Page 1
EKS 513 - 515
EKS 410
Operating instructions
52025221
EKS 410/513/515k/515
G
12.03 -
07.08
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
Index
A Correct use and application
B Truck Description
1 Application ...........................................................................................B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ...................................................................................................B 3
3 Standard Version Specifications ......................................................... B 4
3.1 Performance data ................................................................................ B 4
3.2 Dimensions (as per data plate) ........................................................... B 6
3.3 EKS 410 mast version ......................................................................... B 7
3.4 EKS 513 – 515 mast version ............................................................... B 7
3.5 EN norms ............................................................................................B 8
3.6 Conditions of use ................................................................................B 8
4 Identification points and data plates ....................................................B 9
4.1 Truck data plate ..................................................................................B 11
4.2 Capacity ..............................................................................................B 11
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by crane .................................................................................... C 1
2.1 Crane points ........................................................................................ C 2
2.2 Lifting the battery by crane .................................................................. C 2
3 Securing the truck during transport ..................................................... C 2
3.1 Basic truck transport safety ................................................................. C 3
3.2 Mast transport safety ........................................................................... C 4
3.3 Mast assembled .................................................................................. C 5
3.4 Safely transporting the truck with the mast folded (EKS 513 - 515) .... C 5
4 Commissioning .................................................................................... C 6
4.1 Moving the truck without a battery ...................................................... C 6
4.2 Installing and removing the mast ........................................................ C 6
5 Starting the truck for the first time ....................................................... C 6
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Charge the battery .............................................................................. D 2
4 Battery removal and installation .......................................................... D 3
5 Battery – checking condition and acid level ........................................ D 7
6 Battery discharge indicator .................................................................. D 7
I 1
0708.GB
Index
A Correct use and application
B Truck Description
1 Application ...........................................................................................B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ...................................................................................................B 3
3 Standard Version Specifications ......................................................... B 4
3.1 Performance data ................................................................................ B 4
3.2 Dimensions (as per data plate) ........................................................... B 6
3.3 EKS 410 mast version ......................................................................... B 7
3.4 EKS 513 – 515 mast version ............................................................... B 7
3.5 EN norms ............................................................................................B 8
3.6 Conditions of use ................................................................................B 8
4 Identification points and data plates ....................................................B 9
4.1 Truck data plate ..................................................................................B 11
4.2 Capacity ..............................................................................................B 11
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by crane .................................................................................... C 1
2.1 Crane points ........................................................................................ C 2
2.2 Lifting the battery by crane .................................................................. C 2
3 Securing the truck during transport ..................................................... C 2
3.1 Basic truck transport safety ................................................................. C 3
3.2 Mast transport safety ........................................................................... C 4
3.3 Mast assembled .................................................................................. C 5
3.4 Safely transporting the truck with the mast folded (EKS 513 - 515) .... C 5
4 Commissioning .................................................................................... C 6
4.1 Moving the truck without a battery ...................................................... C 6
4.2 Installing and removing the mast ........................................................ C 6
5 Starting the truck for the first time ....................................................... C 6
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Charge the battery .............................................................................. D 2
4 Battery removal and installation .......................................................... D 3
5 Battery – checking condition and acid level ........................................ D 7
6 Battery discharge indicator .................................................................. D 7
Page 5
0708.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Operating and Display Equipment ......................................................E 2
2.1 Operating and display equipment on control panel .............................E 2
2.2 Display unit controls and displays .......................................................E 4
2.3 Lower range symbols and keys ........................................................... E 5
2.4 Truck operational status symbols ........................................................E 7
3 Starting up the truck ............................................................................ E 8
3.1 Setting the time ...................................................................................E 9
4 Industrial truck operation .....................................................................E 10
4.1 Safety regulations for truck operation .................................................E 10
4.2 Travelling, Steering, Braking ...............................................................E 11
4.3 Lifting–- lowering outside narrow aisles .............................................. E 16
4.4 Lifting–- lowering within narrow aisles ................................................. E 16
4.5 Order picking and stacking ..................................................................E 17
4.6 Parking the truck securely ...................................................................E 19
5 Troubleshooting ..................................................................................E 20
5.1 Emergency stop device .......................................................................E 22
5.2 Driver’s cab / Aux. Lift emergency lowering ........................................ E 22
5.3 Exiting the driver's cab with the emergency abseil device .................. E 23
5.4 Bypassing the chain slack safety device .............................................E 24
5.5 Bypassing the travel cutout (o) .......................................................... E 24
5.6 Lift cutout (o) ......................................................................................E 25
5.7 Aisle end safety device (o) .................................................................E 25
5.8 WG emergency operation ................................................................... E 26
5.9 Recovering the truck from a narrow aisle / Moving the truck
without a battery ..................................................................................E 27
0708.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Operating and Display Equipment ......................................................E 2
2.1 Operating and display equipment on control panel .............................E 2
2.2 Display unit controls and displays .......................................................E 4
2.3 Lower range symbols and keys ........................................................... E 5
2.4 Truck operational status symbols ........................................................E 7
3 Starting up the truck ............................................................................ E 8
3.1 Setting the time ...................................................................................E 9
4 Industrial truck operation .....................................................................E 10
4.1 Safety regulations for truck operation .................................................E 10
4.2 Travelling, Steering, Braking ...............................................................E 11
4.3 Lifting–- lowering outside narrow aisles .............................................. E 16
4.4 Lifting–- lowering within narrow aisles ................................................. E 16
4.5 Order picking and stacking ..................................................................E 17
4.6 Parking the truck securely ...................................................................E 19
5 Troubleshooting ..................................................................................E 20
5.1 Emergency stop device .......................................................................E 22
5.2 Driver’s cab / Aux. Lift emergency lowering ........................................ E 22
5.3 Exiting the driver's cab with the emergency abseil device .................. E 23
5.4 Bypassing the chain slack safety device .............................................E 24
5.5 Bypassing the travel cutout (o) .......................................................... E 24
5.6 Lift cutout (o) ......................................................................................E 25
5.7 Aisle end safety device (o) .................................................................E 25
5.8 WG emergency operation ................................................................... E 26
5.9 Recovering the truck from a narrow aisle / Moving the truck
without a battery ..................................................................................E 27
Page 6
I 3
0708.GB
F Maintenance of the forklift truck
1 Operational safety and environmental protection ................................F 1
2 Maintenance Safety Regulations ........................................................F 1
3 Servicing and inspection ..................................................................... F 3
4 EKS Maintenance Checklist ................................................................F 4
4.1 Lubrication Schedule ........................................................................... F 7
4.2 Fuels, coolants and lubricants .............................................................F 9
5 Maintenance and Repairs ................................................................... F 11
5.1 Prepare the truck for maintenance and repairs ................................... F 11
5.2 Securing the driver’s position carriage ................................................ F 11
5.3 Lift Chain Servicing ............................................................................. F 12
5.4 Inspecting the lift chains ...................................................................... F 12
5.5 Hydraulic oil ......................................................................................... F 13
5.6 Hydraulic hoses ................................................................................... F 14
5.7 Check brake fluid (EKS 513 - 515) ......................................................F 14
5.8 Checking electrical fuses (EKS 410) ...................................................F 15
5.9 Checking electrical fuses (EKS 513 - 515) .......................................... F 16
5.10 Recommissioning ................................................................................F 17
6 Decommissioning the industrial truck ..................................................F 17
6.1 Prior to decommissioning: ...................................................................F 17
6.2 During decommissioning: ....................................................................F 18
6.3 Restoring the truck to operation after decommissioning ..................... F 18
7 Safety checks to be performed at regular intervals and following
any unusual incidents .......................................................................... F 19
8 Final de-commissioning, disposal .......................................................F 19
I 3
0708.GB
F Maintenance of the forklift truck
1 Operational safety and environmental protection ................................F 1
2 Maintenance Safety Regulations ........................................................F 1
3 Servicing and inspection ..................................................................... F 3
4 EKS Maintenance Checklist ................................................................F 4
4.1 Lubrication Schedule ........................................................................... F 7
4.2 Fuels, coolants and lubricants .............................................................F 9
5 Maintenance and Repairs ................................................................... F 11
5.1 Prepare the truck for maintenance and repairs ................................... F 11
5.2 Securing the driver’s position carriage ................................................ F 11
5.3 Lift Chain Servicing ............................................................................. F 12
5.4 Inspecting the lift chains ...................................................................... F 12
5.5 Hydraulic oil ......................................................................................... F 13
5.6 Hydraulic hoses ................................................................................... F 14
5.7 Check brake fluid (EKS 513 - 515) ......................................................F 14
5.8 Checking electrical fuses (EKS 410) ...................................................F 15
5.9 Checking electrical fuses (EKS 513 - 515) .......................................... F 16
5.10 Recommissioning ................................................................................F 17
6 Decommissioning the industrial truck ..................................................F 17
6.1 Prior to decommissioning: ...................................................................F 17
6.2 During decommissioning: ....................................................................F 18
6.3 Restoring the truck to operation after decommissioning ..................... F 18
7 Safety checks to be performed at regular intervals and following
any unusual incidents .......................................................................... F 19
8 Final de-commissioning, disposal .......................................................F 19
Page 7
0708.GB
I 4
0708.GB
I 4
Page 8
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 9
0506.GB 20506.GB
2
Page 10
A 1
1004.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 operator manual is an industrial truck designed for
lifting and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property. 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 diagram 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 industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
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 this operator manual.
M
Failure to comply with the operator manual 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 supplements 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
1004.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 operator manual is an industrial truck designed for
lifting and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property. 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 diagram 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 industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
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 this operator manual.
M
Failure to comply with the operator manual 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 supplements 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 11
1004.GB
A 2
1004.GB
A 2
Page 12
B 1
0708.GB
B Truck Description
1 Application
The EKS is an electric stockpicker. It is designed to be used on level surfaces in
accordance with DIN 15185 to transport and pick goods.
Loads can be stacked and unstacked and transported over long distances.
The driver's cab is raised together with the load handler to provide excellent visibility
and easy access to the rack levels to be operated.
The racks must be suitable for the EKS. The safety distances stipulated by the
manufacturer (e. g. EN 1726-2 item 7.3.2) must be observed. The ground surface
must comply with DIN 15185. Guide rails must be provided in the narrow aisles for
the rail guidance system.
Vulkollan guide rollers attached to the truck chassis guide the truck between the
guide rails.
A guidance wire must be routed in the ground for the inductive guidance system. The
signals from the wire are received on the chassis and processed in the on-board
computer.
The capacity is shown on the data plate.
Travel direction definition
The following determinations have been made for travel direction specification.
Type Capacity Load centre of gravity
EKS 410 1,000 kg 600 mm
EKS 513 1,250 kg 600 mm
EKS 515k/515 1,500 kg 600 mm
Left
Drive
direction
Load
direction
Right
B 1
0708.GB
B Truck Description
1 Application
The EKS is an electric stockpicker. It is designed to be used on level surfaces in
accordance with DIN 15185 to transport and pick goods.
Loads can be stacked and unstacked and transported over long distances.
The driver's cab is raised together with the load handler to provide excellent visibility
and easy access to the rack levels to be operated.
The racks must be suitable for the EKS. The safety distances stipulated by the
manufacturer (e. g. EN 1726-2 item 7.3.2) must be observed. The ground surface
must comply with DIN 15185. Guide rails must be provided in the narrow aisles for
the rail guidance system.
Vulkollan guide rollers attached to the truck chassis guide the truck between the
guide rails.
A guidance wire must be routed in the ground for the inductive guidance system. The
signals from the wire are received on the chassis and processed in the on-board
computer.
The capacity is shown on the data plate.
Travel direction definition
The following determinations have been made for travel direction specification.
Type Capacity Load centre of gravity
EKS 410 1,000 kg 600 mm
EKS 513 1,250 kg 600 mm
EKS 515k/515 1,500 kg 600 mm
Left
Drive
direction
Load
direction
Right
Page 13
0708.GB
B 2
2 Assemblies and Functional Description
Item Description
1
t
Mast
2
t
Aux. lift
3
t
Control panel
4
t
Height-adjustable driver’s position
5
t
Chassis
t = Standard equipment o = Optional Equipment
2
2
1
1
3
3
4
4
5
5
EKS 513 / 515k / 515
EKS 410
0708.GB
B 2
2 Assemblies and Functional Description
Item Description
1
t
Mast
2
t
Aux. lift
3
t
Control panel
4
t
Height-adjustable driver’s position
5
t
Chassis
t = Standard equipment o = Optional Equipment
2
2
1
1
3
3
4
4
5
5
EKS 513 / 515k / 515
EKS 410
Page 14
B 3
0708.GB
2.1 Truck
Safety mechanisms: An enclosed truck geometry with rounded edges ensures safe
handling of the truck. The overhead guard protects the driver from falling objects.
The Emergency Disconnect switch immediately cuts out all truck movements in
hazardous situations. Safety gates on either side of the cab disable all truck
movements as soon as they are opened.
Travelling and lifting can only be activated when the foot switch is pressed.
Drive:
Vertically mounted, heavy duty AC motor (asynchronous). The motor is directly
attached to the single-wheel driving gear, ensuring rapid and trouble-free
maintenance.
Brake system:
– The truck can be braked gently and wear-free by pulling back the travel control
button or steering in the opposite direction. This feeds energy into the battery
(operating brake).
– The electromagnetic spring pressure brake acting on the drive motor serves as a
parking brake and handbrake.
– EKS 513-515 only:
Depending on the lift height, the load wheel brake acting on the front axle (hydraulic
brake) is only activated when the EMERGENCY DISCONNECT switch is pressed
or if the truck is set to EMERGENCY STOP.
Steering:
Particularly smooth steering with threephase drive system. The handy steering wheel
is integrated within the control panel. The position of the steered drive wheel is shown
in the control panel display unit. The steering angle is +/- 90°, offering maximum
manoeuvrability in narrow aisles.
With the mechanical rail guidance system the drive wheel is set to the forward
position at the press of a button.
In wire guidance mode, steering is automatically assumed by the truck controller
when it detects the guidance wire, and manual steering is deactivated.
Controls and Displays
The functions are activated via ergonomic thumb movement to ensure fatigue-free
operation without stressing the wrists; sensitive application of travel and hydraulic
movements to spare and position the goods exactly.
Integrated information display unit for all important driver information such as steering
wheel position, overall lift, truck status reports (e. g. faults), service hours, battery
capacity, time and inductive guidance status etc.
B 3
0708.GB
2.1 Truck
Safety mechanisms: An enclosed truck geometry with rounded edges ensures safe
handling of the truck. The overhead guard protects the driver from falling objects.
The Emergency Disconnect switch immediately cuts out all truck movements in
hazardous situations. Safety gates on either side of the cab disable all truck
movements as soon as they are opened.
Travelling and lifting can only be activated when the foot switch is pressed.
Drive:
Vertically mounted, heavy duty AC motor (asynchronous). The motor is directly
attached to the single-wheel driving gear, ensuring rapid and trouble-free
maintenance.
Brake system:
– The truck can be braked gently and wear-free by pulling back the travel control
button or steering in the opposite direction. This feeds energy into the battery
(operating brake).
– The electromagnetic spring pressure brake acting on the drive motor serves as a
parking brake and handbrake.
– EKS 513-515 only:
Depending on the lift height, the load wheel brake acting on the front axle (hydraulic
brake) is only activated when the EMERGENCY DISCONNECT switch is pressed
or if the truck is set to EMERGENCY STOP.
Steering:
Particularly smooth steering with threephase drive system. The handy steering wheel
is integrated within the control panel. The position of the steered drive wheel is shown
in the control panel display unit. The steering angle is +/- 90°, offering maximum
manoeuvrability in narrow aisles.
With the mechanical rail guidance system the drive wheel is set to the forward
position at the press of a button.
In wire guidance mode, steering is automatically assumed by the truck controller
when it detects the guidance wire, and manual steering is deactivated.
Controls and Displays
The functions are activated via ergonomic thumb movement to ensure fatigue-free
operation without stressing the wrists; sensitive application of travel and hydraulic
movements to spare and position the goods exactly.
Integrated information display unit for all important driver information such as steering
wheel position, overall lift, truck status reports (e. g. faults), service hours, battery
capacity, time and inductive guidance status etc.
Page 15
0708.GB
B 4
Hydraulic system:
All hydraulic movements are controlled by a maintenance-free AC motor with a
flanged low emission gear pump. Oil is distributed via magnetic switch valves. The
varying oil requirements are controlled by the speed of the motor. During a lowering
operation the hydraulic pump drives the motor which then acts as a generator
(regenerative lowering). The energy produced is then fed back to the battery.
Electrical System:
Service laptop connection interface:
– To configure all the key truck data (limit position damping, lift cutout, retardation
and acceleration patterns, cut-outs etc.) rapidly and reliably.
– To read off the error log to analyse fault causes.
– To simulate and analyse program operations.
– Simple functional extension by releasing code numbers.
The controller is fitted with a CAN Bus and a continually measuring sensor system.
The controller provide smooth start-up and braking of the load in all limit positions
through limit position and intermediate cushioning.
Highly efficient threephase technology with energy retention for the drive and lift
motors provides high travel and lift speeds and better use of energy.
The MOSFET threephase controller provides smooth starting for all movements.
For drive battery options see chapter D.
3 Standard Version Specifications
Z
Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
3.1 Performance data
Description EKS
410
EKS
513
EKS
515k/515
Q Capacity (where C = 600 mm) 1000 1250 1500 kg
c Load centre of gravity distance 600 600 600 mm
Travel speed without load (RG) 9 10,5 10,5 km/h
Travel speed with load (RG) 9 10,5 10,5 km/h
Travel speed without load (IG) 7 9 9 km/h
Travel speed with load (IG) 7 9 9 km/h
Lift speed without load 0,40 0,45 0,47 m/s
Lift speed with load 0,36 0,40 0,42 m/s
Lowering speed w / w.o. load 0,40 0,40 0,40 m/s
0708.GB
B 4
Hydraulic system:
All hydraulic movements are controlled by a maintenance-free AC motor with a
flanged low emission gear pump. Oil is distributed via magnetic switch valves. The
varying oil requirements are controlled by the speed of the motor. During a lowering
operation the hydraulic pump drives the motor which then acts as a generator
(regenerative lowering). The energy produced is then fed back to the battery.
Electrical System:
Service laptop connection interface:
– To configure all the key truck data (limit position damping, lift cutout, retardation
and acceleration patterns, cut-outs etc.) rapidly and reliably.
– To read off the error log to analyse fault causes.
– To simulate and analyse program operations.
– Simple functional extension by releasing code numbers.
The controller is fitted with a CAN Bus and a continually measuring sensor system.
