Page 1
Operating instructions
G
Operating instructions
51159400
ERE
07.09 -
11.13
ERE 120n
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
1113.GB
Index
A Correct use and application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies .......................................................................................... B 2
3 Specifications ...................................................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 3
3.3 EN norms ............................................................................................ B 7
3.4 Conditions of use ................................................................................ B 7
4 Identification points and data plates .................................................... B 8
4.1 Truck data plate .................................................................................. B 9
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Removing the Transport Lock ............................................................. C 2
4 Operating the truck without its own drive system ................................ C 3
5 Securing the truck during transport ..................................................... C 4
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Battery removal and installation .......................................................... D 4
5.1 Changing the battery from the top (t) ................................................ D 4
5.2 Lateral Battery Removal (o) ............................................................... D 5
I 1
1113.GB
Index
A Correct use and application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies .......................................................................................... B 2
3 Specifications ...................................................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 3
3.3 EN norms ............................................................................................ B 7
3.4 Conditions of use ................................................................................ B 7
4 Identification points and data plates .................................................... B 8
4.1 Truck data plate .................................................................................. B 9
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Removing the Transport Lock ............................................................. C 2
4 Operating the truck without its own drive system ................................ C 3
5 Securing the truck during transport ..................................................... C 4
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Battery removal and installation .......................................................... D 4
5.1 Changing the battery from the top (t) ................................................ D 4
5.2 Lateral Battery Removal (o) ............................................................... D 5
Page 5
11.13 .GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
3 Starting up the truck ............................................................................ E 6
4 Industrial truck operation ..................................................................... E 7
4.1 Safety regulations for truck operation ................................................. E 7
4.2 Travel, Steering, Braking ..................................................................... E 8
4.3 Collecting and depositing loads .......................................................... E 11
4.4 Parking the truck securely ................................................................... E 12
5 Keypad (CanCode) (o) ....................................................................... E 13
5.1 Code Lock ........................................................................................... E 13
5.2 Travel programs .................................................................................. E 15
5.3 Parameters .......................................................................................... E 15
5.4 Parameter Settings ............................................................................. E 16
5.5 Travel parameters ............................................................................... E 20
5.6 Battery parameters .............................................................................. E 24
6 Battery Discharge Indicator (t) .......................................................... E 25
7 Display instrument (CanDis) (o) ......................................................... E 26
7.1 Discharge monitor function ................................................................. E 27
7.2 Operating hours display ...................................................................... E 27
7.3 Power up test ...................................................................................... E 27
8 Troubleshooting .................................................................................. E 28
F Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance Safety Regulations ........................................................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance Checklist ........................................................................ F 4
5 Maintenance Schedule ........................................................................ F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Maintenance and Repairs ................................................................... F 8
6.1 Preparing the truck for maintenance and repairs ................................ F 8
6.2 Opening the battery panel ................................................................... F 8
6.3 Opening the front panel ....................................................................... F 8
6.4 Replacing the drive wheel ................................................................... F 9
6.5 Checking the hydraulic oil level ........................................................... F 9
6.6 Checking electrical fuses .................................................................... F 10
6.7 Recommissioning ................................................................................ F 11
7 Decommissioning the industrial truck .................................................. F 11
7.1 Prior to decommissioning .................................................................... F 11
7.2 During decommissioning ..................................................................... F 11
7.3 Restoring the truck to operation after decommissioning ..................... F 12
8 Safety checks to be performed at regular intervals and following
any unusual incidents .......................................................................... F 12
9 Final de-commissioning, disposal ....................................................... F 12
11.13 .GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
3 Starting up the truck ............................................................................ E 6
4 Industrial truck operation ..................................................................... E 7
4.1 Safety regulations for truck operation ................................................. E 7
4.2 Travel, Steering, Braking ..................................................................... E 8
4.3 Collecting and depositing loads .......................................................... E 11
4.4 Parking the truck securely ................................................................... E 12
5 Keypad (CanCode) (o) ....................................................................... E 13
5.1 Code Lock ........................................................................................... E 13
5.2 Travel programs .................................................................................. E 15
5.3 Parameters .......................................................................................... E 15
5.4 Parameter Settings ............................................................................. E 16
5.5 Travel parameters ............................................................................... E 20
5.6 Battery parameters .............................................................................. E 24
6 Battery Discharge Indicator (t) .......................................................... E 25
7 Display instrument (CanDis) (o) ......................................................... E 26
7.1 Discharge monitor function ................................................................. E 27
7.2 Operating hours display ...................................................................... E 27
7.3 Power up test ...................................................................................... E 27
8 Troubleshooting .................................................................................. E 28
F Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance Safety Regulations ........................................................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance Checklist ........................................................................ F 4
5 Maintenance Schedule ........................................................................ F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Maintenance and Repairs ................................................................... F 8
6.1 Preparing the truck for maintenance and repairs ................................ F 8
6.2 Opening the battery panel ................................................................... F 8
6.3 Opening the front panel ....................................................................... F 8
6.4 Replacing the drive wheel ................................................................... F 9
6.5 Checking the hydraulic oil level ........................................................... F 9
6.6 Checking electrical fuses .................................................................... F 10
6.7 Recommissioning ................................................................................ F 11
7 Decommissioning the industrial truck .................................................. F 11
7.1 Prior to decommissioning .................................................................... F 11
7.2 During decommissioning ..................................................................... F 11
7.3 Restoring the truck to operation after decommissioning ..................... F 12
8 Safety checks to be performed at regular intervals and following
any unusual incidents .......................................................................... F 12
9 Final de-commissioning, disposal ....................................................... F 12
Page 6
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
Page 7
0506.GB 20506.GB
2
Page 8
A 1
0505.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 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 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
0505.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 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 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 9
0505.D
A 2
0505.D
A 2
Page 10
B 1
0709.GB
B Truck Description
1 Application
The truck is a tiller operated electric pallet truck with a folding operator platform and
side arms.
A fixed operator platform is optionally available.
The truck is designed for lifting and transporting goods on a level surface. The truck
can pick up, outside the load wheel area, open bottom or diagonal board pallets as
well as roll cages. The capacity of the truck is shown on the data plate or the data
capacity plate Qmax.
B 1
0709.GB
B Truck Description
1 Application
The truck is a tiller operated electric pallet truck with a folding operator platform and
side arms.
A fixed operator platform is optionally available.
The truck is designed for lifting and transporting goods on a level surface. The truck
can pick up, outside the load wheel area, open bottom or diagonal board pallets as
well as roll cages. The capacity of the truck is shown on the data plate or the data
capacity plate Qmax.
Page 11
0709.GB
B 2
2 Assemblies
Item Description Item Description
1 t Travel switch 8 t Castor wheel
2 t Tiller 9 t Drive wheel
3 o Display instrument
(CanDis)
10 t Folding operator platform
4 t Key switch 11 t Ram protection
5 o Keypad
(CanCode)
12 t Side arm
6 t Battery discharge
indicator
13 o Fixed operator platform
7 t Battery connector 14 o Pressure sensitive mat
t = Standard Equipment o = Optional Equipment
13
14
3, 6
4, 5
1
2
7
88
11
12
10
9
0709.GB
B 2
2 Assemblies
Item Description Item Description
1 t Travel switch 8 t Castor wheel
2 t Tiller 9 t Drive wheel
3 o Display instrument
(CanDis)
10 t Folding operator platform
4 t Key switch 11 t Ram protection
5 o Keypad
(CanCode)
12 t Side arm
6 t Battery discharge
indicator
13 o Fixed operator platform
7 t Battery connector 14 o Pressure sensitive mat
t = Standard Equipment o = Optional Equipment
13
14
3, 6
4, 5
1
2
7
88
11
12
10
9
Page 12
B 3
0709.GB
3 Specifications
Z
Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
3.1 Performance data
3.2 Dimensions
Description
Q Capacity 2.000 kg
c Load centre of gravity 600 mm
Travel speed,
pedestrian (walk-along) mode w / w.o. load
4,2 km/h
Travel speed,
operator position mode w / w.o. load
7,5 / 8,5 km/h
Lift time w / w.o. load 2,3 / 1,8 s
Lowering speed w / w.o. load 2,4 / 2,4 s
Max. gradeability (above 5 mins) w / w.o. load 8,0 / 16,0 %
Description
h
14
Tiller height in min/max travel position 1130 / 1450 mm
h
13
Lowered fork height 85 mm
h
3
Lift 122 mm
b1 Truck width 700 mm
b5 Width across forks 532 / 672 mm
e Fork width 162 mm
a Safety distance 200 mm
Net weight see truck data plate
B 3
0709.GB
3 Specifications
Z
Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
3.1 Performance data
3.2 Dimensions
Description
Q Capacity 2.000 kg
c Load centre of gravity 600 mm
Travel speed,
pedestrian (walk-along) mode w / w.o. load
4,2 km/h
Travel speed,
operator position mode w / w.o. load
7,5 / 8,5 km/h
Lift time w / w.o. load 2,3 / 1,8 s
Lowering speed w / w.o. load 2,4 / 2,4 s
Max. gradeability (above 5 mins) w / w.o. load 8,0 / 16,0 %
Description
h
14
Tiller height in min/max travel position 1130 / 1450 mm
h
13
Lowered fork height 85 mm
h
3
Lift 122 mm
b1 Truck width 700 mm
b5 Width across forks 532 / 672 mm
e Fork width 162 mm
a Safety distance 200 mm
Net weight see truck data plate
Page 13
0709.GB
B 4
Dimensions sheet with folding platform
b
21
h
31
m
2
s
h
3
b
5
b
11
b
3
b
1
h
14
005
l
6
l
1
l
2
164
058
1006
l
y
Q
c
x
A
ts
W
a
e
/
a
2 /a 2
0709.GB
B 4
Dimensions sheet with folding platform
b
21
h
31
m
2
s
h
3
b
5
b
11
b
3
b
1
h
14
005
l
6
l
1
l
2
164
058
1006
l
y
Q
c
x
A
ts
W
a
e
/
a
2 /a 2
Page 14
B 5
0709.GB
Dimensions sheet with fixed platform
B 5
0709.GB
Dimensions sheet with fixed platform
Page 15
0709.GB
B 6
Length including fork shank I
2
= 754 mm (walk-along mode)
Details in mm
l1 = l2 + l
* y
= l1
- 242 mm - 186 mm
** y = l1 - 242 mm - 560 mm
Ast = Wa + l6 - x + a (pallet longit.)
1)
Load section raised; if load section lowered: +55 mm
2)
For rider mode: +462 mm
3)
Battery XL version; for battery long version (l2 = 682 mm): -72 mm
lI
1
3
)y
1)3
)x
1
)I6b12 W
a
1)2)3
)A
st
2)3
)
1000 1754 1326 * 759 1000 800 1537 1978
1150 1904 1476 * 909 1200 800 1687 2178
1200 1954 1526 * 959 1200 800 1737 2178
1400 2154 1726 * 1159 1400 700 1937 2378
1600 2354 1926 ** 1359 1600 1200 2137 2578
1950 2704 1902 ** 1335 2000 800 2113 2978
2150 2904 2102 ** 1535 2100 700 2313 3078
2400 3154 2352 ** 1785 2400 1200 2563 3378
0709.GB
B 6
Length including fork shank I
2
= 754 mm (walk-along mode)
Details in mm
l1 = l2 + l
* y
= l1
- 242 mm - 186 mm
** y = l1 - 242 mm - 560 mm
Ast = Wa + l6 - x + a (pallet longit.)
1)
Load section raised; if load section lowered: +55 mm
2)
For rider mode: +462 mm
3)
Battery XL version; for battery long version (l2 = 682 mm): -72 mm
lI
1
3
)y
1)3
)x
1
)I6b12 W
a
1)2)3
)A
st
2)3
)
1000 1754 1326 * 759 1000 800 1537 1978
1150 1904 1476 * 909 1200 800 1687 2178
1200 1954 1526 * 959 1200 800 1737 2178
1400 2154 1726 * 1159 1400 700 1937 2378
1600 2354 1926 ** 1359 1600 1200 2137 2578
1950 2704 1902 ** 1335 2000 800 2113 2978
2150 2904 2102 ** 1535 2100 700 2313 3078
2400 3154 2352 ** 1785 2400 1200 2563 3378
Page 16
B 7
0709.GB
3.3 EN norms
Noise emission: 66 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.
Vibration: 0.67 m/s
2
In accordance with EN 13059.
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. 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.
3.4 Conditions of use
Ambient temperature
- operating at -10 °C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
B 7
0709.GB
3.3 EN norms
Noise emission: 66 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.
Vibration: 0.67 m/s
2
In accordance with EN 13059.
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. 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.
3.4 Conditions of use
Ambient temperature
- operating at -10 °C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
Page 17
0709.GB
B 8
4 Identification points and data plates
Z
The truck data plate (15) is visible when the load section is raised.
The battery data plate (18) can be seen on the battery (see Chapter D).
Item Description
15 Truck data plate
16 Rated capacity
17 Strap point for crane lifting
18 Battery data plate
16
17
18
15
0709.GB
B 8
4 Identification points and data plates
Z
The truck data plate (15) is visible when the load section is raised.
The battery data plate (18) can be seen on the battery (see Chapter D).
Item Description
15 Truck data plate
16 Rated capacity
17 Strap point for crane lifting
18 Battery data plate
16
17
18
15
Page 18
B 9
0709.GB
4.1 Truck data plate
Z
For queries regarding the truck or ordering spare parts always quote the truck serial
number (35).
Item Description Item Description
20 Type 29 Manufacturer’s logo
21 Name 30 Max. battery weight in kg
22 Battery: Voltage (V) 31 Min. battery weight in kg
23 Rated capacity (kg) 32 Output (kW)
24 Net weight w.o. battery (kg) 33 Load centre (mm)
25 Net weight with battery (kg) 34 Year of manufacture
26 Manufacturer 35 Serial No.
27 Production 36 Option
28 Production address
31
30
24
3223
3322
3421
20
36
35
25
26
27 28 29
B 9
0709.GB
4.1 Truck data plate
Z
For queries regarding the truck or ordering spare parts always quote the truck serial
number (35).
