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ese 20

Jungheinrich ese 20 Operating Instructions Manual

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Page 1
Operating instructions
50042902
ESE 20
G
04.99-
07.99
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.
A
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
Page 4
I 1
0499.GB
Table of contents
A Correct use and application of the truck ............................... A 1
B Description of the truck
1 Design and application.......................................................................... B 1
2 Assemblies............................................................................................ B 2
2.1 Technical data - standard version......................................................... B 3
2.2 Performance data ................................................................................. B 3
2.3 Dimensions ........................................................................................... B 4
2.4 EN standards ........................................................................................ B 6
2.5 Conditions for application...................................................................... B 6
3 Labels ................................................................................................... B 7
3.1 Truck identification plate ....................................................................... B 8
C Transportation and commissioning
1 Transportation by crane........................................................................ C 1
2 Commissioning ..................................................................................... C 1
3 Moving the truck with the drive unit inoperative.................................... C 2
D Battery - servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ......... D 1
2 Battery types......................................................................................... D 2
3 Exposing the battery ............................................................................. D 2
4 Charging the battery ............................................................................. D 3
5 Removing and installing the battery...................................................... D 4
6 o Combined instrument ....................................................................... D 5
7 o Battery discharge indicator, battery discharge monitor,
operating hour meter............................................................................. D 6
I 1
0499.GB
Table of contents
A Correct use and application of the truck ............................... A 1
B Description of the truck
1 Design and application.......................................................................... B 1
2 Assemblies............................................................................................ B 2
2.1 Technical data - standard version......................................................... B 3
2.2 Performance data ................................................................................. B 3
2.3 Dimensions ........................................................................................... B 4
2.4 EN standards ........................................................................................ B 6
2.5 Conditions for application...................................................................... B 6
3 Labels ................................................................................................... B 7
3.1 Truck identification plate ....................................................................... B 8
C Transportation and commissioning
1 Transportation by crane........................................................................ C 1
2 Commissioning ..................................................................................... C 1
3 Moving the truck with the drive unit inoperative.................................... C 2
D Battery - servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ......... D 1
2 Battery types......................................................................................... D 2
3 Exposing the battery ............................................................................. D 2
4 Charging the battery ............................................................................. D 3
5 Removing and installing the battery...................................................... D 4
6 o Combined instrument ....................................................................... D 5
7 o Battery discharge indicator, battery discharge monitor,
operating hour meter............................................................................. D 6
I 1
0499.GB
Table of contents
A Correct use and application of the truck ............................... A 1
B Description of the truck
1 Design and application.......................................................................... B 1
2 Assemblies............................................................................................ B 2
2.1 Technical data - standard version......................................................... B 3
2.2 Performance data ................................................................................. B 3
2.3 Dimensions ........................................................................................... B 4
2.4 EN standards ........................................................................................ B 6
2.5 Conditions for application...................................................................... B 6
3 Labels ................................................................................................... B 7
3.1 Truck identification plate ....................................................................... B 8
C Transportation and commissioning
1 Transportation by crane........................................................................ C 1
2 Commissioning ..................................................................................... C 1
3 Moving the truck with the drive unit inoperative.................................... C 2
D Battery - servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ......... D 1
2 Battery types......................................................................................... D 2
3 Exposing the battery ............................................................................. D 2
4 Charging the battery ............................................................................. D 3
5 Removing and installing the battery...................................................... D 4
6 o Combined instrument ....................................................................... D 5
7 o Battery discharge indicator, battery discharge monitor,
operating hour meter............................................................................. D 6
Page 5
I 2
0499.GB
EOperation
1 Safety regulations governing the operation of the fork-lift truck............ E 1
2 Description of the operating controls and indicators............................. E 2
3 Starting up the truck.............................................................................. E 4
4 Operation of the fork-lift truck................................................................ E 6
4.1 Safety regulations applicable when operating the truck........................ E 6
4.2 Adjusting the sitting aid......................................................................... E 7
4.3 Driving, steering, braking ...................................................................... E 8
4.4 Picking up and setting down loads........................................................ E 11
4.5 Safe parking of the truck ....................................................................... E 12
5 o Information and service indicator (LISA) .......................................... E 13
5.1 o LED indicators .................................................................................. E 13
5.2 o Keyboard assignment....................................................................... E13
5.3 o Indicators .......................................................................................... E14
5.4 o Changing driving parameters ........................................................... E 15
6 Fault location......................................................................................... E16
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ................................. F 1
2 Safety regulations applicable to truck maintenance.............................. F 1
3 Servicing and inspection....................................................................... F 3
4 Maintenance checklist ESE 20 ............................................................. F 4
5 Lubrication schedule ESE 20................................................................ F 6
5.1 Fuels, coolants and lubricants .............................................................. F 7
6 Instructions for the servicing operations ............................................... F 8
6.1 Preparing the truck for servicing and maintenance operations............. F 8
6.2 Tightening the wheel screws................................................................. F 8
6.3 Removing the drive cover ..................................................................... F 9
6.4 Checking the electric fuses................................................................... F 10
6.5 Recommissioning the truck................................................................... F 11
7 Decommissioning the fork-lift truck ....................................................... F 11