The controller provide smooth start-up and braking of the load in all limit positions
through limit position and intermediate cushioning.
Highly efficient threephase technology with energy retention for the drive and lift
motors provides high travel and lift speeds and better use of energy.
The MOSFET threephase controller provides smooth starting for all movements.
For drive battery options see chapter D.
3 Standard Version Specifications
Z
Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
3.1 Performance data
Description EKS
410
EKS
513
EKS
515k/515
Q Capacity (where C = 600 mm) 1000 1250 1500 kg
c Load centre of gravity distance 600 600 600 mm
Travel speed without load (RG) 9 10,5 10,5 km/h
Travel speed with load (RG) 9 10,5 10,5 km/h
Travel speed without load (IG) 7 9 9 km/h
Travel speed with load (IG) 7 9 9 km/h
Lift speed without load 0,40 0,45 0,47 m/s
Lift speed with load 0,36 0,40 0,42 m/s
Lowering speed w / w.o. load 0,40 0,40 0,40 m/s
Page 16
B 5
0708.GB
A
st
W
a
h
15
h
10
h
3
h
9
h
7
h
6
h
1
h
4
b
2
l
1
l
2
m
2
R
b
5
l
B 5
0708.GB
A
st
W
a
h
15
h
10
h
3
h
9
h
7
h
6
h
1
h
4
b
2
l
1
l
2
m
2
R
b
5
l
Page 17
0708.GB
B 6
3.2 Dimensions (as per data plate)
1)
ZT mast performance data measured for 400 ZT.
2)
ZT mast performance data measured for 350 ZT.
3)
ZT mast performance data measured for 500 ZT.
Description EKS
410
EKS
513
EKS
515k
EKS
515
h1Mast height
(retracted)
3100
1)
2955
2)
2955
2)
3705
3)
mm
h3Lift 4000
1)
3500
2)
3500
2)
5000
3)
mm
h4Mast height
(extended)
6550
1)
6050
2)
6050
2)
7550
3)
mm
h7Seat height / standing height 395 470 470 470 mm
h9Aux. lift 840 840 840 840 mm
h10Overall lift 4840
1)
4340
2)
4340
2)
5840
3)
mm
h15Stockpicking height 5995
1)
5570
2)
5570
2)
7070
3)
mm
Ast Working aisle width for
pallets 1000 x 1200 traverse
1640 1640 1640 1640 mm
b2Overall width 1440 1450 1500 1500 mm
b5Distance between forks,
outer
(PAL width 1200)
793 535 535 535 mm
b6Width across guide rollers 1620 1540 1540 1540 mm
l1Overall length w.o. load
(PAL width 1200)
3577 3340 3440 3736 mm
l2Length including fork back
(PAL width 1200)
3273 3200 3300 3596 mm
l Fork length 1200 1200 1200 1200 mm
WaTurning radius 2035 2101 2201 2497 mm
m2Ground clearance centre
wheelbase
80 85 85 85 mm
Net weight incl. battery, w.o.
load
5218 6499 6926 8083 kg
0708.GB
B 6
3.2 Dimensions (as per data plate)
1)
ZT mast performance data measured for 400 ZT.
2)
ZT mast performance data measured for 350 ZT.
3)
ZT mast performance data measured for 500 ZT.
Description EKS
410
EKS
513
EKS
515k
EKS
515
h1Mast height
(retracted)
3100
1)
2955
2)
2955
2)
3705
3)
mm
h3Lift 4000
1)
3500
2)
3500
2)
5000
3)
mm
h4Mast height
(extended)
6550
1)
6050
2)
6050
2)
7550
3)
mm
h7Seat height / standing height 395 470 470 470 mm
h9Aux. lift 840 840 840 840 mm
h10Overall lift 4840
1)
4340
2)
4340
2)
5840
3)
mm
h15Stockpicking height 5995
1)
5570
2)
5570
2)
7070
3)
mm
Ast Working aisle width for
pallets 1000 x 1200 traverse
1640 1640 1640 1640 mm
b2Overall width 1440 1450 1500 1500 mm
b5Distance between forks,
outer
(PAL width 1200)
793 535 535 535 mm
b6Width across guide rollers 1620 1540 1540 1540 mm
l1Overall length w.o. load
(PAL width 1200)
3577 3340 3440 3736 mm
l2Length including fork back
(PAL width 1200)
3273 3200 3300 3596 mm
l Fork length 1200 1200 1200 1200 mm
WaTurning radius 2035 2101 2201 2497 mm
m2Ground clearance centre
wheelbase
80 85 85 85 mm
Net weight incl. battery, w.o.
load
5218 6499 6926 8083 kg
Page 18
B 7
0708.GB
3.3 EKS 410 mast version
3.4 EKS 513 – 515 mast version
Description EKS 410
h1Retracted height (ZT) 2550 - 4100 mm
h3Lift 2500 - 6000 mm
h4Extended height 5050 - 8550 mm
h6Height above overhead
guard
2550 mm
h9Aux. lift 840 mm
h10Overall lift height 3340 - 6840 mm
h15Stockpicking height 4495 - 7995 mm
Description EKS
513
EKS
515k
EKS
515
h1Retracted height (ZT) 2705 - 5055 2705 - 6155 2705 - 6405 mm
h1Retracted height (DZ) 2595 - 3895 2595 - 4695 2595 - 5795 mm
h3Lift (ZT) 3000 - 7500 3000 - 9500 3000 - 10000 mm
h3Lift (DZ) 4250 - 7500 4250 - 9500 4250 - 12500 mm
h4Extended height (ZT) 5550 - 10050 5550 - 12050 5550 - 12550 mm
h4Extended height (DZ) 6800 - 10050 6800 - 12050 6800 - 15050 mm
h6Height above overhead
guard
2550 2550 2550 mm
h9Aux. lift 840 840 840 mm
h10Overall lift height (ZT) 3840 - 8340 3840 - 10340 3840 - 10840 mm
h10Overall lift height (DZ) 5090 - 8340 5090 - 10340 5090 - 13340 mm
h15Picking height (ZT) 5070 - 9570 5070 - 11570 5070 - 12070 mm
h15Picking height (DZ) 6320 - 9570 6320 - 11570 5070 - 14570 mm
B 7
0708.GB
3.3 EKS 410 mast version
3.4 EKS 513 – 515 mast version
Description EKS 410
h1Retracted height (ZT) 2550 - 4100 mm
h3Lift 2500 - 6000 mm
h4Extended height 5050 - 8550 mm
h6Height above overhead
guard
2550 mm
h9Aux. lift 840 mm
h10Overall lift height 3340 - 6840 mm
h15Stockpicking height 4495 - 7995 mm
Description EKS
513
EKS
515k
EKS
515
h1Retracted height (ZT) 2705 - 5055 2705 - 6155 2705 - 6405 mm
h1Retracted height (DZ) 2595 - 3895 2595 - 4695 2595 - 5795 mm
h3Lift (ZT) 3000 - 7500 3000 - 9500 3000 - 10000 mm
h3Lift (DZ) 4250 - 7500 4250 - 9500 4250 - 12500 mm
h4Extended height (ZT) 5550 - 10050 5550 - 12050 5550 - 12550 mm
h4Extended height (DZ) 6800 - 10050 6800 - 12050 6800 - 15050 mm
h6Height above overhead
guard
2550 2550 2550 mm
h9Aux. lift 840 840 840 mm
h10Overall lift height (ZT) 3840 - 8340 3840 - 10340 3840 - 10840 mm
h10Overall lift height (DZ) 5090 - 8340 5090 - 10340 5090 - 13340 mm
h15Picking height (ZT) 5070 - 9570 5070 - 11570 5070 - 12070 mm
h15Picking height (DZ) 6320 - 9570 6320 - 11570 5070 - 14570 mm
Page 19
0708.GB
B 8
3.5 EN norms
EKS 410 EKS 513 - 515
Noise emission: 61 dB(A) 68 dB(A)
in accordance with EN 12053 as harmonised with ISO
4871.
Z
The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the driver’s ear.
EKS 410 EKS 513 - 515
Vibration: 0.79 m/s2 in accordance with EN 130590.79 m/s2 in
accordance with EN 13059
Seat vibration: 0.56 m/s
2
0.64 m/s
2
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over bumps at constant speed.
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 changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
3.6 Conditions of use
Ambient temperature
operating at 5°C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
The truck is not authorised for use in cold stores.
The truck may only be used in closed areas. The following applies:
– Ambient temperature in 24-hour mode: max. 25 °C
– max. air humidity (inside) 70%, non-condensing.
0708.GB
B 8
3.5 EN norms
EKS 410 EKS 513 - 515
Noise emission: 61 dB(A) 68 dB(A)
in accordance with EN 12053 as harmonised with ISO
4871.
Z
The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the driver’s ear.
EKS 410 EKS 513 - 515
Vibration: 0.79 m/s2 in accordance with EN 130590.79 m/s2 in
accordance with EN 13059
Seat vibration: 0.56 m/s
2
0.64 m/s
2
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over bumps at constant speed.
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 changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
3.6 Conditions of use
Ambient temperature
operating at 5°C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
The truck is not authorised for use in cold stores.
The truck may only be used in closed areas. The following applies:
– Ambient temperature in 24-hour mode: max. 25 °C
– max. air humidity (inside) 70%, non-condensing.
Page 20
B 9
0708.GB
4 Identification points and data plates
F
Warning and information labels, such as capacity diagrams, attachment points and
identification plates, must be readable at all times or be replaced, if necessary.
EKS 410
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
6
18
6
mV
1,5 V
12
16
17
13
15
11
10
8
7
D (mm)
h3 (mm) Q (kg)
14
9
9
6
19
13
B 9
0708.GB
4 Identification points and data plates
F
Warning and information labels, such as capacity diagrams, attachment points and
identification plates, must be readable at all times or be replaced, if necessary.
EKS 410
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
6
18
6
mV
1,5 V
12
16
17
13
15
11
10
8
7
D (mm)
h3 (mm) Q (kg)
14
9
9
6
19
13
Page 21
0708.GB
B 10
EKS 513 - 515
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
8
7
11
10
D (mm)
h3 (mm) Q (kg)
12
6
13
13
15
16
17
18
mV
1,5 V
6
14
9
9
19
0708.GB
B 10
EKS 513 - 515
Item Description
6 Strap points for crane lifting
7 Truck data plate
8 Capacity plate
9 Decal: “Abseil device”
10 Decal: “No passengers”
11 Test sticker (o)
12 Decal: Do not step onto or beneath the load, risk of trapping
13 Jack contact points
14 Serial number (engraved in chassis underneath the battery cover)
15 “Add hydraulic oil” notice
16 “Emergency drain” decal
17 “Emergency drain key” decal
18 Decal: “Caution: Low voltage electronics system"
19 “Read operating instructions" notice
8
7
11
10
D (mm)
h3 (mm) Q (kg)
12
6
13
13
15
16
17
18
mV
1,5 V
6
14
9
9
19
Page 22
B 11
0708.GB
4.1 Truck data plate
For queries relating to the truck or spare parts orders, please state the truck serial no.
(21).
4.2 Capacity
The plate (8) gives the capacity (Q in kg) of the truck as a function of the load centre
of gravity distance (D in mm) and lift height (H in mm) in tabular form.
Item Description Item Description
20 Type 26 Manufacturer
21 Serial no. 27 Min./max. battery weight (kg)
22 Rated capacity (kg) 28 Drive output (kW)
23 Battery voltage (V) 29 Load centre of gravity (mm)
24 Net weight w.o. battery (kg) 30 Year of manufacture
25 Manufacturer’s logo 31 Option
26
25
27
24
28
23
29
22
30
21
31
20
8
D (mm)
h3 (mm) Q (kg)
B 11
0708.GB
4.1 Truck data plate
For queries relating to the truck or spare parts orders, please state the truck serial no.
(21).
4.2 Capacity
The plate (8) gives the capacity (Q in kg) of the truck as a function of the load centre
of gravity distance (D in mm) and lift height (H in mm) in tabular form.
Item Description Item Description
20 Type 26 Manufacturer
21 Serial no. 27 Min./max. battery weight (kg)
22 Rated capacity (kg) 28 Drive output (kW)
23 Battery voltage (V) 29 Load centre of gravity (mm)
24 Net weight w.o. battery (kg) 30 Year of manufacture
25 Manufacturer’s logo 31 Option
26
25
27
24
28
23
29
22
30
21
31
20
8
D (mm)
h3 (mm) Q (kg)
Page 23
0708.GB
B 12
0708.GB
B 12
Page 24
C 1
1004.GB
C Transport and Commissioning
1 Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions.
– Vertically, with mast and load lifting device assembled (for low heights)
– Vertically, with mast and load lifting device disassembled (for large heights)
– EKS 513-515 only: vertically, with the mast folded.
M
Only personnel trained by the manufacturer may assemble the truck on site,
commission it and instruct the driver.
2 Lifting by crane
M
Only use lifting gear with sufficient capacity (for truck weight see truck data plate. See
Chapter B).
M
The truck must only be lifted by crane with the battery removed.
– Parking the truck securely
(see Chapter E).
M
Attach the crane slings to the strap points (1-3) so that the truck cannot slip.
2
1
3
1
2
3
4
5
7
8
6
EKS 410
EKS 513 - 515
C 1
1004.GB
C Transport and Commissioning
1 Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions.
– Vertically, with mast and load lifting device assembled (for low heights)
– Vertically, with mast and load lifting device disassembled (for large heights)
– EKS 513-515 only: vertically, with the mast folded.
M
Only personnel trained by the manufacturer may assemble the truck on site,
commission it and instruct the driver.
2 Lifting by crane
M
Only use lifting gear with sufficient capacity (for truck weight see truck data plate. See
Chapter B).
M
The truck must only be lifted by crane with the battery removed.
– Parking the truck securely
(see Chapter E).
M
Attach the crane slings to the strap points (1-3) so that the truck cannot slip.
2
1
3
1
2
3
4
5
7
8
6
EKS 410
EKS 513 - 515
Page 25
1004.GB
C 2
2.1 Crane points
EKS 410:
The crane points (1) are the eyes in the mast.
To access the crane points (2), remove the battery panels (4) and the drive panel (8).
The side panels (6) must also be removed. To do this, remove the 2 screws at the top
(5) and on the inside (7).
The crane points (3) are the mast's lower strap points connecting it to the chassis.
EKS 513 - 515:
The crane points (1) are the eyes in the mast.
The crane points (2) are the eyes on the drive compartment.
The crane points (3) are the mast's lower strap points connecting it to the chassis.
When lifting by crane, use the following crane points:
– Crane points for complete truck with mast assembled:
points (1) and (2) (for weight see data plate)
– Crane points for the basic truck:
items (2) and (3) (weight 2000 kg (EKS 410), 3000 kg (EKS 513-515)
– Mast crane points including driver’s cab and load handler:
items (1) and (3) (weight 2,600 kg (EKS 410), 6,500 kg (EKS 513-515)
2.2 Lifting the battery by crane
When lifting the battery with a crane attach suitable lifting gear to the four eyes of the
battery container (for weight see battery data plate).
For battery removal see Chapter D, Section 4.
3 Securing the truck during transport
F
The truck must be securely fastened when being transported on a lorry or a trailer.
The lorry / trailer must have fastening rings.
M
Loading shall be carried out by staff especially trained for that purpose in accordance
with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case
correct measurements shall be determined and appropriate safety measures
adopted.
1004.GB
C 2
2.1 Crane points
EKS 410:
The crane points (1) are the eyes in the mast.
To access the crane points (2), remove the battery panels (4) and the drive panel (8).
The side panels (6) must also be removed. To do this, remove the 2 screws at the top
(5) and on the inside (7).
The crane points (3) are the mast's lower strap points connecting it to the chassis.
EKS 513 - 515:
The crane points (1) are the eyes in the mast.
The crane points (2) are the eyes on the drive compartment.
The crane points (3) are the mast's lower strap points connecting it to the chassis.
When lifting by crane, use the following crane points:
– Crane points for complete truck with mast assembled:
points (1) and (2) (for weight see data plate)
– Crane points for the basic truck:
items (2) and (3) (weight 2000 kg (EKS 410), 3000 kg (EKS 513-515)
– Mast crane points including driver’s cab and load handler:
items (1) and (3) (weight 2,600 kg (EKS 410), 6,500 kg (EKS 513-515)
2.2 Lifting the battery by crane
When lifting the battery with a crane attach suitable lifting gear to the four eyes of the
battery container (for weight see battery data plate).
For battery removal see Chapter D, Section 4.
3 Securing the truck during transport
F
The truck must be securely fastened when being transported on a lorry or a trailer.
The lorry / trailer must have fastening rings.
M
Loading shall be carried out by staff especially trained for that purpose in accordance
with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case
correct measurements shall be determined and appropriate safety measures
adopted.
Page 26
C 3
1004.GB
3.1 Basic truck transport safety
M
The mast must only be disassembled by the manufacturer’s authorised service
department.
To ensure secure transport of a disassembled EKS, use the prescribed attachment
points for fastening/quick release belts.
Z
With the EKS 410 only use straps with a rated capacity of > 5 tonnes and with the
EKS 513-515 only straps with a rated capacity of > 9 tonnes.
M
When transporting, always relieve the drive wheel by placing the entire surface of a
wooden beam (11) underneath the counterweight (minimum chassis width). In
addition, secure the load wheels with a wedge (13).
M
If the truck’s battery is supplied in the chassis, disconnect the battery.
Fastening belts should be attached to at least 4 different lorry eyes (12).
Belts placed over “sharp” edges must be protected by a suitable support material ,
e. g. foam.
The top holes of the counterweight attachment (10) can be used as attachment points
for the rear end of the truck chassis.
The tensioning belts should be tightened over both outriggers at the front end of the
truck chassis.
M
Note the cable routing and cover sharp edges with a suitable material.
The tensioning belt above the upper chassis section is routed behind the two mast
attachment bars (9).
To do this remove the side panels and open the battery panel. After tensioning the
belt, fit the side panels back again and close the battery panel.
9
12
10
13
11
C 3
1004.GB
3.1 Basic truck transport safety
M
The mast must only be disassembled by the manufacturer’s authorised service
department.
To ensure secure transport of a disassembled EKS, use the prescribed attachment
points for fastening/quick release belts.
Z
With the EKS 410 only use straps with a rated capacity of > 5 tonnes and with the
EKS 513-515 only straps with a rated capacity of > 9 tonnes.
M
When transporting, always relieve the drive wheel by placing the entire surface of a
wooden beam (11) underneath the counterweight (minimum chassis width). In
addition, secure the load wheels with a wedge (13).
M
If the truck’s battery is supplied in the chassis, disconnect the battery.
Fastening belts should be attached to at least 4 different lorry eyes (12).
