Page 1
ECE 118
08.06-
Operating instructions
51092878
07.08
G
Page 2
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
F
Used before safety instructions which must be observed to avoid danger to
personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
F
Used before safety instructions which must be observed to avoid danger to
personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
Page 3
0108.GB
0108.GB
Page 4
I 1
0708.GB
Table of Contents
A Correct Use and Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies .......................................................................................... B 2
3 Technical specifications ...................................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 3
3.3 Table of dimensions ............................................................................ B 3
3.4 EN standards ...................................................................................... B 5
3.5 Operating conditions ........................................................................... B 5
4 Identification points and data plates ................................................... B 6
4.1 Truck data plate .................................................................................. B 7
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Using the truck for the first time .......................................................... C 1
3 Removing the transport lock ............................................................... C 2
4 Moving the truck without using the drive unit ...................................... C 3
5 Securing the truck during transport ..................................................... C 4
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
3.1 Standard version ................................................................................. D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with a stationary charger ................................... D 3
5 Battery removal and installation .......................................................... D 4
6 Battery discharge indicator (t) ........................................................... D 5
I 1
0708.GB
Table of Contents
A Correct Use and Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies .......................................................................................... B 2
3 Technical specifications ...................................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 3
3.3 Table of dimensions ............................................................................ B 3
3.4 EN standards ...................................................................................... B 5
3.5 Operating conditions ........................................................................... B 5
4 Identification points and data plates ................................................... B 6
4.1 Truck data plate .................................................................................. B 7
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Using the truck for the first time .......................................................... C 1
3 Removing the transport lock ............................................................... C 2
4 Moving the truck without using the drive unit ...................................... C 3
5 Securing the truck during transport ..................................................... C 4
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
3.1 Standard version ................................................................................. D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with a stationary charger ................................... D 3
5 Battery removal and installation .......................................................... D 4
6 Battery discharge indicator (t) ........................................................... D 5
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0708.GB
I 2
E Operation
1 Safety regulations for the operation of industrial trucks ...................... E 1
2 Controls and indicators ....................................................................... E 2
3 Starting up the truck ............................................................................ E 4
3.1 Switching on the truck ......................................................................... E 4
4 Industrial truck operation ..................................................................... E 5
4.1 Safety regulations for truck operation ................................................. E 5
4.2 Driving, steering, braking .................................................................... E 6
4.3 Lifting and depositing loads ................................................................. E 9
4.4 Parking the truck securely ................................................................... E 10
5 Keypad (CANCODE) (o) .................................................................... E 11
5.1 Code lock ............................................................................................ E 11
5.2 Travel programs .................................................................................. E 13
5.3 Parameters .......................................................................................... E 13
5.4 Parameter settings .............................................................................. E 14
5.5 Travel parameters ............................................................................... E 18
6 Display instrument (CANDIS) (o) ....................................................... E 21
6.1 Discharge monitor function ................................................................. E 22
6.2 Operating hours display ...................................................................... E 22
6.3 Power up test ...................................................................................... E 22
7 Troubleshooting .................................................................................. E 23
F Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance safety regulations .......................................................... F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ........................................................................ F 4
5 Maintenance schedule ........................................................................ F 6
5.1 Consumables ...................................................................................... F 7
6 Maintenance and repairs ..................................................................... F 8
6.1 Preparing the truck for maintenance and repairs ................................ F 8
6.2 Opening the battery panel ................................................................... F 8
6.3 Opening the front panel ....................................................................... F 8
6.4 Replacing the drive wheel ................................................................... F 9
6.5 Checking the hydraulic oil level ........................................................... F 9
6.6 Checking electrical fuses .................................................................... F 10
6.7 Recommissioning ................................................................................ F 11
7 Decommissioning the industrial truck .................................................. F 11
7.1 Prior to decommissioning: ................................................................... F 11
7.2 During decommissioning: .................................................................... F 11
7.3 Returning the truck to operation after decommissioning ..................... F 12
8 Safety checks to be performed at regular intervals and
following any unusual incidents ........................................................... F 12
9 Final de-commissioning, disposal ....................................................... F 12
0708.GB
I 2
E Operation
1 Safety regulations for the operation of industrial trucks ...................... E 1
2 Controls and indicators ....................................................................... E 2
3 Starting up the truck ............................................................................ E 4
3.1 Switching on the truck ......................................................................... E 4
4 Industrial truck operation ..................................................................... E 5
4.1 Safety regulations for truck operation ................................................. E 5
4.2 Driving, steering, braking .................................................................... E 6
4.3 Lifting and depositing loads ................................................................. E 9
4.4 Parking the truck securely ................................................................... E 10
5 Keypad (CANCODE) (o) .................................................................... E 11
5.1 Code lock ............................................................................................ E 11
5.2 Travel programs .................................................................................. E 13
5.3 Parameters .......................................................................................... E 13
5.4 Parameter settings .............................................................................. E 14
5.5 Travel parameters ............................................................................... E 18
6 Display instrument (CANDIS) (o) ....................................................... E 21
6.1 Discharge monitor function ................................................................. E 22
6.2 Operating hours display ...................................................................... E 22
6.3 Power up test ...................................................................................... E 22
7 Troubleshooting .................................................................................. E 23
F Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance safety regulations .......................................................... F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ........................................................................ F 4
5 Maintenance schedule ........................................................................ F 6
5.1 Consumables ...................................................................................... F 7
6 Maintenance and repairs ..................................................................... F 8
6.1 Preparing the truck for maintenance and repairs ................................ F 8
6.2 Opening the battery panel ................................................................... F 8
6.3 Opening the front panel ....................................................................... F 8
6.4 Replacing the drive wheel ................................................................... F 9
6.5 Checking the hydraulic oil level ........................................................... F 9
6.6 Checking electrical fuses .................................................................... F 10
6.7 Recommissioning ................................................................................ F 11
7 Decommissioning the industrial truck .................................................. F 11
7.1 Prior to decommissioning: ................................................................... F 11
7.2 During decommissioning: .................................................................... F 11
7.3 Returning the truck to operation after decommissioning ..................... F 12
8 Safety checks to be performed at regular intervals and
following any unusual incidents ........................................................... F 12
9 Final de-commissioning, disposal ....................................................... F 12
Page 6
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
Page 7
0506.GB 20506.GB
2
Page 8
A 1
0406.GB
A Correct Use and Application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be used, operated and serviced in accordance with the present instructions.
All other types of use lie beyond the scope of application and can result in damage to
personnel, the truck or property. In particular, avoid overloading the truck with loads
which are too heavy or placed on one side. The data plate attached to the truck or the
load chart are binding for the maximum load capacity. The industrial truck must not
be used in fire or explosion endangered areas, or areas threatened by corrosion or
excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual
the “proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the truck is used only for the purpose it is intended
for, and that no danger to life and limb of the user and third parties will result.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood these operating instructions.
M
Failure to comply with the operating instructions shall invalidate the warranty.
The same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which
affects or enhances the performance of the industrial truck requires the written
permission of the manufacturer. In some cases, local authority approval shall be
required.
Approval of the local authorities however does not constitute the manufacturer’s
approval.
A 1
0406.GB
A Correct Use and Application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be used, operated and serviced in accordance with the present instructions.
All other types of use lie beyond the scope of application and can result in damage to
personnel, the truck or property. In particular, avoid overloading the truck with loads
which are too heavy or placed on one side. The data plate attached to the truck or the
load chart are binding for the maximum load capacity. The industrial truck must not
be used in fire or explosion endangered areas, or areas threatened by corrosion or
excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual
the “proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the truck is used only for the purpose it is intended
for, and that no danger to life and limb of the user and third parties will result.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood these operating instructions.
M
Failure to comply with the operating instructions shall invalidate the warranty.
The same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which
affects or enhances the performance of the industrial truck requires the written
permission of the manufacturer. In some cases, local authority approval shall be
required.
Approval of the local authorities however does not constitute the manufacturer’s
approval.
Page 9
0406.GB
A 2
0406.GB
A 2
Page 10
B 1
0708.GB
B Truck Description
1 Application
The ECE 118 is a tiller guided electric truck with an operator position and a backrest.
The truck is designed for lifting and transporting goods on a level surface. The truck
can lift open-bottom or diagonal-board pallets or roll cages that extend beyond
the area of the load wheels. The capacity of the truck is shown on the data plate or
the data capacity plate Qmax.
B 1
0708.GB
B Truck Description
1 Application
The ECE 118 is a tiller guided electric truck with an operator position and a backrest.
The truck is designed for lifting and transporting goods on a level surface. The truck
can lift open-bottom or diagonal-board pallets or roll cages that extend beyond
the area of the load wheels. The capacity of the truck is shown on the data plate or
the data capacity plate Qmax.
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0708.GB
B 2
2 Assemblies
Item Description Item Description
1 t Travel switch 8 t Castor wheel
2 t Tiller 9 t Drive wheel
3 o
Display instrument
(CANDIS)
10 t Operator position with pressure
sensitive mat
4 t Key switch 11 t Backrest
5 o
Keypad
(CANCODE)
12 t Forks
6 t Battery discharge
indicator
7 t Battery connector
t = Standard equipment o = Optional equipment
1
2
788
10
3, 6
4, 5
9
11
12
0708.GB
B 2
2 Assemblies
Item Description Item Description
1 t Travel switch 8 t Castor wheel
2 t Tiller 9 t Drive wheel
3 o
Display instrument
(CANDIS)
10 t Operator position with pressure
sensitive mat
4 t Key switch 11 t Backrest
5 o
Keypad
(CANCODE)
12 t Forks
6 t Battery discharge
indicator
7 t Battery connector
t = Standard equipment o = Optional equipment
1
2
788
10
3, 6
4, 5
9
11
12
Page 12
B 3
0708.GB
3 Technical specifications
Z
Technical data specified in accordance with VDI 2198.
Subject to technical modifications and addenda
3.1 Performance data
*: for standard travel program no. 3
3.2 Dimensions
3.3 Table of dimensions
1) Load section raised; if load section lowered: +72 mm
2) Battery XL version; for battery long version: +72 mm
Ast = Wa+l6-x+a (palett longit.)
Description
Q Capacity 1,800 kg
c Load centre of gravity distance 600 mm
Travel speed, operator position mode
Maximum / standard* 10.5 / 10.5 km/h
Travel speed, pedestrian mode
Maximum / standard* 7.0 / 4.5 km/h
Lift time w / w.o. load 2 / 2 s
Lowering speed w / w.o. load 2.2 / 2.9 s
Max. gradeability (above 5 mins) w / w.o. load 5.0 / 10.0 %
Description
h14Tiller height in min/max travel position 1130 / 1450 mm
h13Lowered fork height 85 mm
h3Lift 122 mm
b1Truck width 700 mm
b5Width across forks 532 / 672 mm
e Fork width 162 mm
a Safety distance 200 mm
Net weight: see truck data plate
ll
1
2)
y
1) 2)
x
1)
l
6
b
12
W
a
1) 2)
A
st
1) 2)
1150 2352 1870 910 1200 800 2180 2786
1400 2602 2120 1160 1400 700 2430 3036
1600 2802 2320 1360 1600 1200 2630 3236
2400 3602 3120 2160 2400 1200 3430 4036
B 3
0708.GB
3 Technical specifications
Z
Technical data specified in accordance with VDI 2198.
Subject to technical modifications and addenda
3.1 Performance data
*: for standard travel program no. 3
3.2 Dimensions
3.3 Table of dimensions
1) Load section raised; if load section lowered: +72 mm
2) Battery XL version; for battery long version: +72 mm
Ast = Wa+l6-x+a (palett longit.)
