not return the industrial truck to service until you have identified and rectified the
fault. fault.
Remove any spilled hydraulic immediately with an appropriate bonding agent. Remove any spilled hydraulic immediately with an appropriate bonding agent.
The bonding agent / consumable mixture must be disposed of in accordance with The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
WARNING! WARNING!
Faulty hydraulic hoses can result in injury and infection Faulty hydraulic hoses can result in injury and infection
Pressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulic Pressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulic
hoses. Brittle hydraulic hoses can burst during operation. People standing near the hoses. Brittle hydraulic hoses can burst during operation. People standing near the
truck can be injured by the hydraulic oil. truck can be injured by the hydraulic oil.
Call for a doctor immediately in the event of an injury. Call for a doctor immediately in the event of an injury.
Do not touch pressurised hydraulic hoses. Do not touch pressurised hydraulic hoses.
Report any defects immediately to your supervisor. Report any defects immediately to your supervisor.
Mark defective truck and take it out of service. Mark defective truck and take it out of service.
Do not return the industrial truck to service until you have identified and rectified the Do not return the industrial truck to service until you have identified and rectified the
fault. fault.
NOTE NOTE
Testing and replacing hydraulic hoses Testing and replacing hydraulic hoses
Hydraulic hoses can become brittle through age and must be checked at regular Hydraulic hoses can become brittle through age and must be checked at regular
intervals. The application conditions of the industrial truck have a considerable impact intervals. The application conditions of the industrial truck have a considerable impact
on the ageing of the hydraulic hoses. on the ageing of the hydraulic hoses.
Check the hydraulic hoses at least annually and replace if necessary. Check the hydraulic hoses at least annually and replace if necessary.
If the operating conditions become more arduous the inspection intervals must be If the operating conditions become more arduous the inspection intervals must be
reduced accordingly. reduced accordingly.
In normal operating conditions a precautionary replacement of the hydraulic hoses In normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6. The owner must carry out a risk assessment to ensure is recommended after 6. The owner must carry out a risk assessment to ensure
safe, prolonged use. The resulting protection measures must be observed and the safe, prolonged use. The resulting protection measures must be observed and the
inspection interval reduced accordingly. inspection interval reduced accordingly.
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3 Servicing and Inspection 3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe 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 operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment. failure and poses a potential hazard to personnel and equipment.
WARNING! WARNING!
The application conditions of an industrial truck have a considerable impact on the The application conditions of an industrial truck have a considerable impact on the
wear of the service components. wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage application analysis on site to work out specific service intervals to prevent damage
due to wear. due to wear.
The service intervals stated are based on single shift operation under normal 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 operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts. conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as: respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly W = Every 50 service hours, at least weekly
A = Every 500 service hours A = Every 500 service hours
B = Every 1000 service hours, or at least annually B = 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
t = Standard maintenance interval t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance Cold store maintenance interval (in addition to standard maintenance
k = k =
interval) interval)
Z W maintenance intervals must be performed by the owner. Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check the During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary. wheel nuts / bolts and re-tighten if necessary.
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4 Maintenance checklist 4 Maintenance checklist
4.1 Owner 4.1 Owner
Brakes W A B C Brakes W A B C
1 Test brakes. t 1 Test brakes. t
Travel W A B C Travel W A B C
1 Check wheels for wear and damage. t 1 Check wheels for wear and damage. t
Steering W A B C Steering W A B C
1 Check tiller recuperating function. t 1 Check tiller recuperating function. t
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4.2 Customer Service 4.2 Customer Service
Brakes W A B C Brakes W A B C
1 Test brakes. t 1 Test brakes. t
2 Check magnetic brake air gap. t 2 Check magnetic brake air gap. t
Travel W A B C Travel W A B C
1 Check transmission for noise and leakage. t 1 Check transmission for noise and leakage. t
2 Check wheel suspension and attachment. t 2 Check wheel suspension and attachment. t
3 Check wheels for wear and damage. t 3 Check wheels for wear and damage. t
4 Checking bedding and attachment of the drive system. t 4 Checking bedding and attachment of the drive system. t
5 Note: Replace transmission oil after 10000 service hours. 5 Note: Replace transmission oil after 10000 service hours.
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Hydraulic operations W A B C Hydraulic operations W A B C
1 Check forks or load handler for wear and damage. t 1 Check forks or load handler for wear and damage. t
2 Test hydraulic system. t 2 Test hydraulic system. t
Check that hydraulic ports, hose and pipe lines are secure, check for Check that hydraulic ports, hose and pipe lines are secure, check for
3 t 3 t
leaks and damage. leaks and damage.
Check cylinders and piston rods for damage and leaks, and make Check cylinders and piston rods for damage and leaks, and make
4 t 4 t
sure they are secure. sure they are secure.