Belts placed over “sharp” edges must be protected by a suitable support material ,
e. g. foam.
The top holes of the counterweight attachment (10) can be used as attachment points
for the rear end of the truck chassis.
The tensioning belts should be tightened over both outriggers at the front end of the
truck chassis.
M
Note the cable routing and cover sharp edges with a suitable material.
The tensioning belt above the upper chassis section is routed behind the two mast
attachment bars (9).
To do this remove the side panels and open the battery panel. After tensioning the
belt, fit the side panels back again and close the battery panel.
9
12
10
13
11
Page 27
1004.GB
C 4
3.2 Mast transport safety
M
Use a transport retaining device (20) to prevent the operator compartment carriage
(14) from sliding.
If the mast is stored on a pallet(s), fasten them securely to the mast (18).
Use the attachment latch (19) as the "mast bottom" strap point for securing to the lorry
eyes (17).
Route the belt over the lift cylinder/chains to act as the "mast top” strap point.
M
Protect the belt placed over the lift chains with a suitable material (15).
Any supplied parts (forks (16), guide rollers etc.) can be attached to a pallet, which
can then be fastened to the mast.
14
15
16
17
18
1717
20
19
1004.GB
C 4
3.2 Mast transport safety
M
Use a transport retaining device (20) to prevent the operator compartment carriage
(14) from sliding.
If the mast is stored on a pallet(s), fasten them securely to the mast (18).
Use the attachment latch (19) as the "mast bottom" strap point for securing to the lorry
eyes (17).
Route the belt over the lift cylinder/chains to act as the "mast top” strap point.
M
Protect the belt placed over the lift chains with a suitable material (15).
Any supplied parts (forks (16), guide rollers etc.) can be attached to a pallet, which
can then be fastened to the mast.
14
15
16
17
18
1717
20
19
Page 28
C 5
1004.GB
3.3 Mast assembled
Safely transporting the truck with the mast assembled
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
M
When transporting, always relieve
the drive wheel by placing the entire
surface of a wooden beam (23)
underneath the counterweight
(minimum chassis width). In addition,
secure the load wheels with a wedge
(24).
Z
Only use belts with a rated capacity
of .
EKS 410 > 5 to
EKS 513 > 9 to
At least 4 belts, 2 on the left and 2 on
the right (20, 21) must be attached to
the mast.
3.4 Safely transporting the truck with
the mast folded
(EKS 513 - 515)
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
Z
Only use belts with a rated capacity
of >9 tonnes.
Fastening belts should be attached to
at least 4 different lorry / truck eyes
(25).
F
Attention Risk of tipover through high
centre of gravity.
The tensioning belts are tensioned on the mast.
Using wooden planks, a pallet or a rubber mat (27) from the outrigger to the front of
the transporter, ensure a positive fit.
Z
Place the entire surface area of a wooden beam (26) underneath the counterweight,
the chassis width as minimum, to discharge the drive wheel.
21
22
23
24
25
25
27
26
C 5
1004.GB
3.3 Mast assembled
Safely transporting the truck with the mast assembled
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
M
When transporting, always relieve
the drive wheel by placing the entire
surface of a wooden beam (23)
underneath the counterweight
(minimum chassis width). In addition,
secure the load wheels with a wedge
(24).
Z
Only use belts with a rated capacity
of .
EKS 410 > 5 to
EKS 513 > 9 to
At least 4 belts, 2 on the left and 2 on
the right (20, 21) must be attached to
the mast.
3.4 Safely transporting the truck with
the mast folded
(EKS 513 - 515)
M
If the truck’s battery is supplied in the
chassis, disconnect the battery.
Z
Only use belts with a rated capacity
of >9 tonnes.
Fastening belts should be attached to
at least 4 different lorry / truck eyes
(25).
F
Attention Risk of tipover through high
centre of gravity.
The tensioning belts are tensioned on the mast.
Using wooden planks, a pallet or a rubber mat (27) from the outrigger to the front of
the transporter, ensure a positive fit.
Z
Place the entire surface area of a wooden beam (26) underneath the counterweight,
the chassis width as minimum, to discharge the drive wheel.
21
22
23
24
25
25
27
26
Page 29
1004.GB
C 6
4 Commissioning
4.1 Moving the truck without a battery
M
This operation must only be performed by suitably trained maintenance personnel.
M
This operation is forbidden on slopes and inclines (no brakes).
See also chapter E, “Recovering the truck from a narrow aisle / Moving the truck
without a battery”.
4.2 Installing and removing the mast
M
This operation must only be performed by the manufacturer or a customer service
team authorised by the manufacturer.
5 Starting the truck for the first time
M
Operate the truck only with battery current. Rectified AC current will damage the
electronic components. The battery leads (tow cable) must be less than 6m long.
To prepare the truck after delivery or after transport, proceed as follows:
– Install and charge the battery if necessary (see Chapter D, Sections 4 and 3).
– Commission the truck as per instructions (See Chapter E, Section 3).
Z
With the EKS 410/513/515k/515 a tipover retaining device (30) is fitted, depending on
the tipover test. When a tipover retaining device is used, an X (29) is engraved on the
truck chassis on the right hand side of the battery compartment, after the serial
number.
M
Before operating, check the trucks to ensure the tilt safety devices (30) are present
(if required).
M
Check that all safety devices are present and operational.
29
30
1004.GB
C 6
4 Commissioning
4.1 Moving the truck without a battery
M
This operation must only be performed by suitably trained maintenance personnel.
M
This operation is forbidden on slopes and inclines (no brakes).
See also chapter E, “Recovering the truck from a narrow aisle / Moving the truck
without a battery”.
4.2 Installing and removing the mast
M
This operation must only be performed by the manufacturer or a customer service
team authorised by the manufacturer.
5 Starting the truck for the first time
M
Operate the truck only with battery current. Rectified AC current will damage the
electronic components. The battery leads (tow cable) must be less than 6m long.
To prepare the truck after delivery or after transport, proceed as follows:
– Install and charge the battery if necessary (see Chapter D, Sections 4 and 3).
– Commission the truck as per instructions (See Chapter E, Section 3).
Z
With the EKS 410/513/515k/515 a tipover retaining device (30) is fitted, depending on
the tipover test. When a tipover retaining device is used, an X (29) is engraved on the
truck chassis on the right hand side of the battery compartment, after the serial
number.
M
Before operating, check the trucks to ensure the tilt safety devices (30) are present
(if required).
M
Check that all safety devices are present and operational.
29
30
Page 30
D 1
1004.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the industrial 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. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection: Smoking and naked flames must be avoided when working with
batteries Wherever an industrial truck is parked for charging there shall be no
inflammable material or lubricants capable of creating sparks within 2 metres around
the truck. The area must be well ventilated. Fire protection equipment must be
provided.
Battery maintenance: The battery cell covers must be kept dry and clean. The
terminals and cable shoes must be clean, secure and have a light coating of dielectric
grease.
Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Above all avoid any contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water - where the skin or eyes are affected
call a doctor immediately. Immediately neutralise any spilled battery acid.
M
Only batteries with a sealed battery container may be used.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the industrial truck. Battery equipment may only be replaced with
the agreement of the manufacturer.
D 1
1004.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the industrial 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. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection: Smoking and naked flames must be avoided when working with
batteries Wherever an industrial truck is parked for charging there shall be no
inflammable material or lubricants capable of creating sparks within 2 metres around
the truck. The area must be well ventilated. Fire protection equipment must be
provided.
Battery maintenance: The battery cell covers must be kept dry and clean. The
terminals and cable shoes must be clean, secure and have a light coating of dielectric
grease.
Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Above all avoid any contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water - where the skin or eyes are affected
call a doctor immediately. Immediately neutralise any spilled battery acid.
M
Only batteries with a sealed battery container may be used.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the industrial truck. Battery equipment may only be replaced with
the agreement of the manufacturer.
Page 31
1004.GB
D 2
2Battery types
The EKS can be fitted with a variety of battery types. All battery types comply with
DIN 43531-A. The following table shows which combinations can be included as
standard:
The battery weights can be taken from the battery data plate.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the industrial truck. Battery equipment may only be replaced with
the agreement of the manufacturer.
3 Charge the battery
F
Park the truck securely (see Chapter E).
– Turn key switch to "0" (zero).
– Fully open the battery panels.
F
Only connect and disconnect the battery connector and the socket when the mains
and charger are switched off.
– Disconnect the battery.
– If necessary, remove the insulating mat from the battery.
F
When charging, the tops of the battery cells must be exposed to provide sufficient
ventilation. Do not place any metal objects on the battery. Before charging, check all
cables and plug connections for visible signs of damage.
– Connect the charger lead of the battery charger station with the battery connector.
– Switch on the charger.
– Charge the battery in accordance with the battery and charging station
manufacturers’ instructions.
F
It is essential to follow the safety regulations of the battery and charger station
manufacturers.
Battery type Battery type Truck type
48V 4EPzS460 Single part EKS 410
48V 4EPzS575 Single part EKS 410
48V 4EPzS690 Single part EKS 410
80V 3EPzS420 Single part / two part EKS 513 / EKS 515k
80V 4EPzS560 Single part / two part EKS 515k
80V 5EPzS700 Single part / two part EKS 515
80V 6EPzS840 Single part / two part EKS 515
1004.GB
D 2
2Battery types
The EKS can be fitted with a variety of battery types. All battery types comply with
DIN 43531-A. The following table shows which combinations can be included as
standard:
The battery weights can be taken from the battery data plate.
F
The weight and dimensions of the battery have a considerable effect on the
operational safety of the industrial truck. Battery equipment may only be replaced with
the agreement of the manufacturer.
3 Charge the battery
F
Park the truck securely (see Chapter E).
– Turn key switch to "0" (zero).
– Fully open the battery panels.
F
Only connect and disconnect the battery connector and the socket when the mains
and charger are switched off.
– Disconnect the battery.
– If necessary, remove the insulating mat from the battery.
F
When charging, the tops of the battery cells must be exposed to provide sufficient
ventilation. Do not place any metal objects on the battery. Before charging, check all
cables and plug connections for visible signs of damage.
– Connect the charger lead of the battery charger station with the battery connector.
– Switch on the charger.
– Charge the battery in accordance with the battery and charging station
manufacturers’ instructions.
F
It is essential to follow the safety regulations of the battery and charger station
manufacturers.
Battery type Battery type Truck type
48V 4EPzS460 Single part EKS 410
48V 4EPzS575 Single part EKS 410
48V 4EPzS690 Single part EKS 410
80V 3EPzS420 Single part / two part EKS 513 / EKS 515k
80V 4EPzS560 Single part / two part EKS 515k
80V 5EPzS700 Single part / two part EKS 515
80V 6EPzS840 Single part / two part EKS 515
Page 32
D 3
1004.GB
4 Battery removal and installation
F
Only batteries with insulated cells and terminal connectors may be used. When
replacing a battery always use the same battery type. Extra weights must not be
removed and must remain in the same position.
F
The truck must be horizontal in order to prevent the battery from falling out when the
battery retainer is removed.
F
Only connect and disconnect the battery connector and the socket when the mains
and charger are switched off.
t EKS 410 (installing/removing a battery with a battery trolley):
– Turn key switch (2) to "0" (zero).
– Lift up the battery panels (4) and disconnect the battery (3).
– Remove the battery panels (4).
– Undo the battery retainer (5) by moving the lever (6) down and remove the retainer.
– Pull the battery (7) onto the side of the prepared battery trolley.
F
Make sure the battery trolley is properly secured.
F
After replacing/fitting the battery, make sure that the battery is well secured in the
battery compartment.
Z
The battery retainers (5, 8) can swap positions. This means that they can both be
fitted in either the left or right side of the truck’s chassis.
Assembly is the reverse order.
M
To avoid pushing the battery (7) through on assembly, the battery retainer (8) must
first be plugged in on the opposite side.
F
After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
– the battery retainer (5) is fitted and secured by the lever (6),
– the battery panels (4) are properly closed.
4
1
2
3
6
5
7
8
D 3
1004.GB
4 Battery removal and installation
F
Only batteries with insulated cells and terminal connectors may be used. When
replacing a battery always use the same battery type. Extra weights must not be
removed and must remain in the same position.
F
The truck must be horizontal in order to prevent the battery from falling out when the
battery retainer is removed.
F
Only connect and disconnect the battery connector and the socket when the mains
and charger are switched off.
t EKS 410 (installing/removing a battery with a battery trolley):
– Turn key switch (2) to "0" (zero).
– Lift up the battery panels (4) and disconnect the battery (3).
– Remove the battery panels (4).
– Undo the battery retainer (5) by moving the lever (6) down and remove the retainer.
– Pull the battery (7) onto the side of the prepared battery trolley.
F
Make sure the battery trolley is properly secured.
F
After replacing/fitting the battery, make sure that the battery is well secured in the
battery compartment.
Z
The battery retainers (5, 8) can swap positions. This means that they can both be
fitted in either the left or right side of the truck’s chassis.
Assembly is the reverse order.
M
To avoid pushing the battery (7) through on assembly, the battery retainer (8) must
first be plugged in on the opposite side.
F
After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
– the battery retainer (5) is fitted and secured by the lever (6),
– the battery panels (4) are properly closed.
4
1
2
3
6
5
7
8
Page 33
1004.GB
D 4
t EKS 513 - 515 (installing/removing a battery with a battery trolley):
– Turn key switch (9) to "0" (zero).
– Lift up the battery panel (11).
– Pull the battery panels (12) up and lift them off.
– Disconnect the battery (15).
– Undo the battery retainer (13) by moving the lever (14) down and remove the
retainer.
– Pull the battery (16) onto the side of the prepared battery trolley.
F
Make sure the battery trolley is properly secured.
F
After replacing/fitting the battery, make sure that the battery is well secured in the
battery compartment.
Z
The battery retainers (13, 17) can swap positions. This means that they can both be
fitted in either the left or right side of the truck’s chassis.
Assembly is the reverse order.
M
To avoid pushing the battery (16) through on assembly, the battery retainer (17) must
first be plugged in on the opposite side.
F
After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
– the battery retainer (13) is fitted and secured by the lever (14),
– the battery panels (11, 12) are properly closed.
12
15
16
17
10
9
11
13
11
14
1004.GB
D 4
t EKS 513 - 515 (installing/removing a battery with a battery trolley):
– Turn key switch (9) to "0" (zero).
– Lift up the battery panel (11).
– Pull the battery panels (12) up and lift them off.
– Disconnect the battery (15).
– Undo the battery retainer (13) by moving the lever (14) down and remove the
retainer.
– Pull the battery (16) onto the side of the prepared battery trolley.
F
Make sure the battery trolley is properly secured.
F
After replacing/fitting the battery, make sure that the battery is well secured in the
battery compartment.
Z
The battery retainers (13, 17) can swap positions. This means that they can both be
fitted in either the left or right side of the truck’s chassis.
Assembly is the reverse order.
M
To avoid pushing the battery (16) through on assembly, the battery retainer (17) must
first be plugged in on the opposite side.
F
After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
– the battery retainer (13) is fitted and secured by the lever (14),
– the battery panels (11, 12) are properly closed.
12
15
16
17
10
9
11
13
11
14
Page 34
D 5
1004.GB
o EKS 513 – 515 (Installing/removing batteries in the battery replacement
carriage with a forklift):
– Turn key switch (18) to "0" (zero).
– Lift up the battery panel (20).
– Pull the battery panels (21) up and lift them off.
– Remove the battery connector (23) from the left and right-hand side of the battery
compartment.
– Remove the battery retainers (22) from the left and right-hand side of the battery
compartment.
– Carefully pull out the batteries (24) from the left or right hand side using a forklift
truck. To do this, enter the forklift’s load handler into the fork shoes (25) of the
battery replacement carriage.
Assembly is the reverse order.
M
When fitting the batteries (24) in the battery replacement carriage, make sure that the
load handler of the forklift truck used for assembly is located in the fork shoes (25) of
the battery frame. In addition, the fork tips of the load handler must not project beyond
the battery replacement carriage.
F
After replacing/fitting the battery, make sure that the battery is well secured in the
battery compartment.
F
After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
– the battery retainers (22) are inserted and are secure,
– the battery panels (20, 21) are properly closed.
D 5
1004.GB
o EKS 513 – 515 (Installing/removing batteries in the battery replacement
carriage with a forklift):
– Turn key switch (18) to "0" (zero).
– Lift up the battery panel (20).
– Pull the battery panels (21) up and lift them off.
– Remove the battery connector (23) from the left and right-hand side of the battery
compartment.
– Remove the battery retainers (22) from the left and right-hand side of the battery
compartment.
– Carefully pull out the batteries (24) from the left or right hand side using a forklift
truck. To do this, enter the forklift’s load handler into the fork shoes (25) of the
battery replacement carriage.
Assembly is the reverse order.
M
When fitting the batteries (24) in the battery replacement carriage, make sure that the
load handler of the forklift truck used for assembly is located in the fork shoes (25) of
the battery frame. In addition, the fork tips of the load handler must not project beyond
the battery replacement carriage.
F
After replacing/fitting the battery, make sure that the battery is well secured in the
battery compartment.
F
After installing again, check all cables and connectors for signs of visible damage and
before using the truck again check that:
– the battery retainers (22) are inserted and are secure,
– the battery panels (20, 21) are properly closed.
Page 35
1004.GB
D 6
21
23
22
25
24
19
18
20
20
24
22
1004.GB
D 6
21
23
22
25
24
19
18
20
20
24
22
Page 36
D 7
1004.GB
5 Battery – checking condition and acid level
– The battery manufacturer’s maintenance instructions apply.
– Check the battery housing for cracks and any spilled acid.
– Remove any oxydation remains from the battery terminals and apply an acid-free
grease to the battery terminals.
– Unscrew the stops and check the acid level.
The acid level should be at least 10-15 mm above the top of the plates.
– If necessary, re-charge the battery.
6 Battery discharge indicator
When you turn the EMERGENCY
DISCONNECT switch and turn the key
in the key switch clockwise, the battery
discharge indicator will show the
residual capacity available. The display
flashes at a residual capacity of 30%. Lift
cut-out occurs at a 20% capacity
display.
For maintenance-free and special
batteries the display and cutout points
can be adjusted by authorised personnel
by assigning parameters.
+-
50%
D 7
1004.GB
5 Battery – checking condition and acid level
– The battery manufacturer’s maintenance instructions apply.
– Check the battery housing for cracks and any spilled acid.
– Remove any oxydation remains from the battery terminals and apply an acid-free
grease to the battery terminals.
– Unscrew the stops and check the acid level.
The acid level should be at least 10-15 mm above the top of the plates.
– If necessary, re-charge the battery.