7.1 Operations to be performed prior to decommissioning......................... F 11
7.2 Measures to be taken during decommissioning.................................... F12
7.3 Recommissioning the truck................................................................... F 12
8 Safety checks to be performed at regular intervals and following any
untoward incidents
(D: Accident prevention check according to VBG 36)........................... F13
I 2
0499.GB
EOperation
1 Safety regulations governing the operation of the fork-lift truck............ E 1
2 Description of the operating controls and indicators............................. E 2
3 Starting up the truck.............................................................................. E 4
4 Operation of the fork-lift truck................................................................ E 6
4.1 Safety regulations applicable when operating the truck........................ E 6
4.2 Adjusting the sitting aid......................................................................... E 7
4.3 Driving, steering, braking ...................................................................... E 8
4.4 Picking up and setting down loads........................................................ E 11
4.5 Safe parking of the truck ....................................................................... E 12
5 o Information and service indicator (LISA) .......................................... E 13
5.1 o LED indicators .................................................................................. E 13
5.2 o Keyboard assignment....................................................................... E13
5.3 o Indicators .......................................................................................... E14
5.4 o Changing driving parameters ........................................................... E 15
6 Fault location......................................................................................... E16
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ................................. F 1
2 Safety regulations applicable to truck maintenance.............................. F 1
3 Servicing and inspection....................................................................... F 3
4 Maintenance checklist ESE 20 ............................................................. F 4
5 Lubrication schedule ESE 20................................................................ F 6
5.1 Fuels, coolants and lubricants .............................................................. F 7
6 Instructions for the servicing operations ............................................... F 8
6.1 Preparing the truck for servicing and maintenance operations............. F 8
6.2 Tightening the wheel screws................................................................. F 8
6.3 Removing the drive cover ..................................................................... F 9
6.4 Checking the electric fuses................................................................... F 10
6.5 Recommissioning the truck................................................................... F 11
7 Decommissioning the fork-lift truck ....................................................... F 11
7.1 Operations to be performed prior to decommissioning......................... F 11
7.2 Measures to be taken during decommissioning.................................... F12
7.3 Recommissioning the truck................................................................... F 12
8 Safety checks to be performed at regular intervals and following any
untoward incidents
(D: Accident prevention check according to VBG 36)........................... F13
I 2
0499.GB
EOperation
1 Safety regulations governing the operation of the fork-lift truck............ E 1
2 Description of the operating controls and indicators............................. E 2
3 Starting up the truck.............................................................................. E 4
4 Operation of the fork-lift truck................................................................ E 6
4.1 Safety regulations applicable when operating the truck........................ E 6
4.2 Adjusting the sitting aid......................................................................... E 7
4.3 Driving, steering, braking ...................................................................... E 8
4.4 Picking up and setting down loads........................................................ E 11
4.5 Safe parking of the truck ....................................................................... E 12
5 o Information and service indicator (LISA) .......................................... E 13
5.1 o LED indicators .................................................................................. E 13
5.2 o Keyboard assignment....................................................................... E13
5.3 o Indicators .......................................................................................... E14
5.4 o Changing driving parameters ........................................................... E 15
6 Fault location......................................................................................... E16
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ................................. F 1
2 Safety regulations applicable to truck maintenance.............................. F 1
3 Servicing and inspection....................................................................... F 3
4 Maintenance checklist ESE 20 ............................................................. F 4
5 Lubrication schedule ESE 20................................................................ F 6
5.1 Fuels, coolants and lubricants .............................................................. F 7
6 Instructions for the servicing operations ............................................... F 8
6.1 Preparing the truck for servicing and maintenance operations............. F 8
6.2 Tightening the wheel screws................................................................. F 8
6.3 Removing the drive cover ..................................................................... F 9
6.4 Checking the electric fuses................................................................... F 10
6.5 Recommissioning the truck................................................................... F 11
7 Decommissioning the fork-lift truck ....................................................... F 11
7.1 Operations to be performed prior to decommissioning......................... F 11
7.2 Measures to be taken during decommissioning.................................... F12
7.3 Recommissioning the truck................................................................... F 12
8 Safety checks to be performed at regular intervals and following any
untoward incidents
(D: Accident prevention check according to VBG 36)........................... F13
Page 6
A 1
0600.GB
A Correct use and application of the truck
A
The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating instructions and must always be heeded. National regulations are fully applica- ble.
The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these ope- rating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A „user“ within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the opera- ting duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these Operating Instruction are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
A 1
0600.GB
A Correct use and application of the truck
A
The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating instructions and must always be heeded. National regulations are fully applica- ble.
The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these ope- rating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A „user“ within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the opera- ting duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these Operating Instruction are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
A 1
0600.GB
A Correct use and application of the truck
A
The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these ope- rating instructions and must always be heeded. National regulations are fully applica- ble.
The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these ope- rating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A „user“ within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the opera- ting duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
m
If these Operating Instruction are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
Page 7
A 2
0499.GB
A 2
0499.GB
A 2
0499.GB
Page 8
B 1
0799.GB
B Description of the truck
1 Design and application
The ESE 20 is an electric four-wheel forklift truck with a lateral standing platform and a sitting aid. It is provided with an electrical steering wheel steering system. The ESE is designed for transport and order-picking operations on level ground. Pal- lets with open ground support or pallets fitted with lateral boards (provided that the boards are outside the range of the load-bearing wheels) can be picked up. The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax.
B 1
0799.GB
B Description of the truck
1 Design and application
The ESE 20 is an electric four-wheel forklift truck with a lateral standing platform and a sitting aid. It is provided with an electrical steering wheel steering system. The ESE is designed for transport and order-picking operations on level ground. Pal- lets with open ground support or pallets fitted with lateral boards (provided that the boards are outside the range of the load-bearing wheels) can be picked up. The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax.