Item Description Item Description
20 Type 29 Manufacturer’s logo
21 Name 30 Max. battery weight in kg
22 Battery: Voltage (V) 31 Min. battery weight in kg
23 Rated capacity (kg) 32 Output (kW)
24 Net weight w.o. battery (kg) 33 Load centre (mm)
25 Net weight with battery (kg) 34 Year of manufacture
26 Manufacturer 35 Serial No.
27 Production 36 Option
28 Production address
31
30
24
3223
3322
3421
20
36
35
25
26
27 28 29
Page 19
0709.GB
B 10
0709.GB
B 10
Page 20
C 1
0108.GB
C Transport and Commissioning
1 Lifting by crane
F
Only use lifting gear with sufficient
capacity (for truck weight see truck
data plate, chapter B).
Z
Lifting gear attachment points (1) are
provided on the chassis and the fork in
case the truck is to be lifted or transported by crane.
– Park the truck securely (see
Chapter E).
– Secure the lifting gear to the
attachment points (1).
M
The lifting gear must be attached to the
attachment points in such a manner
that it cannot slip under any circumstances and cannot come into contact
with any attachments of the truck when
the truck is lifted.
2 Commissioning
M
Only operate the truck 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:
– Check the truck for completeness and satisfactory condition of the equipment.
– Install battery (where required). Do not damage battery cable.
– Charge the battery (see Chapter D).
– If necessary, adjust the combination instrument to match the battery type (see
Chapter D).
111
C 1
0108.GB
C Transport and Commissioning
1 Lifting by crane
F
Only use lifting gear with sufficient
capacity (for truck weight see truck
data plate, chapter B).
Z
Lifting gear attachment points (1) are
provided on the chassis and the fork in
case the truck is to be lifted or trans-
ported by crane.
– Park the truck securely (see
Chapter E).
– Secure the lifting gear to the
attachment points (1).
M
The lifting gear must be attached to the
attachment points in such a manner
that it cannot slip under any circum-
stances and cannot come into contact
with any attachments of the truck when
the truck is lifted.
2 Commissioning
M
Only operate the truck 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:
– Check the truck for completeness and satisfactory condition of the equipment.
– Install battery (where required). Do not damage battery cable.
– Charge the battery (see Chapter D).
– If necessary, adjust the combination instrument to match the battery type (see
Chapter D).
111
Page 21
0108.GB
C 2
3 Removing the Transport Lock
There is an instruction decal by the front panel for the transport retainer (2), this must
be removed once the battery has been installed.
– Fold down the driver’s platform.
– Open the front panel (see Chapter F).
– Remove the cable binder latch (3), loosen the nut (2) and remove the transport lock.
– Leave the transport retainer on the truck for later transportation without a battery.
Z
The transport lock ensures that the truck is braked without the mass of the battery.
– Commission the truck in accordance with instructions (see Chapter E).
Z
When the truck is parked, the surface of the tyres will flatten. The flattening will
disappear after a short period of operation.
2
3
0108.GB
C 2
3 Removing the Transport Lock
There is an instruction decal by the front panel for the transport retainer (2), this must
be removed once the battery has been installed.
– Fold down the driver’s platform.
– Open the front panel (see Chapter F).
– Remove the cable binder latch (3), loosen the nut (2) and remove the transport lock.
– Leave the transport retainer on the truck for later transportation without a battery.
Z
The transport lock ensures that the truck is braked without the mass of the battery.
– Commission the truck in accordance with instructions (see Chapter E).
Z
When the truck is parked, the surface of the tyres will flatten. The flattening will
disappear after a short period of operation.
2
3
Page 22
C 3
0108.GB
4 Operating the truck without its own drive system
F
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as
follows:
– Set the key switch OFF and remove the key.
– Disconnect the battery.
– Prevent the truck from rolling away.
– Open and put away the front cover (refer to chapter F).
– Pull up the anchor plate (4) by screwing in two M5x16 screws as far as the stop.
The brake has now been released and the truck can be moved.
F
On reaching your destination, ensure that the brake is restored to its initial state. The
truck must never be parked with the brake released.
– Remove the screws.
The brake is now applied again.
– Refit the front cover.
4
C 3
0108.GB
4 Operating the truck without its own drive system
F
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as
follows:
– Set the key switch OFF and remove the key.
– Disconnect the battery.
– Prevent the truck from rolling away.
– Open and put away the front cover (refer to chapter F).
– Pull up the anchor plate (4) by screwing in two M5x16 screws as far as the stop.
The brake has now been released and the truck can be moved.
F
On reaching your destination, ensure that the brake is restored to its initial state. The
truck must never be parked with the brake released.
– Remove the screws.
The brake is now applied again.
– Refit the front cover.
4
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0108.GB
C 4
5 Securing the truck during transport
The truck must be securely fastened when being transported on a lorry or a trailer.
The lorry / trailer must have fastening rings. Fold the side protection and the folding
platform in or up so that they do not protrude beyond the geometry of the truck.
– To secure the truck, hook the tensioning belt (6) with the integrated load hook into
the load handling points (5) and attach it to the fastening rings.
– Tighten the tensioning belt with the tensioner (7).
Carry out this process on both sides of the truck.
Loading must be carried out by staff specially 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.
5
7
6
0108.GB
C 4
5 Securing the truck during transport
The truck must be securely fastened when being transported on a lorry or a trailer.
The lorry / trailer must have fastening rings. Fold the side protection and the folding
platform in or up so that they do not protrude beyond the geometry of the truck.
– To secure the truck, hook the tensioning belt (6) with the integrated load hook into
the load handling points (5) and attach it to the fastening rings.
– Tighten the tensioning belt with the tensioner (7).
Carry out this process on both sides of the truck.
Loading must be carried out by staff specially 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.
5
7
6
Page 24
D 1
0709.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. 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 a truck is parked for charging there shall be no inflammable
material or operating fluids 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. Batteries with non insulated terminals must be covered with a non slip
insulation mat.
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 considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.
D 1
0709.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. 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 a truck is parked for charging there shall be no inflammable
material or operating fluids 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. Batteries with non insulated terminals must be covered with a non slip
insulation mat.
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 considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.
Page 25
0709.GB
D 2
2Battery types
The battery types correspond to EN 60254-2.
The following table shows the combinations to be used, with reference to their
capacity:
The battery weight is indicated on the battery data plate.
Depending on the type of battery, both enhance and maintenance-free batteries can
be used.
F
When replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck.
3 Exposing the battery
F
Park the truck securely (see Chapter E).
– Remove the battery connector (3).
– Lift up the battery panel (1) using the grip mould (2) and fold it back.
Battery type Battery
compartment
approx. 227 mm
Weight Battery
compartment
approx. 299 mm
Weight
24 volt battery
(enhanced)
2 EPzS 240 Ah 231 kg 3 EPzS 360 Ah 303 kg
3
2
1
0709.GB
D 2
2Battery types
The battery types correspond to EN 60254-2.
The following table shows the combinations to be used, with reference to their
capacity:
The battery weight is indicated on the battery data plate.
Depending on the type of battery, both enhance and maintenance-free batteries can
be used.
F
When replacing or installing batteries, ensure that the battery is correctly secured in
the battery compartment of the truck.
3 Exposing the battery
F
Park the truck securely (see Chapter E).
– Remove the battery connector (3).
– Lift up the battery panel (1) using the grip mould (2) and fold it back.
Battery type Battery
compartment
approx. 227 mm
Weight Battery
compartment
approx. 299 mm
Weight
24 volt battery
(enhanced)
2 EPzS 240 Ah 231 kg 3 EPzS 360 Ah 303 kg
3
2
1
Page 26
D 3
0709.GB
4 Charging the battery
F
To charge the battery, the truck must be parked in a closed and properly ventilated
room. When charging, the tops of the battery cells must be 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.
M
It is essential to follow the safety regulations of the battery and charging station
manufacturers.
– Expose the battery (see Section 3).
– Connect the battery plug (4) with the charging lead of the stationary charger (5) and
turn on the charger.
4
5
D 3
0709.GB
4 Charging the battery
F
To charge the battery, the truck must be parked in a closed and properly ventilated
room. When charging, the tops of the battery cells must be 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.
M
It is essential to follow the safety regulations of the battery and charging station
manufacturers.
– Expose the battery (see Section 3).
– Connect the battery plug (4) with the charging lead of the stationary charger (5) and
turn on the charger.
4
5
Page 27
0709.GB
D 4
5 Battery removal and installation
5.1 Changing the battery from the top (t)
F
The truck must be level. To prevent short circuits, batteries with exposed terminals or
connectors must be covered with a rubber mat. Place the battery connector or the
battery cable in such a way that they will not get caught on the truck when the battery
is removed.
Z
When transporting batteries using a crane, ensure that the crane is of adequate
capacity (the battery weight is indicated on the battery data plate on the battery
container). The crane lifting gear must exert a vertical pull. The hooks of the lifting
gear must never fall into the battery cells.
– Expose the battery (see Section 3).
– Remove the battery connector (3).
– Undo the screw (6) of the battery retainer and remove the battery retainer (7).
– Strap the crane lifting gear to the eyes (8).
– Pull the battery up out of the container.
M
Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly.
– After installing the battery again, check all cables and plug connections for visible
signs of damage.
F
Close the battery panel carefully and slowly.
Do not reach between the battery panel and the chassis.
7 86
0709.GB
D 4
5 Battery removal and installation
5.1 Changing the battery from the top (t)
F
The truck must be level. To prevent short circuits, batteries with exposed terminals or
connectors must be covered with a rubber mat. Place the battery connector or the
battery cable in such a way that they will not get caught on the truck when the battery
is removed.
Z
When transporting batteries using a crane, ensure that the crane is of adequate
capacity (the battery weight is indicated on the battery data plate on the battery
container). The crane lifting gear must exert a vertical pull. The hooks of the lifting
gear must never fall into the battery cells.
– Expose the battery (see Section 3).
– Remove the battery connector (3).
– Undo the screw (6) of the battery retainer and remove the battery retainer (7).
– Strap the crane lifting gear to the eyes (8).
– Pull the battery up out of the container.
M
Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly.
– After installing the battery again, check all cables and plug connections for visible
signs of damage.
F
Close the battery panel carefully and slowly.
Do not reach between the battery panel and the chassis.
7 86
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D 5
0709.GB
5.2 Lateral Battery Removal (o)
F
The truck must be level. To prevent short
circuits, batteries with exposed terminals or
connectors must be covered with a rubber mat.
Place the battery connector or the battery cable
in such a way that they will not get caught on the
truck when the battery is removed.
Battery removal
– Expose the battery (see Section 3).
– Remove the battery connector (3).
– Turn the battery lock (9) as far as the stop.
– Pull the battery out from the side.
Battery installation
M
Installation is the reverse order. When
reinstalling the battery, note the proper
installation position and make sure the battery
is connected correctly.
– After installing the battery again, check all
cables and plug connections for visible signs
of damage.
F
Close the battery panel carefully and slowly.
Do not reach between the battery panel and the
chassis.
9
9
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0709.GB
5.2 Lateral Battery Removal (o)
F
The truck must be level. To prevent short
circuits, batteries with exposed terminals or
connectors must be covered with a rubber mat.
Place the battery connector or the battery cable
in such a way that they will not get caught on the
truck when the battery is removed.
Battery removal
– Expose the battery (see Section 3).
– Remove the battery connector (3).
– Turn the battery lock (9) as far as the stop.
– Pull the battery out from the side.
Battery installation
M
Installation is the reverse order. When
reinstalling the battery, note the proper
installation position and make sure the battery
is connected correctly.
– After installing the battery again, check all
cables and plug connections for visible signs
of damage.
F
Close the battery panel carefully and slowly.
Do not reach between the battery panel and the
chassis.
9
9
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0709.GB
D 6
Page 30
E 1
1113.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. Safety
shoes must be worn with pedestrian operated trucks.
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 authorisation to do so. The driver must never
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 with sufficient notice. If
unauthorised personnel are still within the hazardous area the truck shall be brought
to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
E 1
1113.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. Safety
shoes must be worn with pedestrian operated trucks.
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 authorisation to do so. The driver must never
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 with sufficient notice. If
unauthorised personnel are still within the hazardous area the truck shall be brought
to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
Page 31
1113.GB
E 2
2 Controls and Displays
Item Control / Display
Function
1 Folding operator platform t Pedestrian mode:
– Operator platform in upper position:
Pedestrian travel speed restricted to
max. 4.5 km/h.
Rider mode, operator platform acts as deadman
switch:
– Operator platform in lower position and unladen:
travelling inhibited.
– Operator platform in lower position and laden by
operator (both arms must be folded fully out or in):
travelling released.
2Side arm t When the side arms are not unfolded and the
operator platform is laden and unfolded:
travel speed restricted to max. 6km/h.
3 Collision safety switch t Pedestrian mode:
Safety function which, when activated, forces the
truck to reverse for approx. 3 seconds and then
cuts out until the controller is briefly restored to
neutral.
Rider mode:
No function (optionally with the same function as
pedestrian mode).
4 Controller t Controls travel direction and speed (see
Section 4.2)
5 Tiller t Moving tiller;
Steering and braking:
Set to brake zone (B) (see page E9):
Truck decelerates mechanically.
Set to travel zone (F) (see page E9):
The mechanical brake is released and the truck is
ready for operation.
6 Warning signal (horn) button t Triggers a warning signal.
7 “Lower” button t Lowers load forks.
8 “Lift” button t Raises load forks.
9 Battery discharge indicator t Battery charge status.
10 Display instrument (CanDis) o Operating hourmeter
Displays battery capacity.