6 Battery discharge indicator
When you turn the EMERGENCY
DISCONNECT switch and turn the key
in the key switch clockwise, the battery
discharge indicator will show the
residual capacity available. The display
flashes at a residual capacity of 30%. Lift
cut-out occurs at a 20% capacity
display.
For maintenance-free and special
batteries the display and cutout points
can be adjusted by authorised personnel
by assigning parameters.
+-
50%
Page 37
1004.GB
D 8
1004.GB
D 8
Page 38
E 1
0206.GB
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation The forklift 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. The driver shall be afforded all due rights.
Unauthorised Use of Truck: The driver is responsible for the truck during the time
it is in use. He shall prevent unauthorised persons from driving or operating the truck.
It is forbidden to carry passengers or lift personnel.
Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the forklift truck. Trucks not safe 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 forklift truck
without the necessary training and authoristion to do so. On no account may the
driver disable or adjust safety mechanisms or switches.
Hazardous 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 in good time. 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 in the present operating instructions shall be strictly observed.
E 1
0206.GB
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation The forklift 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. The driver shall be afforded all due rights.
Unauthorised Use of Truck: The driver is responsible for the truck during the time
it is in use. He shall prevent unauthorised persons from driving or operating the truck.
It is forbidden to carry passengers or lift personnel.
Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the forklift truck. Trucks not safe 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 forklift truck
without the necessary training and authoristion to do so. On no account may the
driver disable or adjust safety mechanisms or switches.
Hazardous 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 in good time. 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 in the present operating instructions shall be strictly observed.
Page 39
0206.GB
E 2
2 Operating and Display Equipment
2.1 Operating and display equipment on control panel
1
22 21
98 13
14
7
7
15
16
17
10 11 12
20 19 18
3
4
6
5
2
0206.GB
E 2
2 Operating and Display Equipment
2.1 Operating and display equipment on control panel
1
22 21
98 13
14
7
7
15
16
17
10 11 12
20 19 18
3
4
6
5
2
Page 40
E 3
0206.GB
Item Control / Display Function
1 Control panel t All displays and functions
2 Key switch t Switches control curr ent on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel.
3 Control panel
stop
t Sets the height and distance of the control
panel.
4 Cabin safety gate t Prevents operator from falling out
5 Seat height adjustment t The driver’s seat can be vertically adjusted.
6 Deadman switch
(foot switch)
t Release parking brake. When activated,
releases the spring pressure brake and travel.
Releasing the deadman switch causes the truck
to brake immediately until it comes to a halt.
7 Hand rest and
contact point
t Two-handed operation
8 Hydraulic control switch t Raising and lowering of Main and Aux. lift, reach
and swivel of load forks
9 Display unit t Operating information and warning message
display
10 “Parking brake on”
display
t Lit when the parking brake is applied
11 “EMERGENCY STOP”
display
t Lit when the EMERGENCY STOP device is
automatically activated
12 “Fault” display t Lit when a fault occurs
13 Travel control button t Controls the travel direction and speed of the
truck
14 “Main and Aux. Lift
Lower” key
t Enables simultaneous lowering of Main and
Aux. Lift.
15 “Aux. Lift” key t Switches the hydraulic control button to lift and
lower the fork carriage without the driver’s cab
16 No function t No function
17 No function t No function
18 EMERGENCY
DISCONNECT switch
t Interrupts the main supply, all truck movements
are disabled
19 Switch t Activate or confirm the function related to the
symbol displayed above it
20 “Cancel sub-menu” key t Sets the menu to standard display
21 Steering wheel t Steers the truck in the required direction.
22 “Warning” switch t Activates a warning
t = Standard equipment o = Optional Equipment
E 3
0206.GB
Item Control / Display Function
1 Control panel t All displays and functions
2 Key switch t Switches control curr ent on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel.
3 Control panel
stop
t Sets the height and distance of the control
panel.
4 Cabin safety gate t Prevents operator from falling out
5 Seat height adjustment t The driver’s seat can be vertically adjusted.
6 Deadman switch
(foot switch)
t Release parking brake. When activated,
releases the spring pressure brake and travel.
Releasing the deadman switch causes the truck
to brake immediately until it comes to a halt.
7 Hand rest and
contact point
t Two-handed operation
8 Hydraulic control switch t Raising and lowering of Main and Aux. lift, reach
and swivel of load forks
9 Display unit t Operating information and warning message
display
10 “Parking brake on”
display
t Lit when the parking brake is applied
11 “EMERGENCY STOP”
display
t Lit when the EMERGENCY STOP device is
automatically activated
12 “Fault” display t Lit when a fault occurs
13 Travel control button t Controls the travel direction and speed of the
truck
14 “Main and Aux. Lift
Lower” key
t Enables simultaneous lowering of Main and
Aux. Lift.
15 “Aux. Lift” key t Switches the hydraulic control button to lift and
lower the fork carriage without the driver’s cab
16 No function t No function
17 No function t No function
18 EMERGENCY
DISCONNECT switch
t Interrupts the main supply, all truck movements
are disabled
19 Switch t Activate or confirm the function related to the
symbol displayed above it
20 “Cancel sub-menu” key t Sets the menu to standard display
21 Steering wheel t Steers the truck in the required direction.
22 “Warning” switch t Activates a warning
t = Standard equipment o = Optional Equipment
Page 41
0206.GB
E 4
2.2 Display unit controls and displays
Upper range symbols
Item Symbol Control / Display Function
23 Displays possible
travel speeds:
Turtle
Rabbit
t
Creep mode
Max. travel speed
24 “Guidance wire
recognition” display
IG Sensors which have recognised the
guidance wire have a dark background
25 Steering angle display
changes with display
– “Tracking in
progress”
– “Automatically
guided”
– “Deviation from
guidance wire”
t
R
G
IG
IG
IG
IG
Indicates the current steering angle with
reference to the centre position
Centre position is permanently displayed
once the truck is engaged in the track
The steering angle display fades and is
replaced by guidance wire symbols
– when the truck is tracked onto the
guidance wire (inductive guidance)
– when the truck is automatically guided
by the guidance wire
– when the truck deviates without
guidance from the guidance wire and
automatic guidance
23
24
25 26 27 28 29
30
19
0206.GB
E 4
2.2 Display unit controls and displays
Upper range symbols
Item Symbol Control / Display Function
23 Displays possible
travel speeds:
Turtle
Rabbit
t
Creep mode
Max. travel speed
24 “Guidance wire
recognition” display
IG Sensors which have recognised the
guidance wire have a dark background
25 Steering angle display
changes with display
– “Tracking in
progress”
– “Automatically
guided”
– “Deviation from
guidance wire”
t
R
G
IG
IG
IG
IG
Indicates the current steering angle with
reference to the centre position
Centre position is permanently displayed
once the truck is engaged in the track
The steering angle display fades and is
replaced by guidance wire symbols
– when the truck is tracked onto the
guidance wire (inductive guidance)
– when the truck is automatically guided
by the guidance wire
– when the truck deviates without
guidance from the guidance wire and
automatic guidance
23
24
25 26 27 28 29
30
19
Page 42
E 5
0206.GB
2.3 Lower range symbols and keys
Activate switch (19) under the respective symbols (30) displayed or confirm the
related function. The symbol will be given a dark background.
26 Display
“Overall lift”
“Referencing
required” display:
Primary raise - lift
Primary raise - lower
t Displays the height of the forks
Requests Primary raise to lift
Requests Primary raise to lower
27 “Time” display t Time display
28 “Operating hours”
display
t Displays the number of service hours
since the truck was commissioned
29 Battery discharge
indicator
t Displays the battery charge condition
(residual capacity as a percentage)
Symbol Control or Display Function
Warnings
“Slack chain safety
device” display
t Displayed when the slack chain safety
device engages
“Slack chain safety
device override” switch
Overrides the slack chain safety device to
lift the driver's position freely
“Fwd./Rev. travel only”
display
t Displayed when lift cutout is actvated due to
low battery capacity and only forward or
reverse travel is possible.
“Acknowledge lift cutout
due to battery discharge”
switch
Confirms lift cutout due to low battery
capacity and releases travel (the Fwd./Rev.
Travel Only display has a dark background)
“Lift height dependent lift
cutout” display
o Displayed when the lift height dependent lift
cutout is activated
“Height dependent lift
cutout bypass” switch
Bypasses the height dependent lift cutout
(display has a dark background). Observe
the maximum passage heights
“Lower limit” display o Indicates that the automatic lowering limit
has been activated.
“Lowering limit override”
switch
Overrides the lowering limit, controlled by
hydraulic control button
“Travel cutout” display o Indicates that automatic, height dependent
travel cutout has been activated
“Travel cutout override”
switch
Overrides the automatic, height dependent
travel cutout
“Aisle endsafety device”
display (option)
o Indicates that the aisle end safety device
has been activated. The truck brakes.
Item Symbol Control / Display Function
E 5
0206.GB
2.3 Lower range symbols and keys
Activate switch (19) under the respective symbols (30) displayed or confirm the
related function. The symbol will be given a dark background.
26 Display
“Overall lift”
“Referencing
required” display:
Primary raise - lift
Primary raise - lower
t Displays the height of the forks
Requests Primary raise to lift
Requests Primary raise to lower
27 “Time” display t Time display
28 “Operating hours”
display
t Displays the number of service hours
since the truck was commissioned
29 Battery discharge
indicator
t Displays the battery charge condition
(residual capacity as a percentage)
Symbol Control or Display Function
Warnings
“Slack chain safety
device” display
t Displayed when the slack chain safety
device engages
“Slack chain safety
device override” switch
Overrides the slack chain safety device to
lift the driver's position freely
“Fwd./Rev. travel only”
display
t Displayed when lift cutout is actvated due to
low battery capacity and only forward or
reverse travel is possible.
“Acknowledge lift cutout
due to battery discharge”
switch
Confirms lift cutout due to low battery
capacity and releases travel (the Fwd./Rev.
Travel Only display has a dark background)
“Lift height dependent lift
cutout” display
o Displayed when the lift height dependent lift
cutout is activated
“Height dependent lift
cutout bypass” switch
Bypasses the height dependent lift cutout
(display has a dark background). Observe
the maximum passage heights
“Lower limit” display o Indicates that the automatic lowering limit
has been activated.
“Lowering limit override”
switch
Overrides the lowering limit, controlled by
hydraulic control button
“Travel cutout” display o Indicates that automatic, height dependent
travel cutout has been activated
“Travel cutout override”
switch
Overrides the automatic, height dependent
travel cutout
“Aisle endsafety device”
display (option)
o Indicates that the aisle end safety device
has been activated. The truck brakes.
Item Symbol Control / Display Function
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E 6
“Personalsafety system”
display (PSS)
o Indicates that the personal safety system
has identified persons or objects in the aisle.
The truck brakes.
“Personalsafety system”
switch (PSS)
Bypasses the protective function and
enables creep mode if there is sufficient
distance from the obstacle.
If a personal safety system is fitted, read the
accompanying operator manual.
Select “Warning submenu” display
o Indicates that several warnings (e.g. slack
chain safety device height dependent lift
cutout) have been issued.
Quit “warnings” submenu.
Displays individual warnings
Quit “warnings” submenu.
o Indicates that the sub-menu can be quit.
“Cancel warnings submenu” switch
Sets the “warnings” sub-menu to the
standard menu
Guidance systems
“Guidance on” display
not active
“Guidance on” display
active
t
R
G
W
G
Displays automatic guidance in the aisle:
Rail guidance display
(drive wheel set to forward position)
Indicates that inductive guidance is
activated
“Guidance on” switch R
G
W
G
Sets the drive wheel to forward position
Activates the blending in process (and
frequency selection for multi-frequencies)
Displays “Select
Frequency 1” (similar to
other frequencies)
(“Guidance on” submenu)
o
IG
Indicates that guidance is possible via
Frequency 1
“Select Frequency 1”
switch (similar to other
frequencies)
Activates guidance via Frequency 1 (submenu is quit automatically after 1 sec.)
“Special attachment”
display
o Indicates that the special attachment can be
controlled
“Special attachment” key Activates control of the special attachment,
controlled via the hydraulic control button
t = Standard equipment o = Optional Equipment
RG = Rail guidance IG = Inductive guidance
Symbol Control or Display Function
0206.GB
E 6
“Personalsafety system”
display (PSS)
o Indicates that the personal safety system
has identified persons or objects in the aisle.
The truck brakes.
“Personalsafety system”
switch (PSS)
Bypasses the protective function and
enables creep mode if there is sufficient
distance from the obstacle.
If a personal safety system is fitted, read the
accompanying operator manual.
Select “Warning sub-
menu” display
o Indicates that several warnings (e.g. slack
chain safety device height dependent lift
cutout) have been issued.
Quit “warnings” sub-
menu.
Displays individual warnings
Quit “warnings” sub-
menu.
o Indicates that the sub-menu can be quit.
“Cancel warnings sub-
menu” switch
Sets the “warnings” sub-menu to the
standard menu
Guidance systems
“Guidance on” display
not active
“Guidance on” display
active
t
R
G
W
G
Displays automatic guidance in the aisle:
Rail guidance display
(drive wheel set to forward position)
Indicates that inductive guidance is
activated
“Guidance on” switch R
G
W
G
Sets the drive wheel to forward position
Activates the blending in process (and
frequency selection for multi-frequencies)
Displays “Select
Frequency 1” (similar to
other frequencies)
(“Guidance on” sub-
menu)
o
IG
Indicates that guidance is possible via
Frequency 1
“Select Frequency 1”
switch (similar to other
frequencies)
Activates guidance via Frequency 1 (sub-
menu is quit automatically after 1 sec.)
“Special attachment”
display
o Indicates that the special attachment can be
controlled
“Special attachment” key Activates control of the special attachment,
controlled via the hydraulic control button
t = Standard equipment o = Optional Equipment
RG = Rail guidance IG = Inductive guidance
Symbol Control or Display Function
Page 44
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0206.GB
2.4 Truck operational status symbols
The operational status of the truck when it is switched on is indicated by symbols in
the display unit.
Safety gates open
Foot switch not pressed
When the following symbols are displayed you must carry out a reference movement
in accordance with the display, i.e. the Primary raise must be raised approx. 10 cm
and then lowered again. This is the only way for the controller to release all the truck
movements at full speed.
Referencing: Primary raise - lift
Referencing: Primary raise - lower
E 7
0206.GB
2.4 Truck operational status symbols
The operational status of the truck when it is switched on is indicated by symbols in
the display unit.
Safety gates open
Foot switch not pressed
When the following symbols are displayed you must carry out a reference movement
in accordance with the display, i.e. the Primary raise must be raised approx. 10 cm
and then lowered again. This is the only way for the controller to release all the truck
movements at full speed.
Referencing: Primary raise - lift
Referencing: Primary raise - lower
Page 45
0206.GB
E 8
3 Starting up the truck
F
Before the truck can be commissioned, operated or a load unit lifted, the driver must
ensure that there is nobody within the hazardous area.
Checks and operations to be performed before starting daily work
– Check the whole of the outside of the truck for signs of damage and leaks.
– Check the battery attachment and wire connections for damage, make sure they
are secure.
– Check the battery connector is secure.
– Check the overhead guard for damage.
– Check the load handler for visible damage such as cracks, bent or severely worn
load forks.
– Check the load wheels for damage.
– Make sure the load chains are evenly tensioned.
– Make sure all safety mechanisms are correct and working.
– For rail guidance systems check the guide rollers are smooth and not damaged.
F
It is forbidden for more than one person to enter the driver’s cab at a time.
Adjusting the driver’s seat
– Pull up the adjusting lever and add or remove weight to obtain the correct height.
Control panel angle adjustment
Z
The control panel can be tilted to one of 5 positions.
– Press the control panel (1) to the right and adjust
the angle until the pin engages again.
Control panel height adjustment
– Release the lever (3).
– Position the control panel (upwards or downwards)
– Apply the lever (3).
To prepare the truck for operation
– Close the safety gates securely on both sides.
– Turn the EMERGENCY DISCONNECT switch (18)
to loosen it.
– Put the key in the key switch (2) and turn it
clockwise.
– Test the warning device (horn).
– Test the operating and parking brakes.
– Carry out a reference/test run on the lift mast to
adjust the height display (see page E 8).
F
Press the EMERGENCY DISCONNECT switch
immediately if the truck starts to move or lift when it
is switched on.
F
Brief steering movements arising from steering referencing are permissible.
18
2
18
3
1
0206.GB
E 8
3 Starting up the truck
F
Before the truck can be commissioned, operated or a load unit lifted, the driver must
ensure that there is nobody within the hazardous area.
Checks and operations to be performed before starting daily work
– Check the whole of the outside of the truck for signs of damage and leaks.
– Check the battery attachment and wire connections for damage, make sure they
are secure.
– Check the battery connector is secure.
– Check the overhead guard for damage.
– Check the load handler for visible damage such as cracks, bent or severely worn
load forks.
– Check the load wheels for damage.
– Make sure the load chains are evenly tensioned.
– Make sure all safety mechanisms are correct and working.
– For rail guidance systems check the guide rollers are smooth and not damaged.
F
It is forbidden for more than one person to enter the driver’s cab at a time.
Adjusting the driver’s seat
– Pull up the adjusting lever and add or remove weight to obtain the correct height.
Control panel angle adjustment
Z
The control panel can be tilted to one of 5 positions.
– Press the control panel (1) to the right and adjust
the angle until the pin engages again.
Control panel height adjustment
– Release the lever (3).
– Position the control panel (upwards or downwards)
– Apply the lever (3).
To prepare the truck for operation
– Close the safety gates securely on both sides.
– Turn the EMERGENCY DISCONNECT switch (18)
to loosen it.
– Put the key in the key switch (2) and turn it
clockwise.
– Test the warning device (horn).
– Test the operating and parking brakes.
– Carry out a reference/test run on the lift mast to
adjust the height display (see page E 8).
F
Press the EMERGENCY DISCONNECT switch
immediately if the truck starts to move or lift when it
is switched on.
F
Brief steering movements arising from steering referencing are permissible.
18
2
18
3
1
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0206.GB
3.1 Setting the time
Selecting the “Set Time” menu:
Press switch 31, the display changes to the sub
menu.
Z
Truck movements are inhibited in this sub-menu.
Now press switch 32 twice; the “Set Time” menu now
appears in the display unit.
Setting the time:
Simultaneously press switches 32
–and 33: to set the time forward by an hour.
–and 34: to set the time back by an hour.
–and 35: to set the time forward by a minute.
–and 36: to set the time back by a minute.
The set time (37) is then shown in the display
unit.
Quitting the “Set Time” menu:
Press switch 31, the display changes to the sub menu.