B 1
0799.GB
B Description of the truck
1 Design and application
The ESE 20 is an electric four-wheel forklift truck with a lateral standing platform and a sitting aid. It is provided with an electrical steering wheel steering system. The ESE is designed for transport and order-picking operations on level ground. Pal- lets with open ground support or pallets fitted with lateral boards (provided that the boards are outside the range of the load-bearing wheels) can be picked up. The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax.
Page 9
B 2
0799.GB
2 Assemblies
Item Designation Item Designation
1 t Controller 6 t Battery hood 2 o
o
Combined instrument
Information and service indicator
7 t Lifting device
8 t Drive wheel
9 t Supporting wheel 3 t Steering 10 t Dead man's switch 4 t Key switch 11 t Drive cover
5 t Master switch (emerg. stop) 12 t Sitting aid
t= Standard equipment o = Optional equipment
2 3 4 5
7
8
9
6
10
12
11
1
B 2
0799.GB
2 Assemblies
Item Designation Item Designation
1 t Controller 6 t Battery hood 2 o
o
Combined instrument
Information and service indicator
7 t Lifting device
8 t Drive wheel
9 t Supporting wheel 3 t Steering 10 t Dead man's switch 4 t Key switch 11 t Drive cover
5 t Master switch (emerg. stop) 12 t Sitting aid
t= Standard equipment o = Optional equipment
2 3 4 5
7
8
9
6
10
12
11
1
B 2
0799.GB
2 Assemblies
Item Designation Item Designation
1 t Controller 6 t Battery hood 2 o
o
Combined instrument
Information and service indicator
7 t Lifting device
8 t Drive wheel
9 t Supporting wheel 3 t Steering 10 t Dead man's switch 4 t Key switch 11 t Drive cover
5 t Master switch (emerg. stop) 12 t Sitting aid
t= Standard equipment o = Optional equipment
2 3 4 5
7
8
9
6
10
12
11
1
Page 10
B 3
0799.GB
2.1 Technical data - standard version
A
Indication of technical data according to VDI 2198, subject to modification and supplementing.
2.2 Performance data
Designation
StandardtRapid drive
o
Q Rated capacity 2000 2000 kg
C Load centre distance 600 600 mm
Travelling speed
with / without rated load
8.5 / 10.5 9.5 / 12.5 km/h
Lifting speed
with / without rated load
4.0 / 5.0 4.0 / 5.0 cm/s
Lowering speed
with / without rated load
6.5 / 4.0 6.5 / 4.0 cm/s
h
3
l
2
b
1
a
_ 2
a
_ 2
b
12
l
1
l
6
A
st3
W
a
x
l
y
C
Q
h
13
b5b
3
e
b
11
B 3
0799.GB
2.1 Technical data - standard version
A
Indication of technical data according to VDI 2198, subject to modification and supplementing.
2.2 Performance data
Designation
StandardtRapid drive
o
Q Rated capacity 2000 2000 kg
C Load centre distance 600 600 mm
Travelling speed
with / without rated load
8.5 / 10.5 9.5 / 12.5 km/h
Lifting speed
with / without rated load
4.0 / 5.0 4.0 / 5.0 cm/s
Lowering speed
with / without rated load
6.5 / 4.0 6.5 / 4.0 cm/s
h
3
l
2
b
1
a
_ 2
a
_ 2
b
12
l
1
l
6
A
st3
W
a
x
l
y
C
Q
h
13
b5b
3
e
b
11
B 3
0799.GB
2.1 Technical data - standard version
A
Indication of technical data according to VDI 2198, subject to modification and supplementing.
2.2 Performance data
Designation
StandardtRapid drive
o
Q Rated capacity 2000 2000 kg
C Load centre distance 600 600 mm
Travelling speed
with / without rated load
8.5 / 10.5 9.5 / 12.5 km/h
Lifting speed
with / without rated load
4.0 / 5.0 4.0 / 5.0 cm/s
Lowering speed
with / without rated load
6.5 / 4.0 6.5 / 4.0 cm/s
h
3
l
2
b
1
a
_ 2
a
_ 2
b
12
l
1
l
6
A
st3
W
a
x
l
y
C
Q
h
13
b5b
3
e
b
11
Page 11
B 4
0799.GB
2.3 Dimensions (all dimensions in mm)
Working aisle widths (Short l2 = 874) (all dimensions in mm)
1)
With the load part lifted, the values are reduced by 90 mm.
Designation
Short
Long
l
2
Design length of front 874 946
h
13
Height of fork when lowered 90 90
h
3
Lift 125 125
b
1
Truck width 760 760
b
5
Distance between forks, outside 510 / 540 / 660 510 / 540 / 660
b
11
Track 340 / 370 / 490 340 / 370 / 490
b
3
Distance between forks, inside 170 / 200 / 330 170 / 200 / 330
e Fork width 170 170
a Safety distance 200 200
Dead weight Refer to truck identification label
ll1y
1)
x
1)
l
6
W
a
1)
A
st3
1000 1874 1509 814 1000 1688 2074
1150 2024 1659 964 1200 1838 2274
1200 2074 1709 1014 1200 1888 2274
1400 2274 1909 1214 1400 2088 2474
1600 2474 2109 1414 1600 2288 2674
1950 2824 2087 1392 2000 2266 3074
2150 3024 2287 1592 2100 2466 3174
2400 3274 2535 1840 2400 2714 3474
B 4
0799.GB
2.3 Dimensions (all dimensions in mm)
Working aisle widths (Short l2 = 874) (all dimensions in mm)
1)
With the load part lifted, the values are reduced by 90 mm.