Shows the battery residual capacity and the
operating hours completed by the truck
t = Standard equipment o = Optional equipment
1113.GB
E 2
2 Controls and Displays
Item Control / Display
Function
1 Folding operator platform t Pedestrian mode:
– Operator platform in upper position:
Pedestrian travel speed restricted to
max. 4.5 km/h.
Rider mode, operator platform acts as deadman
switch:
– Operator platform in lower position and unladen:
travelling inhibited.
– Operator platform in lower position and laden by
operator (both arms must be folded fully out or in):
travelling released.
2Side arm t When the side arms are not unfolded and the
operator platform is laden and unfolded:
travel speed restricted to max. 6km/h.
3 Collision safety switch t Pedestrian mode:
Safety function which, when activated, forces the
truck to reverse for approx. 3 seconds and then
cuts out until the controller is briefly restored to
neutral.
Rider mode:
No function (optionally with the same function as
pedestrian mode).
4 Controller t Controls travel direction and speed (see
Section 4.2)
5 Tiller t Moving tiller;
Steering and braking:
Set to brake zone (B) (see page E9):
Truck decelerates mechanically.
Set to travel zone (F) (see page E9):
The mechanical brake is released and the truck is
ready for operation.
6 Warning signal (horn) button t Triggers a warning signal.
7 “Lower” button t Lowers load forks.
8 “Lift” button t Raises load forks.
9 Battery discharge indicator t Battery charge status.
10 Display instrument (CanDis) o Operating hourmeter
Displays battery capacity.
Shows the battery residual capacity and the
operating hours completed by the truck
t = Standard equipment o = Optional equipment
Page 32
E 3
1113.GB
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15
5
9, 10
11, 12
3
4
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2
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6
E 3
1113.GB
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Page 33
1113.GB
E 4
Item Control / Display Function
11 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel.
12 Code lock o Replaces the key switch.
Switches control current on and off.
Releases the truck functions.
CanCode keypad o Switches control current on and off.
Code settings.
For releasing and selecting of travel
programs.
Entering travel parameters.
ISM Access Module o Code settings.
For releasing and selecting of travel
programs.
Entering travel parameters.
13 Battery connector (emergency
disconnect)
t The supply current is interrupted, all electrical
functions are deactivated and the truck is
automatically braked.
14 Rigid side arm
(“Fixed operator platform”
version)
o Only rider mode available.
15 Pressure sensitive mat
(all functions released when
occupied)
o – Pressure sensitive mat occupied:
Travel and all functions released.
– Pressure sensitive mat unoccupied:
The truck coasts.
t = Standard equipment o = Optional equipment
1113.GB
E 4
Item Control / Display Function
11 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel.
12 Code lock o Replaces the key switch.
Switches control current on and off.
Releases the truck functions.
CanCode keypad o Switches control current on and off.
Code settings.
For releasing and selecting of travel
programs.
Entering travel parameters.
ISM Access Module o Code settings.
For releasing and selecting of travel
programs.
Entering travel parameters.
13 Battery connector (emergency
disconnect)
t The supply current is interrupted, all electrical
functions are deactivated and the truck is
automatically braked.
14 Rigid side arm
(“Fixed operator platform”
version)
o Only rider mode available.
15 Pressure sensitive mat
(all functions released when
occupied)
o – Pressure sensitive mat occupied:
Travel and all functions released.
– Pressure sensitive mat unoccupied:
The truck coasts.
t = Standard equipment o = Optional equipment
Page 34
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11, 12
3
4
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2
1
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1113.GB
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5
9, 10
11, 12
3
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Page 35
1113.GB
E 6
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
– Visually inspect the entire truck (in particular wheels and load handler) for obvious
damage.
– Visually inspect the battery attachment and cable connections.
Switching on the truck
– Make sure the battery is connected (13).
– Insert the key in the key switch (11) and turn it to the right as far as it will go (position
“I”) or for CanCode (12) (o) enter the release code.
(see Section 5).
– Test the warning button (6).
The truck is now operational.
o The battery discharge indicator (9) or the CanDis display instrument (10) indicates the
existing battery charge status.
– Test the braking operation of the tiller (5) (see section 4.2).
6
13
11, 12
9, 10
5
1113.GB
E 6
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
– Visually inspect the entire truck (in particular wheels and load handler) for obvious
damage.
– Visually inspect the battery attachment and cable connections.
Switching on the truck
– Make sure the battery is connected (13).
– Insert the key in the key switch (11) and turn it to the right as far as it will go (position
“I”) or for CanCode (12) (o) enter the release code.
(see Section 5).
– Test the warning button (6).
The truck is now operational.
o The battery discharge indicator (9) or the CanDis display instrument (10) indicates the
existing battery charge status.
– Test the braking operation of the tiller (5) (see section 4.2).
6
13
11, 12
9, 10
5
Page 36
E 7
1113.GB
4 Industrial truck operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised 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.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. Loads which affect visibility 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.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The truck must always be driven with the load unit facing uphill. The
industrial truck must not be turned, operated at an angle or parked on inclines or
slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake
at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the 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.
Nature of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Only carry loads that are positioned safely and carefully. Use
suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or
falling down.
E 7
1113.GB
4 Industrial truck operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised 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.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. Loads which affect visibility 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.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The truck must always be driven with the load unit facing uphill. The
industrial truck must not be turned, operated at an angle or parked on inclines or
slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake
at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the 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.
Nature of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Only carry loads that are positioned safely and carefully. Use
suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or
falling down.
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4.2 Travel, Steering, Braking
F
Be extremely careful when driving and steering, especially when operating outside
the geometry of the truck.
In walk-along mode make sure you have sufficient distance from the truck.
Emergency Disconnect
– Remove the battery connector (13). All electrical functions are deactivated.
Emergency Stop
Automatic braking (emergency stop) occurs when the tiller (5) is released – the tiller
automatically reverts to the upper brake zone (B).
F
If the tiller moves slowly to the braking zone, the cause of this fault must be rectified.
If necessary, replace the recuperating spring.
Travel
We distinguish between two travel modes:
Truck with a folding operator platform and moving tiller.
F
Do not reach between the operator platform and the truck panel when you fold up the
platform.
– Pedestrian mode: Push the side arms in, fold up the operator platform (1). The truck
can only be operated at the reduced travel speed.
– Rider mode: Push the side arms out, fold down the operator platform (1). The truck
can be operated at maximum speed.
General:
– Set the tiller (5) to the travel zone (F).
– Turn the controller (4) to the required direction (fwd. or rev.).
Z
Travelling is inhibited when the operator platform is unladen and the side arms are
not folded out.
If the operator platform is occupied and the side arms are not folded out, the truck can
only be operated at reduced speed.
If the operator platform is occupied and only one side arm is folded out, traveling is
inhibited.
o Trucks with a fixed operator platform:
– Step onto the operator platform (15).
– Set the tiller (5) to the travel zone (F).
– Turn the controller (4) to the required direction (fwd. or rev.).
F
Do not drive the truck unless the panels are closed and properly locked. When
travelling through swing doors etc. make sure that the doors do not activate the
collision safety button (3).
– Start up the truck (see section 3).
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4.2 Travel, Steering, Braking
F
Be extremely careful when driving and steering, especially when operating outside
the geometry of the truck.
In walk-along mode make sure you have sufficient distance from the truck.
Emergency Disconnect
– Remove the battery connector (13). All electrical functions are deactivated.
Emergency Stop
Automatic braking (emergency stop) occurs when the tiller (5) is released – the tiller
automatically reverts to the upper brake zone (B).
F
If the tiller moves slowly to the braking zone, the cause of this fault must be rectified.
If necessary, replace the recuperating spring.
Travel
We distinguish between two travel modes:
Truck with a folding operator platform and moving tiller.
F
Do not reach between the operator platform and the truck panel when you fold up the
platform.
– Pedestrian mode: Push the side arms in, fold up the operator platform (1). The truck
can only be operated at the reduced travel speed.
– Rider mode: Push the side arms out, fold down the operator platform (1). The truck
can be operated at maximum speed.
General:
– Set the tiller (5) to the travel zone (F).
– Turn the controller (4) to the required direction (fwd. or rev.).
Z
Travelling is inhibited when the operator platform is unladen and the side arms are
not folded out.
If the operator platform is occupied and the side arms are not folded out, the truck can
only be operated at reduced speed.
If the operator platform is occupied and only one side arm is folded out, traveling is
inhibited.
o Trucks with a fixed operator platform:
– Step onto the operator platform (15).
– Set the tiller (5) to the travel zone (F).
– Turn the controller (4) to the required direction (fwd. or rev.).
F
Do not drive the truck unless the panels are closed and properly locked. When
travelling through swing doors etc. make sure that the doors do not activate the
collision safety button (3).
– Start up the truck (see section 3).
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4
1
5
13
B
B
B
F
R
V
0
3
2
R
V
E 9
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4
1
5
13
B
B
B
F
R
V
0
3
2
R
V
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E 10
Travelling on inclines
M
Loads must always be carried at that end of the truck facing uphill.
Steering
F
In narrow bends the driver extends beyond the geometry of the truck.
– Move the tiller (5) to the left or right.
Braking
F
The brake pattern of the truck depends largely on the ground conditions. The driver
must take this into account when operating the truck.
The truck can brake in three different ways:
– by plugging
– by using the operating brake
– with the battery connector (Emergency Disconnect)
Plugging:
– When travelling, set the controller (8) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z
The rate of braking depends on the position of the controller.
Braking with the service brake:
– Set the tiller (5) to one of the brake zones (B).
The drive motor brakes regeneratively (motor brake). Only when this brake fails to
achieve the necessary brake force is the mechanical brake (magnetic brake) applied.
When the truck is idle the magnetic brake (magnetic brake) applies.
Z
When the tiller is released it reverts to the upper braking zone (B).
Braking with the battery connector:
– Pull the battery connector (13) up.
The circuit is interrupted, all electrical functions are cut out and the truck automatically
brakes (magnetic brake).
1113.GB
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Travelling on inclines
M
Loads must always be carried at that end of the truck facing uphill.
Steering
F
In narrow bends the driver extends beyond the geometry of the truck.
– Move the tiller (5) to the left or right.
Braking
F
The brake pattern of the truck depends largely on the ground conditions. The driver
must take this into account when operating the truck.
The truck can brake in three different ways:
– by plugging
– by using the operating brake
– with the battery connector (Emergency Disconnect)
Plugging:
– When travelling, set the controller (8) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z
The rate of braking depends on the position of the controller.
Braking with the service brake:
– Set the tiller (5) to one of the brake zones (B).
The drive motor brakes regeneratively (motor brake). Only when this brake fails to
achieve the necessary brake force is the mechanical brake (magnetic brake) applied.
When the truck is idle the magnetic brake (magnetic brake) applies.
Z
When the tiller is released it reverts to the upper braking zone (B).
Braking with the battery connector:
– Pull the battery connector (13) up.
The circuit is interrupted, all electrical functions are cut out and the truck automatically
brakes (magnetic brake).
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4.3 Collecting and depositing loads
M
Before picking up a load, the driver must
ensure that it is correctly palletised and
that the capacity of the truck is not
exceeded. It is forbidden to collect long
loads at an angle.
– Fully insert the truck and the load
handler underneath the load unit.
Z
When the operator platform is unfolded
it must be occupied by the operator to
release lifting/lowering (similar to trucks
with a fixed operator platform).
Z
The lifting and lowering speeds are
specified.
Lift
– Press the “Lift” (8) button until you reach the desired lift height.
M
Release the button as soon as you reach the limit position of the load handler.
Lower
– Press the “Lower ” button (7) until you reach the required lifting height.
M
Do not deposit the load in a sudden manner.
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4.3 Collecting and depositing loads
M
Before picking up a load, the driver must
ensure that it is correctly palletised and
that the capacity of the truck is not
exceeded. It is forbidden to collect long
loads at an angle.
– Fully insert the truck and the load
handler underneath the load unit.
Z
When the operator platform is unfolded
it must be occupied by the operator to
release lifting/lowering (similar to trucks
with a fixed operator platform).
Z
The lifting and lowering speeds are
specified.
Lift
– Press the “Lift” (8) button until you reach the desired lift height.
M
Release the button as soon as you reach the limit position of the load handler.
Lower
– Press the “Lower ” button (7) until you reach the required lifting height.
M
Do not deposit the load in a sudden manner.
77
88
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4.4 Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.
– Do not park the truck on an incline.
– Fully lower the load forks.
– Set the key switch (11) to the "0" position and remove the key.
– For CanCode (6), press the o key.
– Remove the battery connector (13).
– Fold in the folding side arm (where applicable).
F
Do not reach between the operator platform and the truck panel when you fold up the
folding platform (where applicable).
– Grab hold of the folding platform (where applicable) at one of the bevelled edges
and fold it up.
13
11,12
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4.4 Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.
– Do not park the truck on an incline.
– Fully lower the load forks.
– Set the key switch (11) to the "0" position and remove the key.
– For CanCode (6), press the o key.
– Remove the battery connector (13).
– Fold in the folding side arm (where applicable).
F
Do not reach between the operator platform and the truck panel when you fold up the
folding platform (where applicable).
– Grab hold of the folding platform (where applicable) at one of the bevelled edges
and fold it up.
13
11,12
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5 Keypad (CanCode) (o)
The keypad consists of 10 digit keys, a Set key
and a o key.
Activation of the travel programs via switches
1,2,3 is indicated by green LEDs.
The o key indicates operating statuses via a red/
green LED.
It contains the following functions:
– Code lock function (commissioning the truck).
– Travel program selection.
– Setting the travel and battery parameters, only
in conjunction with the display instrument
(CanDis (o)).
The o switch has top priority and resets the truck from any condition to its default
condition without modifying any settings.
5.1 Code Lock
When the correct code has been entered, the machine is ready for use. You can
allocate an individual code to each truck, driver or group of drivers.