5 Check hydraulic oil level and top up if necessary. t 5 Check hydraulic oil level and top up if necessary. t
6 Check tie / plunger rods. t 6 Check tie / plunger rods. t
7 Test lifting mechanism, check for wear, damage and test the settings. t 7 Test lifting mechanism, check for wear, damage and test the settings. t
Test "hydraulic" controls and make sure the labels are present, Test "hydraulic" controls and make sure the labels are present,
8 t 8 t
legible and complete. legible and complete.
9 Test relief valve and adjust if necessary. t 9 Test relief valve and adjust if necessary. t
10 Replace hydraulic oil. k t 10 Replace hydraulic oil. k t
11 Replace hydraulic oil filter, ventilation/discharge filter. k t 11 Replace hydraulic oil filter, ventilation/discharge filter. k t
Steering W A B C Steering W A B C
1 Check tiller recuperating function. t 1 Check tiller recuperating function. t
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On-board charger On-board charger
Charger W A B C Charger W A B C
1 Check mains connector and mains cable. t 1 Check mains connector and mains cable. t
Check the start-up protection system for trucks with an on-board Check the start-up protection system for trucks with an on-board
2 t 2 t
charger. charger.
Check the wires and electrical connections are secure and not Check the wires and electrical connections are secure and not
3 t 3 t
damaged. damaged.
4 Potential measurement on chassis while charging is in progress. t 4 Potential measurement on chassis while charging is in progress. t
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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 Consumables must always be handled correctly. Follow the manufacturer’s
instructions. instructions.
WARNING! WARNING!
Improper handling is hazardous to health, life and the environment Improper handling is hazardous to health, life and the environment
Consumables can be flammable. Consumables can be flammable.
Keep consumables away from hot components and naked flames. Keep consumables away from hot components and naked flames.
Always keep consumables in prescribed containers. Always keep consumables in prescribed containers.
Always fill consumables in clean containers. Always fill consumables in clean containers.
Do not mix up different grades of consumable. The only exception to this is when Do not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions. mixing is expressly stipulated in the operating instructions.
CAUTION! CAUTION!
Spilled liquids can cause slipping and endanger the environment Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water. Risk of slipping from spilled liquids. The risk is greater when combined with water.
Do not spill fluids. Do not spill fluids.
Spilled fluids must be removed immediately with an appropriate bonding agent. Spilled fluids must be removed immediately with an appropriate bonding agent.
The bonding agent / consumable mixture must be disposed of in accordance with The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
WARNING! WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous. Oils (chain spray / hydraulic oil) are flammable and poisonous.
Dispose of used oils in accordance with regulations. Store used oil safely until it can Dispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations. be disposed of in accordance with regulations.
Do not spill oil. Do not spill oil.
Spilled fluids must be removed immediately with an appropriate bonding agent. Spilled fluids must be removed immediately with an appropriate bonding agent.
The bonding agent / consumable mixture must be disposed of in accordance with The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
Observe national regulations when handling oils. Observe national regulations when handling oils.
Wear safety gloves when handling oils. Wear safety gloves when handling oils.
Prevent oil from coming into contact with hot motor parts. Prevent oil from coming into contact with hot motor parts.
Do not smoke when handling oil. Do not smoke when handling oil.
Avoid contact and digestion. If you swallow oil do not induce vomiting but call for a Avoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately. doctor immediately.
Seek fresh air after breathing in oil fumes or vapours. Seek fresh air after breathing in oil fumes or vapours.
If oil has come into contact with your skin, rinse your skin with water. If oil has come into contact with your skin, rinse your skin with water.
If oil has come into contact with your eyes, rinse them with water and call for a If oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately. doctor immediately.
Replace oil-soaked clothing and shoes immediately. Replace oil-soaked clothing and shoes immediately.
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Consumables and used parts Consumables and used parts
CAUTION! CAUTION!
Consumables and used parts are an environmental hazard Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant 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 environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task. customer service department, who have been specially trained for this task.
Note the safety regulations when handling these materials. Note the safety regulations when handling these materials.