Designation
Short
Long
l
2
Design length of front 874 946
h
13
Height of fork when lowered 90 90
h
3
Lift 125 125
b
1
Truck width 760 760
b
5
Distance between forks, outside 510 / 540 / 660 510 / 540 / 660
b
11
Track 340 / 370 / 490 340 / 370 / 490
b
3
Distance between forks, inside 170 / 200 / 330 170 / 200 / 330
e Fork width 170 170
a Safety distance 200 200
Dead weight Refer to truck identification label
ll1y
1)
x
1)
l
6
W
a
1)
A
st3
1000 1874 1509 814 1000 1688 2074
1150 2024 1659 964 1200 1838 2274
1200 2074 1709 1014 1200 1888 2274
1400 2274 1909 1214 1400 2088 2474
1600 2474 2109 1414 1600 2288 2674
1950 2824 2087 1392 2000 2266 3074
2150 3024 2287 1592 2100 2466 3174
2400 3274 2535 1840 2400 2714 3474
B 4
0799.GB
2.3 Dimensions (all dimensions in mm)
Working aisle widths (Short l2 = 874) (all dimensions in mm)
1)
With the load part lifted, the values are reduced by 90 mm.
Designation
Short
Long
l
2
Design length of front 874 946
h
13
Height of fork when lowered 90 90
h
3
Lift 125 125
b
1
Truck width 760 760
b
5
Distance between forks, outside 510 / 540 / 660 510 / 540 / 660
b
11
Track 340 / 370 / 490 340 / 370 / 490
b
3
Distance between forks, inside 170 / 200 / 330 170 / 200 / 330
e Fork width 170 170
a Safety distance 200 200
Dead weight Refer to truck identification label
ll1y
1)
x
1)
l
6
W
a
1)
A
st3
1000 1874 1509 814 1000 1688 2074
1150 2024 1659 964 1200 1838 2274
1200 2074 1709 1014 1200 1888 2274
1400 2274 1909 1214 1400 2088 2474
1600 2474 2109 1414 1600 2288 2674
1950 2824 2087 1392 2000 2266 3074
2150 3024 2287 1592 2100 2466 3174
2400 3274 2535 1840 2400 2714 3474
Page 12
B 5
0799.GB
Working aisle widths (Long l2 = 946) (all dimensions in mm)
1)
With the load part lifted, the values are reduced by 90 mm.
ll
1
y
1)
x
1)
l
6
W
a
1)
A
st3
1000 1946 1581 814 1000 1760 2146
1150 2096 1731 964 1200 1910 2346
1200 2146 1781 1014 1200 1950 2346
1400 2346 1981 1214 1400 2160 2546
1600 2546 2181 1414 1600 2360 2746
1950 2896 2159 1392 2000 2338 3146
2150 3096 2359 1592 2100 2538 3246
2400 3346 2607 1840 2400 2786 3546
h
3
l
2
b
1
a
_ 2
a
_ 2
b
12
l
1
l
6
A
st3
W
a
x
l
y
C
Q
h
13
b5b
3
e
b
11
B 5
0799.GB
Working aisle widths (Long l2 = 946) (all dimensions in mm)
1)
With the load part lifted, the values are reduced by 90 mm.
ll
1
y
1)
x
1)
l
6
W
a
1)
A
st3
1000 1946 1581 814 1000 1760 2146
1150 2096 1731 964 1200 1910 2346
1200 2146 1781 1014 1200 1950 2346
1400 2346 1981 1214 1400 2160 2546
1600 2546 2181 1414 1600 2360 2746
1950 2896 2159 1392 2000 2338 3146
2150 3096 2359 1592 2100 2538 3246
2400 3346 2607 1840 2400 2786 3546
h
3
l
2
b
1
a
_ 2
a
_ 2
b
12
l
1
l
6
A
st3
W
a
x
l
y
C
Q
h
13
b5b
3
e
b
11
B 5
0799.GB
Working aisle widths (Long l2 = 946) (all dimensions in mm)
1)
With the load part lifted, the values are reduced by 90 mm.
ll
1
y
1)
x
1)
l
6
W
a
1)
A
st3
1000 1946 1581 814 1000 1760 2146
1150 2096 1731 964 1200 1910 2346
1200 2146 1781 1014 1200 1950 2346
1400 2346 1981 1214 1400 2160 2546
1600 2546 2181 1414 1600 2360 2746
1950 2896 2159 1392 2000 2338 3146
2150 3096 2359 1592 2100 2538 3246
2400 3346 2607 1840 2400 2786 3546
h
3
l
2
b
1
a
_ 2
a
_ 2
b
12
l
1
l
6
A
st3
W
a
x
l
y
C
Q
h
13
b5b
3
e
b
11
Page 13
B 6
0799.GB
2.4 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871.
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0,62m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The following limit values are observed according to prEN 12895 “Electromagnetic Compatibility of Industrial Trucks”:
- interference emission (EN 50 081-1)
- interference immunity (EN 50 082-2)
- electrostatic discharge (EN 61 000-4-2)
A
Electrical or electronic components and their arrangement may only be modified after written approval by the JUNGHEINRICH AG has been obtained.
2.5 Conditions for application
Ambient temperature:
- in operation: 5°C to 40°C
A
When the truck is continually operated at temperatures below 5°C, in cold stores or at extreme fluctuations of temperature or humidity, special equipment and a special approval are required for industrial trucks.