Description
Q Capacity 1,800 kg
c Load centre of gravity distance 600 mm
Travel speed, operator position mode
Maximum / standard* 10.5 / 10.5 km/h
Travel speed, pedestrian mode
Maximum / standard* 7.0 / 4.5 km/h
Lift time w / w.o. load 2 / 2 s
Lowering speed w / w.o. load 2.2 / 2.9 s
Max. gradeability (above 5 mins) w / w.o. load 5.0 / 10.0 %
Description
h14Tiller height in min/max travel position 1130 / 1450 mm
h13Lowered fork height 85 mm
h3Lift 122 mm
b1Truck width 700 mm
b5Width across forks 532 / 672 mm
e Fork width 162 mm
a Safety distance 200 mm
Net weight: see truck data plate
ll
1
2)
y
1) 2)
x
1)
l
6
b
12
W
a
1) 2)
A
st
1) 2)
1150 2352 1870 910 1200 800 2180 2786
1400 2602 2120 1160 1400 700 2430 3036
1600 2802 2320 1360 1600 1200 2630 3236
2400 3602 3120 2160 2400 1200 3430 4036
Page 13
0708.GB
B 4
Dimensions
b1
10
06
850
0708.GB
B 4
Dimensions
b1
10
06
850
Page 14
B 5
0708.GB
3.4 EN standards
Noise emission: 68 dB(A)
as defined in EN 12053, harmonised by ISO 4871.
Z
The noise emission level is calculated by standard procedures, and takes into
account the noise level when travelling, lifting and idling. The noise level is measured
at the driver’s ear.
Vibration: 0.67 m/s
2
In accordance with EN 13059.
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. This is calculated when travelling over bumps at constant
speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with
tolerance levels for electromagnetic emissions and
resistance as well as static electricity discharge testing in
accordance with EN 12895 including the normative
procedures contained therein.
Z
No modifications may be made to electrical or electronic components, or their layout,
without the written consent of the manufacturer.
3.5 Operating conditions
Ambient temperature
- in operation -10 °C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
B 5
0708.GB
3.4 EN standards
Noise emission: 68 dB(A)
as defined in EN 12053, harmonised by ISO 4871.
Z
The noise emission level is calculated by standard procedures, and takes into
account the noise level when travelling, lifting and idling. The noise level is measured
at the driver’s ear.
Vibration: 0.67 m/s
2
In accordance with EN 13059.
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. This is calculated when travelling over bumps at constant
speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with
tolerance levels for electromagnetic emissions and
resistance as well as static electricity discharge testing in
accordance with EN 12895 including the normative
procedures contained therein.
Z
No modifications may be made to electrical or electronic components, or their layout,
without the written consent of the manufacturer.
3.5 Operating conditions
Ambient temperature
- in operation -10 °C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
Page 15
0708.GB
B 6
4 Identification points and data plates
Z
The truck data plate (15) is visible when the load section is raised.
The battery data plate (18) can be seen on the battery (see Chapter D).
Item Description
15 Truck data plate
16 Nominal load capacity
17 Attachment point for crane lifting
18 Battery data plate
19 Test sticker (o)
16
17
18
15
19
1800
0708.GB
B 6
4 Identification points and data plates
Z
The truck data plate (15) is visible when the load section is raised.
The battery data plate (18) can be seen on the battery (see Chapter D).
Item Description
15 Truck data plate
16 Nominal load capacity
17 Attachment point for crane lifting
18 Battery data plate
19 Test sticker (o)
16
17
18
15
19
1800
Page 16
B 7
0708.GB
4.1 Truck data plate
Z
For queries regarding the truck or ordering spare parts always quote the truck serial
number (21).
Item Description Item Description
20 Model 26 Manufacturer
21 Serial no. 27 Min./max. battery weight (kg)
22 Rated capacity (kg) 28 Drive power in kW
23 Battery: Voltage (V) 29 Load centre of gravity (mm)
24 Unloaded weight w.o. battery (kg) 30 Year of manufacture
25 Manufacturer’s logo 31 Option
26
25
2724
2823
2922
3021
3120
B 7
0708.GB
4.1 Truck data plate
Z
For queries regarding the truck or ordering spare parts always quote the truck serial
number (21).
Item Description Item Description
20 Model 26 Manufacturer
21 Serial no. 27 Min./max. battery weight (kg)
22 Rated capacity (kg) 28 Drive power in kW
23 Battery: Voltage (V) 29 Load centre of gravity (mm)
24 Unloaded weight w.o. battery (kg) 30 Year of manufacture
25 Manufacturer’s logo 31 Option
26
25
2724
2823
2922
3021
3120
Page 17
0708.GB
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B 8
Page 18
C 1
0406.GB
C Transport and Commissioning
1 Lifting by crane
F
Only use lifting gear with sufficient
capacity (for truck weight see truck
data plate, Chapter B).
Z
Lifting gear attachment points (1) are
provided on the chassis and the fork in
case the truck is to be lifted or
transported by crane.
– Park the truck securely (see
Chapter E).
– Secure the lifting slings to the
attachment points (1).
M
The lifting gear must be attached to the
attachment points in such a manner
that it cannot slip under any
circumstances and cannot come into
contact with any attachments of the
truck when the truck is lifted.
2 Using the truck for the first time
M
Drive the truck using battery power only! Rectified AC current will damage
the electronic components. Battery connecting leads (trailing cables) must be less
than 6m long.
To prepare the truck after delivery or after transport, proceed as follows:
– Make sure the truck’s equipment is complete and in a satisfactory condition.
– Install the battery (if required). Do not damage the battery cable.
– Charge the battery (see Chapter D).
– If necessary, adjust the combination instrument to match the battery type
(see Chapter D).
1
1
1
C 1
0406.GB
C Transport and Commissioning
1 Lifting by crane
F
Only use lifting gear with sufficient
capacity (for truck weight see truck
data plate, Chapter B).
Z
Lifting gear attachment points (1) are
provided on the chassis and the fork in
case the truck is to be lifted or
transported by crane.
– Park the truck securely (see
Chapter E).
– Secure the lifting slings to the
attachment points (1).
M
The lifting gear must be attached to the
attachment points in such a manner
that it cannot slip under any
circumstances and cannot come into
contact with any attachments of the
truck when the truck is lifted.
2 Using the truck for the first time
M
Drive the truck using battery power only! Rectified AC current will damage
the electronic components. Battery connecting leads (trailing cables) must be less
than 6m long.
To prepare the truck after delivery or after transport, proceed as follows:
– Make sure the truck’s equipment is complete and in a satisfactory condition.
– Install the battery (if required). Do not damage the battery cable.
– Charge the battery (see Chapter D).
– If necessary, adjust the combination instrument to match the battery type
(see Chapter D).
1
1
1
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0406.GB
C 2
3 Removing the transport lock
There is an instruction decal by the front panel for the transport retainer (2), this must
be removed once the battery has been installed.
– Fold down the driver’s platform.
– Open the front panel (see Chapter F).
– Remove the cable binder latch (3), loosen the nut (2) and remove the transport lock.
– Leave the transport retainer on the truck for later transportation without a battery.
Z
The transport lock ensures that the truck is braked without the mass of the battery.
– Start up the truck in accordance with instructions (see Chapter E).
Z
When the truck is parked, there may be flattening of the contact surface of the tyres.
This will disappear quickly once the truck is operated.
2
3
0406.GB
C 2
3 Removing the transport lock
There is an instruction decal by the front panel for the transport retainer (2), this must
be removed once the battery has been installed.
– Fold down the driver’s platform.
– Open the front panel (see Chapter F).
– Remove the cable binder latch (3), loosen the nut (2) and remove the transport lock.
– Leave the transport retainer on the truck for later transportation without a battery.
Z
The transport lock ensures that the truck is braked without the mass of the battery.
– Start up the truck in accordance with instructions (see Chapter E).
Z
When the truck is parked, there may be flattening of the contact surface of the tyres.
This will disappear quickly once the truck is operated.
2
3
Page 20
C 3
0406.GB
4 Moving the truck without using the drive unit
F
This operation is not permitted on slopes and gradients.
If the truck has to be moved after a failure occurs preventing driving operations,
proceed as follows:
– Set the key switch to the “Off” position and remove the key.
– Disconnect the battery.
– Immobilise the truck.
– Open and put away the front cover (see Chapter F).
– Turn the screws (4) anti-clockwise as far as the stop.
The brake is now released and the truck can be moved.
F
After reaching the destination, the brake must be returned to its original state! Never
park the truck with the brake released.
– Now turn the screws (4) clockwise as far as the stop.
The brake is now applied again.
4
C 3
0406.GB
4 Moving the truck without using the drive unit
F
This operation is not permitted on slopes and gradients.
If the truck has to be moved after a failure occurs preventing driving operations,
proceed as follows:
– Set the key switch to the “Off” position and remove the key.
– Disconnect the battery.
– Immobilise the truck.
– Open and put away the front cover (see Chapter F).
– Turn the screws (4) anti-clockwise as far as the stop.
The brake is now released and the truck can be moved.
F
After reaching the destination, the brake must be returned to its original state! Never
park the truck with the brake released.
– Now turn the screws (4) clockwise as far as the stop.
The brake is now applied again.
4
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0406.GB
C 4
5 Securing the truck during transport
The truck must be lashed securely if transported on a lorry or trailer. The lorry / trailer
must be fitted with lashing rings. Fold the side protection and the folding platform in
or up so that they do not protrude beyond the geometry of the truck.
– To secure the truck, hook the tensioning belt (3) with the integrated load hook into
the load handling points (1) and attach it to the fastening rings.
– Tighten the tensioning belt with the tensioner (4).
Carry out this process on both sides of the truck.
Loading must be carried out by specially trained personnel in accordance with
the recommendations in Guidelines VDI 2700 and VDI 2703. In each case correct
measurements must be made and appropriate safety measures adopted.
3
1
4
0406.GB
C 4
5 Securing the truck during transport
The truck must be lashed securely if transported on a lorry or trailer. The lorry / trailer
must be fitted with lashing rings. Fold the side protection and the folding platform in
or up so that they do not protrude beyond the geometry of the truck.
– To secure the truck, hook the tensioning belt (3) with the integrated load hook into
the load handling points (1) and attach it to the fastening rings.
– Tighten the tensioning belt with the tensioner (4).
Carry out this process on both sides of the truck.
Loading must be carried out by specially trained personnel in accordance with
the recommendations in Guidelines VDI 2700 and VDI 2703. In each case correct
measurements must be made and appropriate safety measures adopted.
3
1
4
Page 22
D 1
0406.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. Follow these operating instructions and the instructions of the
manufacturer of the battery and charging station when carrying out the work.
Fire protection: When working with batteries, do not smoke and keep away from
naked flames. Wherever a truck is parked for charging, there must be no inflammable
material or operating fluids capable of creating sparks within a 2 metre radius of the
truck. The area must be well ventilated. Fire protection equipment must be provided.
Battery maintenance: The battery covers must be kept dry and clean. The terminals
and cable shoes must be clean, firmly attached, and be lightly coated with dielectric
grease. Batteries with non-insulated terminals must be covered with a non-slip
insulating mat.
Battery disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or waste disposal laws. Follow the
manufacturer’s disposal instructions.
M
Before closing the battery panel, make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution that is poisonous and corrosive. Therefore, always
wear protective clothing and eye protection when working on batteries. Above all,
avoid any contact with battery acid.
However, if clothing, skin or eyes still come into contact with acid, the affected parts
should be rinsed with plenty of clean water. If skin or eyes are affected, seek medical
attention. Neutralise any spilled battery acid immediately.
M
Only use batteries with a sealed battery container.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the truck. The battery equipment is to be replaced only after
agreement with the manufacturer.
D 1
0406.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. Follow these operating instructions and the instructions of the
manufacturer of the battery and charging station when carrying out the work.
Fire protection: When working with batteries, do not smoke and keep away from
naked flames. Wherever a truck is parked for charging, there must be no inflammable
material or operating fluids capable of creating sparks within a 2 metre radius of the
truck. The area must be well ventilated. Fire protection equipment must be provided.
Battery maintenance: The battery covers must be kept dry and clean. The terminals
and cable shoes must be clean, firmly attached, and be lightly coated with dielectric
grease. Batteries with non-insulated terminals must be covered with a non-slip
insulating mat.
Battery disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or waste disposal laws. Follow the
manufacturer’s disposal instructions.
M
Before closing the battery panel, make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution that is poisonous and corrosive. Therefore, always
wear protective clothing and eye protection when working on batteries. Above all,
avoid any contact with battery acid.