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5.2 Lubrication Schedule 5.2 Lubrication Schedule
E E
0,9 l 0,9 l
E E
E E
B B
0,55 l 0,55 l
g Contact surfaces k Cold Store Application g Contact surfaces k Cold Store Application
s Grease nipple a Transmission oil drain plug s Grease nipple a Transmission oil drain plug
c Hydraulic oil drain plug c Hydraulic oil drain plug
Hydraulic oil filler neck Hydraulic oil filler neck
b Transmission oil filler neck Transmission oil overflow and b Transmission oil filler neck Transmission oil overflow and
dipstick dipstick
1 Compound ratio for cold store usage 1:1 1 Compound ratio for cold store usage 1:1
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86 86
5.3 Consumables 5.3 Consumables
Code Order no. Package Component Used for Code Order no. Package Component Used for
quantity quantity
A 5044 9669 5.0 l H-LP 46, DIN 51524 Hydraulic System A 5044 9669 5.0 l H-LP 46, DIN 51524 Hydraulic System
5113 2827 * 5.0 l Jungheinrich 5113 2827 * 5.0 l Jungheinrich
Hydraulic oil Hydraulic oil
B 5038 0904 5.0 l Fuchs Titan Gear Transmission B 5038 0904 5.0 l Fuchs Titan Gear Transmission
HSY 75W-90 HSY 75W-90
C 5103 7497 5.0 l H-LP 22, DIN 51524 Hydraulic System C 5103 7497 5.0 l H-LP 22, DIN 51524 Hydraulic System
E 2920 1430 1.0 kg Grease, DIN 51825 Lubrication E 2920 1430 1.0 kg Grease, DIN 51825 Lubrication
F 5043 0702 1.0 kg Grease, DIN 51818 Lubrication F 5043 0702 1.0 kg Grease, DIN 51818 Lubrication
Low temperature Low temperature
Code Saponification Dew point Worked NLG1 class Application Code Saponification Dew point Worked NLG1 class Application
°C penetration temperature °C penetration temperature
at 25 °C °C at 25 °C °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
*The trucks are factory-equipped with a special hydraulic oil (the Jungheinrich *The trucks are factory-equipped with a special hydraulic oil (the Jungheinrich
hydraulic oil with a blue colouration) and the cold store hydraulic oil (red hydraulic oil with a blue colouration) and the cold store hydraulic oil (red
colouration). The Jungheinrich hydraulic oil can only be obtained from the colouration). The Jungheinrich hydraulic oil can only be obtained from the
Jungheinrich service department. The use of named alternative hydraulic oils is not Jungheinrich service department. The use of named alternative hydraulic oils is not
prohibited but may lead to a decline in functionality. The Jungheinrich hydraulic oil prohibited but may lead to a decline in functionality. The Jungheinrich hydraulic oil
may be mixed with one of the named alternative hydraulic oils. may be mixed with one of the named alternative hydraulic oils.
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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 All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made: maintenance and repairs. The following preparations must be made:
Procedure Procedure
• Park the truck on a level surface. • Park the truck on a level surface.
• Fully lower the main and auxiliary lift. • Fully lower the main and auxiliary lift.
• Park the truck securely, (see "Parking the truck securely" on page 48). • Park the truck securely, (see "Parking the truck securely" on page 48).
• Disconnect the battery to prevent the truck from being switched on accidentally. • 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 • When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away. or sliding away.
WARNING! WARNING!
Risk of accidents when working under the load handler, driver's cab and lift Risk of accidents when working under the load handler, driver's cab and lift
truck truck
When working under a raised load handler, driver's cab or a raised truck, secure When 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. them to prevent the truck from from lowering, tipping or sliding away.
When raising the truck, follow the instructions, (see "Transport and When raising the truck, follow the instructions, (see "Transport and
Commissioning" on page 23). When working on the parking brake, prevent the Commissioning" on page 23). When working on the parking brake, prevent the
truck from accidentally rolling away (e.g. with wedges). truck from accidentally rolling away (e.g. with wedges).
6.2 Removing the front panel 6.2 Removing the front panel
Fit the panel Fit the panel
Procedure Procedure
• Remove the screws (69). • Remove the screws (69).
• Lift and remove the front panel (11). • Lift and remove the front panel (11).
• Place the front panel (11) safely to one side. • Place the front panel (11) safely to one side.
The front panel is now disassembled. The front panel is now disassembled.
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6.3 Removing the drive panel 6.3 Removing the drive panel
The drive panel consists of two halves (50 and 70). The drive panel consists of two halves (50 and 70).
Disassembling the panel Disassembling the panel
69 69
11 11
70 50 71 70 50 71
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6.4 Checking electrical fuses 6.4 Checking electrical fuses
Checking fuses Checking fuses
Requirements Requirements
– Truck prepared for maintenance and repairs, (see "Preparing the truck for – Truck prepared for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 88). maintenance and repairs" on page 88).
– Front panel removed, (see "Removing the front panel" on page 88). – Front panel removed, (see "Removing the front panel" on page 88).
Procedure Procedure
• Check the fuse ratings against the table and replace if necessary. • Check the fuse ratings against the table and replace if necessary.
The fuses are now checked. The fuses are now checked.
72 73 74 75 76 72 73 74 75 76
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90 90
6.5 Restoring the truck to service after maintenance and repairs 6.5 Restoring the truck to service after maintenance and repairs
Procedure Procedure
• Thoroughly clean the truck. • Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication • Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 86). Schedule" on page 86).
• Clean the battery, grease the terminals and connect the battery. • Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Charging the battery" on page 31). • Charge the battery, (see "Charging the battery" on page 31).