B 6
0799.GB
2.4 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871.
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0,62m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The following limit values are observed according to prEN 12895 “Electromagnetic Compatibility of Industrial Trucks”:
- interference emission (EN 50 081-1)
- interference immunity (EN 50 082-2)
- electrostatic discharge (EN 61 000-4-2)
A
Electrical or electronic components and their arrangement may only be modified after written approval by the JUNGHEINRICH AG has been obtained.
2.5 Conditions for application
Ambient temperature:
- in operation: 5°C to 40°C
A
When the truck is continually operated at temperatures below 5°C, in cold stores or at extreme fluctuations of temperature or humidity, special equipment and a special approval are required for industrial trucks.
B 6
0799.GB
2.4 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871.
A
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0,62m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The following limit values are observed according to prEN 12895 “Electromagnetic Compatibility of Industrial Trucks”:
- interference emission (EN 50 081-1)
- interference immunity (EN 50 082-2)
- electrostatic discharge (EN 61 000-4-2)
A
Electrical or electronic components and their arrangement may only be modified after written approval by the JUNGHEINRICH AG has been obtained.
2.5 Conditions for application
Ambient temperature:
- in operation: 5°C to 40°C
A
When the truck is continually operated at temperatures below 5°C, in cold stores or at extreme fluctuations of temperature or humidity, special equipment and a special approval are required for industrial trucks.
Page 14
B 7
0799.GB
3 Labels
A
The capacity label (15) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded.
Item Designation
13 Accident prevention inspection label (D only)
14 Truck identification plate
15 Capacity Qmax
16 Attachment point of hooks for transportation by crane
17 Label “CAUTION: Low-voltage electronics”
Nächste Prüfung
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2
00
0
Regelmäßige Prüfung
nach UVV VBG 12 a/ 12 b
§20 durch Sachkundigen
Ihr Kundendienst-Partner
Kundendienst
Jungheinrich Aktiengesellschaft • Hamburg
V kg kg
kgkg mm
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxx
Xxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Ah
Q
max
2000
kg
16
13
14
15
16
mV
1,5 V
17
B 7
0799.GB
3 Labels
A
The capacity label (15) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded.
Item Designation
13 Accident prevention inspection label (D only)
14 Truck identification plate
15 Capacity Qmax
16 Attachment point of hooks for transportation by crane
17 Label “CAUTION: Low-voltage electronics”
Nächste Prüfung
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2
00
0
Regelmäßige Prüfung
nach UVV VBG 12 a/ 12 b
§20 durch Sachkundigen
Ihr Kundendienst-Partner
Kundendienst
Jungheinrich Aktiengesellschaft • Hamburg
V kg kg
kgkg mm
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxx
Xxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Ah
Q
max
2000
kg
16
13
14
15
16
mV
1,5 V
17
B 7
0799.GB
3 Labels
A
The capacity label (15) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded.
Item Designation
13 Accident prevention inspection label (D only)
14 Truck identification plate
15 Capacity Qmax
16 Attachment point of hooks for transportation by crane
17 Label “CAUTION: Low-voltage electronics”
Nächste Prüfung
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2
00
0
Regelmäßige Prüfung
nach UVV VBG 12 a/ 12 b
§20 durch Sachkundigen
Ihr Kundendienst-Partner
Kundendienst
Jungheinrich Aktiengesellschaft • Hamburg
V kg kg
kgkg mm
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxx
Xxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Ah
Q
max
2000
kg
16
13
14
15
16
mV
1,5 V
17
Page 15
B 8
0799.GB
3.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial No. (19) of the truck.
Item Designation Item Designation
18 Type 24 Load centre distance in mm
19 Serial No. (truck No.) 25 Min./max. battery weight in kg
20 Order No. 26 Net weight without battery in kg
21 Rated capacity in kg 27 Year of manufacture
22 Battery: Voltage V
Ampere hours Ah
28 Type No.
23 Manufacturer
Jungheinrich Aktiengesellschaft • Hamburg
V kg kg
kgkg mm
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxx
Xxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Ah
18
19
20
21
22
23
24
28
27
26
25
B 8
0799.GB
3.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial No. (19) of the truck.
Item Designation Item Designation
18 Type 24 Load centre distance in mm
19 Serial No. (truck No.) 25 Min./max. battery weight in kg
20 Order No. 26 Net weight without battery in kg
21 Rated capacity in kg 27 Year of manufacture
22 Battery: Voltage V
Ampere hours Ah
28 Type No.
23 Manufacturer
Jungheinrich Aktiengesellschaft • Hamburg
V kg kg
kgkg mm
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxx
Xxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Ah
18
19
20
21
22
23
24
28
27
26
25
B 8
0799.GB
3.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial No. (19) of the truck.
Item Designation Item Designation
18 Type 24 Load centre distance in mm
19 Serial No. (truck No.) 25 Min./max. battery weight in kg
20 Order No. 26 Net weight without battery in kg
21 Rated capacity in kg 27 Year of manufacture
22 Battery: Voltage V
Ampere hours Ah
28 Type No.
23 Manufacturer
Jungheinrich Aktiengesellschaft • Hamburg
V kg kg
kgkg mm
Xxx Xxxx
Xxxxxxx Xxxxxxxxx
Xxxxxx
Xxxxxxxxx Xxxxxxxxxx
Xxxxx Xxxx
Xxxxxxx Xxxxxx
Xxxxxx Xxxxxx
Xxxxxx
Xxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Ah
18
19
20
21
22
23
24
28
27
26
25
Page 16
C 1
0499.GB
C Transportation and commissioning
1 Transportation by crane
f
Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).