However, if clothing, skin or eyes still come into contact with acid, the affected parts
should be rinsed with plenty of clean water. If skin or eyes are affected, seek medical
attention. Neutralise any spilled battery acid immediately.
M
Only use batteries with a sealed battery container.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the truck. The battery equipment is to be replaced only after
agreement with the manufacturer.
Page 23
0406.GB
D 2
2Battery types
The battery types correspond to EN 60254-2.
The following table shows the combinations to be used, with reference to their
capacity:
The battery weight is indicated on the battery data plate.
Depending on battery type, high-performance or maintenance-free batteries can be
used.
F
When replacing or installing the battery, ensure that it is correctly secured in
the battery compartment.
3 Exposing the battery
F
Park the truck securely (see Chapter E).
3.1 Standard version
– Remove the battery connector (3).
– Lift up the battery panel (1) using the grip mould (2) and fold it back.
Battery type Battery
compartment
approx. 227 mm
Weight Battery
compartment
approx. 299 mm
Weight
24 V battery 3EPzS 230 Ah 210 kg 3 EPzS 345 Ah 290 kg
24 V battery
(increased output)
2EPzS 250 Ah 210 kg 3 EPzS 375 Ah 290 kg
3
2
1
0406.GB
D 2
2Battery types
The battery types correspond to EN 60254-2.
The following table shows the combinations to be used, with reference to their
capacity:
The battery weight is indicated on the battery data plate.
Depending on battery type, high-performance or maintenance-free batteries can be
used.
F
When replacing or installing the battery, ensure that it is correctly secured in
the battery compartment.
3 Exposing the battery
F
Park the truck securely (see Chapter E).
3.1 Standard version
– Remove the battery connector (3).
– Lift up the battery panel (1) using the grip mould (2) and fold it back.
Battery type Battery
compartment
approx. 227 mm
Weight Battery
compartment
approx. 299 mm
Weight
24 V battery 3EPzS 230 Ah 210 kg 3 EPzS 345 Ah 290 kg
24 V battery
(increased output)
2EPzS 250 Ah 210 kg 3 EPzS 375 Ah 290 kg
3
2
1
Page 24
D 3
0406.GB
4 Charging the battery
M
To charge the battery, the truck must be parked in a closed and properly ventilated
room. When charging, the tops of the battery cells must be laid open to provide
sufficient ventilation. Do not place any metal objects across the battery. Before
charging, check all cables and plug connections for visible signs of damage.
All safety notices provided by the battery supplier and battery charger supplier must
be strictly observed.
4.1 Charging the battery with a stationary charger
– Expose the battery (see Section 3).
– Connect the battery plug (4) with the charging lead of the stationary charger (5) and
turn on the charger.
4
5
D 3
0406.GB
4 Charging the battery
M
To charge the battery, the truck must be parked in a closed and properly ventilated
room. When charging, the tops of the battery cells must be laid open to provide
sufficient ventilation. Do not place any metal objects across the battery. Before
charging, check all cables and plug connections for visible signs of damage.
All safety notices provided by the battery supplier and battery charger supplier must
be strictly observed.
4.1 Charging the battery with a stationary charger
– Expose the battery (see Section 3).
– Connect the battery plug (4) with the charging lead of the stationary charger (5) and
turn on the charger.
4
5
Page 25
0406.GB
D 4
5 Battery removal and installation
F
The truck must be level. To prevent short circuits, batteries with exposed terminals or
connectors must be covered with a rubber mat. Place the battery connector or battery
cable in such a way that they do not catch on the truck when the battery is removed.
Z
When transporting batteries using a crane, ensure that the crane is of adequate
capacity (the battery weight is indicated on the battery data plate on the battery
container). The crane lifting gear must exert a vertical pull. The hooks of the lifting
gear must never fall into the battery cells.
– Expose the battery (see Section 3).
– Remove the battery connector (3).
– Undo the screw (6) of the battery retainer and remove the battery retainer (7).
– Strap the crane lifting gear to the eyes (8).
– Pull the battery up out of the container.
M
Installation is the reverse order. When re-installing the battery, ensure it is correctly
positioned and that the battery is connected correctly.
– After installing the battery, check all cables and plug connections for visible signs
of damage.
F
Close the battery panel carefully and slowly.
Do not reach between the battery panel and the chassis.
7 86
0406.GB
D 4
5 Battery removal and installation
F
The truck must be level. To prevent short circuits, batteries with exposed terminals or
connectors must be covered with a rubber mat. Place the battery connector or battery
cable in such a way that they do not catch on the truck when the battery is removed.
Z
When transporting batteries using a crane, ensure that the crane is of adequate
capacity (the battery weight is indicated on the battery data plate on the battery
container). The crane lifting gear must exert a vertical pull. The hooks of the lifting
gear must never fall into the battery cells.
– Expose the battery (see Section 3).
– Remove the battery connector (3).
– Undo the screw (6) of the battery retainer and remove the battery retainer (7).
– Strap the crane lifting gear to the eyes (8).
– Pull the battery up out of the container.
M
Installation is the reverse order. When re-installing the battery, ensure it is correctly
positioned and that the battery is connected correctly.
– After installing the battery, check all cables and plug connections for visible signs
of damage.
F
Close the battery panel carefully and slowly.
Do not reach between the battery panel and the chassis.
7 86
Page 26
D 5
0406.GB
6 Battery discharge indicator (t)
After the truck has been released via the key switch
or CANCODE, the battery charge status is
displayed.
The colours of the LEDs (9) represent the following conditions:
Z
If the LED is red, load units can no longer be lifted. Lifting is only released when the
battery connected is at least 70 % charged.
If the charge status calculated when the truck is switched on is at least 70 % of that
of a fully charged battery, the display is reset to 100 %. The display reduces in
increments of 10 % depending on the charge status. The displayed status is reduced
to a maximum of 10 % within 3 minutes.
The displayed status cannot rise again during the present operation.
The status display is reset to 100 % when the battery type is adjusted.
If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a fault code of the truck controller.
The flashing sequence indicates the type of fault.
LED colour Value
Green Standard battery residual capacity 40 - 100 %
Maintenance free battery residual capacity 60 - 100 %
Orange Standard battery residual capacity 30 - 40 %
Maintenance free battery residual capacity 50 - 60 %
Green/orange
flashing 1Hz
Standard battery residual capacity 20 - 30 %
Maintenance free battery residual capacity 40 - 50 %
Red Standard battery residual capacity 0 - 20 %
Maintenance free battery residual capacity 0 - 40 %
9
D 5
0406.GB
6 Battery discharge indicator (t)
After the truck has been released via the key switch
or CANCODE, the battery charge status is
displayed.
The colours of the LEDs (9) represent the following conditions:
Z
If the LED is red, load units can no longer be lifted. Lifting is only released when the
battery connected is at least 70 % charged.
If the charge status calculated when the truck is switched on is at least 70 % of that
of a fully charged battery, the display is reset to 100 %. The display reduces in
increments of 10 % depending on the charge status. The displayed status is reduced
to a maximum of 10 % within 3 minutes.
The displayed status cannot rise again during the present operation.
The status display is reset to 100 % when the battery type is adjusted.
If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a fault code of the truck controller.
The flashing sequence indicates the type of fault.
LED colour Value
Green Standard battery residual capacity 40 - 100 %
Maintenance free battery residual capacity 60 - 100 %
Orange Standard battery residual capacity 30 - 40 %
Maintenance free battery residual capacity 50 - 60 %
Green/orange
flashing 1Hz
Standard battery residual capacity 20 - 30 %
Maintenance free battery residual capacity 40 - 50 %
Red Standard battery residual capacity 0 - 20 %
Maintenance free battery residual capacity 0 - 40 %
9
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0406.GB
D 6
Page 28
E 1
0406.GB
E Operation
1 Safety regulations for the operation of industrial trucks
Permission to operate: The industrial truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they
can drive and handle loads and have been authorised to operate the truck by the
proprietor or his representative.
Driver’s rights, obligations and responsibilities: 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 operator manual. He shall be afforded all due rights. Safety shoes
must be worn with pedestrian operated trucks.
Prohibition of unauthorized use: The driver is responsible for the truck during
the time it is in use. The driver must prevent unauthorised persons from driving or
operating the truck. Do not carry passengers or lift other people.
Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the industrial truck or attachment. Trucks which are unsafe for operation
(e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the industrial truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
Dangerous area: A hazardous area is defined as the area in which a person is at risk
due to truck movement, lifting operations, the load handler (e.g. forks or attachments)
or the load itself. This also includes areas which can be reached by falling loads or
lowering operating equipment.
F
Unauthorised persons must be kept away from the hazardous area. Where there
is danger to personnel, a warning must be sounded with sufficient notice.
If unauthorised personnel are still within the hazardous area the truck shall be
brought to a halt immediately.
Safety devices and warning signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
E 1
0406.GB
E Operation
1 Safety regulations for the operation of industrial trucks
Permission to operate: The industrial truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they
can drive and handle loads and have been authorised to operate the truck by the
proprietor or his representative.
Driver’s rights, obligations and responsibilities: 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 operator manual. He shall be afforded all due rights. Safety shoes
must be worn with pedestrian operated trucks.
Prohibition of unauthorized use: The driver is responsible for the truck during
the time it is in use. The driver must prevent unauthorised persons from driving or
operating the truck. Do not carry passengers or lift other people.
Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the industrial truck or attachment. Trucks which are unsafe for operation
(e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the industrial truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
Dangerous area: A hazardous area is defined as the area in which a person is at risk
due to truck movement, lifting operations, the load handler (e.g. forks or attachments)
or the load itself. This also includes areas which can be reached by falling loads or
lowering operating equipment.
F
Unauthorised persons must be kept away from the hazardous area. Where there
is danger to personnel, a warning must be sounded with sufficient notice.
If unauthorised personnel are still within the hazardous area the truck shall be
brought to a halt immediately.
Safety devices and warning signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
Page 29
0406.GB
E 2
2 Controls and indicators
Item Control / display Function
1 Front panel t The complete hydraulics and control electronics
are located behind the front panel.
2 Tiller t Important control elements are located in the tiller
arm.
3 Brake button t The truck brakes at the maximum rate until it
comes to a halt.
4Controller t Controls travel direction and speed
(see Section 4.2)
5 Tiller t Moving tiller;
Steering and braking:
Set to brake zone (B) (see page E9):
Truck is braked mechanically.
Set to travel zone (F) (see page E9):
The mechanical brake is released and the truck
is ready for operation.
6 Warning signal (horn) button t Sets off the warning signal.
7 “Lower” button t Lowers the load forks.
8 “Lift” button t Raises the load forks.
9 Battery discharge indicator t Battery charge status.
10 Display instrument (CANDIS) o Hourmeter display
Displays battery capacity.
Shows the battery residual capacity and the
operating hours completed by the truck
11 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel.
12 CANCODE keypad o Code settings
Travel program release
13 Battery connector
(Emergency Disconnect)
t Pulling the battery connector interrupts the supply
current and deactivates all electrical functions,
causing the truck to brake automatically.
14 Pressure sensitive mat
(all functions released when
occupied)
t – Pressure sensitive mat occupied:
Travel and all functions released.
– Pressure sensitive mat unoccupied:
The truck coasts.
t = Standard equipment o = Optional equipment
0406.GB
E 2
2 Controls and indicators
Item Control / display Function
1 Front panel t The complete hydraulics and control electronics
are located behind the front panel.
2 Tiller t Important control elements are located in the tiller
arm.
3 Brake button t The truck brakes at the maximum rate until it
comes to a halt.
4Controller t Controls travel direction and speed
(see Section 4.2)
5 Tiller t Moving tiller;
Steering and braking:
Set to brake zone (B) (see page E9):
Truck is braked mechanically.
Set to travel zone (F) (see page E9):
The mechanical brake is released and the truck
is ready for operation.
6 Warning signal (horn) button t Sets off the warning signal.
7 “Lower” button t Lowers the load forks.
8 “Lift” button t Raises the load forks.
9 Battery discharge indicator t Battery charge status.
10 Display instrument (CANDIS) o Hourmeter display
Displays battery capacity.
Shows the battery residual capacity and the
operating hours completed by the truck
11 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel.