Now press switch 36, the display changes to the “Truck Functions” sub menu.
32
36
31
31
32
33
35
34
36
13:22
37
E 9
0206.GB
3.1 Setting the time
Selecting the “Set Time” menu:
Press switch 31, the display changes to the sub
menu.
Z
Truck movements are inhibited in this sub-menu.
Now press switch 32 twice; the “Set Time” menu now
appears in the display unit.
Setting the time:
Simultaneously press switches 32
–and 33: to set the time forward by an hour.
–and 34: to set the time back by an hour.
–and 35: to set the time forward by a minute.
–and 36: to set the time back by a minute.
The set time (37) is then shown in the display
unit.
Quitting the “Set Time” menu:
Press switch 31, the display changes to the sub menu.
Now press switch 36, the display changes to the “Truck Functions” sub menu.
32
36
31
31
32
33
35
34
36
13:22
37
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0206.GB
E 10
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 persons 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 forklift truck and the vehicle in
front and must be in control of the truck at all times. Abrupt stopping (except in
emergencies), rapid U turns and overtaking at dangerous or blind spots are not
permitted. It is forbidden to lean out of or reach beyond the working and operating
area.
Visibility when travelling outside the narrow aisle: The driver must look in the
direction of travel and must always have a clear view of the route ahead. When
carrying loads which affect visibility, these must be stored at the rear of the truck. If
this is not possible, a second person must walk in front of the truck as a lookout.
M
Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines.
M
Negotiating docks: It is forbidden to negotiate docks.
Negotiating lifts: Lifts may only be negotiated if they have sufficient capacity, are
suitable for driving on and authorised for truck traffic by the owner. The driver must
satisfy himself of the above before entering these areas. The truck must enter lifts
with the load in front and must take up a position which does not allow it to come into
contact with the walls of the lift shaft.
Persons riding in the lift with the forklift truck must only enter the lift after the truck has
come to a rest and must leave the lift before the truck.
Type of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Do not carry loads unless they are positioned safely and
carefully. Use suitable precautions to prevent parts of the load from tipping or falling
down.
0206.GB
E 10
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 persons 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 forklift truck and the vehicle in
front and must be in control of the truck at all times. Abrupt stopping (except in
emergencies), rapid U turns and overtaking at dangerous or blind spots are not
permitted. It is forbidden to lean out of or reach beyond the working and operating
area.
Visibility when travelling outside the narrow aisle: The driver must look in the
direction of travel and must always have a clear view of the route ahead. When
carrying loads which affect visibility, these must be stored at the rear of the truck. If
this is not possible, a second person must walk in front of the truck as a lookout.
M
Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines.
M
Negotiating docks: It is forbidden to negotiate docks.
Negotiating lifts: Lifts may only be negotiated if they have sufficient capacity, are
suitable for driving on and authorised for truck traffic by the owner. The driver must
satisfy himself of the above before entering these areas. The truck must enter lifts
with the load in front and must take up a position which does not allow it to come into
contact with the walls of the lift shaft.
Persons riding in the lift with the forklift truck must only enter the lift after the truck has
come to a rest and must leave the lift before the truck.
Type of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Do not carry loads unless they are positioned safely and
carefully. Use suitable precautions to prevent parts of the load from tipping or falling
down.
Page 48
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0206.GB
4.2 Travelling, Steering, Braking
EMERGENCY DISCONNECT
– Press the EMERGENCY
DISCONNECT switch (18) down.
All truck movements are inhibited.
The operation of the switch must not
be affected by any objects placed in its
way.
Travel
The truck can be driven in 3 modes:
Free travel, with wire or rail guidance.
The operating mode employed depends on the guidance system of the racking
system operated.
M
Do not drive the truck unless the panels are closed and properly locked.
The foot switch must be kept depressed for travel.
Travelling in apron field
– Close the safety gates.
– Turn the EMERGENCY
DISCONNECT switch (18) to undo it.
– Put the key in the key switch and turn
it clockwise;
– Apply the foot switch (6).
– Carry out a test run, see Page E7.
– Fully lower the Aux. lift and raise the
Primary raise with the hydraulic
control button (8) until the forks are
clear of the ground.
– Slowly turn the travel control button
(13) with the right thumb.
Right turn = Forward travel
Left turn = Reverse travel
– You can control the travel speed by
continuing to turn or by retracting the
travel control button.
– Use the steering wheel (21) to steer
the truck in the required direction.
18
6
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0206.GB
4.2 Travelling, Steering, Braking
EMERGENCY DISCONNECT
– Press the EMERGENCY
DISCONNECT switch (18) down.
All truck movements are inhibited.
The operation of the switch must not
be affected by any objects placed in its
way.
Travel
The truck can be driven in 3 modes:
Free travel, with wire or rail guidance.
The operating mode employed depends on the guidance system of the racking
system operated.
M
Do not drive the truck unless the panels are closed and properly locked.
The foot switch must be kept depressed for travel.
Travelling in apron field
– Close the safety gates.
– Turn the EMERGENCY
DISCONNECT switch (18) to undo it.
– Put the key in the key switch and turn
it clockwise;
– Apply the foot switch (6).
– Carry out a test run, see Page E7.
– Fully lower the Aux. lift and raise the
Primary raise with the hydraulic
control button (8) until the forks are
clear of the ground.
– Slowly turn the travel control button
(13) with the right thumb.
Right turn = Forward travel
Left turn = Reverse travel
– You can control the travel speed by
continuing to turn or by retracting the
travel control button.
– Use the steering wheel (21) to steer
the truck in the required direction.
18
6
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E 12
Steering
Use the steering wheel to steer the truck
outside narrow aisles.
The position of the drive wheel is shown
in the display unit (9).
Brakes
Z
The truck’s braking characteristics depend largely on the ground conditions. The
driver must take this into consideration when handling the truck.
– The truck can be braked in three different ways:
- with the operating brake
- with the foot switch.
- with the EMERGENCY DISCONNECT switch
Braking with the operating brake
While travelling, set the travel direction switch to the zero position or the opposite
travel direction; the traction current controller will cause the truck to brake.
Braking with the foot switch
Releasing the foot switch causes the truck to brake.
Z
This type of braking can only be used as a parking brake and not as an operating
brake.
Braking with the EMERGENCY DISCONNECT switch
Applying the EMERGENCY DISCONNECT switch will cause the truck to brake to a
halt.
M
The EMERGENCY DISCONNECT switch must only be used in dangerous situations.
9
0206.GB
E 12
Steering
Use the steering wheel to steer the truck
outside narrow aisles.
The position of the drive wheel is shown
in the display unit (9).
Brakes
Z
The truck’s braking characteristics depend largely on the ground conditions. The
driver must take this into consideration when handling the truck.
– The truck can be braked in three different ways:
- with the operating brake
- with the foot switch.
- with the EMERGENCY DISCONNECT switch
Braking with the operating brake
While travelling, set the travel direction switch to the zero position or the opposite
travel direction; the traction current controller will cause the truck to brake.
Braking with the foot switch
Releasing the foot switch causes the truck to brake.
Z
This type of braking can only be used as a parking brake and not as an operating
brake.
Braking with the EMERGENCY DISCONNECT switch
Applying the EMERGENCY DISCONNECT switch will cause the truck to brake to a
halt.
M
The EMERGENCY DISCONNECT switch must only be used in dangerous situations.
9
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0206.GB
Negotiating narrow aisles
M
It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes in
racking systems with safety distances < 500 mm) or for personnel to cross through
them. These work areas must be marked and identified accordingly. Carry out a daily
inspection of the safety mechanisms on the truck or the racking sysem to avoid
hazards and protect personnel. These must not be rendered ineffective, misused,
adjusted or removed. Immediately report and rectify any faulty safety devices.
M
Observe the instructions of DIN 15185 Part 2.
Z
Before entering a narrow aisle, the driver must look for people or other trucks in the
aisle. Never enter a narrow aisle where there are people or other trucks. If there are
people in the aisle, stop the truck immediately.
Z
Only enter narrow aisles in trucks which are designated for this purpose If a narrow
aisle is equipped with a guidance wire for wire guidance and the system is faulty or
switched off, the truck may only be removed from the narrow aisle at crawl speed.
Rail guidance truck
Rail guidance trucks are equipped with
sensors which activate aisle recognition
when they enter narrow aisles.
– Approach the aisle at reduced speed
so that the truck is aligned with the
narrow aisle and is within the
demarcation.
Z
Observe the notices attached along the
route.
Z
Travel and hydraulic operations can only
be activated in the narrow aisle with two-handed operation.
– Slowly enter the narrow aisle.
Ensure that the truck guide rollers enter the narrow aisle guidance rails.
– Press the “guidance on” (34) switch.
– The “guidance on” display light (38) changes to active mode.
– The drive wheel is automatically set forward. The steering angle display (25) shows
the steering angle permanently in the centre position after alignment. Manual
steering is disabled.
– Grab the hand rest in the traction controller and hydraulic controller handle (7) (two-
handed operation).
– Turn the travel selection switch (13) to change travel speed and direction. Right
turn =Forward travel; Left turn = Reverse travel
– Continue to travel along the narrow aisle at your required speed.
34
38
25
7 7
13
E 13
0206.GB
Negotiating narrow aisles
M
It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes in
racking systems with safety distances < 500 mm) or for personnel to cross through
them. These work areas must be marked and identified accordingly. Carry out a daily
inspection of the safety mechanisms on the truck or the racking sysem to avoid
hazards and protect personnel. These must not be rendered ineffective, misused,
adjusted or removed. Immediately report and rectify any faulty safety devices.
M
Observe the instructions of DIN 15185 Part 2.
Z
Before entering a narrow aisle, the driver must look for people or other trucks in the
aisle. Never enter a narrow aisle where there are people or other trucks. If there are
people in the aisle, stop the truck immediately.
Z
Only enter narrow aisles in trucks which are designated for this purpose If a narrow
aisle is equipped with a guidance wire for wire guidance and the system is faulty or
switched off, the truck may only be removed from the narrow aisle at crawl speed.
Rail guidance truck
Rail guidance trucks are equipped with
sensors which activate aisle recognition
when they enter narrow aisles.
– Approach the aisle at reduced speed
so that the truck is aligned with the
narrow aisle and is within the
demarcation.
Z
Observe the notices attached along the
route.
Z
Travel and hydraulic operations can only
be activated in the narrow aisle with two-handed operation.
– Slowly enter the narrow aisle.
Ensure that the truck guide rollers enter the narrow aisle guidance rails.
– Press the “guidance on” (34) switch.
– The “guidance on” display light (38) changes to active mode.
– The drive wheel is automatically set forward. The steering angle display (25) shows
the steering angle permanently in the centre position after alignment. Manual
steering is disabled.
– Grab the hand rest in the traction controller and hydraulic controller handle (7) (two-
handed operation).
– Turn the travel selection switch (13) to change travel speed and direction. Right
turn =Forward travel; Left turn = Reverse travel
– Continue to travel along the narrow aisle at your required speed.
34
38
25
7 7
13
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E 14
Wire guidance trucks
F
When starting or continuing the truck after the wire guidance has been deactivated,
note the position of the drive wheel as manual steering is now activated again.
F
If an automatically guided truck is switched off, the wire guidance is no longer active
when it is switched on again. Risk of accidents! When you continue to travel a warning
is sounded and the speed is reduced. Use push button (34) to re-activate the wire
guidance (“Guidance on” light (38) goes on in active mode) and re-align the truck.
F
During alignment, the rear part may veer out when it reaches the guidance wire.
– Approach the guidance wire (40) at an
angle at reduced speed.
When aligning, the truck should not be
parallel to the guidance wire. The
optimum approachment angle is
between 10° and 50°.
The travelspeedremains limited to
reduced speed.
Tracking should preferably be in the load
direction, as this involves less time and
distance.
– When the truck is close to the
guidance wire, switch on the wire
guidance with pressure switch (34).
The “guidance on” display light (38)
changes to active mode.
When the guidance wire has been
reached the truck is automatically
guided.
When the guidance wire is reached
tracking automtically ensues at reduced
speed. The steering angle display (25)
changes to “Tracking On” (41). The
audible tracking signal is sounded.
39
40
34
3841
25
34
38
0206.GB
E 14
Wire guidance trucks
F
When starting or continuing the truck after the wire guidance has been deactivated,
note the position of the drive wheel as manual steering is now activated again.
F
If an automatically guided truck is switched off, the wire guidance is no longer active
when it is switched on again. Risk of accidents! When you continue to travel a warning
is sounded and the speed is reduced. Use push button (34) to re-activate the wire
guidance (“Guidance on” light (38) goes on in active mode) and re-align the truck.
F
During alignment, the rear part may veer out when it reaches the guidance wire.
– Approach the guidance wire (40) at an
angle at reduced speed.
When aligning, the truck should not be
parallel to the guidance wire. The
optimum approachment angle is
between 10° and 50°.
The travelspeedremains limited to
reduced speed.
Tracking should preferably be in the load
direction, as this involves less time and
distance.
– When the truck is close to the
guidance wire, switch on the wire
guidance with pressure switch (34).
The “guidance on” display light (38)
changes to active mode.
When the guidance wire has been
reached the truck is automatically
guided.
When the guidance wire is reached
tracking automtically ensues at reduced
speed. The steering angle display (25)
changes to “Tracking On” (41). The
audible tracking signal is sounded.
39
40
34
3841
25
34
38
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0206.GB
Inductive automatic steering takes over
the steering of the truck and applies it to
the guidance wire.
Tracking is complete once the truck has
been led precisely to the guidance wire.
“Tracking on” (41) changes to “guidance
wire applied” (42). The tracking signal is
no longer sounded. The track is now
automatically guided.
Z
Travel and hydraulic operations can only
be activated in the narrow aisle with two-handed operation.
Grab the hand rest in the traction
controller and hydraulic controller
handle (7) (two-handed operation). Turn
the travel selection switch (13) to
change travel speed and direction.
Press the push button (34) to quit the
guidance wire. The display (38) changes
to non-active mode. In addition, the
”guidance wire applied” (42) display
changes to the steering angle display
(25).
Diagonal travel
Z
Diagonal travel is only possible if the truck is wire or rail guided.
Diagonal travel is possible (simultaneous travelling and lifting / lowering) when both
control switches (8 and 13) are pressed.
F
You can only change from automatic to manual steering once the truck has fully left
the narrow aisle.
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Inductive automatic steering takes over
the steering of the truck and applies it to
the guidance wire.
Tracking is complete once the truck has
been led precisely to the guidance wire.
“Tracking on” (41) changes to “guidance
wire applied” (42). The tracking signal is
no longer sounded. The track is now
automatically guided.
Z
Travel and hydraulic operations can only
be activated in the narrow aisle with two-handed operation.
Grab the hand rest in the traction
controller and hydraulic controller
handle (7) (two-handed operation). Turn
the travel selection switch (13) to
change travel speed and direction.
Press the push button (34) to quit the
guidance wire. The display (38) changes
to non-active mode. In addition, the
”guidance wire applied” (42) display
changes to the steering angle display
(25).
Diagonal travel
Z
Diagonal travel is only possible if the truck is wire or rail guided.
Diagonal travel is possible (simultaneous travelling and lifting / lowering) when both
control switches (8 and 13) are pressed.
F
You can only change from automatic to manual steering once the truck has fully left
the narrow aisle.
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34
38
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4.3 Lifting–- lowering outside narrow aisles
F
Risk of injury when the driver’s cab and the load handler are lowered.
There must be nobody in the danger zone.
Lift – Lower (Primary raise)
– Apply the foot switch.
– Turn the hydraulic control switch (8)
Right = Lower
Left = Lift
Z
The lift and lower speeds are
proportional to the degree of turn of the
hydraulic control switch.
Z
If the line break safety devices applies
for an unauthorised
lowering speed (E 287), lift and slowly
lower the primary raise.
Lift – Lower (Aux. Lift)
– Apply the foot switch.
– Press the aux. lift pressure switch
(15).
– Turn the hydraulic control switch (8)
simultaneously
Left turn = Lift
Right turn = Lower
The lift and lower speeds are
proportional to the amount of turn.
Lowering Primary raise and Aux. Lift
simultaneously
– Apply the foot switch.
– Press the push button (14) underneath the traction controller handle (= primary and
aux. raise lower).
– At the same time, turn the hydraulic control switch (8) to the right.
The lower speed is proportional to the amount of turn.
4.4 Lifting–- lowering within narrow aisles
Z
The driver must not leave the operator position when raised – it is forbidden to climb
onto objects or other trucks.
Lifting and lowering inside the narrow aisle requires two-handed operation.
Otherwise, operation is the same as for outside narrow aisles.
8
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4.3 Lifting–- lowering outside narrow aisles
F
Risk of injury when the driver’s cab and the load handler are lowered.
There must be nobody in the danger zone.
Lift – Lower (Primary raise)
– Apply the foot switch.
– Turn the hydraulic control switch (8)
Right = Lower
Left = Lift
Z
The lift and lower speeds are
proportional to the degree of turn of the
hydraulic control switch.
Z
If the line break safety devices applies
for an unauthorised
lowering speed (E 287), lift and slowly
lower the primary raise.
Lift – Lower (Aux. Lift)
– Apply the foot switch.
– Press the aux. lift pressure switch
(15).
– Turn the hydraulic control switch (8)
simultaneously
Left turn = Lift
Right turn = Lower
The lift and lower speeds are
proportional to the amount of turn.
Lowering Primary raise and Aux. Lift
simultaneously
– Apply the foot switch.
– Press the push button (14) underneath the traction controller handle (= primary and
aux. raise lower).
– At the same time, turn the hydraulic control switch (8) to the right.
The lower speed is proportional to the amount of turn.
4.4 Lifting–- lowering within narrow aisles
Z
The driver must not leave the operator position when raised – it is forbidden to climb
onto objects or other trucks.
Lifting and lowering inside the narrow aisle requires two-handed operation.
Otherwise, operation is the same as for outside narrow aisles.
8
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4.5 Order picking and stacking
Collecting, transporting and depositing loads
M
Before picking up a load unit the driver must make sure that it has been correctly
palletised and does not exceed the truck’s capacity. Observe the load diagram.
– Check the fork distance for the pallet and adjust if necessary.
Adjusting the forks
To pick up the load securely, the forks
must be as far apart as possible and
centrally positioned with respect to the
fork carriage. The load centre of gravity
must be centrally aligned between the
forks.
– Raise the locking lever (43).
– Push the forks (44) to the correct
position on the fork carriage (45).
– Swivel the locking lever (43) down and
move the forks until the locking pin
engages in a notch.
M
Never remove the stop bolt (46).