A
Lifting gear attachment points are provided on the chassis (1) and the fork (2) in case the truck is to be lifted or transported by crane.
- Park the truck and render it safe (refer to chapter E, section 4.5).
- Secure the lifting gear to the attachment points (1) and (2).
m
The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip and cannot come into contact with any attachments of the truck when the truck is lifted.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
- Check the truck for completeness and satisfactory condition of the equipment.
- If necessary, install the battery. Do not damage the battery cable. (See chapter D, section 5.)
- Charge the battery (refer to chapter D, section 4).
o
- If necessary, check whether the combined instrument setting or the information and service indicator displays the required battery type (see chapter D, section 7 and/or section 7).
- Commission the truck as detailed in chapter E, section 3.
A
When the truck is parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
1
2
C 1
0499.GB
C Transportation and commissioning
1 Transportation by crane
f
Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).
A
Lifting gear attachment points are provided on the chassis (1) and the fork (2) in case the truck is to be lifted or transported by crane.
- Park the truck and render it safe (refer to chapter E, section 4.5).
- Secure the lifting gear to the attachment points (1) and (2).
m
The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip and cannot come into contact with any attachments of the truck when the truck is lifted.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
- Check the truck for completeness and satisfactory condition of the equipment.
- If necessary, install the battery. Do not damage the battery cable. (See chapter D, section 5.)
- Charge the battery (refer to chapter D, section 4).
o
- If necessary, check whether the combined instrument setting or the information and service indicator displays the required battery type (see chapter D, section 7 and/or section 7).
- Commission the truck as detailed in chapter E, section 3.
A
When the truck is parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
1
2
C 1
0499.GB
C Transportation and commissioning
1 Transportation by crane
f
Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).
A
Lifting gear attachment points are provided on the chassis (1) and the fork (2) in case the truck is to be lifted or transported by crane.
- Park the truck and render it safe (refer to chapter E, section 4.5).
- Secure the lifting gear to the attachment points (1) and (2).
m
The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip and cannot come into contact with any attachments of the truck when the truck is lifted.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
- Check the truck for completeness and satisfactory condition of the equipment.
- If necessary, install the battery. Do not damage the battery cable. (See chapter D, section 5.)
- Charge the battery (refer to chapter D, section 4).
o
- If necessary, check whether the combined instrument setting or the information and service indicator displays the required battery type (see chapter D, section 7 and/or section 7).
- Commission the truck as detailed in chapter E, section 3.
A
When the truck is parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
1
2
Page 17
C 2
0499.GB
3 Moving the truck with the drive unit inoperative
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 master switch to position “OFF”.
- Set the key switch to position “OFF” (“0”) and remove the key.
- Ensure that the truck cannot accidentally move.
- Remove the drive cover (5) and put it aside.
- Slacken the lock nuts (4) and tighten the screws (3).
The brake has now been released and the truck can be moved.
f
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition.
- Loosen the screws (3) by approx. 5 mm and lock by tightening the lock nuts (4).
The brake is now applied again.
- Mount the drive cover (5).
4
3
4
3
5
C 2
0499.GB
3 Moving the truck with the drive unit inoperative
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 master switch to position “OFF”.
- Set the key switch to position “OFF” (“0”) and remove the key.
- Ensure that the truck cannot accidentally move.
- Remove the drive cover (5) and put it aside.
- Slacken the lock nuts (4) and tighten the screws (3).
The brake has now been released and the truck can be moved.
f
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition.
- Loosen the screws (3) by approx. 5 mm and lock by tightening the lock nuts (4).
The brake is now applied again.
- Mount the drive cover (5).
4
3
4
3
5
C 2
0499.GB
3 Moving the truck with the drive unit inoperative
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 master switch to position “OFF”.
- Set the key switch to position “OFF” (“0”) and remove the key.
- Ensure that the truck cannot accidentally move.
- Remove the drive cover (5) and put it aside.
- Slacken the lock nuts (4) and tighten the screws (3).
The brake has now been released and the truck can be moved.
f
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition.
- Loosen the screws (3) by approx. 5 mm and lock by tightening the lock nuts (4).
The brake is now applied again.
- Mount the drive cover (5).
4
3
4
3
5
Page 18
D 1
0499.GB
D Battery - servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
f
Before undertaking any operations on the batteries, park the truck and render it safe (refer to chapter E, section 4.5).
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual and the instructions as prepared by the battery supplier and as available at the battery recharging station must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 metres of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with non-isolated poles must be covered with a non- slip isolation mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be damaged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.
m
Only batteries with closed battery trough may be used.
f
The battery weight and dimensions have a considerable effect on the operational safety of the truck. Battery type changes are therefore permitted only after obtaining approval from JUNGHEINRICH.
D 1
0499.GB
D Battery - servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
f
Before undertaking any operations on the batteries, park the truck and render it safe (refer to chapter E, section 4.5).
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual and the instructions as prepared by the battery supplier and as available at the battery recharging station must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 metres of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with non-isolated poles must be covered with a non- slip isolation mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be damaged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.
m
Only batteries with closed battery trough may be used.
f
The battery weight and dimensions have a considerable effect on the operational safety of the truck. Battery type changes are therefore permitted only after obtaining approval from JUNGHEINRICH.
D 1
0499.GB
D Battery - servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
f
Before undertaking any operations on the batteries, park the truck and render it safe (refer to chapter E, section 4.5).
