Operating instructions
G
Operating instructions
51159400
ERE
07.09 -
11.13
ERE 120n
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
0108.GB
0108.GB
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
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
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.
0506.GB 20506.GB
2
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.
0505.D
A 2
0505.D
A 2
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.
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
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
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
B 5
0709.GB
Dimensions sheet with fixed platform
B 5
0709.GB
Dimensions sheet with fixed platform
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
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.
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
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
0709.GB
B 10
0709.GB
B 10
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
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
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
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
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.
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
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
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
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
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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