• Check the transmission oil for condensation water and replace if necessary. • Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary. • Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out Z The manufacturer's customer service department is specially trained to carry out
these operations. these operations.
WARNING! WARNING!
Faulty brakes can cause accidents Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times. As soon as the truck has been started, test the brakes several times.
Report any defects immediately to your supervisor. Report any defects immediately to your supervisor.
Tag out and decommission a faulty lift truck. Tag out and decommission a faulty lift truck.
Only return the truck to service when you have identified and rectified the fault. Only return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 46). • Start up the truck, (see "Starting up the truck" on page 46).
Z If there are switching problems in the electrical system, apply contact spray to the Z 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 exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly. applying them repeatedly.
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7 Decommissioning the industrial truck 7 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial 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 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. must be taken before, during and after decommissioning as described hereafter.
WARNING! WARNING!
Lifting and jacking up the truck safely Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose. provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured 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. with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows: In order to raise and jack up the truck safely, proceed as follows:
Jack up the truck only on a level surface and prevent it from moving accidentally. Jack up the truck only on a level surface and prevent it from moving accidentally.
Only use a jack with sufficient capacity. When jacking up the truck, take appropriate Only 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). measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the points In 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 specially provided for this purpose. (see "Identification points and data plates" on
page 20). page 20).
When jacking up the truck, take appropriate measures to prevent it from slipping or When jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks). 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 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 of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged. are not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department. the manufacturer's customer service department.
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7.1 Prior to decommissioning 7.1 Prior to decommissioning
Procedure Procedure
• Thoroughly clean the truck. • Thoroughly clean the truck.
WARNING! WARNING!
Faulty brakes can cause accidents Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times. As soon as the truck has been started, test the brakes several times.
Report any defects immediately to your supervisor. Report any defects immediately to your supervisor.
Tag out and decommission a faulty lift truck. Tag out and decommission a faulty lift truck.
Only return the truck to service when you have identified and rectified the fault. Only return the truck to service when you have identified and rectified the fault.
7.2 Action to be taken during decommissioning 7.2 Action to be taken during decommissioning
NOTE NOTE
Full discharge can damage the battery Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery. useful life of the battery.
Charge the battery at least every 2 months. Charge the battery at least every 2 months.
Z Charge the battery (see "Charging the battery" on page 31). Z Charge the battery (see "Charging the battery" on page 31).
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7.3 Restoring the truck to service after decommissioning 7.3 Restoring the truck to service after decommissioning
Procedure Procedure
• Thoroughly clean the truck. • Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication • Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 86). Schedule" on page 86).
• Clean the battery, grease the terminals and connect the battery. • Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Charging the battery" on page 31). • Charge the battery, (see "Charging the battery" on page 31).
• Check the transmission oil for condensation water and replace if necessary. • Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary. • Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out Z The manufacturer's customer service department is specially trained to carry out
these operations. these operations.
WARNING! WARNING!
Faulty brakes can cause accidents Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times. As soon as the truck has been started, test the brakes several times.
Report any defects immediately to your supervisor. Report any defects immediately to your supervisor.
Tag out and decommission a faulty lift truck. Tag out and decommission a faulty lift truck.
Only return the truck to service when you have identified and rectified the fault. Only return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 46). • Start up the truck, (see "Starting up the truck" on page 46).
Z If there are switching problems in the electrical system, apply contact spray to the Z 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 exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly. applying them repeatedly.
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8 Safety tests to be performed at intervals and after unusual 8 Safety tests to be performed at intervals and after unusual
incidents incidents
Z Perform a safety check in accordance with national regulations. Jungheinrich Z Perform a safety check in accordance with national regulations. Jungheinrich
recommends the truck be checked to FEM guideline 4.004. The 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. 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 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 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 condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of 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 safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks. the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition 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 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 possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections. 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. 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. This plate indicates the due date for the next inspection.
The truck must only be disassembled by trained personnel in accordance with the The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety procedures as specified by the manufacturer. Note the manufacturer’s safety
instructions as specified in the service documentation. instructions as specified in the service documentation.
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A Traction Battery Appendix A Traction Battery Appendix
Contents Contents
03.13 EN
1 1
1 Correct Use and Application 1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-original Failure to observe the operating instructions, carrying out repairs with non-original
spare parts, tampering with the battery or using electrolyte additives will invalidate the spare parts, tampering with the battery or using electrolyte additives will invalidate the
warranty. warranty.
Observe the instructions for maintaining the safety rating during operation for Observe the instructions for maintaining the safety rating during operation for
batteries in accordance with Ex I and Ex II (see relevant certification). batteries in accordance with Ex I and Ex II (see relevant certification).
1,2 3 1,2 3
4 5 4 5
6 7 6 7
8 9 8 9
10 15 10 15
11 11
13 13
12 12
14 14
03.13 EN
2 2
3 Safety Instructions, Warning Indications and other Notes 3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste. Used batteries must be treated as hazardous waste.