Z
When delivered from the factory, the operator code (factory setting 2-5-8-0) is
indicated on a removable sticker.
M
When starting the truck for the first time, change the master and operating codes.
(refer to section 5.4)
123
456
789
0
Set
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5 Keypad (CanCode) (o)
The keypad consists of 10 digit keys, a Set key
and a o key.
Activation of the travel programs via switches
1,2,3 is indicated by green LEDs.
The o key indicates operating statuses via a red/
green LED.
It contains the following functions:
– Code lock function (commissioning the truck).
– Travel program selection.
– Setting the travel and battery parameters, only
in conjunction with the display instrument
(CanDis (o)).
The o switch has top priority and resets the truck from any condition to its default
condition without modifying any settings.
5.1 Code Lock
When the correct code has been entered, the machine is ready for use. You can
allocate an individual code to each truck, driver or group of drivers.
Z
When delivered from the factory, the operator code (factory setting 2-5-8-0) is
indicated on a removable sticker.
M
When starting the truck for the first time, change the master and operating codes.
(refer to section 5.4)
123
456
789
0
Set
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Starting the truck for the first time
When the main switch is turned on the LED (16) goes red.
When you enter the correct operator code (factory setting 2-5-8-0) the LED (16) turns
green.
If the wrong code is entered LED (16) flashes red for two seconds. The correct code
can then be entered.
Z
The Set key (17) has no function in operating mode
Switching off
To switch the truck off, press the o key (21).
Z
The truck can switch off automatically after a
pre-determined time. To do this, the corresponding code lock parameter must be set
(refer to section 5.4).
123
456
789
0
Set
18
17
16
21
2019
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E 14
Starting the truck for the first time
When the main switch is turned on the LED (16) goes red.
When you enter the correct operator code (factory setting 2-5-8-0) the LED (16) turns
green.
If the wrong code is entered LED (16) flashes red for two seconds. The correct code
can then be entered.
Z
The Set key (17) has no function in operating mode
Switching off
To switch the truck off, press the o key (21).
Z
The truck can switch off automatically after a
pre-determined time. To do this, the corre-
sponding code lock parameter must be set
(refer to section 5.4).
123
456
789
0
Set
18
17
16
21
2019
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5.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated
programme is indicated by the green LEDs (18), (19), (20) in the corresponding key.
Z
The travel programs differ with respect to travel speed, acceleration and deceleration
force.
Factory settings:
– Program 1: Soft operation
– Program 2: Normal mode (pre-selected when using the truck for the first time)
– Program 3: Power mode
Z
The travel programs can be individually adapted (see Section 5.5).
5.3 Parameters
In programming mode, the operator keypad enables you to set the code lock
functions and adapt travel programs. In addition, the battery parameters can also be
set.
M
For trucks without a display instrument (CanDis (o)) the parameters must be
adjusted with particular care to avoid incorrect entries.
The internal parameter numbers for the code lock are comprised of three digits.
All other parameter numbers are comprised of four digits.
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5.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated
programme is indicated by the green LEDs (18), (19), (20) in the corresponding key.
Z
The travel programs differ with respect to travel speed, acceleration and deceleration
force.
Factory settings:
– Program 1: Soft operation
– Program 2: Normal mode (pre-selected when using the truck for the first time)
– Program 3: Power mode
Z
The travel programs can be individually adapted (see Section 5.5).
5.3 Parameters
In programming mode, the operator keypad enables you to set the code lock
functions and adapt travel programs. In addition, the battery parameters can also be
set.
M
For trucks without a display instrument (CanDis (o)) the parameters must be
adjusted with particular care to avoid incorrect entries.
The internal parameter numbers for the code lock are comprised of three digits.
All other parameter numbers are comprised of four digits.
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5.4 Parameter Settings
To change the truck setting you must enter the master code.
Z
The factory setting for the master code is 7-2-9-5.
M
When starting the truck for the first time, change the master code (see Section 5.1).
F
Safety instructions for trucks with a display instrument (CanDis (o))
– Parameter settings must be made carefully and only by special trained personnel.
If in doubt, consult the manufacturer's service department.
– Every setting procedure must be monitored on the LC display of the display
instrument (o). If in doubt, the setting procedure must be cancelled by pressing the
o key (21).
– Since changing any parameter will affect the truck's travel pattern, you must carry
out a test run in a specially designated work area.
To enter the master code:
– Press the o key
– Enter master code
Code Lock Parameters
Setting procedure for trucks without display instrument (CanDis (o)):
– Enter the three digit parameter number, confirm with the Set key (17).
– Enter the setting according to the parameter list or change and confirm with the Set
key (17).
Z
If the entry is incorrect, the LED (16) of the o key (21) flashes red. If you enter the
parameter number again the setting can be entered or changed.
– To enter more parameters, repeat the procedure.
– When all the parameters have been entered, carry out the “SaveParameters”
function by pressing keys 1-2-3-Set.
– When you have finished entering the parameters, press the o button (21).
Display instrument
(CanDis)
LED (16)
o key
LED (18)
Key 1
LED (19)
Key 2
LED (20)
Key 3
Service hours
are indicated
284.0
Green
flashing
Off Off Off
1113.GB
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5.4 Parameter Settings
To change the truck setting you must enter the master code.
Z
The factory setting for the master code is 7-2-9-5.
M
When starting the truck for the first time, change the master code (see Section 5.1).
F
Safety instructions for trucks with a display instrument (CanDis (o))
– Parameter settings must be made carefully and only by special trained personnel.
If in doubt, consult the manufacturer's service department.
– Every setting procedure must be monitored on the LC display of the display
instrument (o). If in doubt, the setting procedure must be cancelled by pressing the
o key (21).
– Since changing any parameter will affect the truck's travel pattern, you must carry
out a test run in a specially designated work area.
To enter the master code:
– Press the o key
– Enter master code
Code Lock Parameters
Setting procedure for trucks without display instrument (CanDis (o)):
– Enter the three digit parameter number, confirm with the Set key (17).
– Enter the setting according to the parameter list or change and confirm with the Set
key (17).
Z
If the entry is incorrect, the LED (16) of the o key (21) flashes red. If you enter the
parameter number again the setting can be entered or changed.
– To enter more parameters, repeat the procedure.
– When all the parameters have been entered, carry out the “SaveParameters”
function by pressing keys 1-2-3-Set.
– When you have finished entering the parameters, press the o button (21).
Display instrument
(CanDis)
LED (16)
o key
LED (18)
Key 1
LED (19)
Key 2
LED (20)
Key 3
Service hours
are indicated
284.0
Green
flashing
Off Off Off
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Setting procedure for trucks with and without display instrument (CanDis (o)):
– Enter the three digit parameter number, confirm with the Set key (17).
– The display instrument (CanDis (o)) continues to display the operating hours. If the
display changes, cancel the setting with the o key (21) and restart from the
beginning.
– Enter the setting according to the parameter list or change and confirm with the Set
key (17).
Z
If the entry is incorrect, the LED (16) of the o key (21) flashes red. If you enter the
parameter number again the setting can be entered or changed.
– To enter more parameters, repeat the procedure.
– When all the parameters have been entered, carry out the “SaveParameters”
function by pressing keys 1-2-3-Set.
– When you have finished entering the parameters, press the o button (21).
The following parameters may be entered.
Code Lock Parameter List
No. Function Range of
Setting
Standard
Setting
Comments
Procedure
Code Lock
000 Change Master Code
The length (4-6 digits) of
the master code also predetermines the length of
the operator code
(4-6 digits). Provided the
operator codes are
programmed, only news
codes of the same length
can be entered. If the
code length is to be
changed, all operator
codes must first be
deleted.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 18 flashes)
Enter current code
Confirm (Set)
(LED 19 flashes)
Enter new code
Confirm (Set)
(LED 20 flashes)
Repeat new code
Confirm (Set)
001 Add operator code
(max. 600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 19 flashes)
Enter code
Confirm (Set)
(LED 20 flashes)
Repeat code entry
Confirm (Set)
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Setting procedure for trucks with and without display instrument (CanDis (o)):
– Enter the three digit parameter number, confirm with the Set key (17).
– The display instrument (CanDis (o)) continues to display the operating hours. If the
display changes, cancel the setting with the o key (21) and restart from the
beginning.
– Enter the setting according to the parameter list or change and confirm with the Set
key (17).
Z
If the entry is incorrect, the LED (16) of the o key (21) flashes red. If you enter the
parameter number again the setting can be entered or changed.
– To enter more parameters, repeat the procedure.
– When all the parameters have been entered, carry out the “SaveParameters”
function by pressing keys 1-2-3-Set.
– When you have finished entering the parameters, press the o button (21).
The following parameters may be entered.
Code Lock Parameter List
No. Function Range of
Setting
Standard
Setting
Comments
Procedure
Code Lock
000 Change Master Code
The length (4-6 digits) of
the master code also pre-
determines the length of
the operator code
(4-6 digits). Provided the
operator codes are
programmed, only news
codes of the same length
can be entered. If the
code length is to be
changed, all operator
codes must first be
deleted.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 18 flashes)
Enter current code
Confirm (Set)
(LED 19 flashes)
Enter new code
Confirm (Set)
(LED 20 flashes)
Repeat new code
Confirm (Set)
001 Add operator code
(max. 600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 19 flashes)
Enter code
Confirm (Set)
(LED 20 flashes)
Repeat code entry
Confirm (Set)
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LEDs 18-20 are located in key fields 1-3 (see Section 5.2)
No. Function Range of
Setting
Standard
Setting
Comments
Procedure
Code Lock
002 Change Operator Code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 18 flashes)
Enter current code
Confirm (Set)
(LED 19 flashes)
Enter new code
Confirm (Set)
(LED 20 flashes)
Repeat code entry
confirm
003 Delete Operator Code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 19 flashes)
Enter code
Confirm (Set)
(LED 20 flashes)
Repeat code entry
Confirm (Set)
004 Delete code memory
(Deletes all user codes)
3265 3265 = delete
other inputs= do not
delete
010 Automatic time cutout 00 - 31 00 00 = no cutout
01 to 30 =
Cutout time in
minutes
31 = Cutout after
10 seconds
1113.GB
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LEDs 18-20 are located in key fields 1-3 (see Section 5.2)
No. Function Range of
Setting
Standard
Setting
Comments
Procedure
Code Lock
002 Change Operator Code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 18 flashes)
Enter current code
Confirm (Set)
(LED 19 flashes)
Enter new code
Confirm (Set)
(LED 20 flashes)
Repeat code entry
confirm
003 Delete Operator Code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 19 flashes)
Enter code
Confirm (Set)
(LED 20 flashes)
Repeat code entry
Confirm (Set)
004 Delete code memory
(Deletes all user codes)
3265 3265 = delete
other inputs= do not
delete
010 Automatic time cutout 00 - 31 00 00 = no cutout
01 to 30 =
Cutout time in
minutes
31 = Cutout after
10 seconds
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The travel programs are connected to the user code.The travel programs can be
individually released or blocked for each user code. A start travel program can be
assigned to each user code.
When a user code has been set up, all travel programs are globally released and the
valid start travel program is 2.
The user code configuration can then be altered via program number 024.
024 - SET – user code - SET - configuration (4-digit) SET – confirm configuration (4-digit) - SET
1st digit: travel program 1 release (0 or 1)
2nd digit: travel program 2 release (0 or I)
3rd digit: travel program 3 release (0 or 1)
4th digit: start travel program (0, I, 2 or 3)
Error messages on keypad
LED (14) flashes red to indicate the following errors:
– New master code is already operator code.
– New operator code is already master code.
– Operator code to be changed does not exist.
– Tried to change the operator code to another user code that already exists.
– Operator code to be deleted does not exist.
– Code memory full
No. Function Range of
Setting
Standard
Setting
Comments
Procedure
Code Lock
024 User code configuration 1112
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The travel programs are connected to the user code.The travel programs can be
individually released or blocked for each user code. A start travel program can be
assigned to each user code.
When a user code has been set up, all travel programs are globally released and the
valid start travel program is 2.
The user code configuration can then be altered via program number 024.
024 - SET – user code - SET - configuration (4-digit) -
SET – confirm configuration (4-digit) - SET
1st digit: travel program 1 release (0 or 1)
2nd digit: travel program 2 release (0 or I)
3rd digit: travel program 3 release (0 or 1)
4th digit: start travel program (0, I, 2 or 3)
Error messages on keypad
LED (14) flashes red to indicate the following errors:
– New master code is already operator code.
– New operator code is already master code.
– Operator code to be changed does not exist.
– Tried to change the operator code to another user code that already exists.
– Operator code to be deleted does not exist.
– Code memory full
No. Function Range of
Setting
Standard
Setting
Comments
Procedure
Code Lock
024 User code configuration 1112
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5.5 Travel parameters
M
For trucks without a display instrument (CanDis (o)) the parameters must be
adjusted with particular care to avoid incorrect entries.
The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 0256).
Acceleration example
– Enter the four-digit parameter number (0256) and confirm with the Set key (15).
– Enter the subindex “2” and confirm with the set key (15).
– Check the LC display of the display instrument (CanDis (o)) (parameter number
and current parameter value are displayed).
– Enter the parameter according to the parameter list and confirm with the Set key
(15).
– The LED (14) of the o key (19) switches briefly to a steady light and starts flashing
again after approx. 2 seconds.
– The parameter and subindex are displayed alternating with the entry 0256-2 <->
0000-5).
Z
If the entry is incorrect, the LED (14) of the o key (19) flashes red. If you enter the
parameter number again the setting can be entered or changed.
Repeat the procedure to enter further parameters as soon as the LED (14) of the o
key (19) flashes. To complete your entry, press the o key (19).
Z
Travel is disabled while the parameters are being entered. If the setting is to be
checked in programming mode, follow this sequence:
– Select the edited travel program after entering the parameter, and confirm with the
Set key (15).
– The truck is now in travel mode and can be checked.