12 CANCODE keypad o Code settings
Travel program release
13 Battery connector
(Emergency Disconnect)
t Pulling the battery connector interrupts the supply
current and deactivates all electrical functions,
causing the truck to brake automatically.
14 Pressure sensitive mat
(all functions released when
occupied)
t – Pressure sensitive mat occupied:
Travel and all functions released.
– Pressure sensitive mat unoccupied:
The truck coasts.
t = Standard equipment o = Optional equipment
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0406.GB
E 4
3 Starting up the truck
F
Before the truck can be started, operated or a load lifted, the driver must ensure that
there is nobody within the hazardous area.
Daily checks and operations to be performed before starting work
– Complete visual inspection of the truck (especially wheels and load handler)
for visible signs of damage.
– Visual inspection of battery fastening and cable connections.
3.1 Switching on the truck
– Make sure the battery is connected (13).
– Insert the key in the key switch (11) and turn it to the right as far as it will go
(position “I”) or, for CANCODE (12) (o), enter the release code (see Section 5).
– Test the warning button (6).
The truck is now operational.
o The battery discharge indicator (9) or the CANDIS display instrument (10) indicates
the existing battery charge status.
– Test the tiller brake function (5) (see section 4.2).
6
13
11, 12
9, 10
5
0406.GB
E 4
3 Starting up the truck
F
Before the truck can be started, operated or a load lifted, the driver must ensure that
there is nobody within the hazardous area.
Daily checks and operations to be performed before starting work
– Complete visual inspection of the truck (especially wheels and load handler)
for visible signs of damage.
– Visual inspection of battery fastening and cable connections.
3.1 Switching on the truck
– Make sure the battery is connected (13).
– Insert the key in the key switch (11) and turn it to the right as far as it will go
(position “I”) or, for CANCODE (12) (o), enter the release code (see Section 5).
– Test the warning button (6).
The truck is now operational.
o The battery discharge indicator (9) or the CANDIS display instrument (10) indicates
the existing battery charge status.
– Test the tiller brake function (5) (see section 4.2).
6
13
11, 12
9, 10
5
Page 32
E 5
0406.GB
4 Industrial truck operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must
only be stored in places specially designated for this purpose.
Driving conduct: The driver must adapt the travel speed to local conditions.
The truck must be driven at slow speed when negotiating bends or narrow
passageways, when passing through swing doors and at blind spots. The driver must
always observe an adequate braking distance between the industrial truck and the
vehicle in front and must be in control of the truck at all times. Abrupt stopping (except
in emergencies), rapid U turns and overtaking at dangerous or blind spots are not
permitted. It is forbidden to lean out of or reach beyond the working and operating
area.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. Loads that affect visibility must be positioned at the
rear of the truck. If this is not possible, a second person must walk in front of the truck
as a lookout.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The truck must always be driven with the load unit facing uphill.
The industrial truck must not be turned, operated at an angle or parked on inclines or
slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake
at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the proprietor.
The driver must satisfy himself of the above before entering these areas. The truck
must enter lifts with the load in front and must take up a position which does not allow
it to come into contact with the walls of the lift shaft.
Persons riding in the lift with the industrial truck must only enter the lift after the truck
has come to a rest and must leave the lift before the truck.
Nature of loads to be carried: The operator must make sure that the load is in
correct condition. Only loads that are positioned securely and carefully must be
moved. Use suitable precautions, e.g. a load guard, to prevent parts of the load from
tipping or falling off.
E 5
0406.GB
4 Industrial truck operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must
only be stored in places specially designated for this purpose.
Driving conduct: The driver must adapt the travel speed to local conditions.
The truck must be driven at slow speed when negotiating bends or narrow
passageways, when passing through swing doors and at blind spots. The driver must
always observe an adequate braking distance between the industrial truck and the
vehicle in front and must be in control of the truck at all times. Abrupt stopping (except
in emergencies), rapid U turns and overtaking at dangerous or blind spots are not
permitted. It is forbidden to lean out of or reach beyond the working and operating
area.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. Loads that affect visibility must be positioned at the
rear of the truck. If this is not possible, a second person must walk in front of the truck
as a lookout.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The truck must always be driven with the load unit facing uphill.
The industrial truck must not be turned, operated at an angle or parked on inclines or
slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake
at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the proprietor.
The driver must satisfy himself of the above before entering these areas. The truck
must enter lifts with the load in front and must take up a position which does not allow
it to come into contact with the walls of the lift shaft.
Persons riding in the lift with the industrial truck must only enter the lift after the truck
has come to a rest and must leave the lift before the truck.
Nature of loads to be carried: The operator must make sure that the load is in
correct condition. Only loads that are positioned securely and carefully must be
moved. Use suitable precautions, e.g. a load guard, to prevent parts of the load from
tipping or falling off.
Page 33
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E 6
4.2 Driving, steering, braking
F
Full attention is required when driving and steering, especially when outside of
the truck envelope.
In walk-along mode make sure you have sufficient distance from the truck.
Emergency Off
– Remove the battery connector (13). All electrical functions are shut down.
Emergency Stop
Automatic braking (emergency stop) occurs when the tiller (5) is released – the tiller
automatically reverts to the upper brake zone (B).
F
If the tiller moves only slowly to the brake zone, the cause of the fault must be
rectified. If necessary, replace the return spring.
Travel
We distinguish between two travel modes:
– Rider mode (the operator platform is occupied): the truck can be operated at
maximum travel speed.
– Pedestrian mode (optional); (the operator platform is not occupied): The truck can
only be operated at the reduced travel speed (crawl speed).
General:
– Stand on the operator platform (14).
– Set the tiller (5) to the travel zone (F).
– Turn the controller (4) to the required direction V (fwd.) or R (rev.).
F
Do not drive the truck unless the panels are closed and properly locked. When
travelling through swing doors etc., take care to prevent the doors from actuating
the collision safety switch (3).
– Start up the truck (see Section 3).
0406.GB
E 6
4.2 Driving, steering, braking
F
Full attention is required when driving and steering, especially when outside of
the truck envelope.
In walk-along mode make sure you have sufficient distance from the truck.
Emergency Off
– Remove the battery connector (13). All electrical functions are shut down.
Emergency Stop
Automatic braking (emergency stop) occurs when the tiller (5) is released – the tiller
automatically reverts to the upper brake zone (B).
F
If the tiller moves only slowly to the brake zone, the cause of the fault must be
rectified. If necessary, replace the return spring.
Travel
We distinguish between two travel modes:
– Rider mode (the operator platform is occupied): the truck can be operated at
maximum travel speed.
– Pedestrian mode (optional); (the operator platform is not occupied): The truck can
only be operated at the reduced travel speed (crawl speed).
General:
– Stand on the operator platform (14).
– Set the tiller (5) to the travel zone (F).
– Turn the controller (4) to the required direction V (fwd.) or R (rev.).
F
Do not drive the truck unless the panels are closed and properly locked. When
travelling through swing doors etc., take care to prevent the doors from actuating
the collision safety switch (3).
– Start up the truck (see Section 3).
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Page 35
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E 8
Steering
F
In narrow bends the driver extends beyond the geometry of the truck.
– Move the tiller (5) to the left or right.
Brakes
F
The braking characteristics of the truck depends largely on the track conditions.
The driver must allow for these when operating the truck.
The truck can be braked in two different ways:
– by plugging
– by using the service brake
Braking by plugging (counter current):
– When travelling, set the controller (4) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z
The brake force depends on the position of the controller.
Braking with the service brake:
– Set the tiller (5) to one of the brake zones (B).
The drive motor brakes regeneratively (motor brake).
When the truck is idle the magnetic brake applies.
Z
When the tiller is released it reverts to the upper braking zone (B).
0406.GB
E 8
Steering
F
In narrow bends the driver extends beyond the geometry of the truck.
– Move the tiller (5) to the left or right.
Brakes
F
The braking characteristics of the truck depends largely on the track conditions.
The driver must allow for these when operating the truck.
The truck can be braked in two different ways:
– by plugging
– by using the service brake
Braking by plugging (counter current):
– When travelling, set the controller (4) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z
The brake force depends on the position of the controller.
Braking with the service brake:
– Set the tiller (5) to one of the brake zones (B).
The drive motor brakes regeneratively (motor brake).
When the truck is idle the magnetic brake applies.
Z
When the tiller is released it reverts to the upper braking zone (B).
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4.3 Lifting and depositing loads
M
Before collecting a load, the driver must
ensure that it is correctly palletised and
that the capacity of the truck is not
exceeded. It is forbidden to collect long
loads at an angle.
– Fully insert the truck and the load
handler underneath the load.
Z
The operator platform must be occupied
by the operator to release lifting/
lowering.
Z
The lifting and lowering speeds are
preset.
Lifting
– Press the “Lift” (8) button until you reach the desired lift height.
M
When you reach the limit position of the load handler, immediately release the button.
Lowering
– Press the “Lower” button (7).
7878
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0406.GB
4.3 Lifting and depositing loads
M
Before collecting a load, the driver must
ensure that it is correctly palletised and
that the capacity of the truck is not
exceeded. It is forbidden to collect long
loads at an angle.
– Fully insert the truck and the load
handler underneath the load.
Z
The operator platform must be occupied
by the operator to release lifting/
lowering.
Z
The lifting and lowering speeds are
preset.
Lifting
– Press the “Lift” (8) button until you reach the desired lift height.
M
When you reach the limit position of the load handler, immediately release the button.
Lowering
– Press the “Lower” button (7).
7878
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4.4 Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.
– Do not park the truck on an incline.
– Fully lower the load forks.
– Set the key switch (11) to the "0" position and remove the key.
– For CANCODE (6), press the o key.
– Remove the battery connector (13).
.
13
11, 12
0406.GB
E 10
4.4 Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.
– Do not park the truck on an incline.
– Fully lower the load forks.
– Set the key switch (11) to the "0" position and remove the key.
– For CANCODE (6), press the o key.
– Remove the battery connector (13).
.
13
11, 12
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5 Keypad (CANCODE) (o)
The keypad consists of 10 digit keys, a Set key
and a o key.
Activation of the travel programs via switches 1,
2, 3 is indicated by green LEDs.
The o key indicates operating statuses via a red/
green LED.
It contains the following functions:
– Code lock function (commissioning the truck).
– Travel program selection.
– Setting the travel and battery parameters, only
in conjunction with the display instrument
(CANDIS (o)).
The o switch has top priority and resets the truck
from any condition to its default condition without
modifying any settings.
5.1 Code lock
When the correct code is entered, the truck is ready for use. You can allocate an
individual code to each truck, driver or group of drivers.
Z
When supplied from the factory, the operator code (factory setting 2-5-8-0) is
indicated on a removable sticker.
M
When starting the truck for the first time, change the master and operating codes.
(refer to Section 5.4)
1 2 3
4 5 6
7 8 9
0
Set
E 11
0406.GB
5 Keypad (CANCODE) (o)
The keypad consists of 10 digit keys, a Set key
and a o key.
Activation of the travel programs via switches 1,
2, 3 is indicated by green LEDs.
The o key indicates operating statuses via a red/
green LED.
It contains the following functions:
– Code lock function (commissioning the truck).
– Travel program selection.
– Setting the travel and battery parameters, only
in conjunction with the display instrument
(CANDIS (o)).
The o switch has top priority and resets the truck
from any condition to its default condition without
modifying any settings.
5.1 Code lock
When the correct code is entered, the truck is ready for use. You can allocate an
individual code to each truck, driver or group of drivers.
Z
When supplied from the factory, the operator code (factory setting 2-5-8-0) is
indicated on a removable sticker.
M
When starting the truck for the first time, change the master and operating codes.
(refer to Section 5.4)
1 2 3
4 5 6
7 8 9
0
Set
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Start-up
When the main switch is turned on the LED (16) goes red.
When you enter the correct operator code (factory setting 2-5-8-0) the LED (16) turns
green.
If the wrong code is entered the LED (16) flashes red for two seconds. The correct
code can then be entered again.
Z
The Set key (17) has no function in operating mode
Switching off
To switch the truck off, press the
o switch (21).