These batteries are marked with the recycling symbol and the sign These batteries are marked with the recycling symbol and the sign
showing a crossed-out rubbish bin, and should not be disposed of showing a crossed-out rubbish bin, and should not be disposed of
with ordinary household waste. with ordinary household waste.
waste. waste.
Buy-back terms and type of recycling are to be agreed with the Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation. manufacturer as described in § 8 of the battery legislation.
No naked flames, glowing embers or sparks near the battery - fire No naked flames, glowing embers or sparks near the battery - fire
and explosion hazard! and explosion hazard!
Avoid fire and explosion hazards and short circuits due to Avoid fire and explosion hazards and short circuits due to
overheating! overheating!
Keep away from naked flames and strong heat sources. Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety Always wear protective clothing (e.g. safety goggles and safety
gloves) when working on cells and batteries. gloves) when working on cells and batteries.
batteries. batteries.
Always wash your hands after completing the work. Use insulated Always wash your hands after completing the work. Use insulated
tools only. Do not physically tools only. Do not physically
alter the battery, strike, crush, compress, notch, dent or modify it in alter the battery, strike, crush, compress, notch, dent or modify it in
any way. any way.
Hazardous electric voltage! The metal parts of the battery cells are Hazardous electric voltage! The metal parts of the battery cells are
permanently live. Therefore do not place any foreign objects or tools permanently live. Therefore do not place any foreign objects or tools
on the battery. on the battery.
Observe national health and safety regulations. Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves. If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the Follow the user instructions and keep them in a visible position in the
charging area. charging area.
Work on the batteries should be performed only as instructed by Work on the batteries should be performed only as instructed by
specialist personnel. specialist personnel.
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3 3
4 Lead acid batteries with armour plated cells and liquid 4 Lead acid batteries with armour plated cells and liquid
electrolyte electrolyte
4.1 Description 4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells and Jungheinrich traction batteries are lead acid batteries with armour plated cells and
liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM. liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte Electrolyte
The rated density of the electrolyte assumes a temperature of 30°C and the rated The rated density of the electrolyte assumes a temperature of 30°C and the rated
electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures
will increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g. will increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.
electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C. electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations. The electrolyte must conform to DIN 43530 Part 2 purity regulations.
03.13 EN
03.13 EN
4 4
4.2 Operation 4.2 Operation
4.2.2 Commissioning filled and charged batteries 4.2.2 Commissioning filled and charged batteries
Checks and operations to be performed before starting daily work Checks and operations to be performed before starting daily work
Procedure Procedure
• Make sure the battery is in physically good condition. • Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative) • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure. and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and • Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. connectors.
• Charge up the battery. • Charge up the battery.
• Check the electrolyte level. • Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator. Z The electrolyte level must be above the cell baffle or the top of the separator.
• Add electrolyte with distilled water up to the nominal level. • Add electrolyte with distilled water up to the nominal level.
Checks completed. Checks completed.
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5 5
4.2.4 Charging the battery 4.2.4 Charging the battery
WARNING! WARNING!
The gases produced during charging can cause explosions The gases produced during charging can cause explosions
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited. must not be ignited.
Always disconnect the charger and truck before connecting or disconnecting the Always disconnect the charger and truck before connecting or disconnecting the
charger and battery. charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology. and battery technology.
Before charging, check all cables and plug connections for visible signs of damage. Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged. Ventilate the room in which the truck is being charged.
Battery cell surfaces must remain exposed during charging in order to ensure Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery. Battery.
Do not smoke and avoid naked flames when handling batteries. Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there must be no inflammable Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of material or consumables capable of creating sparks within a minimum distance of
2 m from the truck. 2 m from the truck.
Fire protection equipment must be available. Fire protection equipment must be available.
Do not place any metallic objects on the battery. Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station Always follow the safety regulations of the battery and charger station
manufacturers. manufacturers.
NOTE NOTE
The battery must only be charged with DC current. All charging processes in The battery must only be charged with DC current. All charging processes in
accordance with DIN 41773 and DIN 41774 are permissible. accordance with DIN 41773 and DIN 41774 are permissible.
03.13 EN
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6 6
Z The electrolyte temperature rises by approx. 10 K during charging. Charging should Z The electrolyte temperature rises by approx. 10 K during charging. Charging should
therefore only begin when the electrolyte temperature is below 45°C. The therefore only begin when the electrolyte temperature is below 45°C. The
electrolyte temperature of batteries must be at least +10°C before charging. electrolyte temperature of batteries must be at least +10°C before charging.
Otherwise the battery will not charge correctly. Below 10°C the battery is Otherwise the battery will not charge correctly. Below 10°C the battery is
insufficiently charged with standard charging systems. insufficiently charged with standard charging systems.