– To continue setting, confirm with the Set key (15) again.
– Repeat the procedure to enter further parameters.
– When all the parameters have been entered, carry out the “SaveParameters”
function by pressing keys 1-2-3-Set.
– When you have finished entering the parameters, press the o key (19).
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5.5 Travel parameters
M
For trucks without a display instrument (CanDis (o)) the parameters must be
adjusted with particular care to avoid incorrect entries.
The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 0256).
Acceleration example
– Enter the four-digit parameter number (0256) and confirm with the Set key (15).
– Enter the subindex “2” and confirm with the set key (15).
– Check the LC display of the display instrument (CanDis (o)) (parameter number
and current parameter value are displayed).
– Enter the parameter according to the parameter list and confirm with the Set key
(15).
– The LED (14) of the o key (19) switches briefly to a steady light and starts flashing
again after approx. 2 seconds.
– The parameter and subindex are displayed alternating with the entry 0256-2 <->
0000-5).
Z
If the entry is incorrect, the LED (14) of the o key (19) flashes red. If you enter the
parameter number again the setting can be entered or changed.
Repeat the procedure to enter further parameters as soon as the LED (14) of the o
key (19) flashes. To complete your entry, press the o key (19).
Z
Travel is disabled while the parameters are being entered. If the setting is to be
checked in programming mode, follow this sequence:
– Select the edited travel program after entering the parameter, and confirm with the
Set key (15).
– The truck is now in travel mode and can be checked.
– To continue setting, confirm with the Set key (15) again.
– Repeat the procedure to enter further parameters.
– When all the parameters have been entered, carry out the “SaveParameters”
function by pressing keys 1-2-3-Set.
– When you have finished entering the parameters, press the o key (19).
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1113.GB
The following parameters may be entered.
Travel programs (speeds and acceleration w.o. load)
No. Function Range of
Setting
Standard
Setting
Comments
Travel program 1
0256 Acceleration 0 - 9
(0,13 - 1,88 m/s²)40,67 m/s²
Platform folded
out, safety gate
folded out
0264 Max. speed in drive
direction
0 - 9
(4,5 - 9,0 km/h)36,0 km/h
0268 Max. speed in forks
direction
0 - 9
(4,5 - 9,0 km/h)36,0 km/h
0257 Acceleration in
pedestrian mode (no
release,)
0 - 9
(0,09 - 0,31 m/s²)80,27 m/s²
Platform folded in,
safety gate folded
in
0265 Pedestrian speed in drive
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0269 Pedestrian speed in forks
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0267 Special travel speed in
drive direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
Platform folded
out, safety gate
folded in
0271 Special travel speed in
forks direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
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1113.GB
The following parameters may be entered.
Travel programs (speeds and acceleration w.o. load)
No. Function Range of
Setting
Standard
Setting
Comments
Travel program 1
0256 Acceleration 0 - 9
(0,13 - 1,88 m/s²)40,67 m/s²
Platform folded
out, safety gate
folded out
0264 Max. speed in drive
direction
0 - 9
(4,5 - 9,0 km/h)36,0 km/h
0268 Max. speed in forks
direction
0 - 9
(4,5 - 9,0 km/h)36,0 km/h
0257 Acceleration in
pedestrian mode (no
release,)
0 - 9
(0,09 - 0,31 m/s²)80,27 m/s²
Platform folded in,
safety gate folded
in
0265 Pedestrian speed in drive
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0269 Pedestrian speed in forks
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0267 Special travel speed in
drive direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
Platform folded
out, safety gate
folded in
0271 Special travel speed in
forks direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
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No. Function Range of
Setting
Standard
Setting
Comments
Travel program 2
0272 Acceleration 0 - 9
(0,13 - 1,88 m/s²)61,08 m/s²
Platform folded
out, safety gate
folded out
0280 Max. speed in drive
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0284 Max. speed in forks
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0273 Acceleration in
pedestrian mode (no
release,)
0 - 9
(0,09 - 0,31 m/s²)80,27 m/s²
Platform folded in,
safety gate folded
in
0281 Pedestrian speed in drive
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0285 Pedestrian speed in forks
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0283 Special travel speed in
drive direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
Platform folded
out, safety gate
folded in
0287 Special travel speed in
forks direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
1113.GB
E 22
No. Function Range of
Setting
Standard
Setting
Comments
Travel program 2
0272 Acceleration 0 - 9
(0,13 - 1,88 m/s²)61,08 m/s²
Platform folded
out, safety gate
folded out
0280 Max. speed in drive
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0284 Max. speed in forks
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0273 Acceleration in
pedestrian mode (no
release,)
0 - 9
(0,09 - 0,31 m/s²)80,27 m/s²
Platform folded in,
safety gate folded
in
0281 Pedestrian speed in drive
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0285 Pedestrian speed in forks
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0283 Special travel speed in
drive direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
Platform folded
out, safety gate
folded in
0287 Special travel speed in
forks direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
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No. Function Range of
Setting
Standard
Setting
Comments
Travel program 3
0288 Acceleration 0 - 9
(0,13 - 1,88 m/s²)81,62 m/s²
Platform folded
out, safety gate
folded out
0296 Max. speed in drive
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0300 Max. speed in forks
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0289 Acceleration in
pedestrian mode (no
release,)
0 - 9
(0,09 - 0,31 m/s²)80,27 m/s²
Platform folded in,
safety gate folded
in
0297 Pedestrian speed in drive
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0301 Pedestrian speed in forks
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0299 Special travel speed in
drive direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
Platform folded
out, safety gate
folded in
0303 Special travel speed in
forks direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
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No. Function Range of
Setting
Standard
Setting
Comments
Travel program 3
0288 Acceleration 0 - 9
(0,13 - 1,88 m/s²)81,62 m/s²
Platform folded
out, safety gate
folded out
0296 Max. speed in drive
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0300 Max. speed in forks
direction
0 - 9
(4,5 - 9,0 km/h)88,5 km/h
0289 Acceleration in
pedestrian mode (no
release,)
0 - 9
(0,09 - 0,31 m/s²)80,27 m/s²
Platform folded in,
safety gate folded
in
0297 Pedestrian speed in drive
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0301 Pedestrian speed in forks
direction
0 - 9
(1,5 - 4,5 km/h)84,2 km/h
0299 Special travel speed in
drive direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
Platform folded
out, safety gate
folded in
0303 Special travel speed in
forks direction
0 - 9
(1,5 - 6,0 km/h)96,0 km/h
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5.6 Battery parameters
M
For trucks without a display instrument (CanDis (o)) the parameters must be
adjusted with particular care to avoid incorrect entries.
The parameters are set in the same way as for the travel parameters.
The following parameters may be entered.
Setting 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Range of
Setting
Standard
Setting
Comments
Battery parameters
1377 Battery type (normal /
enhanced / dry)
0 - 2 1 0 = Normal (wet)
1 = Enhanced (wet)
2 = Dry (maintenance-free)
1389 Discharge monitor
function
0 / 1 1
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5.6 Battery parameters
M
For trucks without a display instrument (CanDis (o)) the parameters must be
adjusted with particular care to avoid incorrect entries.
The parameters are set in the same way as for the travel parameters.
The following parameters may be entered.
Setting 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Range of
Setting
Standard
Setting
Comments
Battery parameters
1377 Battery type (normal /
enhanced / dry)
0 - 2 1 0 = Normal (wet)
1 = Enhanced (wet)
2 = Dry (maintenance-free)
1389 Discharge monitor
function
0 / 1 1
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6 Battery Discharge Indicator (t)
When the truck has been released via the key
switch or CanCode, the battery charge status is
displayed.
The colours of the LEDs (9) represent the following conditions:
Z
If the LED is red, load units can no longer be lifted. Lifting is only released when the
battery connected is at least 70 % charged.
If the charge status calculated when the truck is switched on is at least 70% of that of
a fully charged battery, the display is reset to 100%. The display reduces in
increments of 10% depending on the charge status. The displayed status is reduced
to a maximum of 10% within 3 minutes.
The displayed status cannot rise again during the present operation.
The status display is reset to 100% when the battery type is adjusted.
If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a fault code of the truck controller.
The flashing sequence indicates the type of fault.
LED colour Rating
Green Standard battery residual capacity 40 - 100 %
Maintenance free battery residual capacity 60 - 100 %
Orange Standard battery residual capacity 30 - 40 %
Maintenance free battery residual capacity 50 - 60 %
Flashing
green/orange
1Hz
Standard battery residual capacity 20 - 30 %
Maintenance free battery residual capacity 40 - 50 %
Red Standard battery residual capacity 0 - 20 %
Maintenance free battery residual capacity 0 - 40 %
9
E 25
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6 Battery Discharge Indicator (t)
When the truck has been released via the key
switch or CanCode, the battery charge status is
displayed.
The colours of the LEDs (9) represent the following conditions:
Z
If the LED is red, load units can no longer be lifted. Lifting is only released when the
battery connected is at least 70 % charged.
If the charge status calculated when the truck is switched on is at least 70% of that of
a fully charged battery, the display is reset to 100%. The display reduces in
increments of 10% depending on the charge status. The displayed status is reduced
to a maximum of 10% within 3 minutes.
The displayed status cannot rise again during the present operation.
The status display is reset to 100% when the battery type is adjusted.
If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a fault code of the truck controller.
The flashing sequence indicates the type of fault.
LED colour Rating
Green Standard battery residual capacity 40 - 100 %
Maintenance free battery residual capacity 60 - 100 %
Orange Standard battery residual capacity 30 - 40 %
Maintenance free battery residual capacity 50 - 60 %
Flashing
green/orange
1Hz
Standard battery residual capacity 20 - 30 %
Maintenance free battery residual capacity 40 - 50 %
Red Standard battery residual capacity 0 - 20 %
Maintenance free battery residual capacity 0 - 40 %
9
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7 Display instrument (CanDis) (o)
The instrument indicates:
In addition, service messages for the electronic components and parameter changes
are displayed.
Discharge status display
Setting limits for the additional “Warning” (26) and “Stop” (23) displays will depend on
the battery type.
The available capacity is shown via 8 LED bars.
The current battery capacity is shown by the illuminated LED bars. 8 bars correspond
to full battery capacity, 1 bar corresponds to the minimum available capacity.
If only one LED bar is lit, the battery capacity is almost depleted and the “Warning”
indicator (26) is lit.
If no more LED bars are illuminated, the “Stop” indicator (23) lights up. Lifting is now
inhibited. The battery must be charged.
22 Capacity display bars
Battery residual charge
23 Stop symbol; lift cutout,
battery charge required
24 6 digit LCD display;
hourmeter; entry display;
error display
25 T symbol appears during operation
when the discharge indicator is set to
maintenance-free battery
26 Attention pre-warning symbol,
battery charge required
27 Battery charge display
(on board charger only)
26
25
27
22
23
24
1113.GB
E 26
7 Display instrument (CanDis) (o)
The instrument indicates:
In addition, service messages for the electronic components and parameter changes
are displayed.
Discharge status display
Setting limits for the additional “Warning” (26) and “Stop” (23) displays will depend on
the battery type.
The available capacity is shown via 8 LED bars.
The current battery capacity is shown by the illuminated LED bars. 8 bars correspond
to full battery capacity, 1 bar corresponds to the minimum available capacity.
If only one LED bar is lit, the battery capacity is almost depleted and the “Warning”
indicator (26) is lit.
If no more LED bars are illuminated, the “Stop” indicator (23) lights up. Lifting is now
inhibited. The battery must be charged.
22 Capacity display bars
Battery residual charge
23 Stop symbol; lift cutout,
battery charge required
24 6 digit LCD display;
hourmeter; entry display;
error display
25 T symbol appears during operation
when the discharge indicator is set to
maintenance-free battery
26 Attention pre-warning symbol,
battery charge required
27 Battery charge display
(on board charger only)
26
25
27
22
23
24
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7.1 Discharge monitor function
When the discharge monitor function is enabled, lifting is cut out when the discharge
limit is reached (the Stop LED is lit). Travel and lowering are still possible. For wet
batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. The
batteries should be recharged when they reach 30% (for wet batteries) or 50% (for
maintenance-free batteries). The yellow LED lights up as warning indicator.
7.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. This is a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours display
(25).
Errormessages
The operating hours display is also used for indicating errors. The error display starts
with an ”E” for Error and a three-digit error number. If several errors occur
simultaneously they are displayed one after the other. The errors are displayed until
they are rectified. Error messages overwrite the service hour display. Most errors
cause the emergency stop to be activated. Errors remain displayed until the control
circuit is switched off (Code lock).
If no CanDis is present, the error code is displayed by the flashing of the discharge
monitor LED.
Z
The manufacturer’s service department has detailed component descriptions with
error codes.
Display for parameter changes (travel programs)
The LC display (23) is used in conjunction with the operator keypad (CanCode (o))
to display the setting parameters. The parameter number and subindex are displayed
alternating with the parameter.
Display: 0280-2 (max. speed) <-> 0000-8 (value)
Z
Settings of parameter group 0XX (code lock) are not displayed.
Hourmeter
Service hours are counted while the truck is operational and one of the following
controls is applied:
– Tiller in travel zone "F"
– "Slow travel button"
– "Lift" button
– "Lower" button
7.3 Power up test
On power up the display shows:
– the software version of the display instrument (briefly)
– the operating hours
– the charge status
E 27
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7.1 Discharge monitor function
When the discharge monitor function is enabled, lifting is cut out when the discharge
limit is reached (the Stop LED is lit). Travel and lowering are still possible. For wet
batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. The
batteries should be recharged when they reach 30% (for wet batteries) or 50% (for
maintenance-free batteries). The yellow LED lights up as warning indicator.
7.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. This is a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours display
(25).