Z
The truck can switch off automatically after a
pre-determined time. To do this, the
corresponding code lock parameter must be
set (refer to Section 5.4).
1 2 3
4 5 6
7 8 9
0
Set
18
17
16
21
2019
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Start-up
When the main switch is turned on the LED (16) goes red.
When you enter the correct operator code (factory setting 2-5-8-0) the LED (16) turns
green.
If the wrong code is entered the LED (16) flashes red for two seconds. The correct
code can then be entered again.
Z
The Set key (17) has no function in operating mode
Switching off
To switch the truck off, press the
o switch (21).
Z
The truck can switch off automatically after a
pre-determined time. To do this, the
corresponding code lock parameter must be
set (refer to Section 5.4).
1 2 3
4 5 6
7 8 9
0
Set
18
17
16
21
2019
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0406.GB
5.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated
program is indicated by the green LEDs (18), (19), (20) in the corresponding key.
Z
The travel programs differ with respect to travel speed, acceleration and deceleration
force.
Factory settings:
– Program 1: Gentle operation
– Program 2: Normal mode (pre-selected when using the truck for the first time)
– Program 3: Power mode
Z
The travel programs can be individually adapted (see Section 5.5).
5.3 Parameters
In programming mode, the operator keypad enables you to set the code lock
functions and adapt travel programs. In addition, the battery parameters can also
be set.
Z
For trucks without a display instrument (CANDIS (o)) only the code lock parameters
can be set.
Parameter groups
The parameter number is made up of three digits. The first digit refers to
the parameter group as shown in Table 1. The second and third digits are numbered
in sequence from 00 to 99.
No. Parameter group
0xx Code lock settings
(codes, travel program release, automatic cutout, etc.)
1xx Travel program 1 parameters
(acceleration, coasting brake, speed, etc.)
2xx Travel program 2 parameters
(acceleration, coasting brake, speed, etc.)
3xx Travel program 3 parameters
(acceleration, coasting brake, speed, etc.)
4xx Program-independent parameters
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0406.GB
5.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated
program is indicated by the green LEDs (18), (19), (20) in the corresponding key.
Z
The travel programs differ with respect to travel speed, acceleration and deceleration
force.
Factory settings:
– Program 1: Gentle operation
– Program 2: Normal mode (pre-selected when using the truck for the first time)
– Program 3: Power mode
Z
The travel programs can be individually adapted (see Section 5.5).
5.3 Parameters
In programming mode, the operator keypad enables you to set the code lock
functions and adapt travel programs. In addition, the battery parameters can also
be set.
Z
For trucks without a display instrument (CANDIS (o)) only the code lock parameters
can be set.
Parameter groups
The parameter number is made up of three digits. The first digit refers to
the parameter group as shown in Table 1. The second and third digits are numbered
in sequence from 00 to 99.
No. Parameter group
0xx Code lock settings
(codes, travel program release, automatic cutout, etc.)
1xx Travel program 1 parameters
(acceleration, coasting brake, speed, etc.)
2xx Travel program 2 parameters
(acceleration, coasting brake, speed, etc.)
3xx Travel program 3 parameters
(acceleration, coasting brake, speed, etc.)
4xx Program-independent parameters
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E 14
5.4 Parameter settings
To change the truck setting you must enter the master code.
Z
The factory setting for the master code is 7-2-9-5.
M
When starting the truck for the first time, change the master code (see Section 5.1).
F
Safety instructions for trucks with a display instrument (CANDIS (o))
– Parameter settings must be made carefully and only by special trained personnel.
If in doubt, consult the manufacturer's service department.
– Each setting must be monitored on the LC display of the display instrument
(CANDIS (o)). If in doubt, cancel the setting by pressing the o key (21).
– Since changing any parameter will affect the truck's travel pattern, you must carry
out a test run in a specially designated work area.
To enter the master code:
– Press the o key
– Enter master code
Code lock parameters
Setting procedure for trucks without a display instrument (CANDIS (o)):
– Enter the three-digit parameter number and confirm with Set key (17).
– Enter a value according to the parameter list, or change it and confirm with
the Set key (17).
Z
If the entry is incorrect, the LED (16) on the o key (21) flashes red. If you enter
the parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete the setting, press
the o key (21).
Display instrument
(CANDIS)
LED (16)
o key
LED (18)
Key 1
LED (19)
Key 2
LED (20)
Key 3
Service hours are
displayed
284.0
Green
flashing
Off Off Off
0406.GB
E 14
5.4 Parameter settings
To change the truck setting you must enter the master code.
Z
The factory setting for the master code is 7-2-9-5.
M
When starting the truck for the first time, change the master code (see Section 5.1).
F
Safety instructions for trucks with a display instrument (CANDIS (o))
– Parameter settings must be made carefully and only by special trained personnel.
If in doubt, consult the manufacturer's service department.
– Each setting must be monitored on the LC display of the display instrument
(CANDIS (o)). If in doubt, cancel the setting by pressing the o key (21).
– Since changing any parameter will affect the truck's travel pattern, you must carry
out a test run in a specially designated work area.
To enter the master code:
– Press the o key
– Enter master code
Code lock parameters
Setting procedure for trucks without a display instrument (CANDIS (o)):
– Enter the three-digit parameter number and confirm with Set key (17).
– Enter a value according to the parameter list, or change it and confirm with
the Set key (17).
Z
If the entry is incorrect, the LED (16) on the o key (21) flashes red. If you enter
the parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete the setting, press
the o key (21).
Display instrument
(CANDIS)
LED (16)
o key
LED (18)
Key 1
LED (19)
Key 2
LED (20)
Key 3
Service hours are
displayed
284.0
Green
flashing
Off Off Off
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0406.GB
Setting procedure for trucks with and without display instrument (CANDIS (o)):
– Enter the three-digit parameter number and confirm with Set key (17).
– The display instrument (CANDIS (o)) continues to display the operating hours.
If the display changes, cancel the setting with the o key (21) and restart from
the beginning.
– Enter a value according to the parameter list, or change it and confirm with
the Set key (17).
Z
If the entry is incorrect, the LED (16) on the o key (21) flashes red. If you enter
the parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete the setting, press
the o key (21).
The following parameters can be entered.
Code lock parameter list
No. Function Range
Setting value
Standard
Setting
value
Comments
Procedure
Code lock
000 Changing the master
code
The length (4-6 digits) of
the master code also predetermines the length of
the operator code (4-6
digits). Provided the
operator codes are
programmed, only news
codes of the same length
can be entered. If the
code length is to be
changed, all operator
codes must first be
deleted.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 18 flashes)
Enter the
current code
Confirm (Set)
(LED 19 flashes)
Enter a new code
Confirm (Set)
(LED 20 flashes)
Repeat the new
code
Confirm (Set)
001 Adding an operator code
(max. 600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 19 flashes)
Enter a code
Confirm (Set)
(LED 20 flashes)
Repeat the
code entry
Confirm (Set)
E 15
0406.GB
Setting procedure for trucks with and without display instrument (CANDIS (o)):
– Enter the three-digit parameter number and confirm with Set key (17).
– The display instrument (CANDIS (o)) continues to display the operating hours.
If the display changes, cancel the setting with the o key (21) and restart from
the beginning.
– Enter a value according to the parameter list, or change it and confirm with
the Set key (17).
Z
If the entry is incorrect, the LED (16) on the o key (21) flashes red. If you enter
the parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete the setting, press
the o key (21).
The following parameters can be entered.
Code lock parameter list
No. Function Range
Setting value
Standard
Setting
value
Comments
Procedure
Code lock
000 Changing the master
code
The length (4-6 digits) of
the master code also pre-
determines the length of
the operator code (4-6
digits). Provided the
operator codes are
programmed, only news
codes of the same length
can be entered. If the
code length is to be
changed, all operator
codes must first be
deleted.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 18 flashes)
Enter the
current code
Confirm (Set)
(LED 19 flashes)
Enter a new code
Confirm (Set)
(LED 20 flashes)
Repeat the new
code
Confirm (Set)
001 Adding an operator code
(max. 600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 19 flashes)
Enter a code
Confirm (Set)
(LED 20 flashes)
Repeat the
code entry
Confirm (Set)
Page 43
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E 16
LEDs 18-20 are located in key fields 1-3 (see Section 5.2)
No. Function Range
Setting value
Standard
Setting
value
Comments
Procedure
Code lock
002 Changing an operator
code
0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 18 flashes)
Enter the
current code
Confirm (Set)
(LED 19 flashes)
Enter a new code
Confirm (Set)
(LED 20 flashes)
Repeat the
code entry
Confirm
003 Deleting an operator code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 19 flashes)
Enter a code
Confirm (Set)
(LED 20 flashes)
Repeat the
code entry
Confirm (Set)
004 Clearing the code
memory
(deletes all user codes )
3265 3265 = delete
other input = do not
delete
010 Automatic timeout 00 - 31 00 00 = no cutout
01 to 30 =
Switch-off time
in minutes
31 = Switch off after
10 seconds
0406.GB
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LEDs 18-20 are located in key fields 1-3 (see Section 5.2)
No. Function Range
Setting value
Standard
Setting
value
Comments
Procedure
Code lock
002 Changing an operator
code
0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 18 flashes)
Enter the
current code
Confirm (Set)
(LED 19 flashes)
Enter a new code
Confirm (Set)
(LED 20 flashes)
Repeat the
code entry
Confirm
003 Deleting an operator code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 19 flashes)
Enter a code
Confirm (Set)
(LED 20 flashes)
Repeat the
code entry
Confirm (Set)
004 Clearing the code
memory
(deletes all user codes )
3265 3265 = delete
other input = do not
delete
010 Automatic timeout 00 - 31 00 00 = no cutout
01 to 30 =
Switch-off time
in minutes
31 = Switch off after
10 seconds
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*) only in conjunction with display instrument (CANDIS (o))
**) The start program determines which travel program is active when the truck is
switched on.
Error messages on keypad
LED (16) flashes red to indicate the following errors:
– New master code is already operator code.
– New operator code is already master code.
– Operator code to be changed does not exist.
– Tried to change the operator code to another user code that already exists.
– Operator code to be deleted does not exist.
– Code memory full
No. Function Range
Setting value
Standard
Setting
value
Comments
Procedure
Code lock
020 Start travel program **
)
1 - 3 2 Pre-selected travel
program
1 = 1 (soft operation)
2 = 2
3 = 3
021 Travel program 1
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
022 Travel program 2
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
023 Travel program 3
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
030 Display of the number of
used operator codes*
)
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0406.GB
*) only in conjunction with display instrument (CANDIS (o))
**) The start program determines which travel program is active when the truck is
switched on.
Error messages on keypad
LED (16) flashes red to indicate the following errors:
– New master code is already operator code.
– New operator code is already master code.
– Operator code to be changed does not exist.
– Tried to change the operator code to another user code that already exists.
– Operator code to be deleted does not exist.
– Code memory full
No. Function Range
Setting value
Standard
Setting
value
Comments
Procedure
Code lock
020 Start travel program **
)
1 - 3 2 Pre-selected travel
program
1 = 1 (soft operation)
2 = 2
3 = 3
021 Travel program 1
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
022 Travel program 2
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
023 Travel program 3
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
030 Display of the number of
used operator codes*
)
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E 18
5.5 Travel parameters
Z
For trucks without a display instrument (CANDIS (o)) the code lock parameters can
only be set by the manufacturer's service department.
The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 101).
Acceleration example
– Enter the three digit parameter number (101) and confirm with the Set key (17).
– Check the LC display of the display instrument (CANDIS (o)) (parameter number
and current parameter value are displayed).
Z
If there is no input for approx. 5 seconds, the display switches back to showing
the operating hours.
F
If a parameter number other than the one desired is displayed, you must wait until
the operating hours are displayed again.
– Enter or change the parameter value according to the parameter list.
– Check the LCD display of the display instrument (CANDIS (o)), confirm with
the Set key (17).
– The LED (16) of the o key (21) switches briefly to a steady light and starts flashing
again after approx. 2 seconds.
Z
If the entry is incorrect, the LED (16) on the o key (21) flashes red. If you enter
the parameter number again the setting can be entered or changed.