Requirements Requirements
– Electrolyte temperature min. 10°C to max. 45°C – Electrolyte temperature min. 10°C to max. 45°C
Procedure Procedure
• Open or take off the tray lid or covers from the battery compartment. • Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain on Z Deviations are outlined in the truck's operating instructions. The plugs remain on
the cells or remain closed. the cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are connect • Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative). (positive to positive and negative to negative).
• Switch on the charger. • Switch on the charger.
Battery charged Battery charged
Z Charging is considered to be complete when the electrolyte density and battery Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours. voltage remain constant for more than 2 hours.
Compensation charging is used to ensure the useful life and maintain capacity after Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. The maximum compensation full discharge and repeated insufficient charging. The maximum compensation
charge current is 5 A/100 Ah rated capacity. charge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly. Z Compensation charging should be carried out weekly.
Battery trickle charging is partial charging that extends the daily application time. Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which reduce the useful Higher average temperatures occur during trickle charging which reduce the useful
life of the batteries. life of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Use Z Trickle charges should only be performed when the charge level is below 60 %. Use
replacement batteries instead of regular trickle charging. replacement batteries instead of regular trickle charging.
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7 7
4.3 Servicing lead-acid batteries with armour plated cells 4.3 Servicing lead-acid batteries with armour plated cells
Water quality Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte. exchangers and is then suitable for the production of electrolyte.
03.13 EN
8 8
5 PzV and PzV-BS lead-acid batteries with sealed armour 5 PzV and PzV-BS lead-acid batteries with sealed armour
plated cells plated cells
5.1 Description 5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can be PzV batteries are sealed batteries with fixed electrolytes, to which no water can be
added over the entire lifespan of the battery. Relief valves are used as plugs which added over the entire lifespan of the battery. Relief valves are used as plugs which
are destroyed when opened. During operation the same safety requirements apply to are destroyed when opened. During operation the same safety requirements apply to
the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric
shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if
the cell vessels are destroyed. the cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free. Z PzV batteries are low gassing, but not gassing-free.
Electrolyte Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte
cannot be measured. cannot be measured.
03.13 EN
9 9
5.2 Operation 5.2 Operation
Procedure Procedure
• Make sure the battery is in physically good condition. • Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative) • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure. and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and • Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. connectors.
• Re-charge the battery. • Re-charge the battery.
• Charge the battery. • Charge the battery.
Check completed. Check completed.
WARNING! WARNING!
The gases produced during charging can cause explosions The gases produced during charging can cause explosions
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited. must not be ignited.
Always disconnect the charger and truck before connecting or disconnecting the Always disconnect the charger and truck before connecting or disconnecting the
charger and battery. charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology. and battery technology.
Before charging, check all cables and plug connections for visible signs of damage. Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged. Ventilate the room in which the truck is being charged.
Battery cell surfaces must remain exposed during charging in order to ensure Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery. Battery.
Do not smoke and avoid naked flames when handling batteries. Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there must be no inflammable Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of material or consumables capable of creating sparks within a minimum distance of
2 m from the truck. 2 m from the truck.
Fire protection equipment must be available. Fire protection equipment must be available.
Do not place any metallic objects on the battery. Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station Always follow the safety regulations of the battery and charger station
03.13 EN
03.13 EN
manufacturers. manufacturers.
10 10
NOTE NOTE
Charging the battery incorrectly can result in material damage. Charging the battery incorrectly can result in material damage.
Incorrect battery charging can result in overloading of the electric wires and contacts, Incorrect battery charging can result in overloading of the electric wires and contacts,
hazardous gas formation and electrolyte leakage from the cells. hazardous gas formation and electrolyte leakage from the cells.
Always charge the battery with DC current. Always charge the battery with DC current.
All DIN 41773 charging procedures are permitted in the format approved by the All DIN 41773 charging procedures are permitted in the format approved by the
manufacturer. manufacturer.
Always connect the battery to a charger that is appropriate to the size and type of Always connect the battery to a charger that is appropriate to the size and type of
the battery. the battery.
If necessary have the charger checked by the manufacturer's customer service If necessary have the charger checked by the manufacturer's customer service
department for suitability. department for suitability.
Do not exceed limit currents in the gassing area in accordance with DIN EN 50272- Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3. 3.
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Charging the battery Charging the battery
Requirements Requirements
– Electrolyte temperature between +15°C and 35°C – Electrolyte temperature between +15°C and 35°C
Procedure Procedure
• Open or take off the tray lid or covers from the battery compartment. • Open or take off the tray lid or covers from the battery compartment.
• Connect the battery to the switched off charger, ensuring the terminals are connect • Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative). (positive to positive and negative to negative).
• Switch on the charger. • Switch on the charger.