Errormessages
The operating hours display is also used for indicating errors. The error display starts
with an ”E” for Error and a three-digit error number. If several errors occur
simultaneously they are displayed one after the other. The errors are displayed until
they are rectified. Error messages overwrite the service hour display. Most errors
cause the emergency stop to be activated. Errors remain displayed until the control
circuit is switched off (Code lock).
If no CanDis is present, the error code is displayed by the flashing of the discharge
monitor LED.
Z
The manufacturer’s service department has detailed component descriptions with
error codes.
Display for parameter changes (travel programs)
The LC display (23) is used in conjunction with the operator keypad (CanCode (o))
to display the setting parameters. The parameter number and subindex are displayed
alternating with the parameter.
Display: 0280-2 (max. speed) <-> 0000-8 (value)
Z
Settings of parameter group 0XX (code lock) are not displayed.
Hourmeter
Service hours are counted while the truck is operational and one of the following
controls is applied:
– Tiller in travel zone "F"
– "Slow travel button"
– "Lift" button
– "Lower" button
7.3 Power up test
On power up the display shows:
– the software version of the display instrument (briefly)
– the operating hours
– the charge status
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8 Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table.
Z
If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer’s service department, as any further troubleshooting can only be
performed by specially trained and qualified service personnel.
Fault Possible cause Action
Truck does
not start.
– Battery connector
not connected
– Check the battery connector and connect
if necessary.
– Key switch in “0”
position
– Set key switch to “I”
– Incorrect CanCode
code
– Check code
– Battery charge too low – Check battery charge, charge battery if
necessary
– Faulty fuse – Test fuses (see chapter F)
– Truck in charge mode – Interrupt charging
Load cannot
be lifted
– Charge capacity
below
20 / 40%
– Charging the battery
– Truck not operational – Carry out all measures listed under
“Truck does not start”
– Hydraulic oil level too
low
– Check the hydraulic oil level
– Excessive load – Note maximum capacity (see data plate)
E 29
1113.GB
8 Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table.
Z
If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer’s service department, as any further troubleshooting can only be
performed by specially trained and qualified service personnel.
Fault Possible cause Action
Truck does
not start.
– Battery connector
not connected
– Check the battery connector and connect
if necessary.
– Key switch in “0”
position
– Set key switch to “I”
– Incorrect CanCode
code
– Check code
– Battery charge too low – Check battery charge, charge battery if
necessary
– Faulty fuse – Test fuses (see chapter F)
– Truck in charge mode – Interrupt charging
Load cannot
be lifted
– Charge capacity
below
20 / 40%
– Charging the battery
– Truck not operational – Carry out all measures listed under
“Truck does not start”
– Hydraulic oil level too
low
– Check the hydraulic oil level
– Excessive load – Note maximum capacity (see data plate)
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Page 60
F 1
0709.GB
F Truck Maintenance
1 Operational safety and environmental protection
The servicing and inspection operations contained in this chapter must be performed
in accordance with the intervals indicated in the servicing checklists.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. The operational speeds of the truck must not be changed under any
circumstances.
M
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the 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, carry out the activities listed in the
“Recommissioning” section (see chapter F).
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has
field technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must
only be secured to the points specially provided for this purpose. When jacking up the
truck, take appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks). You may only work underneath a raised lifting device
if it is supported by a sufficiently strong chain.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
implement all necessary safety measures to prevent sparking (e.g. through short
circuits). For battery-operated trucks, the battery connector must be removed. 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 electric and
electronic components must be carefully covered beforehand as moisture can cause
malfunctions. Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
F 1
0709.GB
F Truck Maintenance
1 Operational safety and environmental protection
The servicing and inspection operations contained in this chapter must be performed
in accordance with the intervals indicated in the servicing checklists.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. The operational speeds of the truck must not be changed under any
circumstances.
M
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the 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, carry out the activities listed in the
“Recommissioning” section (see chapter F).
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has
field technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must
only be secured to the points specially provided for this purpose. When jacking up the
truck, take appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks). You may only work underneath a raised lifting device
if it is supported by a sufficiently strong chain.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
implement all necessary safety measures to prevent sparking (e.g. through short
circuits). For battery-operated trucks, the battery connector must be removed. 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 electric and
electronic components must be carefully covered beforehand as moisture can cause
malfunctions. Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
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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.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare parts.
Otherwise the data sheet specifications of the truck cannot be guaranteed. When
changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing
wheels always left and right simultaneously).
Lift chains: Lift chains wear rapidly 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. When replacing
hydraulic components, also replace the hoses in the hydraulic system.
0709.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.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare parts.
Otherwise the data sheet specifications of the truck cannot be guaranteed. When
changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing
wheels always left and right simultaneously).
Lift chains: Lift chains wear rapidly 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. When replacing
hydraulic components, also replace the hoses in the hydraulic system.
Page 62
F 3
0709.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 have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer adviser carries out an application
analysis on site to work out specific service intervals to prevent damage due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, or at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
Z
W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary.
F 3
0709.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 have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer adviser carries out an application
analysis on site to work out specific service intervals to prevent damage due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, or at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
Z
W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary.
Page 63
0709.GB
F 4
4 Maintenance Checklist
Maintenance intervals
Standard = t WA BC
Cold Store = k
Brake 1.1 Check magnetic brake air gap. t
Electrics 2.1 Test instruments, displays and control switches. t
2.2 Test warning and safety device. kt
2.3 Check fuse ratings. t
2.4 Make sure wire connections are secure and check for
damage.
t
2.5 Test micro switch setting. t
2.6 Check contactors and relays. t
2.7 Frame leakage test t
2.8 Test cable and motor attachments. t
2.9 Check carbon brush wear, replace if necessary. t
Power
supply
3.1 Visually inspect battery kt
3.2 Check battery cable connections are secure, grease
terminals if necessary.
kt
3.3 Check acid density, acid level and battery voltage. kt
Travel 4.1 Check motor suspension. t
4.2 Check the transmission for noise and leakage. t
4.3 Replace gear oil if service life exceeded (10,000 hours).
4.4 Check travel mechanism, adjust and lubricate if
necessary.
Check tiller recuperating function.
kt
4.5 Check wheels for wear and damage. kt
4.6 Check wheel bearings and attachments. t
Truck
design
5.1 Test the operator’s platform and check for damage. t
5.2 Check chassis for damage and screw connections. t
5.3 Check labels. t
0709.GB
F 4
4 Maintenance Checklist
Maintenance intervals
Standard = t WA BC
Cold Store = k
Brake 1.1 Check magnetic brake air gap. t
Electrics 2.1 Test instruments, displays and control switches. t
2.2 Test warning and safety device. kt
2.3 Check fuse ratings. t
2.4 Make sure wire connections are secure and check for
damage.
t
2.5 Test micro switch setting. t
2.6 Check contactors and relays. t
2.7 Frame leakage test t
2.8 Test cable and motor attachments. t
2.9 Check carbon brush wear, replace if necessary. t
Power
supply
3.1 Visually inspect battery kt
3.2 Check battery cable connections are secure, grease
terminals if necessary.
kt
3.3 Check acid density, acid level and battery voltage. kt
Travel 4.1 Check motor suspension. t
4.2 Check the transmission for noise and leakage. t
4.3 Replace gear oil if service life exceeded (10,000 hours).
4.4 Check travel mechanism, adjust and lubricate if
necessary.
Check tiller recuperating function.
kt
4.5 Check wheels for wear and damage. kt
4.6 Check wheel bearings and attachments. t
Truck
design
5.1 Test the operator’s platform and check for damage. t
5.2 Check chassis for damage and screw connections. t
5.3 Check labels. t
Page 64
F 5
0709.GB
Maintenance intervals
Standard = t WA BC
Cold Store = k
Hydraulic
operation
6.1 Check operation, wear and setting. t
6.2 Check forks for wear and damage. t
6.3 Test hydraulic system. kt
6.4 Check that hose and pipe lines and their connections
are secure, check for leaks and damage.
kt
6.5 Check cylinders and piston rods for damage and leaks,
and make sure they are secure.
kt
6.6 Check hydraulic oil level. kt
6.7 Replace hydraulic oil filter. kt
6.8 Replace hydraulic oil. kt
6.9 Check wheels for wear and damage. t
Agreed
performance
levels
7.1 Lubricate truck in accordance with Lubrication
Schedule.
kt
7.2 Test run t
7.3 Demonstration after servicing t
F 5
0709.GB
Maintenance intervals
Standard = t WA BC
Cold Store = k
Hydraulic
operation
6.1 Check operation, wear and setting. t
6.2 Check forks for wear and damage. t
6.3 Test hydraulic system. kt
6.4 Check that hose and pipe lines and their connections
are secure, check for leaks and damage.
kt
6.5 Check cylinders and piston rods for damage and leaks,
and make sure they are secure.
kt
6.6 Check hydraulic oil level. kt
6.7 Replace hydraulic oil filter. kt
6.8 Replace hydraulic oil. kt
6.9 Check wheels for wear and damage. t
Agreed
performance
levels
7.1 Lubricate truck in accordance with Lubrication
Schedule.
kt
7.2 Test run t
7.3 Demonstration after servicing t
Page 65
0709.GB
F 6
5 Maintenance Schedule
g Contact surfaces 1) Compound ratio for cold store usage 1 : 1
s Grease nipples
Hydraulic oil filler neck 2) 1.25 – 1.3 litres depending on the type of
transmission (always up to the lower mark of the
filler neck)
b Transmission oil filler neck
a Transmission oil drain plug
Cold Store Application
B
0,55 l
E
E
E
A
0,7l
A+C
1)
0709.GB
F 6
5 Maintenance Schedule
g Contact surfaces 1) Compound ratio for cold store usage 1 : 1
s Grease nipples
Hydraulic oil filler neck 2) 1.25 – 1.3 litres depending on the type of
transmission (always up to the lower mark of the
filler neck)
b Transmission oil filler neck
a Transmission oil drain plug
Cold Store Application
B
0,55 l
E
E
E
A
0,7l
A+C
1)
Page 66
F 7
0709.GB
5.1 Fuels, coolants and lubricants
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
Z
Improper handling is hazardous to health, life and the environment. Consumables
must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated
in the Operating Instructions.
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.
Grease guidelines
Code Order no. Quantity Description Used for
A 50 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic system
B 50 380 904 5,0 l Fuchs Titan Gear
HSY 75W-90
Transmission
C 29 200 810 5,0 l H-LP 10, DIN 51524 Hydraulic system
E 29 202 050 1.0 kg Grease, Polylube GA
352P
Lubrication
Code Saponification Dew point°CWorked penetr.
at 25 °C
NLG1-
class
Application
temperature °C
E Lithium >220 280 - 310 2 -35 / +120
F 7
0709.GB
5.1 Fuels, coolants and lubricants
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
Z
Improper handling is hazardous to health, life and the environment. Consumables
must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated
in the Operating Instructions.
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.
Grease guidelines
Code Order no. Quantity Description Used for
A 50 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic system
B 50 380 904 5,0 l Fuchs Titan Gear
HSY 75W-90
Transmission
C 29 200 810 5,0 l H-LP 10, DIN 51524 Hydraulic system
E 29 202 050 1.0 kg Grease, Polylube GA
352P
Lubrication
Code Saponification Dew point°CWorked penetr.
at 25 °C
NLG1-
class
Application
temperature °C
E Lithium >220 280 - 310 2 -35 / +120
Page 67
0709.GB
F 8
6 Maintenance and Repairs
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Parking the truck securely
(see Chapter E).
Z
Opening the battery panel
(see chapter D).
– Disconnect the battery (1) to prevent
the truck from accidentally starting.
– When working under a raised lift truck,
secure it to prevent it from lowering,
tipping or sliding away.
F
When raising the truck also refer to the
instructions in the “Transport and Commissioning” section (see Chapter C).
6.2 Opening the battery panel
(see chapter D).
6.3 Opening the front panel
Trucks with folding operator platform:
– Fold down the operator platform (5).
General:
– Unlock the panel latches (2) using a
spanner (width 8).
– Remove the screws (3).
– Lift off the panel (4) and place it next to
the truck.
When the work is finished, closed the
panel (4).
11
2
3
4
5
1
2
1
2
0709.GB
F 8
6 Maintenance and Repairs
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Parking the truck securely
(see Chapter E).
Z
Opening the battery panel
(see chapter D).
– Disconnect the battery (1) to prevent
the truck from accidentally starting.
– When working under a raised lift truck,
secure it to prevent it from lowering,
tipping or sliding away.
F
When raising the truck also refer to the
instructions in the “Transport and Commissioning” section (see Chapter C).
6.2 Opening the battery panel
(see chapter D).
6.3 Opening the front panel
Trucks with folding operator platform:
– Fold down the operator platform (5).
General:
– Unlock the panel latches (2) using a
spanner (width 8).
– Remove the screws (3).
– Lift off the panel (4) and place it next to
the truck.
When the work is finished, closed the
panel (4).
11
2
3
4
5
1
2
1
2
Page 68
F 9
0709.GB
6.4 Replacing the drive wheel
Z
The drive wheel must only be replaced by authorised service personnel.
6.5 Checking the hydraulic oil level
– Prepare the truck for maintenance
and repairs (see section 6.1).
– Opening the front panel (see Section
6.3).
– Check hydraulic oil level in hydraulic
reservoir (7).
Z
There are markings (6) on the hydraulic
reservoir. The oil level should lie
between the "max" and "min" markings
when the forks are lowered.
If necessary, add hydraulic oil of the
correct grade up to the "max" mark.
(for hydraulic oil specification, see
Section 5).
min
max
7
6
F 9
0709.GB
6.4 Replacing the drive wheel
Z
The drive wheel must only be replaced by authorised service personnel.
6.5 Checking the hydraulic oil level
– Prepare the truck for maintenance
and repairs (see section 6.1).
– Opening the front panel (see Section
6.3).
– Check hydraulic oil level in hydraulic
reservoir (7).