44
43
45
46
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4.5 Order picking and stacking
Collecting, transporting and depositing loads
M
Before picking up a load unit the driver must make sure that it has been correctly
palletised and does not exceed the truck’s capacity. Observe the load diagram.
– Check the fork distance for the pallet and adjust if necessary.
Adjusting the forks
To pick up the load securely, the forks
must be as far apart as possible and
centrally positioned with respect to the
fork carriage. The load centre of gravity
must be centrally aligned between the
forks.
– Raise the locking lever (43).
– Push the forks (44) to the correct
position on the fork carriage (45).
– Swivel the locking lever (43) down and
move the forks until the locking pin
engages in a notch.
M
Never remove the stop bolt (46).
44
43
45
46
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Picking up a load from the front
– Drive the truck slowly.
– Slowly insert the forks into the pallet
until the fork shank touches the load or
the pallet.
– Raise the load slightly and slowly
reverse the truck.
M
The ground surface must be in good
condition to ensure this works correctly.
Transporting a load
– Always transport a load outside the
narrow aisle as low as possible, allowing for ground clearance.
– Always transport loads with both forks. When transporting heavy loads always
ensure that both forks carry an equal weight.
– Gradually accelerate.
– Drive at constant speed.
– Always be prepared to brake. Only stop suddenly in dangerous situations.
– Reduce speed accordingly at narrow bends.
Depositing a load
– Drive the truck carefully up to the storage location
M
Before a load can be deposited, the driver must ensure that the storage location is
suitable for storing the load (size and capacity).
– Raise the load handler so that the load
can enter the storage location without
striking any objects.
– Carefully push the load into its storage
location.
– Carefully lower the load handler so
that the forks are clear of the load.
M
Avoid placing the load down suddenly to
avoid damaging the load and the load
handler.
– Carefully remove the load handler
from the load.
– Fully lower the load handler.
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Picking up a load from the front
– Drive the truck slowly.
– Slowly insert the forks into the pallet
until the fork shank touches the load or
the pallet.
– Raise the load slightly and slowly
reverse the truck.
M
The ground surface must be in good
condition to ensure this works correctly.
Transporting a load
– Always transport a load outside the
narrow aisle as low as possible, allowing for ground clearance.
– Always transport loads with both forks. When transporting heavy loads always
ensure that both forks carry an equal weight.
– Gradually accelerate.
– Drive at constant speed.
– Always be prepared to brake. Only stop suddenly in dangerous situations.
– Reduce speed accordingly at narrow bends.
Depositing a load
– Drive the truck carefully up to the storage location
M
Before a load can be deposited, the driver must ensure that the storage location is
suitable for storing the load (size and capacity).
– Raise the load handler so that the load
can enter the storage location without
striking any objects.
– Carefully push the load into its storage
location.
– Carefully lower the load handler so
that the forks are clear of the load.
M
Avoid placing the load down suddenly to
avoid damaging the load and the load
handler.
– Carefully remove the load handler
from the load.
– Fully lower the load handler.
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4.6 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.
F
Do not park the truck on an incline. In special cases the truck may need to be secured
with wedges.
Z
Select a parking place where nobody will collide with the forks.
– Always park the truck with the mast completely lowered.
– Lower the forks to the ground.
– Set the key switch to “0” and remove the safety key.
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4.6 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.
F
Do not park the truck on an incline. In special cases the truck may need to be secured
with wedges.
Z
Select a parking place where nobody will collide with the forks.
– Always park the truck with the mast completely lowered.
– Lower the forks to the ground.
– Set the key switch to “0” and remove the safety key.
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5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the results of
incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Action
Truck does
not start.
– Battery plug not
connected.
– Check the battery plug and connect if
necessary.
– Safety gates open – Close the safety gates
– EMERGENCY
DISCONNECT switch
pressed
– Unlatch EMERGENCY DISCONNECT
switch
– Key switch in “0”
position
– Set key switch to “I”
– Battery charge too
low.
– Check battery charge, charge battery if
necessary
– Foot switch not
pressed
– Press foot switch
– Faulty fuse. – Check fuses.
– Travel cutout
activated
– Press travel cutout override switch
– Travel cutout
activated via aisle end
safety device
– Set foot switch or travel button to neutral
and press it again.
– Chains slack – See “Slack Chain Safety Device Override”
section in Chapter E
Load cannot
be lifted
– Truck not operational – Carry out all measures listed under “Truck
does not start”
– Battery charge too
low, lift cutout
– Check battery charge, charge battery if
necessary
– Insufficient hydraulic
oil
– Check hydraulic oil, if necessary top up
– Chains slack – See “Slack Chain Safety Device Override”
section in Chapter E
– Faulty fuse. – Check fuses
Rapid travel
disabled
– Primary raise / Aux.
Lift raised above 0.5m
– Lower Primary raise / Aux. Lift below 0.5m
– WG search mode
activated
– No test run performed
– Align truck or turn off WG mode
– Perform lifting and lowering
Truck cannot
be steered
– Truck not operational – Carry out all measures listed under “Truck
does not start”
– Narrow aisle mode
switch pressed
– Switch off narrow aisle travel function
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5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the results of
incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Action
Truck does
not start.
– Battery plug not
connected.
– Check the battery plug and connect if
necessary.
– Safety gates open – Close the safety gates
– EMERGENCY
DISCONNECT switch
pressed
– Unlatch EMERGENCY DISCONNECT
switch
– Key switch in “0”
position
– Set key switch to “I”
– Battery charge too
low.
– Check battery charge, charge battery if
necessary
– Foot switch not
pressed
– Press foot switch
– Faulty fuse. – Check fuses.
– Travel cutout
activated
– Press travel cutout override switch
– Travel cutout
activated via aisle end
safety device
– Set foot switch or travel button to neutral
and press it again.
– Chains slack – See “Slack Chain Safety Device Override”
section in Chapter E
Load cannot
be lifted
– Truck not operational – Carry out all measures listed under “Truck
does not start”
– Battery charge too
low, lift cutout
– Check battery charge, charge battery if
necessary
– Insufficient hydraulic
oil
– Check hydraulic oil, if necessary top up
– Chains slack – See “Slack Chain Safety Device Override”
section in Chapter E
– Faulty fuse. – Check fuses
Rapid travel
disabled
– Primary raise / Aux.
Lift raised above 0.5m
– Lower Primary raise / Aux. Lift below 0.5m
– WG search mode
activated
– No test run performed
– Align truck or turn off WG mode
– Perform lifting and lowering
Truck cannot
be steered
– Truck not operational – Carry out all measures listed under “Truck
does not start”
– Narrow aisle mode
switch pressed
– Switch off narrow aisle travel function
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Z
If, after carrying out the remedial action, the truck cannot be restored to operation or
if a fault in the electronics system is displayed with a corresponding error code,
contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer has a customer service department specially
trained for these tasks.
To provide targeted and rapid response to faults, the following details are useful and
important to provide for the customer service department:
- Truck serial number
- Display unit error number (if present)
- Error description
- Current location of truck.
Error 144 – Truck has quit
guidance wire
– Restore wire guidance
Error 330 – Travel control button
pressed during powerup test
– Do not press travel control button, switch
truck off and on again
Error 331 – Hydraulic control
button pressed during
power-up test
– Do not press hydraulic control button,
switch truck off and on again
Error 332 – During the power-up
test a key was
pressed below the
display unit
– Do not press key, switch truck off and on
again
Error 333 – During the power up
test a function
preselect key aux. lift
was pressed
– Do not press function preselect key aux.
lift, switch truck off and on again
Error 334 – Foot switch pressed
during power-up test
– Do not press foot switch, switch truck off
and on again
Error 344 – Personal safety
system
– PSA scanner contaminated, clean
Fault Possible cause Action
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Z
If, after carrying out the remedial action, the truck cannot be restored to operation or
if a fault in the electronics system is displayed with a corresponding error code,
contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer has a customer service department specially
trained for these tasks.
To provide targeted and rapid response to faults, the following details are useful and
important to provide for the customer service department:
- Truck serial number
- Display unit error number (if present)
- Error description
- Current location of truck.
Error 144 – Truck has quit
guidance wire
– Restore wire guidance
Error 330 – Travel control button
pressed during power-
up test
– Do not press travel control button, switch
truck off and on again
Error 331 – Hydraulic control
button pressed during
power-up test
– Do not press hydraulic control button,
switch truck off and on again
Error 332 – During the power-up
test a key was
pressed below the
display unit
– Do not press key, switch truck off and on
again
Error 333 – During the power up
test a function
preselect key aux. lift
was pressed
– Do not press function preselect key aux.
lift, switch truck off and on again
Error 334 – Foot switch pressed
during power-up test
– Do not press foot switch, switch truck off
and on again
Error 344 – Personal safety
system
– PSA scanner contaminated, clean
Fault Possible cause Action
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5.1 Emergency stop device
When the automatic emergency stop mechanism applies (e.g. if the wire guidance is
lost, electrical steering fails) the truck brakes to a halt. Before starting again, the
cause of the error must be identified and corrected. Start the truck again in
accordance with manufacturer’s instructions contained in these operating instructions
(see “Starting up the Truck” in Chapter E).
5.2 Driver’s cab / Aux. Lift emergency lowering
F
When using emergency lowering, make sure that nobody is present in the danger
zone. If a second person is used to lower the load handler via the emergency lowering
device, this person must consult with the driver. Both people must be in a safe area
to avoid danger.
The truck may only be started again once the error has been localised and rectified.
If necessary, a second person can be deployed to lower the cabin from the ground.
– Remove the Allen key from the bracket above the beacon.
– Insert the Allen key into the hole (48).
– Slowly open the drain valve (47) using the Allen key.
– The cabin will lower.
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5.1 Emergency stop device
When the automatic emergency stop mechanism applies (e.g. if the wire guidance is
lost, electrical steering fails) the truck brakes to a halt. Before starting again, the
cause of the error must be identified and corrected. Start the truck again in
accordance with manufacturer’s instructions contained in these operating instructions
(see “Starting up the Truck” in Chapter E).
5.2 Driver’s cab / Aux. Lift emergency lowering
F
When using emergency lowering, make sure that nobody is present in the danger
zone. If a second person is used to lower the load handler via the emergency lowering
device, this person must consult with the driver. Both people must be in a safe area
to avoid danger.
The truck may only be started again once the error has been localised and rectified.
If necessary, a second person can be deployed to lower the cabin from the ground.
– Remove the Allen key from the bracket above the beacon.
– Insert the Allen key into the hole (48).
– Slowly open the drain valve (47) using the Allen key.
– The cabin will lower.
48
47
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5.3 Exiting the driver's cab with the emergency abseil device
Industrial trucks with a height-adjustable operator position which can exceed 3m from
the ground, have an emergency lowering mechanism and an emergency abseil
device for the driver which he can use if the operator position ever becomes stuck.
Z
If the driver’s cab cannot be lowered due to a fault, not even with the emergency
lowering (see “Driver’s Cab / Aux. Lift Emergency Lowering” section), the operator
must exit the driver's cab via the emergency abseil device.
The driver must be instructed in how to use the emergency abseil device. To exit the
cabin with the emergency abseil device, proceed as follows:
– Turn the key switch (2) to “0”.
– Press the EMERGENCY DISCONNECT switch (18).
– Remove the abseil device (50) on the
EKS 410 from the compartment under the seat.
on the EKS 513-515 from the compartment in the overhead guard.
– Attach the karabiner hook (53) of the abseil device (left or right) to the eye (49) of
the overhead guard.
– Throw out the rope without knots, the rope must pass over fixed objects. Do not
pass the rope over sharp edges.
– Fit the safety belt or slings in accordance with the accompanying operating
instructions or as instructed.
– Attach the eye of the safety belt to the karabiner hook (54) of the abseil device (50).
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5.3 Exiting the driver's cab with the emergency abseil device
Industrial trucks with a height-adjustable operator position which can exceed 3m from
the ground, have an emergency lowering mechanism and an emergency abseil
device for the driver which he can use if the operator position ever becomes stuck.
Z
If the driver’s cab cannot be lowered due to a fault, not even with the emergency
lowering (see “Driver’s Cab / Aux. Lift Emergency Lowering” section), the operator
must exit the driver's cab via the emergency abseil device.
The driver must be instructed in how to use the emergency abseil device. To exit the
cabin with the emergency abseil device, proceed as follows:
– Turn the key switch (2) to “0”.
– Press the EMERGENCY DISCONNECT switch (18).
– Remove the abseil device (50) on the
EKS 410 from the compartment under the seat.
on the EKS 513-515 from the compartment in the overhead guard.
– Attach the karabiner hook (53) of the abseil device (left or right) to the eye (49) of
the overhead guard.
– Throw out the rope without knots, the rope must pass over fixed objects. Do not
pass the rope over sharp edges.
– Fit the safety belt or slings in accordance with the accompanying operating
instructions or as instructed.
– Attach the eye of the safety belt to the karabiner hook (54) of the abseil device (50).
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Abseiling
F
Do not drop into loose rope. Watch out for obstacles when abseiling.
– Make the rope (52) taut.
– Exit with your face towards the truck.
– To abseil, press the lever (51) on the abseil device down.
– To stop abseiling, release the brake lever (51).
5.4 Bypassing the chain slack safety device
If the slack chain safety device engages (the “Slack chain
override” symbol (55) appears in the display), e.g. when
the fork carriage is put in position or the lift chain becomes
loose or breaks. It is possible to “lift” the primary raise if the
override switch (56) is depressed and held down while the
hydraulic control button is pressed. “Lowering” is now
disabled.
Before starting again, rectify the damage.
Travel is inhibited whatever the position of the fork
carriage.
M
The truck may only be started again once the damage has been removed.
5.5 Bypassing the travel cutout (o)
If travel is inhibited from a certain lift height (the “Travel
cutout override” symbol (57) appears in the display), but
the position of the truck relative to the rack must be
adjusted to load or unload goods, press the “unlock travel”
switch (58) and apply the travel lever as described in
“Travelling”. This allows you to travel at crawl speed.
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55
58
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Abseiling
F
Do not drop into loose rope. Watch out for obstacles when abseiling.
– Make the rope (52) taut.
– Exit with your face towards the truck.
– To abseil, press the lever (51) on the abseil device down.
– To stop abseiling, release the brake lever (51).
5.4 Bypassing the chain slack safety device
If the slack chain safety device engages (the “Slack chain
override” symbol (55) appears in the display), e.g. when
the fork carriage is put in position or the lift chain becomes
loose or breaks. It is possible to “lift” the primary raise if the
override switch (56) is depressed and held down while the
hydraulic control button is pressed. “Lowering” is now
disabled.
Before starting again, rectify the damage.
Travel is inhibited whatever the position of the fork
carriage.
M
The truck may only be started again once the damage has been removed.
5.5 Bypassing the travel cutout (o)
If travel is inhibited from a certain lift height (the “Travel
cutout override” symbol (57) appears in the display), but
the position of the truck relative to the rack must be
adjusted to load or unload goods, press the “unlock travel”
switch (58) and apply the travel lever as described in
“Travelling”. This allows you to travel at crawl speed.
56
55
58
57
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5.6 Lift cutout (o)
If local conditions require, an automatic lift cutout to apply from a given lift height can
be fitted for safety reasons. The display unit shows the "Lift Cutout Override" symbol
(59).
M
Lift cutout only becomes effective after a test run has been
carried out. You can tell when this is the case, because the
actual height is shown in the display unit.
F
When disabling the lift cutout the driver must look out for
obstacles when the mast is extended.
Pressing the “lift cutout override” switch (60) disables the
lift cutout.
Z
Lift cutout is re-activated each time the mast falls below the
lift limit height.
5.7 Aisle end safety device (o)
Trucks with the aisle end safety device brake before the aisle exit or in the transfer
aisle. There are two basic versions for this:
1. Braking to a halt
2. Braking to 2.5 km/h
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
1. Braking to a halt:
When the truck passes over the aisle end safety magnets heading for the aisle end,
it comes to a halt.
To continue traveling:
– Briefly release the foot switch and then apply it again
The truck can be driven out of the narrow aisle at max. 2.5 km/h.
2. Braking to 2.5 km/h
When the truck passes over the aisle end safety magnets heading for the aisle end,
it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.
M
In both cases the braking distance depends on the travel speed.
F
Aisle end safety braking is an additional function designed to support the operator,
but which does not release him from his responsiblities, e.g. to monitor braking at the
aisle end and if necessary to apply the brakes.
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5.6 Lift cutout (o)
If local conditions require, an automatic lift cutout to apply from a given lift height can
be fitted for safety reasons. The display unit shows the "Lift Cutout Override" symbol
(59).
M
Lift cutout only becomes effective after a test run has been
carried out. You can tell when this is the case, because the
actual height is shown in the display unit.
F
When disabling the lift cutout the driver must look out for
obstacles when the mast is extended.
Pressing the “lift cutout override” switch (60) disables the
lift cutout.
Z
Lift cutout is re-activated each time the mast falls below the
lift limit height.
5.7 Aisle end safety device (o)
Trucks with the aisle end safety device brake before the aisle exit or in the transfer
aisle. There are two basic versions for this:
1. Braking to a halt
2. Braking to 2.5 km/h
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
1. Braking to a halt:
When the truck passes over the aisle end safety magnets heading for the aisle end,
it comes to a halt.
To continue traveling:
– Briefly release the foot switch and then apply it again
The truck can be driven out of the narrow aisle at max. 2.5 km/h.
2. Braking to 2.5 km/h
When the truck passes over the aisle end safety magnets heading for the aisle end,
it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.
M
In both cases the braking distance depends on the travel speed.
F
Aisle end safety braking is an additional function designed to support the operator,
but which does not release him from his responsiblities, e.g. to monitor braking at the
aisle end and if necessary to apply the brakes.
60
59
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5.8 WG emergency operation
If in a wire guidance system the guiding antenna extends beyond the pre-determined
range of the guidance wire, an emergency stop is immediately performed.
If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The
“tracking on” display and the audible tracking signal however remain permanently on
and hence warn the driver.
Automatic EMERGENCY STOP
If during operation one of the monitors for steering control, steering system, wire
guidance or the safety cutout for the traction electronic system or power electronic
system applies, the truck safety devices will cause the truck to stop.
To enable the truck to travel again after an EMERGENCY STOP, carry out the
following:
– Determine the possible cause of the EMERGENCY STOP.
– Press the EMERGENCY STOP switch and turn it again to release it.
– Error E 144 is displayed.
– Apply inductive automatic steering.
– Press the travel control button and carefully align the truck with the guidance wire.
– Error E 144 disappears from the display.
F
If the truck now starts, check that it is operating correctly.
Automatic and manual EMERGENCY STOP
If, after an automatic or manual EMERGENCY STOP and having rectified the
problem, you cannot start the truck again, turn the key switch off and on again.