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual and the instructions as prepared by the battery supplier and as available at the battery recharging station must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 metres of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with non-isolated poles must be covered with a non- slip isolation mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be damaged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.
m
Only batteries with closed battery trough may be used.
f
The battery weight and dimensions have a considerable effect on the operational safety of the truck. Battery type changes are therefore permitted only after obtaining approval from JUNGHEINRICH.
Page 19
D 2
0499.GB
2 Battery types
Depending on the truck version, the truck will be supplied with different battery types.
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.
m
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 and render it safe (refer to chapter E, section 4.5).
- Press the lock (3) and lift the battery hood (2) slightly up- wards. Then pull it to the front and remove it.
- Press the lock (5), bend the side panel (4) aside and re- move it by pulling it upwards.
f
Open and close the battery hood and side panel carefully.
- Installation is in the reverse order.
f
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
24V - PzS - battery Short 3 PzS 300L-B
24V - PzS - batteryperformance-enhanced Short 3 PzS 360HX-B
24V - PzS - battery Long 4 PzS 440L-B
24V - PzS - batteryperformance-enhanced Long 4 PzS 480HX-B
1
3
5
4
2
D 2
0499.GB
2 Battery types
Depending on the truck version, the truck will be supplied with different battery types.
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.
m
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 and render it safe (refer to chapter E, section 4.5).
- Press the lock (3) and lift the battery hood (2) slightly up- wards. Then pull it to the front and remove it.
- Press the lock (5), bend the side panel (4) aside and re- move it by pulling it upwards.
f
Open and close the battery hood and side panel carefully.
- Installation is in the reverse order.
f
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
24V - PzS - battery Short 3 PzS 300L-B
24V - PzS - batteryperformance-enhanced Short 3 PzS 360HX-B
24V - PzS - battery Long 4 PzS 440L-B
24V - PzS - batteryperformance-enhanced Long 4 PzS 480HX-B
1
3
5
4
2
D 2
0499.GB
2 Battery types
Depending on the truck version, the truck will be supplied with different battery types.
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.
m
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 and render it safe (refer to chapter E, section 4.5).
- Press the lock (3) and lift the battery hood (2) slightly up- wards. Then pull it to the front and remove it.
- Press the lock (5), bend the side panel (4) aside and re- move it by pulling it upwards.
f
Open and close the battery hood and side panel carefully.
- Installation is in the reverse order.
f
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
24V - PzS - battery Short 3 PzS 300L-B
24V - PzS - batteryperformance-enhanced Short 3 PzS 360HX-B
24V - PzS - battery Long 4 PzS 440L-B
24V - PzS - batteryperformance-enhanced Long 4 PzS 480HX-B
1
3
5
4
2
Page 20
D 3
0499.GB
4 Charging the battery
f
To charge the battery, the truck must be parked in a closed and properly ventilated room.
- Expose the battery (refer to chapter D, section 3).
m
The battery connector (1) and the charging cable (6) must only be connected or disconnected with the truck and the battery charger switched off. The master switch must also only be actuated with the truck and the battery charger switched off.
f
During the recharging operation, the tops of the battery cells must be exposed to ensure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
- Withdraw the battery connector (1).
- Remove any insulating mats from the battery.
- Connect the charging cable (6) of the battery charger to the battery connector (1) and switch on the charger.
m
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
1
6
D 3
0499.GB
4 Charging the battery
f
To charge the battery, the truck must be parked in a closed and properly ventilated room.
- Expose the battery (refer to chapter D, section 3).
m
The battery connector (1) and the charging cable (6) must only be connected or disconnected with the truck and the battery charger switched off. The master switch must also only be actuated with the truck and the battery charger switched off.
f
During the recharging operation, the tops of the battery cells must be exposed to ensure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
- Withdraw the battery connector (1).
- Remove any insulating mats from the battery.
- Connect the charging cable (6) of the battery charger to the battery connector (1) and switch on the charger.
m
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
1
6
D 3
0499.GB
4 Charging the battery
f
To charge the battery, the truck must be parked in a closed and properly ventilated room.
- Expose the battery (refer to chapter D, section 3).
m
The battery connector (1) and the charging cable (6) must only be connected or disconnected with the truck and the battery charger switched off. The master switch must also only be actuated with the truck and the battery charger switched off.
f
During the recharging operation, the tops of the battery cells must be exposed to ensure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
- Withdraw the battery connector (1).
- Remove any insulating mats from the battery.
- Connect the charging cable (6) of the battery charger to the battery connector (1) and switch on the charger.
m
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
1
6
Page 21
D 4
0499.GB
5 Removing and installing the battery
f
The truck must be parked on level ground. To prevent short-circuits, batteries with exposed poles or cell connectors must be covered using a rubber mat. Place the battery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
m
When transporting batteries with the aid of a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points in such a way that the lifting gear, when slack, cannot collapse on the battery cells.
- Expose the battery (refer to chapter D, section 3).
- Withdraw the battery connector (1).
- Detach the battery cable from the cable guide (7).
- Remove the red battery lock (9).
- Pull the battery (8) laterally onto the battery change station.
f
Heed the operating instructions of the manufacturer of the battery exchange trolley!
Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.
f
After reinstallation of the battery, visually check all leads and connectors for damage. Ensure that the battery is firmly secured in the truck to prevent any damage caused by sudden movements of the truck. Make sure that the red battery lock (9) is properly attached. The battery hood and the side panel must be properly closed.