Z
There are markings (6) on the hydraulic
reservoir. The oil level should lie
between the "max" and "min" markings
when the forks are lowered.
If necessary, add hydraulic oil of the
correct grade up to the "max" mark.
(for hydraulic oil specification, see
Section 5).
min
max
7
6
Page 69
0709.GB
F 10
6.6 Checking electrical fuses
– Prepare the truck for maintenance and repairs (see Section 6.1).
– Dismantle the front panel (see Section 6.3).
– Check rating of all fuses in accordance with table, replace if necessary.
Item Description To protect: Rating
8 F15 Traction / Lift motor 200 A
9 F13 Solenoid / magnetic brake 10 A
10 1F9 Travel/Lift Controller 5 A
11 6F1 Battery discharge indicator 2 A
11
8
9
10
0709.GB
F 10
6.6 Checking electrical fuses
– Prepare the truck for maintenance and repairs (see Section 6.1).
– Dismantle the front panel (see Section 6.3).
– Check rating of all fuses in accordance with table, replace if necessary.
Item Description To protect: Rating
8 F15 Traction / Lift motor 200 A
9 F13 Solenoid / magnetic brake 10 A
10 1F9 Travel/Lift Controller 5 A
11 6F1 Battery discharge indicator 2 A
11
8
9
10
Page 70
F 11
0709.GB
6.7 Recommissioning
The truck may only be recommissioned after cleaning or repair work, once the
following operations have been performed.
– Test horn.
– Test main switch operation.
– Test brake.
– Lubricate the truck in accordance with the maintenance schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
7.1 Prior to decommissioning
– Thoroughly clean the truck.
– Check the brakes.
– Check the hydraulic oil level and replenish as necessary (see Chapter F).
– Apply a thin layer of oil or grease to any non-painted mechanical components.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and grease the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning
Every 2 months:
– Charge the battery (see Chapter D).
M
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
F 11
0709.GB
6.7 Recommissioning
The truck may only be recommissioned after cleaning or repair work, once the
following operations have been performed.
– Test horn.
– Test main switch operation.
– Test brake.
– Lubricate the truck in accordance with the maintenance schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
7.1 Prior to decommissioning
– Thoroughly clean the truck.
– Check the brakes.
– Check the hydraulic oil level and replenish as necessary (see Chapter F).
– Apply a thin layer of oil or grease to any non-painted mechanical components.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and grease the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning
Every 2 months:
– Charge the battery (see Chapter D).
M
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
Page 71
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F 12
7.3 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (see Chapter D).
– Check transmission oil for condensed water and replace if necessary.
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see Chapter E).
Z
Battery powered trucks:
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8 Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich
recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
0709.GB
F 12
7.3 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (see Chapter D).
– Check transmission oil for condensed water and replace if necessary.
– Check hydraulic oil for condensed water and replace if necessary.
– Start up the truck (see Chapter E).
Z
Battery powered trucks:
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8 Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich
recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
Page 72
1
03.13 EN
A Traction Battery Appendix
Contents
A Traction Battery Appendix....................................................... 1
1 Correct Use and Application.................................................................... 2
2 Data plate ................................................................................................ 2
3 Safety Instructions, Warning Indications and other Notes....................... 3
4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 4
4.1 Description............................................................................................... 4
4.2 Operation................................................................................................. 5
4.3 Servicing lead-acid batteries with armour plated cells............................. 8
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 9
5.1 Description............................................................................................... 9
5.2 Operation................................................................................................. 10
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 13
6 Aquamatik water replenishment system.................................................. 14
6.1 Water replenishment system design ....................................................... 14
6.2 Functional Description ............................................................................. 15
6.3 Adding water............................................................................................ 15
6.4 Water pressure ........................................................................................ 15
6.5 Filling time ............................................................................................... 16
6.6 Water quality............................................................................................ 16
6.7 Battery tubing .......................................................................................... 16
6.8 Operating temperature ............................................................................ 16
6.9 Cleaning measures.................................................................................. 17
6.10 Service mobile vehicle............................................................................. 17
7 Electrolyte circulation............................................................................... 18
7.1 Functional Description ............................................................................. 18
8 Cleaning batteries.................................................................................... 20
9 Storing the battery ................................................................................... 22
10 Troubleshooting....................................................................................... 22
11 Disposal................................................................................................... 22
1
03.13 EN
A Traction Battery Appendix
Contents
A Traction Battery Appendix....................................................... 1
1 Correct Use and Application.................................................................... 2
2 Data plate ................................................................................................ 2
3 Safety Instructions, Warning Indications and other Notes....................... 3
4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 4
4.1 Description............................................................................................... 4
4.2 Operation................................................................................................. 5
4.3 Servicing lead-acid batteries with armour plated cells............................. 8
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 9
5.1 Description............................................................................................... 9
5.2 Operation................................................................................................. 10
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 13
6 Aquamatik water replenishment system.................................................. 14
6.1 Water replenishment system design ....................................................... 14
6.2 Functional Description ............................................................................. 15
6.3 Adding water............................................................................................ 15
6.4 Water pressure ........................................................................................ 15
6.5 Filling time ............................................................................................... 16
6.6 Water quality............................................................................................ 16
6.7 Battery tubing .......................................................................................... 16
6.8 Operating temperature ............................................................................ 16
6.9 Cleaning measures.................................................................................. 17
6.10 Service mobile vehicle............................................................................. 17
7 Electrolyte circulation............................................................................... 18
7.1 Functional Description ............................................................................. 18
8 Cleaning batteries.................................................................................... 20
9 Storing the battery ................................................................................... 22
10 Troubleshooting....................................................................................... 22
11 Disposal................................................................................................... 22
Page 73
03.13 EN
2
1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-original
spare parts, tampering with the battery or using electrolyte additives will invalidate the
warranty.
Observe the instructions for maintaining the safety rating during operation for
batteries in accordance with Ex I and Ex II (see relevant certification).
2 Data plate
1,2
4
8
10
11
6
3
5
9
7
12
13
14
15
1 Battery name
2 Battery type
3 Production week/year manf.
4 Serial number
5 Supplier number
6 Rated voltage
7 Rated capacity
9 Battery weight in kg
8 Number of cells
15 Electrolyte volume in litres
10 Battery number
11 Manufacturer
13 Manufacturer's logo
12 CE mark only for batteries beyond 75 volts
14 Safety instructions and warning information
03.13 EN
2
1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-original
spare parts, tampering with the battery or using electrolyte additives will invalidate the
warranty.
Observe the instructions for maintaining the safety rating during operation for
batteries in accordance with Ex I and Ex II (see relevant certification).
2 Data plate
1,2
4
8
10
11
6
3
5
9
7
12
13
14
15
1 Battery name
2 Battery type
3 Production week/year manf.
4 Serial number
5 Supplier number
6 Rated voltage
7 Rated capacity
9 Battery weight in kg
8 Number of cells
15 Electrolyte volume in litres
10 Battery number
11 Manufacturer
13 Manufacturer's logo
12 CE mark only for batteries beyond 75 volts
14 Safety instructions and warning information
Page 74
3
03.13 EN
3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste.
These batteries are marked with the recycling symbol and the sign
showing a crossed-out rubbish bin, and should not be disposed of
with ordinary household waste.
waste.
Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation.
Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire
and explosion hazard!
Avoid fire and explosion hazards and short circuits due to
overheating!
Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety
gloves) when working on cells and batteries.
batteries.
Always wash your hands after completing the work. Use insulated
tools only. Do not physically
alter the battery, strike, crush, compress, notch, dent or modify it in
any way.
Hazardous electric voltage! The metal parts of the battery cells are
permanently live. Therefore do not place any foreign objects or tools
on the battery.
Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the
charging area.
Work on the batteries should be performed only as instructed by
specialist personnel.
3
03.13 EN
3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste.
These batteries are marked with the recycling symbol and the sign
showing a crossed-out rubbish bin, and should not be disposed of
with ordinary household waste.
waste.
Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation.
Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire
and explosion hazard!
Avoid fire and explosion hazards and short circuits due to
overheating!
Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety
gloves) when working on cells and batteries.
batteries.
Always wash your hands after completing the work. Use insulated
tools only. Do not physically
alter the battery, strike, crush, compress, notch, dent or modify it in
any way.
Hazardous electric voltage! The metal parts of the battery cells are
permanently live. Therefore do not place any foreign objects or tools
on the battery.
Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the
charging area.
Work on the batteries should be performed only as instructed by
specialist personnel.
Page 75
03.13 EN
4
4 Lead acid batteries with armour plated cells and liquid
electrolyte
4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells and
liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte
The rated density of the electrolyte assumes a temperature of 30°C and the rated
electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures
will increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.
electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations.
4.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Nominal electrolyte density
1
1. Reached within the first 10 cycles.
1.29 kg/l
6. Nominal temperature
2
2. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
30 °C
7. System rated electrolyte level up to "Max" electrolyte level marking
Limit temperature
3
3. Not permissible as operating temperature.
55°C
03.13 EN
4
4 Lead acid batteries with armour plated cells and liquid
electrolyte
4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells and
liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte
The rated density of the electrolyte assumes a temperature of 30°C and the rated
electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures
will increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.
electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations.
4.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Nominal electrolyte density
1
1. Reached within the first 10 cycles.
1.29 kg/l
6. Nominal temperature
2
2. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
30 °C
7. System rated electrolyte level up to "Max" electrolyte level marking
Limit temperature
3
3. Not permissible as operating temperature.
55°C
Page 76
5
03.13 EN
4.2 Operation
4.2.1 Commissioning unfilled batteries
Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the
manufacturer.
4.2.2 Commissioning filled and charged batteries
Checks and operations to be performed before starting daily work
Procedure
• Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors.
• Charge up the battery.
• Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator.
• Add electrolyte with distilled water up to the nominal level.
Checks completed.
4.2.3 Discharging the battery
Z To achieve an optimum useful life avoid operational discharge of more than 80% of
nominal capacity (full discharge). This corresponds to a minimum electrolyte
density of 1.13 kg/l at the end of the discharge. Recharge a discharged battery
immediately.
5
03.13 EN
4.2 Operation
4.2.1 Commissioning unfilled batteries
Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the
manufacturer.
4.2.2 Commissioning filled and charged batteries
Checks and operations to be performed before starting daily work
Procedure
• Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors.
• Charge up the battery.
• Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator.
• Add electrolyte with distilled water up to the nominal level.
Checks completed.
4.2.3 Discharging the battery
Z To achieve an optimum useful life avoid operational discharge of more than 80% of
nominal capacity (full discharge). This corresponds to a minimum electrolyte
density of 1.13 kg/l at the end of the discharge. Recharge a discharged battery
immediately.
Page 77
03.13 EN
6
4.2.4 Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged.
Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
Fire protection equipment must be available.
Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The battery must only be charged with DC current. All charging processes in
accordance with DIN 41773 and DIN 41774 are permissible.
03.13 EN
6
4.2.4 Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged.
Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
Fire protection equipment must be available.
Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The battery must only be charged with DC current. All charging processes in
accordance with DIN 41773 and DIN 41774 are permissible.
Page 78
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03.13 EN
Z The electrolyte temperature rises by approx. 10 K during charging. Charging should
therefore only begin when the electrolyte temperature is below 45°C. The
electrolyte temperature of batteries must be at least +10°C before charging.
Otherwise the battery will not charge correctly. Below 10°C the battery is
insufficiently charged with standard charging systems.
Charging the battery
Requirements
– Electrolyte temperature min. 10°C to max. 45°C
Procedure
• Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain on
the cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
• Switch on the charger.
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. The maximum compensation
charge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which reduce the useful
life of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Use
replacement batteries instead of regular trickle charging.
7
03.13 EN
Z The electrolyte temperature rises by approx. 10 K during charging. Charging should
therefore only begin when the electrolyte temperature is below 45°C. The
electrolyte temperature of batteries must be at least +10°C before charging.
Otherwise the battery will not charge correctly. Below 10°C the battery is
insufficiently charged with standard charging systems.
Charging the battery
Requirements
– Electrolyte temperature min. 10°C to max. 45°C
Procedure
• Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain on
the cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
• Switch on the charger.
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. The maximum compensation
charge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which reduce the useful
life of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Use
replacement batteries instead of regular trickle charging.
Page 79
03.13 EN
8
4.3 Servicing lead-acid batteries with armour plated cells
Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
4.3.1 Daily
– Charge the battery after each discharge.
– After charging, check the electrolyte level.
– If necessary, add purified water up to the rated level after charging.
Z The height of the electrolyte level should not be below the cell baffle or above the
top of the separator, or the "Min" and "Max" electrolyte markings respectively.
4.3.2 Weekly
– After re-charging, carry out a visual inspection for dirt and physical damage.
– If the battery is charged regularly according to the IU characteristic, carry out a
compensation charge.
4.3.3 Monthly
– Towards the end of the charging process measure and record the voltages of all
the cells with the charger switched on.
– After charging measure and record the electrolyte density and the electrolyte
temperature in all the cells.
– Compare the results with the previous ones.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
4.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage.
03.13 EN
8
4.3 Servicing lead-acid batteries with armour plated cells
Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
4.3.1 Daily
– Charge the battery after each discharge.
– After charging, check the electrolyte level.
– If necessary, add purified water up to the rated level after charging.
Z The height of the electrolyte level should not be below the cell baffle or above the
top of the separator, or the "Min" and "Max" electrolyte markings respectively.
4.3.2 Weekly
– After re-charging, carry out a visual inspection for dirt and physical damage.
– If the battery is charged regularly according to the IU characteristic, carry out a
compensation charge.
4.3.3 Monthly
– Towards the end of the charging process measure and record the voltages of all
the cells with the charger switched on.
– After charging measure and record the electrolyte density and the electrolyte
temperature in all the cells.
– Compare the results with the previous ones.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
4.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage.