Repeat the process to enter more parameters as soon as the LED (16) of the o key
(21) flashes. To complete the setting, press the o key (21).
Z
Travel is disabled while the parameters are being entered. If the setting is to be
checked in programming mode, follow this sequence:
– Select the edited travel program after entering the parameter, and confirm with
the Set key (17).
– The truck is now in travel mode and can be checked.
– To continue setting, confirm with the Set key (17) again.
Display instrument
(CANDIS)
LED (16)
o key
LED (18)
Key 1
LED (19)
Key 2
LED (20)
Key 3
Current setting
is displayed
101 6
Green
flashing
Off Off Off
Changed setting
is displayed
101 8
Green
flashing
Off Off Off
Parameter
number
Parameter
setting
0406.GB
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5.5 Travel parameters
Z
For trucks without a display instrument (CANDIS (o)) the code lock parameters can
only be set by the manufacturer's service department.
The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 101).
Acceleration example
– Enter the three digit parameter number (101) and confirm with the Set key (17).
– Check the LC display of the display instrument (CANDIS (o)) (parameter number
and current parameter value are displayed).
Z
If there is no input for approx. 5 seconds, the display switches back to showing
the operating hours.
F
If a parameter number other than the one desired is displayed, you must wait until
the operating hours are displayed again.
– Enter or change the parameter value according to the parameter list.
– Check the LCD display of the display instrument (CANDIS (o)), confirm with
the Set key (17).
– The LED (16) of the o key (21) switches briefly to a steady light and starts flashing
again after approx. 2 seconds.
Z
If the entry is incorrect, the LED (16) on the o key (21) flashes red. If you enter
the parameter number again the setting can be entered or changed.
Repeat the process to enter more parameters as soon as the LED (16) of the o key
(21) flashes. To complete the setting, press the o key (21).
Z
Travel is disabled while the parameters are being entered. If the setting is to be
checked in programming mode, follow this sequence:
– Select the edited travel program after entering the parameter, and confirm with
the Set key (17).
– The truck is now in travel mode and can be checked.
– To continue setting, confirm with the Set key (17) again.
Display instrument
(CANDIS)
LED (16)
o key
LED (18)
Key 1
LED (19)
Key 2
LED (20)
Key 3
Current setting
is displayed
101 6
Green
flashing
Off Off Off
Changed setting
is displayed
101 8
Green
flashing
Off Off Off
Parameter
number
Parameter
setting
Page 46
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0406.GB
The following parameters can be entered.
Travel programs (speeds and acceleration w.o. load)
No. Function Range
Setting value
Standard
Setting
value
Comments
Travel program 1
101 Acceleration 0 - 9
(0.13 – 1.88 m/s2)40.67 m/s2)
102 Coasting brake 0 - 9
(0.11 – 1.79 m/s2)
7
(1.41 m/s2)
104 Maximum speed in drive
direction via controller
0 - 9
(4.5 - 9 km/h)3(6 km/h)
Depending on travel
switch
108 Maximum speed in fork
direction via controller
0 - 9
(4.5 - 9 km/h)3(6 km/h)
Depending on travel
switch
No. Function Range
Setting value
Standard
Setting
value
Comments
Travel program 2
201 Acceleration 0 - 9
(0.13 – 1.88 m/s)6(1.08 m/s)
202 Coasting brake 0 - 9
(0.11 – 1.79 m/s)8(1.61 m/s)
204 Maximum speed in tiller
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
208 Maximum speed in fork
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
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0406.GB
The following parameters can be entered.
Travel programs (speeds and acceleration w.o. load)
No. Function Range
Setting value
Standard
Setting
value
Comments
Travel program 1
101 Acceleration 0 - 9
(0.13 – 1.88 m/s2)40.67 m/s2)
102 Coasting brake 0 - 9
(0.11 – 1.79 m/s2)
7
(1.41 m/s2)
104 Maximum speed in drive
direction via controller
0 - 9
(4.5 - 9 km/h)3(6 km/h)
Depending on travel
switch
108 Maximum speed in fork
direction via controller
0 - 9
(4.5 - 9 km/h)3(6 km/h)
Depending on travel
switch
No. Function Range
Setting value
Standard
Setting
value
Comments
Travel program 2
201 Acceleration 0 - 9
(0.13 – 1.88 m/s)6(1.08 m/s)
202 Coasting brake 0 - 9
(0.11 – 1.79 m/s)8(1.61 m/s)
204 Maximum speed in tiller
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
208 Maximum speed in fork
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
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Battery parameters
Z
For trucks without a display instrument (CANDIS (o)) the code lock parameters can
only be set by the manufacturer's service department.
The parameters are set in the same way as for the travel parameters.
The following parameters can be entered.
Setting 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Range
Setting value
Standard
Setting
value
Comments
Travel program 3
301 Acceleration 0 - 9
(0.13 – 1.88 m/s2)8(1.62 m/s2)
302 Coasting brake 0 - 9
(0.11 – 1.79 m/s2)91.79 m/s2)
304 Maximum speed in tiller
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
308 Maximum speed in fork
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
No. Function Range
Setting value
Standard
Setting
value
Comments
Battery parameters
411 Battery type (normal/
high performance/dry)
0 - 2 0 0 = Normal (wet)
1 = Enhanced (wet)
2 = Dry
(maintenance-free)
412 Discharge monitor
function
0 / 1 1
0406.GB
E 20
Battery parameters
Z
For trucks without a display instrument (CANDIS (o)) the code lock parameters can
only be set by the manufacturer's service department.
The parameters are set in the same way as for the travel parameters.
The following parameters can be entered.
Setting 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Range
Setting value
Standard
Setting
value
Comments
Travel program 3
301 Acceleration 0 - 9
(0.13 – 1.88 m/s2)8(1.62 m/s2)
302 Coasting brake 0 - 9
(0.11 – 1.79 m/s2)91.79 m/s2)
304 Maximum speed in tiller
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
308 Maximum speed in fork
direction via controller
0 - 9
(4.5 - 9 km/h)8(8.5 km/h)
Depending on travel
switch
No. Function Range
Setting value
Standard
Setting
value
Comments
Battery parameters
411 Battery type (normal/
high performance/dry)
0 - 2 0 0 = Normal (wet)
1 = Enhanced (wet)
2 = Dry
(maintenance-free)
412 Discharge monitor
function
0 / 1 1
Page 48
E 21
0406.GB
6 Display instrument (CANDIS) (o)
The instrument indicates:
– battery residual charge status
(LED bars (23),
– Service hours
(LCD display (25)).
In addition, service messages for the
electronic components and
parameterchanges are displayed.
Discharge status display
Setting limits for the additional “Warning” (22) and “Stop” (24) displays will depend on
the battery type.
Number
of bars
Charge
level
Wet battery Maintenance free battery
LED (yellow)
Warning
LED (red)
Stop
LED (yellow)
Warning
LED (red)
Stop
10 90.1- 100 % Off Off Off Off
9 80.1 - 90 % Off Off Off Off
8 70.1 - 80 % Off Off Off Off
7 60.1 - 70 % Off Off Off Off
6 50.1 - 60 % Off Off Off Off
5 40.1 - 50 % Off Off On Off
4 30.1 - 40 % Off Off On On
3 20.1 - 30 % On Off On On
2 10.1 - 20 % On On On On
Avoid falling below the 20% limit for wet batteries or the 40 % limit for maintenancefree batteries.
23
24
25
22
E 21
0406.GB
6 Display instrument (CANDIS) (o)
The instrument indicates:
– battery residual charge status
(LED bars (23),
– Service hours
(LCD display (25)).
In addition, service messages for the
electronic components and
parameterchanges are displayed.
Discharge status display
Setting limits for the additional “Warning” (22) and “Stop” (24) displays will depend on
the battery type.
Number
of bars
Charge
level
Wet battery Maintenance free battery
LED (yellow)
Warning
LED (red)
Stop
LED (yellow)
Warning
LED (red)
Stop
10 90.1- 100 % Off Off Off Off
9 80.1 - 90 % Off Off Off Off
8 70.1 - 80 % Off Off Off Off
7 60.1 - 70 % Off Off Off Off
6 50.1 - 60 % Off Off Off Off
5 40.1 - 50 % Off Off On Off
4 30.1 - 40 % Off Off On On
3 20.1 - 30 % On Off On On
2 10.1 - 20 % On On On On
Avoid falling below the 20% limit for wet batteries or the 40 % limit for maintenance-
free batteries.
23
24
25
22
Page 49
0406.GB
E 22
6.1 Discharge monitor function
When the discharge monitor function is enabled, lifting is cut out when the discharge
limit is reached (the Stop LED is lit). Travel and lowering are still possible. For wet
batteries the residual capacity is 20 %, for maintenance-free batteries it is 40 %.
The batteries should be recharged when they reach 30 % (for wet batteries) or 50 %
(for maintenance-free batteries). The yellow LED lights up as warning indicator.
6.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is
a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours
display (25).
Errormessages
The operating hours display is also used to display errors. The error is displayed in
two parts, starting with a “C” for component and a three-digit component number,
followed by an “E” for error with alternating three-digit error number.
If several errors occur simultaneously, they are displayed one after the other.
The errors are displayed as long as they are present (always in combination Cxxx /
Exxx). Error messages overwrite the service hour display. Most errors cause the
emergency stop to be activated. Errors remain displayed until the control circuit is
switched off (Code lock).
If no CANDIS is present, the error code is displayed by the flashing of the discharge
monitor LED.
Z
The manufacturer’s service department has detailed component descriptions with
error codes.
Display for parameter changes (travel programs)
The LC display (25) is used in conjunction with the operator keypad (CANCODE (o))
to display the setting parameters. The first three digits of the display show
the parameter numbers, the last three digits indicate the parameter setting.
Z
Settings of parameter group 0XX (code lock) are not displayed.
6.3 Power up test
On power up the display shows:
– the software version of the display instrument (briefly),
– the operating hours
– the charge status
0406.GB
E 22
6.1 Discharge monitor function
When the discharge monitor function is enabled, lifting is cut out when the discharge
limit is reached (the Stop LED is lit). Travel and lowering are still possible. For wet
batteries the residual capacity is 20 %, for maintenance-free batteries it is 40 %.
The batteries should be recharged when they reach 30 % (for wet batteries) or 50 %
(for maintenance-free batteries). The yellow LED lights up as warning indicator.
6.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is
a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours
display (25).
Errormessages
The operating hours display is also used to display errors. The error is displayed in
two parts, starting with a “C” for component and a three-digit component number,
followed by an “E” for error with alternating three-digit error number.
If several errors occur simultaneously, they are displayed one after the other.
The errors are displayed as long as they are present (always in combination Cxxx /
Exxx). Error messages overwrite the service hour display. Most errors cause the
emergency stop to be activated. Errors remain displayed until the control circuit is
switched off (Code lock).
If no CANDIS is present, the error code is displayed by the flashing of the discharge
monitor LED.
Z
The manufacturer’s service department has detailed component descriptions with
error codes.
Display for parameter changes (travel programs)
The LC display (25) is used in conjunction with the operator keypad (CANCODE (o))
to display the setting parameters. The first three digits of the display show
the parameter numbers, the last three digits indicate the parameter setting.
Z
Settings of parameter group 0XX (code lock) are not displayed.
6.3 Power up test
On power up the display shows:
– the software version of the display instrument (briefly),
– the operating hours
– the charge status
Page 50
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0406.GB
7 Troubleshooting
This chapter is designed to help the user identify and correct basic faults or the results
of incorrect operation. To locate a fault, proceed in the order shown in the table.
Z
If the fault is not rectified by the above remedies, please call the manufacturer’s
service department, as further troubleshooting can only be performed by specially
trained and qualified service personnel.
Fault Probable cause Action
Truck does
not start
– Battery connector not
fitted
– Check the battery connector and connect
if necessary.
– Key switch in "0"
position
– Turn key switch to position "I"
– Incorrect CANCODE
code
– Check code
– Battery charge too low – Check battery charge, charge battery if
necessary
– Faulty fuse – Check fuses F1, F15 and 6F1
– Truck in charge mode – Interrupt charging
Load cannot
be lifted
– Charging capacity
below 20 / 40 %
– Charging the battery
– Truck not operational – Follow the steps listed under “Truck does
not start”
– Hydraulic oil too low – Check the hydraulic oil level
E 23
0406.GB
7 Troubleshooting
This chapter is designed to help the user identify and correct basic faults or the results
of incorrect operation. To locate a fault, proceed in the order shown in the table.