Now carry out a test run as follows:
Lift and lower the primary and aux. raise in accordance with the symbol display until
the respective display goes out.
Carry out a test run:
- REF-Test run: Primary raise - lift
- REF-Test run: Primary raise - lower
The truck is now operational.
0206.GB
E 26
5.8 WG emergency operation
If in a wire guidance system the guiding antenna extends beyond the pre-determined
range of the guidance wire, an emergency stop is immediately performed.
If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The
“tracking on” display and the audible tracking signal however remain permanently on
and hence warn the driver.
Automatic EMERGENCY STOP
If during operation one of the monitors for steering control, steering system, wire
guidance or the safety cutout for the traction electronic system or power electronic
system applies, the truck safety devices will cause the truck to stop.
To enable the truck to travel again after an EMERGENCY STOP, carry out the
following:
– Determine the possible cause of the EMERGENCY STOP.
– Press the EMERGENCY STOP switch and turn it again to release it.
– Error E 144 is displayed.
– Apply inductive automatic steering.
– Press the travel control button and carefully align the truck with the guidance wire.
– Error E 144 disappears from the display.
F
If the truck now starts, check that it is operating correctly.
Automatic and manual EMERGENCY STOP
If, after an automatic or manual EMERGENCY STOP and having rectified the
problem, you cannot start the truck again, turn the key switch off and on again.
Now carry out a test run as follows:
Lift and lower the primary and aux. raise in accordance with the symbol display until
the respective display goes out.
Carry out a test run:
- REF-Test run: Primary raise - lift
- REF-Test run: Primary raise - lower
The truck is now operational.
Page 64
E 27
0206.GB
5.9 Recovering the truck from a narrow aisle / Moving the truck without a battery
F
Before recovering the truck from a narrow aisle, disconnect the battery.
M
This operation must only be performed by suitably trained maintenance personnel.
When the brakes are de-activated the truck must be parked on an even ground as the
brakes are no longer effective.
– Fully lower the mast
Z
Seek assistance from another person. The other person must be trained and familiar
with recovery operations.
To recover the truck from the aisle, release the brakes.
Release the magnetic brake
– Remove the electronic compartment cover at the back.
– Screw in the setscrews (62) on the magnetic brake (63) above the traction motor to
release it.
– The setscrews are located in the lamp bracket (61).
M
When using the truck again, check the braking deceleration.
62
63
61
E 27
0206.GB
5.9 Recovering the truck from a narrow aisle / Moving the truck without a battery
F
Before recovering the truck from a narrow aisle, disconnect the battery.
M
This operation must only be performed by suitably trained maintenance personnel.
When the brakes are de-activated the truck must be parked on an even ground as the
brakes are no longer effective.
– Fully lower the mast
Z
Seek assistance from another person. The other person must be trained and familiar
with recovery operations.
To recover the truck from the aisle, release the brakes.
Release the magnetic brake
– Remove the electronic compartment cover at the back.
– Screw in the setscrews (62) on the magnetic brake (63) above the traction motor to
release it.
– The setscrews are located in the lamp bracket (61).
M
When using the truck again, check the braking deceleration.
62
63
61
Page 65
0206.GB
E 28
Releasing the load wheel brake (hydraulic brake) - EKS 513 – 515 only
– Remove the electronic compartment cover at the back.
– Remove the protective cap from the bleed valve (68).
– Remove the cover (64) from the brake fluid retainer.
– Push the hose (66) onto the vent connection (68) of the bleed valve (67) and attach
the other end of the hose to the brake fluid retainer (65) above it.
F
The brake fluid retainer is pressurised. Risk of scalding.
– Open the bleed valve (67) and drain the excess brake fluid into the brake fluid
retainer (65).
– Close the bleed valve (66), remove the hose (65) from the vent connection (67) and
cover the vent connection with the protective cap.
– Close the brake fluid retainer (65) with the lid (64).
Z
The brake system is restored to operation by powering down the truck and activating
the foot switch several times.
M
When using the truck again, check the braking deceleration.
67
68
66
65
64
0206.GB
E 28
Releasing the load wheel brake (hydraulic brake) - EKS 513 – 515 only
– Remove the electronic compartment cover at the back.
– Remove the protective cap from the bleed valve (68).
– Remove the cover (64) from the brake fluid retainer.
– Push the hose (66) onto the vent connection (68) of the bleed valve (67) and attach
the other end of the hose to the brake fluid retainer (65) above it.
F
The brake fluid retainer is pressurised. Risk of scalding.
– Open the bleed valve (67) and drain the excess brake fluid into the brake fluid
retainer (65).
– Close the bleed valve (66), remove the hose (65) from the vent connection (67) and
cover the vent connection with the protective cap.
– Close the brake fluid retainer (65) with the lid (64).
Z
The brake system is restored to operation by powering down the truck and activating
the foot switch several times.
M
When using the truck again, check the braking deceleration.
67
68
66
65
64
Page 66
E 29
0206.GB
Adjust the steering angle
F
The battery must be disconnected when
adjusting the steering angle.
Using an Allen key set the steered wheel to
the required direction via the screw in the
steering motor (69).
Z
It is advisable to discharge the wheel if setting
an angle greater than 4 degrees.
Emergency recovery in drive direction:
– Remove the electronic compartment cover
at the back.
– Guide the tow rope (70), tow force > 5 tonnes, around the counterweight (70) by the
left or right sides of the antenna (71).
M
Note the wire routing in the drive compartment and the antenna (72)!
– Carefully and slowly pull the truck out of the narrow aisle.
Emergency recovery in load direction:
– Guide the tow rope (70), tow force > 5 tonnes, around the aux. raise (73).
– Carefully and slowly pull the truck out of the narrow aisle.
F
After recovery, prevent the truck from accidentally moving.
To do this, unscrew the setscrews on the magnetic brake above the drive motor. If
the brake is not functional, prevent the truck from moving by placing wedges
underneath the wheels.
69
Drive direction
Load direction
70
70
71
73
72
E 29
0206.GB
Adjust the steering angle
F
The battery must be disconnected when
adjusting the steering angle.
Using an Allen key set the steered wheel to
the required direction via the screw in the
steering motor (69).
Z
It is advisable to discharge the wheel if setting
an angle greater than 4 degrees.
Emergency recovery in drive direction:
– Remove the electronic compartment cover
at the back.
– Guide the tow rope (70), tow force > 5 tonnes, around the counterweight (70) by the
left or right sides of the antenna (71).
M
Note the wire routing in the drive compartment and the antenna (72)!
– Carefully and slowly pull the truck out of the narrow aisle.
Emergency recovery in load direction:
– Guide the tow rope (70), tow force > 5 tonnes, around the aux. raise (73).
– Carefully and slowly pull the truck out of the narrow aisle.
F
After recovery, prevent the truck from accidentally moving.
To do this, unscrew the setscrews on the magnetic brake above the drive motor. If
the brake is not functional, prevent the truck from moving by placing wedges
underneath the wheels.
69
Drive direction
Load direction
70
70
71
73
72
Page 67
0206.GB
E 30
0206.GB
E 30
Page 68
F 1
0708.GB
F Maintenance of the forklift truck
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 modifications to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. The operating speeds of the truck must not be increased under any
circumstances.
M
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the forklift 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, the tasks contained in the
“Recommissioning” section must be performed (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 the truck is to
be jacked up, take appropriate measures to prevent the truck from slipping or tipping
over (e.g. wedges, wooden blocks). Only work under a raised load handler and cab
if they are secured by a chain of sufficient capacity or by the retaining bolt (see
“Securing the Driver's Position Carriage” in Chapter F).
Z
Jacking point see chapter B.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
all safety measures required to prevent sparking (e.g. through short circuits) must be
taken. For battery-operated trucks, the battery connector must be removed. Only
weak suction or compressed air and non-conductive antistatic brushes may be used
for cleaning electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions.
Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
F 1
0708.GB
F Maintenance of the forklift truck
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 modifications to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. The operating speeds of the truck must not be increased under any
circumstances.
M
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the forklift 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, the tasks contained in the
“Recommissioning” section must be performed (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 the truck is to
be jacked up, take appropriate measures to prevent the truck from slipping or tipping
over (e.g. wedges, wooden blocks). Only work under a raised load handler and cab
if they are secured by a chain of sufficient capacity or by the retaining bolt (see
“Securing the Driver's Position Carriage” in Chapter F).
Z
Jacking point see chapter B.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
all safety measures required to prevent sparking (e.g. through short circuits) must be
taken. For battery-operated trucks, the battery connector must be removed. Only
weak suction or compressed air and non-conductive antistatic brushes may be used
for cleaning electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions.
Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
Page 69
0708.GB
F 2
Electrical 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.
Wheels: The quality of wheels affects the stability and performance of the truck.
When replacing factory fitted wheels, only use manufacturer’s original spare parts.
Otherwise the truck's rated performance cannot be ensured.
When replacing wheels, ensure that the truck does not slew (e.g. always replace left
and right wheels at the same time).
Lift chains: Lift chains wear rapidly if 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.
0708.GB
F 2
Electrical 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.
Wheels: The quality of wheels affects the stability and performance of the truck.
When replacing factory fitted wheels, only use manufacturer’s original spare parts.
Otherwise the truck's rated performance cannot be ensured.
When replacing wheels, ensure that the truck does not slew (e.g. always replace left
and right wheels at the same time).
Lift chains: Lift chains wear rapidly if 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.
Page 70
F 3
0708.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck considerably affect the wear levels of
the service components.
We recommend an application analysis carried out on site by a Jungheinrich
customer adviser to establish specific maintenance intervals in order to restrict
damage caused by wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 operating hours
B = Every 1000 operating hours, or at least annually
C = Every 2000 operating hours, or at least annually
Z
W service intervals are to be performed by the customer.
F 3
0708.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck considerably affect the wear levels of
the service components.
We recommend an application analysis carried out on site by a Jungheinrich
customer adviser to establish specific maintenance intervals in order to restrict
damage caused by wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 operating hours
B = Every 1000 operating hours, or at least annually
C = Every 2000 operating hours, or at least annually
Z
W service intervals are to be performed by the customer.
Page 71
0708.GB
F 4
4 EKS Maintenance Checklist
b) applies only to the EKS 513-515
Maintenance intervals
Standard = t WABC
Chassis/
Structure:
1.1 Check all load bearing components for damage t
1.2 Check screw connections t
1.3 Test the operator’s platform and check for damage t
1.4 Check that identification points, data plates and
warnings are legible and replace if necessary
t
1.5 Check battery panel and sides are secure t
1.6 Test gas pressure damper and check for damage b) t
Drive: 2.1 Lubricate the bearing between the drive motor and
transmission
t
2.2 Check transmission for noise and leakage t
2.3 Change transmission oil t
Wheels: 3.1 Check wheels for wear and damage t
3.2 Check bearings and attachment t
Steering: 4.1 Test wheel position indicator t
4.2 Check the distance between the guide rollers and the
rail guidance over the entire length of the rails. The play
between the two guide rollers and the rails (measured
over the axle) should be 0-5 mm. The rollers should not
jam.
t
Brake
system:
5.1 Test operation and settings t
5.2 Check the brake lining wear t
5.3 Check the brake linkage; adjust and grease
as required b)
t
5.4 Check brake lines, connections and brake fluid level b) t
5.5 Check brake fluid b) t
5.6 Replace brake fluid b) t
0708.GB
F 4
4 EKS Maintenance Checklist
b) applies only to the EKS 513-515
Maintenance intervals
Standard = t WABC
Chassis/
Structure:
1.1 Check all load bearing components for damage t
1.2 Check screw connections t
1.3 Test the operator’s platform and check for damage t
1.4 Check that identification points, data plates and
warnings are legible and replace if necessary
t
1.5 Check battery panel and sides are secure t
1.6 Test gas pressure damper and check for damage b) t
Drive: 2.1 Lubricate the bearing between the drive motor and
transmission
t
2.2 Check transmission for noise and leakage t
2.3 Change transmission oil t
Wheels: 3.1 Check wheels for wear and damage t
3.2 Check bearings and attachment t
Steering: 4.1 Test wheel position indicator t
4.2 Check the distance between the guide rollers and the
rail guidance over the entire length of the rails. The play
between the two guide rollers and the rails (measured
over the axle) should be 0-5 mm. The rollers should not
jam.
t
Brake
system:
5.1 Test operation and settings t
5.2 Check the brake lining wear t
5.3 Check the brake linkage; adjust and grease
as required b)
t
5.4 Check brake lines, connections and brake fluid level b) t
5.5 Check brake fluid b) t
5.6 Replace brake fluid b) t
Page 72
F 5
0708.GB
p) Replace hydraulic hoses after 6 years' operation
Maintenance intervals
Standard = t WABC
Hydraulic
System
6.1 Test operation t
6.2 Check connections and ports for leaks and damage t
6.3 Check hydraulic cylinder for leaks and damage and
make sure it is secure
t
6.4 Check oil level t
6.5 Test hose guide and check for damage t
6.6 Check ventilation and discharge filter on hydraulic
reservoir
t
6.7 Replace ventilation and discharge filter on hydraulic
reservoir
t
6.8 Replace hydraulic oil and filter cartridge t
6.9 Test pressure relief valves t
6.10 Make sure hydraulic hoses are sealed and check for
damage . p)
t
6.11 Test line brake safety device t
Electrical
System
7.1 Test static charge eliminator t
7.2 Test operation t
7.3 Make sure wire connections are secure and check for
damage
t
7.4 Test the operation of the cable guides and check for
damage
t
7.5 Test operation of warning devices and safety switches. t
7.6 Make sure sensors are fixed, not damaged, clean and
operational
t
7.7 Test operation of instruments and displays t
7.8 Check contactors and relays; if necessary replace any
worn parts
t
7.9 Check fuse ratings t
Electric
motors:
8.1 Check motor attachment t
Battery: 9.1 Check acid density, acid level and cell voltage t
9.2 Check terminals are securely attached, and apply
grease
t
9.3 Clean battery connections, make sure they are secure t
9.4 Check battery cables for damage, replace if necessary. t
F 5
0708.GB
p) Replace hydraulic hoses after 6 years' operation
Maintenance intervals
Standard = t WABC
Hydraulic
System
6.1 Test operation t
6.2 Check connections and ports for leaks and damage t
6.3 Check hydraulic cylinder for leaks and damage and
make sure it is secure
t
6.4 Check oil level t
6.5 Test hose guide and check for damage t
6.6 Check ventilation and discharge filter on hydraulic
reservoir
t
6.7 Replace ventilation and discharge filter on hydraulic
reservoir
t
6.8 Replace hydraulic oil and filter cartridge t
6.9 Test pressure relief valves t
6.10 Make sure hydraulic hoses are sealed and check for
damage . p)
t
6.11 Test line brake safety device t
Electrical
System
7.1 Test static charge eliminator t
7.2 Test operation t
7.3 Make sure wire connections are secure and check for
damage
t
7.4 Test the operation of the cable guides and check for
damage
t
7.5 Test operation of warning devices and safety switches. t
7.6 Make sure sensors are fixed, not damaged, clean and
operational
t
7.7 Test operation of instruments and displays t
7.8 Check contactors and relays; if necessary replace any
worn parts
t
7.9 Check fuse ratings t
Electric
motors:
8.1 Check motor attachment t
Battery: 9.1 Check acid density, acid level and cell voltage t
9.2 Check terminals are securely attached, and apply
grease
t
9.3 Clean battery connections, make sure they are secure t
9.4 Check battery cables for damage, replace if necessary. t
Page 73
0708.GB
F 6
e) IG: inductive guidance trucks
Maintenance intervals
Standard = t WABC
Lift
mechanism
10.1 Clean rollers, guide rollers and contact surfaces in the
mast sections and apply grease.
M
Attention: Danger of crashing!
t
10.2 Check mast attachments (bearings and retaining
screws)
t
10.3 Check lift chains and chain guide for wear, adjust and
lubricate
t
10.4 Lubricate lift chains t
10.5 Visually inspect rollers, slide pieces and stops t
10.6 Check forks and fork carriage for wear and damage t
Attachments 11.1 Test operation and settings t
11.2 Check attachment on truck and load bearing
components
t
Lubrication: 12.1 Lubricate the truck according to the lubrication schedule t
General
Measurements:
13.1 Check electrical system for frame leakage t
13.2 Test travel speed and braking distance t
13.3 Test lift and lowering speeds t
13.4 Test safety devices and cutouts t
13.5 IG: Measure the current in the guidance wire, adjust if
necessary e)
t
13.6 Check travel on the guidance wire, check maximum
deviation and adjust if necessary e)
t
13.7 Check tracking mode on the guidance wire for aisle
tracking
.e)
t
13.8 Check wire guidance EMERGENCY STOP operatione) t
Demonstration:
14.1 Test run with rated load t
14.2 When maintenance is complete, present the truck to the
responsible person.
t
0708.GB
F 6
e) IG: inductive guidance trucks
Maintenance intervals
Standard = t WABC
Lift
mechanism
10.1 Clean rollers, guide rollers and contact surfaces in the
mast sections and apply grease.
M
Attention: Danger of crashing!
t
10.2 Check mast attachments (bearings and retaining
screws)
t
10.3 Check lift chains and chain guide for wear, adjust and
lubricate
t
10.4 Lubricate lift chains t
10.5 Visually inspect rollers, slide pieces and stops t
10.6 Check forks and fork carriage for wear and damage t
Attachments 11.1 Test operation and settings t
11.2 Check attachment on truck and load bearing
components
t
Lubrication: 12.1 Lubricate the truck according to the lubrication schedule t
General
Measure-
ments:
13.1 Check electrical system for frame leakage t
13.2 Test travel speed and braking distance t
13.3 Test lift and lowering speeds t
13.4 Test safety devices and cutouts t
13.5 IG: Measure the current in the guidance wire, adjust if
necessary e)
t
13.6 Check travel on the guidance wire, check maximum
deviation and adjust if necessary e)
t
13.7 Check tracking mode on the guidance wire for aisle
tracking
.e)
t
13.8 Check wire guidance EMERGENCY STOP operatione) t
Demon-
stration:
14.1 Test run with rated load t
14.2 When maintenance is complete, present the truck to the
responsible person.
t
Page 74
F 7
0708.GB
4.1 Lubrication Schedule
Grease nipple consumable E
Inner mast (513 - 515)
Driver’s position (513 – 515)
Fork carriage (513 - 515)
Outer mast (513 - 515)
Centre mast (513 - 515)
F 7
0708.GB
4.1 Lubrication Schedule
Grease nipple consumable E
Inner mast (513 - 515)
Driver’s position (513 – 515)
Fork carriage (513 - 515)
Outer mast (513 - 515)
Centre mast (513 - 515)
Page 75
0708.GB
F 8
g
Contact surfaces a Transmission oil drain plug
s
Grease nipple
Hydraulic oil filler neck
c Hydraulic oil drain plug
G
E
H
E
B
G
E
E
EKS 410
EKS 513 -515
A
A
D
0708.GB
F 8
g
Contact surfaces a Transmission oil drain plug
s
Grease nipple
Hydraulic oil filler neck
c Hydraulic oil drain plug
G
E
H
E
B
G
E
E
EKS 410
EKS 513 -515
A
A
D
Page 76
F 9
0708.GB
4.2 Fuels, coolants and lubricants
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
F
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 the Operating Manual.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent / consumable mixture must be disposed of in
accordance with regulations.