Z The electrolyte temperature rises by approx. 10 K during charging. If the Z The electrolyte temperature rises by approx. 10 K during charging. If the
temperatures are permanently higher than 40°C or lower than 15°C, a temperature- temperatures are permanently higher than 40°C or lower than 15°C, a temperature-
dependent constant voltage control of the charger is required. The adjustment dependent constant voltage control of the charger is required. The adjustment
factor must be applied with -0.004 V/C per K. factor must be applied with -0.004 V/C per K.
Battery charged Battery charged
Z Charging is considered to be complete when the electrolyte density and battery Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours. voltage remain constant for more than 2 hours.
Compensation charging is used to ensure the useful life and maintain capacity after Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. full discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly. Z Compensation charging should be carried out weekly.
Battery trickle charging is partial charging that extends the daily application time. Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which can reduce the Higher average temperatures occur during trickle charging which can reduce the
useful life of the batteries. useful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Use Z Trickle charges should only be performed when the charge level is below 50%. Use
replacement batteries instead of regular trickle charging. replacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries. Z Avoid trickle charging with PzV batteries.
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5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour 5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells plated cells
Z Do not add water! Z Do not add water!
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6 Aquamatik water replenishment system 6 Aquamatik water replenishment system
6.1 Water replenishment system design 6.1 Water replenishment system design
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>3m 18 >3m 18
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+ - + -
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6.2 Functional Description 6.2 Functional Description
The Aquamatik water replenishment system is used to adjust the rated electrolyte The Aquamatik water replenishment system is used to adjust the rated electrolyte
level automatically on traction batteries for industrial trucks. level automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the water The battery cells are interconnected through hoses and are attached to the water
supply (e.g. water container) through a plug connection. When the shut-off cock is supply (e.g. water container) through a plug connection. When the shut-off cock is
opened all the cells are filled with water. The Aquamatik plug controls the amount of opened all the cells are filled with water. The Aquamatik plug controls the amount of
water required and, at the relevant water pressures, ensures the water supply is shut water required and, at the relevant water pressures, ensures the water supply is shut
off and the valve is closed securely. off and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure the The plug systems have an optical level indicator, a diagnostic port to measure the
temperature and electrolyte density and a degassing port. temperature and electrolyte density and a degassing port.
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1 Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1
bar bar
Pressure water Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3 The pressure regulating valve is adjusted to suit the system and must lie between 0.3
- 1.8 bar. - 1.8 bar.
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6.5 Filling time 6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperature The filling time for a battery depends on the electrolyte level, the ambient temperature
and the filling pressure. Filling ends automatically. The water supply line must be and the filling pressure. Filling ends automatically. The water supply line must be
disconnected from the battery when the water has been filled. disconnected from the battery when the water has been filled.
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6.9 Cleaning measures 6.9 Cleaning measures
The plug systems must only be cleaned with purified water in accordance with DIN The plug systems must only be cleaned with purified water in accordance with DIN
43530-4. No parts of the plugs must come into contact with solvent-based materials 43530-4. No parts of the plugs must come into contact with solvent-based materials
or soap. or soap.
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7 Electrolyte circulation 7 Electrolyte circulation
7.1 Functional Description 7.1 Functional Description
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte, Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,
thereby preventing any acid layer, shortening the charge time (charge factor approx. thereby preventing any acid layer, shortening the charge time (charge factor approx.
1.07) and reducing the formation of gas during charging. The charger must be 1.07) and reducing the formation of gas during charging. The charger must be
suitable for the battery and electrolyte circulation. suitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introduced A pump in the charger produces the necessary compressed air which is introduced
to the battery cells via a hose system. The electrolyte is circulated via the inlet air and to the battery cells via a hose system. The electrolyte is circulated via the inlet air and
the electrolyte density level is constant over the entire length of the electrode. the electrolyte density level is constant over the entire length of the electrode.
Pump Pump
In the event of a fault, e.g. if the pressure control system responds for an unknown In the event of a fault, e.g. if the pressure control system responds for an unknown
reason, the filters must be checked and replaced if necessary. reason, the filters must be checked and replaced if necessary.
Battery connection Battery connection
A hose is attached to the pump module which together with the charge leads is routed A hose is attached to the pump module which together with the charge leads is routed
from the charger to the charging connector. The air is passed on to the battery via the from the charger to the charging connector. The air is passed on to the battery via the
electrolyte circulation coupling ducts in the connector. When routing make sure the electrolyte circulation coupling ducts in the connector. When routing make sure the
hose is not bent. hose is not bent.
The electrolyte circulation pump is activated when charging begins. The pressure The electrolyte circulation pump is activated when charging begins. The pressure
monitoring module monitors the build up of pressure during charging. This ensures monitoring module monitors the build up of pressure during charging. This ensures
that the required air pressure is provided for electrolyte circulation charging. that the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as: In the event of malfunctions such as:
– Battery air coupling not connected to circulation module (if coupling is separate) or – Battery air coupling not connected to circulation module (if coupling is separate) or
faulty. faulty.