Z
If the fault is not rectified by the above remedies, please call the manufacturer’s
service department, as further troubleshooting can only be performed by specially
trained and qualified service personnel.
Fault Probable cause Action
Truck does
not start
– Battery connector not
fitted
– Check the battery connector and connect
if necessary.
– Key switch in "0"
position
– Turn key switch to position "I"
– Incorrect CANCODE
code
– Check code
– Battery charge too low – Check battery charge, charge battery if
necessary
– Faulty fuse – Check fuses F1, F15 and 6F1
– Truck in charge mode – Interrupt charging
Load cannot
be lifted
– Charging capacity
below 20 / 40 %
– Charging the battery
– Truck not operational – Follow the steps listed under “Truck does
not start”
– Hydraulic oil too low – Check the hydraulic oil level
Page 51
0406.GB
E 24
0406.GB
E 24
Page 52
F 1
0708.GB
F Truck Maintenance
1 Operational safety and environmental protection
The servicing and inspection duties contained in this chapter must be performed in
accordance with the intervals indicated in the servicing checklists.
F
Any modification to the industrial truck assemblies, in particular the safety
mechanisms, is prohibited. The operational speeds of the truck must not be changed
under any circumstances.
M
Only original spare parts have been certified by our quality assurance department.
To ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts. Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. For oil changes, contact the manufacturer’s
specialist department.
Upon completion of inspection and servicing, carry out the activities listed in
the “Recommissioning” section (see Chapter F).
2 Maintenance safety regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has
field technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must
only be secured to the points specially provided for this purpose. When jacking up
the truck, take appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks). You may only work underneath a raised lifting device
if it is supported by a sufficiently strong chain.
Cleaning operations: Do not use flammable liquids to clean the industrial truck. Prior
to cleaning, implement all necessary safety measures to prevent sparking
(e.g. through short circuits). For battery-operated trucks, the battery connector must
be removed. Use only low vacuum air, low compressed air and non-conducting,
antistatic brushes for the cleaning of electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electric and
electronic components must be carefully covered beforehand as moisture can cause
malfunctions. Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
F 1
0708.GB
F Truck Maintenance
1 Operational safety and environmental protection
The servicing and inspection duties contained in this chapter must be performed in
accordance with the intervals indicated in the servicing checklists.
F
Any modification to the industrial truck assemblies, in particular the safety
mechanisms, is prohibited. The operational speeds of the truck must not be changed
under any circumstances.
M
Only original spare parts have been certified by our quality assurance department.
To ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts. Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. For oil changes, contact the manufacturer’s
specialist department.
Upon completion of inspection and servicing, carry out the activities listed in
the “Recommissioning” section (see Chapter F).
2 Maintenance safety regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has
field technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must
only be secured to the points specially provided for this purpose. When jacking up
the truck, take appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks). You may only work underneath a raised lifting device
if it is supported by a sufficiently strong chain.
Cleaning operations: Do not use flammable liquids to clean the industrial truck. Prior
to cleaning, implement all necessary safety measures to prevent sparking
(e.g. through short circuits). For battery-operated trucks, the battery connector must
be removed. Use only low vacuum air, low compressed air and non-conducting,
antistatic brushes for the cleaning of electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electric and
electronic components must be carefully covered beforehand as moisture can cause
malfunctions. Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
Page 53
0708.GB
F 2
Work on the electric system: Only suitably trained personnel may operate on
the truck’s electrical system. Before working on the electrical system, take all
precautionary measures to avoid electric shocks. For battery-operated trucks, also
de-energise the truck by removing the battery connector.
Welding: To avoid damaging electric or electronic components, remove these from
the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare parts.
Otherwise the data sheet specifications of the truck cannot be guaranteed. When
changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing
wheels always left and right simultaneously).
Lift chains: Lift chains wear rapidly is not lubricated. The intervals stated in
the service checklist apply to normal duty use. More demanding conditions
(dust, temperature) require more regular lubrication. The prescribed chain spray
must be used in accordance with the instructions. Applying grease externally will not
provide sufficient lubrication.
Hydraulic hoses: The hoses must be replaced every six years. When replacing
hydraulic components, also replace the hoses in the hydraulic system.
0708.GB
F 2
Work on the electric system: Only suitably trained personnel may operate on
the truck’s electrical system. Before working on the electrical system, take all
precautionary measures to avoid electric shocks. For battery-operated trucks, also
de-energise the truck by removing the battery connector.
Welding: To avoid damaging electric or electronic components, remove these from
the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare parts.
Otherwise the data sheet specifications of the truck cannot be guaranteed. When
changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing
wheels always left and right simultaneously).
Lift chains: Lift chains wear rapidly is not lubricated. The intervals stated in
the service checklist apply to normal duty use. More demanding conditions
(dust, temperature) require more regular lubrication. The prescribed chain spray
must be used in accordance with the instructions. Applying grease externally will not
provide sufficient lubrication.
Hydraulic hoses: The hoses must be replaced every six years. When replacing
hydraulic components, also replace the hoses in the hydraulic system.
Page 54
F 3
0708.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist specifies the tasks and intervals after which they
should be carried out. The servicing intervals are defined as follows:
W = Every 50 service hours, or at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually.
C = Every 2000 service hours, or at least annually.
Z
W service intervals are to be performed by the proprietor.
During the run-in period – after approx. 100 service hours – the proprietor must
check the wheel nuts/bolts and re-tighten if necessary.
F 3
0708.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist specifies the tasks and intervals after which they
should be carried out. The servicing intervals are defined as follows:
W = Every 50 service hours, or at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually.
C = Every 2000 service hours, or at least annually.
Z
W service intervals are to be performed by the proprietor.
During the run-in period – after approx. 100 service hours – the proprietor must
check the wheel nuts/bolts and re-tighten if necessary.
Page 55
0708.GB
F 4
4 Maintenance checklist
Maintenance intervals
Standard = t WA B C
Cold storage = k
Chassis/
body:
1.1 Check all load bearing parts for damage t
1.2 Check screw connections t
1.3 Test the operator platform and check for damage t
Drive: 2.1 Check transmission for noise and leaks t
2.2 Check transmission fluid level t
2.3 Replace transmission fluid kt
Wheels: 3.1 Check for wear and damage t
3.2 Check suspension and attachment kt
Steering: 4.1 Check the steering play t
Brake
system:
5.1 Test brake function and setting kt
5.2 Check gas pressure spring and return function, check for
leaks and damage
t
5.3 Check brake pads for wear t
5.4 Check brake mechanism, adjust and lubricate if necessary kt
Hydraulic
system:
6.1 Check system function kt
6.2 Check unions and connections for leaks and damage kt
6.3 Check hydraulic cylinders for leaks and damage, and check
that they are securely attached
kt
6.4 Check oil level kt
6.5 Replace hydraulic oil and filter cartridge kt
6.6 Check the function of the pressure relief valves kt
Electrical
system:
7.1 Check system function t
7.2 Check that cables are securely attached, and check for
damage
t
7.3 Check fuse ratings t
7.4 Check that switches and trip cams are securely seated, and
check their functions
t
7.5 Check relays and contacts, and replace worn parts if
necessary
t
7.6 Check the functions of warning devices and safety circuits. kt
Electric
motors:
8.1 Check carbon brushes for wear t
8.2 Check motor mountings t
8.3 Vacuum-clean the motor housing, and check commutator
for wear
kt
0708.GB
F 4
4 Maintenance checklist
Maintenance intervals
Standard = t WA B C
Cold storage = k
Chassis/
body:
1.1 Check all load bearing parts for damage t
1.2 Check screw connections t
1.3 Test the operator platform and check for damage t
Drive: 2.1 Check transmission for noise and leaks t
2.2 Check transmission fluid level t
2.3 Replace transmission fluid kt
Wheels: 3.1 Check for wear and damage t
3.2 Check suspension and attachment kt
Steering: 4.1 Check the steering play t
Brake
system:
5.1 Test brake function and setting kt
5.2 Check gas pressure spring and return function, check for
leaks and damage
t
5.3 Check brake pads for wear t
5.4 Check brake mechanism, adjust and lubricate if necessary kt
Hydraulic
system:
6.1 Check system function kt
6.2 Check unions and connections for leaks and damage kt
6.3 Check hydraulic cylinders for leaks and damage, and check
that they are securely attached
kt
6.4 Check oil level kt
6.5 Replace hydraulic oil and filter cartridge kt
6.6 Check the function of the pressure relief valves kt
Electrical
system:
7.1 Check system function t
7.2 Check that cables are securely attached, and check for
damage
t
7.3 Check fuse ratings t
7.4 Check that switches and trip cams are securely seated, and
check their functions
t
7.5 Check relays and contacts, and replace worn parts if
necessary
t
7.6 Check the functions of warning devices and safety circuits. kt
Electric
motors:
8.1 Check carbon brushes for wear t
8.2 Check motor mountings t
8.3 Vacuum-clean the motor housing, and check commutator
for wear
kt
Page 56
F 5
0708.GB
Maintenance intervals
Standard = t WA B C
Cold storage = k
Battery: 9.1 Check acid density, acid level and battery voltage t
9.2 Check terminals are securely attached, and apply
grease
t
9.3 Clean the battery connections, ensure they are
securely attached
t
9.4 Check battery cables for damage, and replace if
necessary
t
Lifting gear: 10.1 Check the function and setting, check for wear t
10.2 Visual inspection of rollers, sliding pieces and stops t
10.3 Check forks and fork carriage for wear and damage t
Lubrication: 11.1 Lubricate truck in accordance with Maintenance
Schedule
t
General
measurements:
12.1 Check electrical system for body contacts t
12.2 Check drive speed and braking distance t
12.3 Lifting and lowering speeds t
12.4 Check safety devices and cutouts t
Demonstration: 13.1 Test drive with nominal load t
13.2 After maintenance, present the truck to the
authorised person
t
F 5
0708.GB
Maintenance intervals
Standard = t WA B C
Cold storage = k
Battery: 9.1 Check acid density, acid level and battery voltage t
9.2 Check terminals are securely attached, and apply
grease
t
9.3 Clean the battery connections, ensure they are
securely attached
t
9.4 Check battery cables for damage, and replace if
necessary
t
Lifting gear: 10.1 Check the function and setting, check for wear t
10.2 Visual inspection of rollers, sliding pieces and stops t
10.3 Check forks and fork carriage for wear and damage t
Lubrication: 11.1 Lubricate truck in accordance with Maintenance
Schedule
t
General
measurements:
12.1 Check electrical system for body contacts t
12.2 Check drive speed and braking distance t
12.3 Lifting and lowering speeds t
12.4 Check safety devices and cutouts t
Demonstration: 13.1 Test drive with nominal load t
13.2 After maintenance, present the truck to the
authorised person
t
Page 57
0708.GB
F 6
5 Maintenance schedule
g Sliding surfaces 1) Compound ratio for cold store usage 1 : 1
s Grease nipple
Hydraulic oil filling pipe 2) 1.25 – 1.3 litres depending on the type of
transmission (always up to the lower mark of
the filler neck)
b Transmission fluid filling pipe
a Transmission oil drain plug
Cold store usage
B
0,55 l
E
E
E
A
0,7l
A+C
1)
0708.GB
F 6
5 Maintenance schedule
g Sliding surfaces 1) Compound ratio for cold store usage 1 : 1
s Grease nipple
Hydraulic oil filling pipe 2) 1.25 – 1.3 litres depending on the type of
transmission (always up to the lower mark of
the filler neck)
b Transmission fluid filling pipe
a Transmission oil drain plug
Cold store usage
B
0,55 l
E
E
E
A
0,7l
A+C
1)
Page 58
F 7
0708.GB
5.1 Con sum abl es
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
Z
Improper handling is hazardous to health, life and the environment. Consumables
must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated
in these Operating Instructions.