Page 80
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03.13 EN
5 PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can be
added over the entire lifespan of the battery. Relief valves are used as plugs which
are destroyed when opened. During operation the same safety requirements apply to
the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric
shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if
the cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free.
Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte
cannot be measured.
5.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Rated temperature 30 °C
Limit temperature
1
1. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
45°C, not permissible as operating
temperature.
6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured
9
03.13 EN
5 PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can be
added over the entire lifespan of the battery. Relief valves are used as plugs which
are destroyed when opened. During operation the same safety requirements apply to
the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric
shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if
the cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free.
Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte
cannot be measured.
5.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Rated temperature 30 °C
Limit temperature
1
1. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity.
45°C, not permissible as operating
temperature.
6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured
Page 81
03.13 EN
10
5.2 Operation
5.2.1 Commissioning
Checks and operations to be performed before starting daily work
Procedure
• Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors.
• Re-charge the battery.
• Charge the battery.
Check completed.
5.2.2 Discharging the battery
Z To achieve an optimum useful life avoid operational discharges of more than 60%
of nominal capacity.
Z If the battery is discharged during operation by more than 80% of rated capacity the
useful life of the battery will reduce significantly. Fully or partially discharged
batteries must be re-charged immediately and not left unattended.
5.2.3 Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged.
Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
Fire protection equipment must be available.
Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station
manufacturers.
03.13 EN
10
5.2 Operation
5.2.1 Commissioning
Checks and operations to be performed before starting daily work
Procedure
• Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors.
• Re-charge the battery.
• Charge the battery.
Check completed.
5.2.2 Discharging the battery
Z To achieve an optimum useful life avoid operational discharges of more than 60%
of nominal capacity.
Z If the battery is discharged during operation by more than 80% of rated capacity the
useful life of the battery will reduce significantly. Fully or partially discharged
batteries must be re-charged immediately and not left unattended.
5.2.3 Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.
Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged.
Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery.
Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of
2 m from the truck.
Fire protection equipment must be available.
Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station
manufacturers.
Page 82
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03.13 EN
NOTE
Charging the battery incorrectly can result in material damage.
Incorrect battery charging can result in overloading of the electric wires and contacts,
hazardous gas formation and electrolyte leakage from the cells.
Always charge the battery with DC current.
All DIN 41773 charging procedures are permitted in the format approved by the
manufacturer.
Always connect the battery to a charger that is appropriate to the size and type of
the battery.
If necessary have the charger checked by the manufacturer's customer service
department for suitability.
Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3.
11
03.13 EN
NOTE
Charging the battery incorrectly can result in material damage.
Incorrect battery charging can result in overloading of the electric wires and contacts,
hazardous gas formation and electrolyte leakage from the cells.
Always charge the battery with DC current.
All DIN 41773 charging procedures are permitted in the format approved by the
manufacturer.
Always connect the battery to a charger that is appropriate to the size and type of
the battery.
If necessary have the charger checked by the manufacturer's customer service
department for suitability.
Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3.
Page 83
03.13 EN
12
Charging the battery
Requirements
– Electrolyte temperature between +15°C and 35°C
Procedure
• Open or take off the tray lid or covers from the battery compartment.
• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
• Switch on the charger.
Z The electrolyte temperature rises by approx. 10 K during charging. If the
temperatures are permanently higher than 40°C or lower than 15°C, a temperaturedependent constant voltage control of the charger is required. The adjustment
factor must be applied with -0.004 V/C per K.
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which can reduce the
useful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Use
replacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries.
03.13 EN
12
Charging the battery
Requirements
– Electrolyte temperature between +15°C and 35°C
Procedure
• Open or take off the tray lid or covers from the battery compartment.
• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative).
• Switch on the charger.
Z The electrolyte temperature rises by approx. 10 K during charging. If the
temperatures are permanently higher than 40°C or lower than 15°C, a temperature-
dependent constant voltage control of the charger is required. The adjustment
factor must be applied with -0.004 V/C per K.
Battery charged
Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which can reduce the
useful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Use
replacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries.
Page 84
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03.13 EN
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
Z Do not add water!
5.3.1 Daily
– Charge the battery after each discharge.
5.3.2 Weekly
– Visually inspect for dirt and physical damage.
5.3.3 Every three months
– Measure and record the overall voltage.
– Measure and record the individual voltages.
– Compare the results with the previous ones.
Z Carry out the measurements after full charging and subsequent resting for at least
5 hours.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
5.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage.
13
03.13 EN
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
Z Do not add water!
5.3.1 Daily
– Charge the battery after each discharge.
5.3.2 Weekly
– Visually inspect for dirt and physical damage.
5.3.3 Every three months
– Measure and record the overall voltage.
– Measure and record the individual voltages.
– Compare the results with the previous ones.
Z Carry out the measurements after full charging and subsequent resting for at least
5 hours.
Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service
department.
5.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage.
Page 85
03.13 EN
14
6 Aquamatik water replenishment system
6.1 Water replenishment system design
15 Water container
16 Tap connection with ball cock
17 Flow indicator
18 Shut-off cock
19 Locking coupling
20 Battery lock connector
15
16
17
18
19
20
> 3 m
+-
03.13 EN
14
6 Aquamatik water replenishment system
6.1 Water replenishment system design
15 Water container
16 Tap connection with ball cock
17 Flow indicator
18 Shut-off cock
19 Locking coupling
20 Battery lock connector
15
16
17
18
19
20
> 3 m
+-
Page 86
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03.13 EN
6.2 Functional Description
The Aquamatik water replenishment system is used to adjust the rated electrolyte
level automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the water
supply (e.g. water container) through a plug connection. When the shut-off cock is
opened all the cells are filled with water. The Aquamatik plug controls the amount of
water required and, at the relevant water pressures, ensures the water supply is shut
off and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure the
temperature and electrolyte density and a degassing port.
6.3 Adding water
Water should be added to the batteries just before the battery is fully charged. This
ensures that the amount of water added is mixed with the electrolyte.
6.4 Water pressure
The water replenishment system must be operated with a water pressure in the water
line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges will
affect the operation of the systems.
Water drop
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1
bar
Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3
- 1.8 bar.
15
03.13 EN
6.2 Functional Description
The Aquamatik water replenishment system is used to adjust the rated electrolyte
level automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the water
supply (e.g. water container) through a plug connection. When the shut-off cock is
opened all the cells are filled with water. The Aquamatik plug controls the amount of
water required and, at the relevant water pressures, ensures the water supply is shut
off and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure the
temperature and electrolyte density and a degassing port.
6.3 Adding water
Water should be added to the batteries just before the battery is fully charged. This
ensures that the amount of water added is mixed with the electrolyte.
6.4 Water pressure
The water replenishment system must be operated with a water pressure in the water
line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges will
affect the operation of the systems.
Water drop
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1
bar
Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3
- 1.8 bar.
Page 87
03.13 EN
16
6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperature
and the filling pressure. Filling ends automatically. The water supply line must be
disconnected from the battery when the water has been filled.
6.6 Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
6.7 Battery tubing
The tubing of the individual plugs is in accordance with the existing electric circuit. No
changes should be made.
6.8 Operating temperature
Batteries with automatic water replenishment systems should only be stored in rooms
with temperatures > 0°C, as otherwise the systems could freeze.
03.13 EN
16
6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperature
and the filling pressure. Filling ends automatically. The water supply line must be
disconnected from the battery when the water has been filled.
6.6 Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte.
6.7 Battery tubing
The tubing of the individual plugs is in accordance with the existing electric circuit. No
changes should be made.
6.8 Operating temperature
Batteries with automatic water replenishment systems should only be stored in rooms
with temperatures > 0°C, as otherwise the systems could freeze.
Page 88
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03.13 EN
6.9 Cleaning measures
The plug systems must only be cleaned with purified water in accordance with DIN
43530-4. No parts of the plugs must come into contact with solvent-based materials
or soap.
6.10 Service mobile vehicle
Mobile water filling vehicle with pump and filling gun to fill individual cells. The
immersion pump in the container generates the necessary filling pressure. The
service mobile must be at exactly the same height as the battery base.
17
03.13 EN
6.9 Cleaning measures
The plug systems must only be cleaned with purified water in accordance with DIN
43530-4. No parts of the plugs must come into contact with solvent-based materials
or soap.
6.10 Service mobile vehicle
Mobile water filling vehicle with pump and filling gun to fill individual cells. The
immersion pump in the container generates the necessary filling pressure. The
service mobile must be at exactly the same height as the battery base.
Page 89
03.13 EN
18
7 Electrolyte circulation
7.1 Functional Description
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,
thereby preventing any acid layer, shortening the charge time (charge factor approx.
1.07) and reducing the formation of gas during charging. The charger must be
suitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introduced
to the battery cells via a hose system. The electrolyte is circulated via the inlet air and
the electrolyte density level is constant over the entire length of the electrode.
Pump
In the event of a fault, e.g. if the pressure control system responds for an unknown
reason, the filters must be checked and replaced if necessary.
Battery connection
A hose is attached to the pump module which together with the charge leads is routed
from the charger to the charging connector. The air is passed on to the battery via the
electrolyte circulation coupling ducts in the connector. When routing make sure the
hose is not bent.
Pressure monitoring module
The electrolyte circulation pump is activated when charging begins. The pressure
monitoring module monitors the build up of pressure during charging. This ensures
that the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as:
– Battery air coupling not connected to circulation module (if coupling is separate) or
faulty.
– Leaky or faulty hose connections on battery or
– Intake filter contaminated
a visual error message appears on the charger.
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7 Electrolyte circulation
7.1 Functional Description
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,
thereby preventing any acid layer, shortening the charge time (charge factor approx.
1.07) and reducing the formation of gas during charging. The charger must be
suitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introduced
to the battery cells via a hose system. The electrolyte is circulated via the inlet air and
the electrolyte density level is constant over the entire length of the electrode.
Pump
In the event of a fault, e.g. if the pressure control system responds for an unknown
reason, the filters must be checked and replaced if necessary.
Battery connection
A hose is attached to the pump module which together with the charge leads is routed
from the charger to the charging connector. The air is passed on to the battery via the
electrolyte circulation coupling ducts in the connector. When routing make sure the
hose is not bent.
Pressure monitoring module
The electrolyte circulation pump is activated when charging begins. The pressure
monitoring module monitors the build up of pressure during charging. This ensures
that the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as:
– Battery air coupling not connected to circulation module (if coupling is separate) or
faulty.
– Leaky or faulty hose connections on battery or
– Intake filter contaminated
a visual error message appears on the charger.
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03.13 EN
NOTE
If an installed electrolyte circulation system is seldom used or not used at all,
or if the battery is subjected to severe temperature fluctuations, the electrolyte
may flow back into the hose system.
Attach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side.
Schematic illustration
Electrolyte circulation on the battery and air supply via the charger.
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03.13 EN
NOTE
If an installed electrolyte circulation system is seldom used or not used at all,
or if the battery is subjected to severe temperature fluctuations, the electrolyte
may flow back into the hose system.
Attach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side.
Schematic illustration
Electrolyte circulation on the battery and air supply via the charger.
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8 Cleaning batteries
Batteries and trays must be cleaned in order to
– maintain cell insulation and protect cells from ground or external conductive parts.
– Avoid damage from corrosion and stray currents.
– Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents.
– Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that:
– The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water.
– All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water.
– Protective goggles and clothing are worn.
– Cell plugs are not removed or opened.
– Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives.
– After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths.
– Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations.
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8 Cleaning batteries
Batteries and trays must be cleaned in order to
– maintain cell insulation and protect cells from ground or external conductive parts.
– Avoid damage from corrosion and stray currents.
– Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents.
– Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that:
– The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water.
– All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water.
– Protective goggles and clothing are worn.
– Cell plugs are not removed or opened.
– Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives.
– After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths.
– Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations.
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Cleaning the battery with a high pressure cleaner
Requirements
– Cell connectors tight, plugged in securely
– Cell plugs closed
Procedure
• Follow the high pressure cleaner's user instructions.
• Do not use any cleaning additives.
• Observe the permissible cleaning device temperature setting of 140°C.
Z This generally ensures that the temperature does not exceed 60°C at a distance of
30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar.
• Observe a minimum distance of 30 cm from the top of the battery.
• The battery should be sprayed over its entire surface to avoid localised
overheating.
Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C.
• After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths.
Battery cleaned.
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03.13 EN
Cleaning the battery with a high pressure cleaner
Requirements
– Cell connectors tight, plugged in securely
– Cell plugs closed
Procedure
• Follow the high pressure cleaner's user instructions.
• Do not use any cleaning additives.
• Observe the permissible cleaning device temperature setting of 140°C.
Z This generally ensures that the temperature does not exceed 60°C at a distance of
30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar.
• Observe a minimum distance of 30 cm from the top of the battery.
• The battery should be sprayed over its entire surface to avoid localised
overheating.
Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C.
• After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths.
Battery cleaned.
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9 Storing the battery
NOTE
The battery should not be stored for longer than 3 months without charging as
otherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fully
charged in a dry room protected from frost. To ensure the availability of the battery
the following charges can be selected:
– Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge
for PzV batteries.
– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB
batteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, as
far as possible, be charged to 50% of its charge level and stored in a dry room
protected from frost.
10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customer
service department immediately.
Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the
manufacturer.
11 Disposal
Batteries marked with the recycling symbol and the sign showing a
crossed-out rubbish bin should not be disposed of with ordinary
household waste.
Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation.
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9 Storing the battery
NOTE
The battery should not be stored for longer than 3 months without charging as
otherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fully
charged in a dry room protected from frost. To ensure the availability of the battery
the following charges can be selected:
– Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge
for PzV batteries.
– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB
batteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, as
far as possible, be charged to 50% of its charge level and stored in a dry room
protected from frost.
10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customer
service department immediately.
Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the
manufacturer.
11 Disposal
Batteries marked with the recycling symbol and the sign showing a
crossed-out rubbish bin should not be disposed of with ordinary
household waste.
Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation.
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