– Leaky or faulty hose connections on battery or – Leaky or faulty hose connections on battery or
– Intake filter contaminated – Intake filter contaminated
a visual error message appears on the charger. a visual error message appears on the charger.
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NOTE NOTE
If an installed electrolyte circulation system is seldom used or not used at all, If an installed electrolyte circulation system is seldom used or not used at all,
or if the battery is subjected to severe temperature fluctuations, the electrolyte or if the battery is subjected to severe temperature fluctuations, the electrolyte
may flow back into the hose system. may flow back into the hose system.
Attach a separate coupling system to the air inlet line, such as: locking coupling on Attach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side. the battery side and through-coupling on the air supply side.
Electrolyte circulation on the battery and air supply via the charger. Electrolyte circulation on the battery and air supply via the charger.
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8 Cleaning batteries 8 Cleaning batteries
Batteries and trays must be cleaned in order to Batteries and trays must be cleaned in order to
– maintain cell insulation and protect cells from ground or external conductive parts. – maintain cell insulation and protect cells from ground or external conductive parts.
– Avoid damage from corrosion and stray currents. – Avoid damage from corrosion and stray currents.
– Avoid excessive and varying automatic discharge of the individual cells or block – Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents. batteries due to stray currents.
– Avoid electric sparking due to stray currents. – Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that: When cleaning the batteries make sure that:
– The assembly site chosen for cleaning is close to a drainage system for processing – The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water. the electrolytic rinsing water.
– All health and safety as well as water and waste disposal regulations are observed – All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water. when disposing of used electrolyte or rinsing water.
– Protective goggles and clothing are worn. – Protective goggles and clothing are worn.
– Cell plugs are not removed or opened. – Cell plugs are not removed or opened.
– Clean the plastic components of the battery, in particular the cell containers, only – Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives. with water or water-based cloths without any additives.
– After cleaning, the top of the battery is dried with suitable equipment, e.g. – After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths. compressed air or cloths.
– Any fluid that has entered the battery box must be suctioned off and disposed of in – Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations. accordance with the above-mentioned regulations.
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Cleaning the battery with a high pressure cleaner Cleaning the battery with a high pressure cleaner
Requirements Requirements
– Cell connectors tight, plugged in securely – Cell connectors tight, plugged in securely
– Cell plugs closed – Cell plugs closed
Procedure Procedure
• Follow the high pressure cleaner's user instructions. • Follow the high pressure cleaner's user instructions.
• Do not use any cleaning additives. • Do not use any cleaning additives.
• Observe the permissible cleaning device temperature setting of 140°C. • Observe the permissible cleaning device temperature setting of 140°C.
Z This generally ensures that the temperature does not exceed 60°C at a distance of Z This generally ensures that the temperature does not exceed 60°C at a distance of
30cm behind the outlet nozzle. 30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar. • Observe the maximum operating pressure of 50 bar.
• Observe a minimum distance of 30 cm from the top of the battery. • Observe a minimum distance of 30 cm from the top of the battery.
• The battery should be sprayed over its entire surface to avoid localised • The battery should be sprayed over its entire surface to avoid localised
overheating. overheating.
Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C. maximum battery surface temperature of 60°C.
• After cleaning dry the battery surface with suitable materials e.g. compressed air or • After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths. cleaning cloths.
Battery cleaned. Battery cleaned.
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9 Storing the battery 9 Storing the battery
NOTE NOTE
The battery should not be stored for longer than 3 months without charging as The battery should not be stored for longer than 3 months without charging as
otherwise it will no longer be functional. otherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fully If the battery is to be taken out of service for a long period, it should be stored fully
charged in a dry room protected from frost. To ensure the availability of the battery charged in a dry room protected from frost. To ensure the availability of the battery
the following charges can be selected: the following charges can be selected:
– Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge – Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge
for PzV batteries. for PzV batteries.
– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB – Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB
batteries or 2.25 volts x no. of cells for PzV batteries. batteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, as If the battery is to be taken out of service for a long period ( > 3 months), it should, as
far as possible, be charged to 50% of its charge level and stored in a dry room far as possible, be charged to 50% of its charge level and stored in a dry room
protected from frost. protected from frost.
10 Troubleshooting 10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customer If any faults are found on the battery or charger, contact the manufacturer's customer
service department immediately. service department immediately.
Z The operations required must be carried out by the manufacturer's customer Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the service department or a customer service organisation authorised by the
manufacturer. manufacturer.
11 Disposal 11 Disposal
Batteries marked with the recycling symbol and the sign showing a Batteries marked with the recycling symbol and the sign showing a
crossed-out rubbish bin should not be disposed of with ordinary crossed-out rubbish bin should not be disposed of with ordinary
household waste. household waste.
Buy-back terms and type of recycling are to be agreed with the Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation. manufacturer as described in § 8 of the battery legislation.
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