Prevent spillages. Spilled fluids must be removed immediately with a suitable binding
material and the binder / fluid mixture must be disposed of in accordance with
regulations.
Grease data
Code Order no. Package
quantity
Description Used for
A 29 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic system
B 50 380 904 5.0 l Fuchs Titan Gear
HSY 75W-90
Gear unit
C 29 200 810 5.0 l H-LP 10, DIN 51524 Hydraulic system
E 29 430 702 1.0 kg Grease, DIN 51825 Lubrication
Code Saponification Dripping
point °C
Worked
penetration at
25 °C
NLG1
class
Application
temperature °C
E Lithium 190 265 - 295 2 -40 / +120
F 7
0708.GB
5.1 Con sum abl es
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
Z
Improper handling is hazardous to health, life and the environment. Consumables
must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated
in these Operating Instructions.
Prevent spillages. Spilled fluids must be removed immediately with a suitable binding
material and the binder / fluid mixture must be disposed of in accordance with
regulations.
Grease data
Code Order no. Package
quantity
Description Used for
A 29 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic system
B 50 380 904 5.0 l Fuchs Titan Gear
HSY 75W-90
Gear unit
C 29 200 810 5.0 l H-LP 10, DIN 51524 Hydraulic system
E 29 430 702 1.0 kg Grease, DIN 51825 Lubrication
Code Saponification Dripping
point °C
Worked
penetration at
25 °C
NLG1
class
Application
temperature °C
E Lithium 190 265 - 295 2 -40 / +120
Page 59
0708.GB
F 8
6 Maintenance and repairs
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Parking the truck securely
(see Chapter E).
Z
Opening the battery panel
(see chapter D).
– Disconnect the battery (1) to prevent
the truck from starting accidentally.
– When working under a raised lift truck,
secure it to prevent it from lowering,
tipping or sliding away.
F
When raising the truck also refer to the
instructions in the “Transport and
Commissioning” section (see Chapter C ).
6.2 Opening the battery panel
(see Chapter D).
6.3 Opening the front panel
General:
– Unlock the panel latches (2) using a
spanner (width 8).
– Remove the screws (3).
– Lift off the panel (4) and place it next to
the truck.
When the work is finished, close the
panel (4).
11
2
3
4
0708.GB
F 8
6 Maintenance and repairs
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Parking the truck securely
(see Chapter E).
Z
Opening the battery panel
(see chapter D).
– Disconnect the battery (1) to prevent
the truck from starting accidentally.
– When working under a raised lift truck,
secure it to prevent it from lowering,
tipping or sliding away.
F
When raising the truck also refer to the
instructions in the “Transport and
Commissioning” section (see Chapter C ).
6.2 Opening the battery panel
(see Chapter D).
6.3 Opening the front panel
General:
– Unlock the panel latches (2) using a
spanner (width 8).
– Remove the screws (3).
– Lift off the panel (4) and place it next to
the truck.
When the work is finished, close the
panel (4).
11
2
3
4
Page 60
F 9
0708.GB
6.4 Replacing the drive wheel
Z
The drive wheel must only be replaced by authorised service personnel.
6.5 Checking the hydraulic oil level
– Prepare the truck for maintenance
and repairs (see section 6.1).
– Open the front panel
(see Section 6.3).
– Check hydraulic oil level in hydraulic
reservoir (7).
Z
There are markings (6) on the hydraulic
reservoir. The oil level should lie
between the "max" and "min" markings
when the forks are lowered.
If necessary, add hydraulic oil of
the correct grade up to the "max" mark.
(for hydraulic oil specification, see
Section 5).
min
max
7
6
F 9
0708.GB
6.4 Replacing the drive wheel
Z
The drive wheel must only be replaced by authorised service personnel.
6.5 Checking the hydraulic oil level
– Prepare the truck for maintenance
and repairs (see section 6.1).
– Open the front panel
(see Section 6.3).
– Check hydraulic oil level in hydraulic
reservoir (7).
Z
There are markings (6) on the hydraulic
reservoir. The oil level should lie
between the "max" and "min" markings
when the forks are lowered.
If necessary, add hydraulic oil of
the correct grade up to the "max" mark.
(for hydraulic oil specification, see
Section 5).
min
max
7
6
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0708.GB
F 10
6.6 Checking electrical fuses
– Prepare the truck for maintenance and repairs (see Section 6.1).
– Dismantle the front panel (see Section 6.3).
– Referring to the table, check that fuse ratings are correct, and replace if necessary.
Item Description To protect: Value
8 F15 Drive / Lift motor 200 A
9 F1 Overall control circuit fuse 10 A
10 6F1 Battery discharge indicator 2 A
10
9
8
0708.GB
F 10
6.6 Checking electrical fuses
– Prepare the truck for maintenance and repairs (see Section 6.1).
– Dismantle the front panel (see Section 6.3).
– Referring to the table, check that fuse ratings are correct, and replace if necessary.
Item Description To protect: Value
8 F15 Drive / Lift motor 200 A
9 F1 Overall control circuit fuse 10 A
10 6F1 Battery discharge indicator 2 A
10
9
8
Page 62
F 11
0708.GB
6.7 Recommissioning
The truck may only be restored to service after cleaning or repair work, once
the following operations have been performed.
– Test horn.
– Test battery connector function.
– Test brakes.
– Lubricate the truck in accordance with the maintenance schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
7.1 Prior to decommissioning:
– Thoroughly clean the truck.
– Check the brakes.
– Check the hydraulic oil level and replenish as necessary (see Chapter F).
– Apply a thin layer of oil or grease to any non-painted mechanical components.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and apply grease to the battery poles.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning:
Every 2 months:
– Charge the battery (see Chapter D).
M
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
F 11
0708.GB
6.7 Recommissioning
The truck may only be restored to service after cleaning or repair work, once
the following operations have been performed.
– Test horn.
– Test battery connector function.
– Test brakes.
– Lubricate the truck in accordance with the maintenance schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
7.1 Prior to decommissioning:
– Thoroughly clean the truck.
– Check the brakes.
– Check the hydraulic oil level and replenish as necessary (see Chapter F).
– Apply a thin layer of oil or grease to any non-painted mechanical components.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and apply grease to the battery poles.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning:
Every 2 months:
– Charge the battery (see Chapter D).
M
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
Page 63
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F 12
7.3 Returning the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (see Chapter D).
– Check transmission oil for condensed water and replace if necessary.
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see Chapter E).
Z
Battery powered trucks:
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 operating
controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8 Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich
recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
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.
9 Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
0708.GB
F 12
7.3 Returning the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (see Chapter D).
– Check transmission oil for condensed water and replace if necessary.
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see Chapter E).
Z
Battery powered trucks:
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 operating
controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8 Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich
recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
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.
9 Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
Page 64
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0506.GB
Instructions for use
Jungheinrich traction battery
Table of contents
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB.......................................... 2-6
Type plate Jungheinrich traction battery............................................ 7
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
2 Jungheinrich traction battery
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS
............................................................................................13-17
Type plate Jungheinrich traction battery............................................ 17
1
0506.GB
Instructions for use
Jungheinrich traction battery
Table of contents
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB.......................................... 2-6
Type plate Jungheinrich traction battery............................................ 7
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
2 Jungheinrich traction battery
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS
............................................................................................13-17
Type plate Jungheinrich traction battery............................................ 17
Page 65
0506.GB
2
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte*
Type EPzS: 1,29 kg/l
Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C
6. Nominal electrolyte level: up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
0506.GB
2
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte*
Type EPzS: 1,29 kg/l
Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C
6. Nominal electrolyte level: up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other me-
tal objects on the battery!
Page 66
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0506.GB
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
steel
M 10 23 ± 1 Nm
3
0506.GB
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-
scharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-
ded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
steel
M 10 23 ± 1 Nm
Page 67
0506.GB
4
Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
0506.GB
4
Battery container lids and the covers of battery compartments must be opened or re-
moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batte-
ries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-
tentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flamma-
bility due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out follo-
wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-
pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-
peratures shorten the life of the battery, lower temperatures reduce the capacity avai-
lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-
perature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher tempe-
ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
Page 68
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0506.GB
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and recorded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
5
0506.GB
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-
tery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and re-
corded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
Page 69
0506.GB
6
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
0506.GB
6
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault fin-
ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
Page 70
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0506.GB
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
7
0506.GB
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
Page 71
0506.GB
8
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (y ellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm
2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm
– 2/110 – 12/ 660 50,5 mm 51,0 mm
– 2/130 – 12/ 780 50,5 mm 51,0 mm
– 2/150 – 12/ 900 50,5 mm 51,0 mm
– 2/172 – 12/1032 50,5 mm 51,0 mm
– 2/200 – 12/1200 56,0 mm 56,0 mm
– 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm
2/210 – 10/1050 – 61,0 mm 61,0 mm
2/230 – 10/1150 – 61,0 mm 61,0 mm
2/250 – 10/1250 – 61,0 mm 61,0 mm
2/280 – 10/1400 – 72,0 mm 66,0 mm
2/310 – 10/1550 – 72,0 mm 66,0 mm
stroke
length
stroke
length
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
0506.GB
8
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the in-
structions on maintaining the respective protection class during operation (see asso-
ciated certification).
Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (y ellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm
2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm
– 2/110 – 12/ 660 50,5 mm 51,0 mm
– 2/130 – 12/ 780 50,5 mm 51,0 mm
– 2/150 – 12/ 900 50,5 mm 51,0 mm
– 2/172 – 12/1032 50,5 mm 51,0 mm
– 2/200 – 12/1200 56,0 mm 56,0 mm
– 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm
2/210 – 10/1050 – 61,0 mm 61,0 mm
2/230 – 10/1150 – 61,0 mm 61,0 mm
2/250 – 10/1250 – 61,0 mm 61,0 mm
2/280 – 10/1400 – 72,0 mm 66,0 mm
2/310 – 10/1550 – 72,0 mm 66,0 mm
stroke
length
stroke
length
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
Page 72
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Diagrammatic view
Equipment for the
water refilling system
1. Water tank
2. Level switch
3. Discharge point with ball
valve
4. Discharge point with sole-
noid valve
5. Charger
6. Sealing coupler
7. Closing nipple
8. Ion exchange cartridge with
conductance meter and
solenoid valve
9. Connection for untreated
water
10. Charging lead
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
at least 3 m
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0506.GB
Diagrammatic view
Equipment for the
water refilling system
1. Water tank
2. Level switch
3. Discharge point with ball
valve
4. Discharge point with sole-
noid valve
5. Charger
6. Sealing coupler
7. Closing nipple
8. Ion exchange cartridge with
conductance meter and
solenoid valve
9. Connection for untreated
water
10. Charging lead
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjus-
ting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte den-
sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-
matic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose con-
nections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS sys-
tem, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
at least 3 m
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10
4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of filling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
0506.GB
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4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of fil-
ling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-
ter feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
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8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
10. Accessories
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
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8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a tempe-
rature range of > 0° C to a maximum of 55° C.
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling sys-
tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
10. Accessories
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug sys-
tems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
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10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
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10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres-
sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-
ry's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-
tral supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
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2 Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h
4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire, avoid short circuits!
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
13
0506.GB
2 Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h
4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe-
re a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire, avoid short circuits!
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
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14
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors
are:
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left discharged.
This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or removed.
steel
M 10 23 ± 1 Nm
0506.GB
14
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors
are:
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left dischar-
ged.
This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifica-
tions. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or re-
moved.
steel
M 10 23 ± 1 Nm
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With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed chargers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
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0506.GB
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the tem-
peratures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed char-
gers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher tempera-
tures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating tempera-
ture.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
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16
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
• the voltages of the battery
• the voltages of every cells
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
To ensure the battery is always ready for use a choice of charging methods can be
made:
1.a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
2.float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the battery.
0506.GB
16
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
• the voltages of the battery
• the voltages of every cells
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
To ensure the battery is always ready for use a choice of charging methods can be
made:
1.a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
2.float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the batte-
ry.
Page 80
17
0506.GB
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
17
0506.GB
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault fin-
ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
Page 81
0506.GB
18
0506.GB
18
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