EKS 410 fuels and lubricants
* Plus 2% additive 68 ID (order no. 50307735)
F
The trucks are supplied from the factory with “HLP D22” hydraulic oil or the
“Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive.
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
Code Order no.
Quantity
supplied
Capacity Description Used for
A
51037497
51037494
5 l
1 l
approx.
30 l
HLP D22 including 2 %
share additive 68 ID
Hydraulic System
51085361* 5 l
Plantohyd 22 S
(BIO hydraulic oil)
B 50022968 5 l
approx.
3.6 l
SAE 80 EP API GL4 Transmission
E
14038650
400 g
(cartridge)
---
Grease -
Lithium KP2K-30
(DIN 51825)
General
29201430 1 kg
G 29201280 400 ml ---
Chain spray
Tunfluid LT 220
Mast
track
Lift chains
H 50157382 1 kg 400 g
Grease -
Lithium K3K-20
(DIN 51825)
Front wheel
bearings
F 9
0708.GB
4.2 Fuels, coolants and lubricants
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
F
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 the Operating Manual.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent / consumable mixture must be disposed of in
accordance with regulations.
EKS 410 fuels and lubricants
* Plus 2% additive 68 ID (order no. 50307735)
F
The trucks are supplied from the factory with “HLP D22” hydraulic oil or the
“Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive.
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
Code Order no.
Quantity
supplied
Capacity Description Used for
A
51037497
51037494
5 l
1 l
approx.
30 l
HLP D22 including 2 %
share additive 68 ID
Hydraulic System
51085361* 5 l
Plantohyd 22 S
(BIO hydraulic oil)
B 50022968 5 l
approx.
3.6 l
SAE 80 EP API GL4 Transmission
E
14038650
400 g
(cartridge)
---
Grease -
Lithium KP2K-30
(DIN 51825)
General
29201430 1 kg
G 29201280 400 ml ---
Chain spray
Tunfluid LT 220
Mast
track
Lift chains
H 50157382 1 kg 400 g
Grease -
Lithium K3K-20
(DIN 51825)
Front wheel
bearings
Page 77
0708.GB
F 10
EKS 513/515k/515 fuels and lubricants
* Plus 2% additive 68 ID (order no. 50307735)
F
The trucks are supplied from the factory with “HLP D22” hydraulic oil or the
“Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive.
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
Code Order no.
Quantity
supplied
Capacity Description Used for
A
51037497
51037494
5 l
1 l
approx.
110 l
HLP D22 including 2 %
share additive 68 ID
Hydraulic System
51085361* 5 l
Plantohyd 22 S
(BIO hydraulic oil)
B 50022968 5 l
approx.
5,8 l
SAE 80 EP API GL4 Transmission
D 29201580 5 l
approx.
0.18 l
Brake fluid
SAE DOT 4
Hydraulic brake
system
E
14038650
400 g
(cartridge)
---
Grease -
Lithium KP2K-30
(DIN 51825)
General
29201430 1 kg
G 29201280 400 ml ---
Chain spray
Tunfluid LT 220
Mast
track
Lift chains
H 50157382 1 kg 400 g
Grease -
Lithium K3K-20
(DIN 51825)
Front wheel
bearings
0708.GB
F 10
EKS 513/515k/515 fuels and lubricants
* Plus 2% additive 68 ID (order no. 50307735)
F
The trucks are supplied from the factory with “HLP D22” hydraulic oil or the
“Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive.
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
Code Order no.
Quantity
supplied
Capacity Description Used for
A
51037497
51037494
5 l
1 l
approx.
110 l
HLP D22 including 2 %
share additive 68 ID
Hydraulic System
51085361* 5 l
Plantohyd 22 S
(BIO hydraulic oil)
B 50022968 5 l
approx.
5,8 l
SAE 80 EP API GL4 Transmission
D 29201580 5 l
approx.
0.18 l
Brake fluid
SAE DOT 4
Hydraulic brake
system
E
14038650
400 g
(cartridge)
---
Grease -
Lithium KP2K-30
(DIN 51825)
General
29201430 1 kg
G 29201280 400 ml ---
Chain spray
Tunfluid LT 220
Mast
track
Lift chains
H 50157382 1 kg 400 g
Grease -
Lithium K3K-20
(DIN 51825)
Front wheel
bearings
Page 78
F 11
0708.GB
5 Maintenance and Repairs
M
Load bearing parts of the truck, e. g. chassis and mast, may only be welded after
consultation with the manufacturer.
5.1 Prepare 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:
– Park the truck securely (see Chapter E).
– Disconnect the battery to prevent the truck from being switched on accidentally
– When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
F
When working under a raised fork or a raised industrial truck, secure them to prevent
them from lowering, tipping or sliding away. When raising the industrial truck also
refer to the instructions in the “Transport and Commissioning” section.
When working on the parking brake, prevent the industrial truck from rolling away.
5.2 Securing the driver’s position
carriage
The driver’s position carriage can be
secured in the raised position.
– Raise the driver’s position carriage
until the inner mast (1) is above the
carriage (2) of the load lifting safety
device.
– Unscrew the attachment screw (4)
and remove the retaining bolt (3) from
the carriage (2) on the mast.
– Place the retaining bolt (3) on the
vertical hole of the carriage (2) and
secure them.
– Very slowly lower the driver’s position
carriage until the inner mast (1) is
positioned on the retaining bolt.
1
2
4
4
3
F 11
0708.GB
5 Maintenance and Repairs
M
Load bearing parts of the truck, e. g. chassis and mast, may only be welded after
consultation with the manufacturer.
5.1 Prepare 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:
– Park the truck securely (see Chapter E).
– Disconnect the battery to prevent the truck from being switched on accidentally
– When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
F
When working under a raised fork or a raised industrial truck, secure them to prevent
them from lowering, tipping or sliding away. When raising the industrial truck also
refer to the instructions in the “Transport and Commissioning” section.
When working on the parking brake, prevent the industrial truck from rolling away.
5.2 Securing the driver’s position
carriage
The driver’s position carriage can be
secured in the raised position.
– Raise the driver’s position carriage
until the inner mast (1) is above the
carriage (2) of the load lifting safety
device.
– Unscrew the attachment screw (4)
and remove the retaining bolt (3) from
the carriage (2) on the mast.
– Place the retaining bolt (3) on the
vertical hole of the carriage (2) and
secure them.
– Very slowly lower the driver’s position
carriage until the inner mast (1) is
positioned on the retaining bolt.
1
2
4
4
3
Page 79
0708.GB
F 12
5.3 Lift Chain Servicing
M
It is important that all lift chains and pivots are at all times kept clean and well
lubricated. Only lubricate discharged chains. A chain must be lubricated with
particular care at the points where it passes over a pulley. Lift chains are safetycritical parts.
Chains should not have any significant contamination. They should only be cleaned
with paraffin derivatives e. g. petroleum or diesel fuels. Never clean chains with
steam jet high pressure cleaners, cold or chemical cleaning agents.
5.4 Inspecting the lift chains
Unauthorised wear and external damage:
In accordance with official regulations, a chain is considered to be worn if it has
extended in length by 3% in the section which passes over the deflection pulley. For
safety reasons, we advise replacing chains when they elongate by 2%.
Chains should also be replaced immediately when visible damage is noted, as such
damage leads to permanent breakage after a certain time.
M
If the truck is fitted with two lift chains, both chains must always be replaced. This is
the only way to ensure even load distribution over the two chains. When replacing
chains the connecting bolts between the chain anchor and the chain must be
replaced. Only new original parts may be used.
0708.GB
F 12
5.3 Lift Chain Servicing
M
It is important that all lift chains and pivots are at all times kept clean and well
lubricated. Only lubricate discharged chains. A chain must be lubricated with
particular care at the points where it passes over a pulley. Lift chains are safety-
critical parts.
Chains should not have any significant contamination. They should only be cleaned
with paraffin derivatives e. g. petroleum or diesel fuels. Never clean chains with
steam jet high pressure cleaners, cold or chemical cleaning agents.
5.4 Inspecting the lift chains
Unauthorised wear and external damage:
In accordance with official regulations, a chain is considered to be worn if it has
extended in length by 3% in the section which passes over the deflection pulley. For
safety reasons, we advise replacing chains when they elongate by 2%.
Chains should also be replaced immediately when visible damage is noted, as such
damage leads to permanent breakage after a certain time.
M
If the truck is fitted with two lift chains, both chains must always be replaced. This is
the only way to ensure even load distribution over the two chains. When replacing
chains the connecting bolts between the chain anchor and the chain must be
replaced. Only new original parts may be used.
Page 80
F 13
0708.GB
5.5 Hydraulic oil
– Prepare the truck for maintenance and repairs
M
Oil must never be allowed to enter the drainage system or the soil. Used oil must be
preserved until it can be disposed of in the correct manner.
Draining oil:
Suction off the hydraulic oil with the
discharge filter removed (5). If this is not
possible, the hydraulic oil can be drained
from the bottom of the hydraulic
reservoir after the oil drain screw (8a)
has been unscrewed.
Adding oil:
Screw in the oil drain screw (8a).
Replenish with new hydraulic oil up to
the Max. mark on the dipstick (7). Screw
the discharge filter backon.
F
Check which hydraulic oil is being added. If Plantohyd 22 S
BIO hydraulic oil is being used, the warning: “Only add BIO
hydraulic oil” (8b) will be on the hydraulic reservoir. In this case
you may only use Hydrauliköl „Plantohyd 22 S BIO hydraulic
oil to fill the hydraulic reservoir.
F
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
Checking the hydraulic oil level
When the mast is fully lowered, check that the hydraulic oil level is between the min.
and max. markings on the dipstick (7).
If this is not the case, add new hydraulic oil.
5
7
8a
8b
F 13
0708.GB
5.5 Hydraulic oil
– Prepare the truck for maintenance and repairs
M
Oil must never be allowed to enter the drainage system or the soil. Used oil must be
preserved until it can be disposed of in the correct manner.
Draining oil:
Suction off the hydraulic oil with the
discharge filter removed (5). If this is not
possible, the hydraulic oil can be drained
from the bottom of the hydraulic
reservoir after the oil drain screw (8a)
has been unscrewed.
Adding oil:
Screw in the oil drain screw (8a).
Replenish with new hydraulic oil up to
the Max. mark on the dipstick (7). Screw
the discharge filter backon.
F
Check which hydraulic oil is being added. If Plantohyd 22 S
BIO hydraulic oil is being used, the warning: “Only add BIO
hydraulic oil” (8b) will be on the hydraulic reservoir. In this case
you may only use Hydrauliköl „Plantohyd 22 S BIO hydraulic
oil to fill the hydraulic reservoir.
F
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same
applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil.
Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
Checking the hydraulic oil level
When the mast is fully lowered, check that the hydraulic oil level is between the min.
and max. markings on the dipstick (7).
If this is not the case, add new hydraulic oil.
5
7
8a
8b
Page 81
0708.GB
F 14
5.6 Hydraulic hoses
Hose lines must be replaced every six years, see Safety Regulations for Hydraulic
Hose Lines ZH 1/74.
5.7 Check brake fluid
(EKS 513 - 515)
F
Brake fluid is poisonous and should therefore
only be stored in sealed, original containers. It
should also be noted that brake fluid corrodes
the truck paint.
M
Brake fluid is added in the factory and must be
replaced after 12 months at the latest, as it
changes over time and loses its original
qualities.
The brake fluid container (11) is located at the
rear of the truck and can be accessed by
removing the panel. The container should
always be filled to 2cm below the container lid.
Only use the prescribed brake fluid.
The entire brake system must be checked for
leaks.
11
0708.GB
F 14
5.6 Hydraulic hoses
Hose lines must be replaced every six years, see Safety Regulations for Hydraulic
Hose Lines ZH 1/74.
5.7 Check brake fluid
(EKS 513 - 515)
F
Brake fluid is poisonous and should therefore
only be stored in sealed, original containers. It
should also be noted that brake fluid corrodes
the truck paint.
M
Brake fluid is added in the factory and must be
replaced after 12 months at the latest, as it
changes over time and loses its original
qualities.
The brake fluid container (11) is located at the
rear of the truck and can be accessed by
removing the panel. The container should
always be filled to 2cm below the container lid.
Only use the prescribed brake fluid.
The entire brake system must be checked for
leaks.
11
Page 82
F 15
0708.GB
5.8 Checking electrical fuses (EKS 410)
F
Electric fuses must only be checked and replaced by authorized personnel.
– Prepare the truck for maintenance and repairs
(see Chapter F).
– Check all fuse ratings in accordance with the table; replace if necessary.
F
Only use the rating indicated on the controller. DIN and EN standardised fuses must
not be used for UL standardised fuses. The opposite also applies.
Item Description To protect: Rating
12 1F11 Travel 160 A (DIN, EN) 250 A (UL)
13 3F10 Steering 35 A (DIN, EN) 35 A (UL)
14 2F15 Hydraulics 250 A (DIN, EN) 400 A (UL)
15 F2.1 DC/DC converter U1 input 48 V 48 V / 10 A (UL)
16 5F1 Lighting and special equipment 48 V 48 V / 10 A (UL)
17 F3.1 DC/DC converter U1 output 24 V 24 V / 10 A (UL)
18 F1.2 DC/DC converter U16 input 48 V 48 V / 4 A (UL)
19 5F2 DC/DC converter U16 output 24 V 24 V / 6,3 A (UL)
20 1F3 Drive controller 1 A (UL)
1213
14
15
16
20 19 18 17
F 15
0708.GB
5.8 Checking electrical fuses (EKS 410)
F
Electric fuses must only be checked and replaced by authorized personnel.
– Prepare the truck for maintenance and repairs
(see Chapter F).
– Check all fuse ratings in accordance with the table; replace if necessary.
F
Only use the rating indicated on the controller. DIN and EN standardised fuses must
not be used for UL standardised fuses. The opposite also applies.
Item Description To protect: Rating
12 1F11 Travel 160 A (DIN, EN) 250 A (UL)
13 3F10 Steering 35 A (DIN, EN) 35 A (UL)
14 2F15 Hydraulics 250 A (DIN, EN) 400 A (UL)
15 F2.1 DC/DC converter U1 input 48 V 48 V / 10 A (UL)
16 5F1 Lighting and special equipment 48 V 48 V / 10 A (UL)
17 F3.1 DC/DC converter U1 output 24 V 24 V / 10 A (UL)
18 F1.2 DC/DC converter U16 input 48 V 48 V / 4 A (UL)
19 5F2 DC/DC converter U16 output 24 V 24 V / 6,3 A (UL)
20 1F3 Drive controller 1 A (UL)
1213
14
15
16
20 19 18 17
Page 83
0708.GB
F 16
5.9 Checking electrical fuses (EKS 513 - 515)
F
Electric fuses must only be checked and replaced by authorized personnel.
– Prepare the truck for maintenance and repairs
(see Chapter F).
– Check all fuse ratings in accordance with the table; replace if necessary.
F
Only use the rating indicated on the controller. DIN and EN standardised fuses must
not be used for UL standardised fuses. The opposite also applies.
Item Description To protect: Rating
21 1F11 Travel 250 A
22 3F10 Steering 35 A
23 2F15 Hydraulics 325 A
24 F2.1 DC/DC converter U1 input 80 V 80 V / 10 A
25 5F1 Lighting and special equipment 80 V 80 V / 10 A
26 F3.1 DC/DC converter U1 output 24 V 24 V / 10 A
27 F1.2 DC/DC converter U16 input 80 V 80 V / 4 A
28 5F2 DC/DC converter U16 output 24 V 24 V / 6.3 A
29 1F3 Drive controller 1 A
2122
23
24
25
29 28 27 26
0708.GB
F 16
5.9 Checking electrical fuses (EKS 513 - 515)
F
Electric fuses must only be checked and replaced by authorized personnel.
– Prepare the truck for maintenance and repairs
(see Chapter F).
– Check all fuse ratings in accordance with the table; replace if necessary.
F
Only use the rating indicated on the controller. DIN and EN standardised fuses must
not be used for UL standardised fuses. The opposite also applies.
Item Description To protect: Rating
21 1F11 Travel 250 A
22 3F10 Steering 35 A
23 2F15 Hydraulics 325 A
24 F2.1 DC/DC converter U1 input 80 V 80 V / 10 A
25 5F1 Lighting and special equipment 80 V 80 V / 10 A
26 F3.1 DC/DC converter U1 output 24 V 24 V / 10 A
27 F1.2 DC/DC converter U16 input 80 V 80 V / 4 A
28 5F2 DC/DC converter U16 output 24 V 24 V / 6.3 A
29 1F3 Drive controller 1 A
2122
23
24
25
29 28 27 26
Page 84
F 17
0708.GB
5.10 Recommissioning
The truck may only be recommissioned after cleaning or repair work, once the
following operations have been performed.
– Test horn.
– Test EMERGENCY DISCONNECT switch.
– Test brake.
6 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than one month, 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 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.
6.1 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 lubrication schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and apply grease to the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
F 17
0708.GB
5.10 Recommissioning
The truck may only be recommissioned after cleaning or repair work, once the
following operations have been performed.
– Test horn.
– Test EMERGENCY DISCONNECT switch.
– Test brake.
6 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than one month, 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 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.
6.1 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 lubrication schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and apply grease to the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
Page 85
0708.GB
F 18
6.2 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.
6.3 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the lubrication 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.
0708.GB
F 18
6.2 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.
6.3 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the lubrication 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.
Page 86
F 19
0708.GB
7 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.
8 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.
F 19
0708.GB
7 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.
8 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 87
0708.GB
F 20
0708.GB
F 20
Page 88
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
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 89
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!
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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
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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.
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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.
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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 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.
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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
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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.
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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
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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
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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 (yellow) 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
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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 (yellow) 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
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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 solenoid 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
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 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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0506.GB
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.
11
0506.GB
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.
Page 99
0506.GB
12
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.
0506.GB
12
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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