8
7
9
D 4
0499.GB
5 Removing and installing the battery
f
The truck must be parked on level ground. To prevent short-circuits, batteries with exposed poles or cell connectors must be covered using a rubber mat. Place the battery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
m
When transporting batteries with the aid of a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points in such a way that the lifting gear, when slack, cannot collapse on the battery cells.
- Expose the battery (refer to chapter D, section 3).
- Withdraw the battery connector (1).
- Detach the battery cable from the cable guide (7).
- Remove the red battery lock (9).
- Pull the battery (8) laterally onto the battery change station.
f
Heed the operating instructions of the manufacturer of the battery exchange trolley!
Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.
f
After reinstallation of the battery, visually check all leads and connectors for damage. Ensure that the battery is firmly secured in the truck to prevent any damage caused by sudden movements of the truck. Make sure that the red battery lock (9) is properly attached. The battery hood and the side panel must be properly closed.
8
7
9
D 4
0499.GB
5 Removing and installing the battery
f
The truck must be parked on level ground. To prevent short-circuits, batteries with exposed poles or cell connectors must be covered using a rubber mat. Place the battery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
m
When transporting batteries with the aid of a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points in such a way that the lifting gear, when slack, cannot collapse on the battery cells.
- Expose the battery (refer to chapter D, section 3).
- Withdraw the battery connector (1).
- Detach the battery cable from the cable guide (7).
- Remove the red battery lock (9).
- Pull the battery (8) laterally onto the battery change station.
f
Heed the operating instructions of the manufacturer of the battery exchange trolley!
Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.
f
After reinstallation of the battery, visually check all leads and connectors for damage. Ensure that the battery is firmly secured in the truck to prevent any damage caused by sudden movements of the truck. Make sure that the red battery lock (9) is properly attached. The battery hood and the side panel must be properly closed.
8
7
9
Page 22
D 5
0499.GB
6
o
Combined instrument
Battery discharge indicator: The charging
condition of the battery is indicated in 10% increments by means of ten bars shown on the battery symbol (10).
With progressive depletion of the battery, the illuminated bars will go out from the top downwards.
m
When using maintenance-free batteries, the instrument must be set so that the “T” symbol (13) will appear next to the operating hour display. When this setting is not performed, the battery might suffer damage caused by exhaustive discharge. Setting of the instrument should be performed by JUNGHEINRICH service staff.
An advance “CAUTION” symbol (11) will appear at a residual battery capacity of
- 30% in the case of standard batteries and
- 50% in the case of maintenance-free batteries.
Battery recharging is now advisable.
The advance “CAUTION” symbol (11) will go out and a flashing “STOP” symbol (12) will appear at a residual battery capacity of
- 20% in the case of standard batteries and
- 40% in the case of maintenance-free batteries.
After a period of 5 minutes, the “STOP” symbol (12) will remain permanently lit. Battery recharging is now required.
Battery discharge monitor: As soon as the “STOP” symbol (12) is permanently displayed, the lifting function of the truck will be automatically switched off.
A
Lifting will only become possible again after the battery has been recharged to at least 70%.
Hour meter: The hour meter (14) integrated into the battery discharge indicator shows the total operating time of the travelling and lifting movements.
A
In the operative condition, the digit after the comma will flash.
h
h
h
STOP
T
T
T
10
11
12
13
14
D 5
0499.GB
6
o
Combined instrument
Battery discharge indicator: The charging
condition of the battery is indicated in 10% increments by means of ten bars shown on the battery symbol (10).
With progressive depletion of the battery, the illuminated bars will go out from the top downwards.
m
When using maintenance-free batteries, the instrument must be set so that the “T” symbol (13) will appear next to the operating hour display. When this setting is not performed, the battery might suffer damage caused by exhaustive discharge. Setting of the instrument should be performed by JUNGHEINRICH service staff.
An advance “CAUTION” symbol (11) will appear at a residual battery capacity of
- 30% in the case of standard batteries and
- 50% in the case of maintenance-free batteries.
Battery recharging is now advisable.
The advance “CAUTION” symbol (11) will go out and a flashing “STOP” symbol (12) will appear at a residual battery capacity of
- 20% in the case of standard batteries and
- 40% in the case of maintenance-free batteries.
After a period of 5 minutes, the “STOP” symbol (12) will remain permanently lit. Battery recharging is now required.
Battery discharge monitor: As soon as the “STOP” symbol (12) is permanently displayed, the lifting function of the truck will be automatically switched off.
A
Lifting will only become possible again after the battery has been recharged to at least 70%.
Hour meter: The hour meter (14) integrated into the battery discharge indicator shows the total operating time of the travelling and lifting movements.
A
In the operative condition, the digit after the comma will flash.
h
h
h
STOP
T
T
T
10
11
12
13
14
D 5
0499.GB
6
o
Combined instrument
Battery discharge indicator: The charging
condition of the battery is indicated in 10% increments by means of ten bars shown on the battery symbol (10).
With progressive depletion of the battery, the illuminated bars will go out from the top downwards.
m
When using maintenance-free batteries, the instrument must be set so that the “T” symbol (13) will appear next to the operating hour display. When this setting is not performed, the battery might suffer damage caused by exhaustive discharge. Setting of the instrument should be performed by JUNGHEINRICH service staff.
An advance “CAUTION” symbol (11) will appear at a residual battery capacity of
- 30% in the case of standard batteries and
- 50% in the case of maintenance-free batteries.
Battery recharging is now advisable.
The advance “CAUTION” symbol (11) will go out and a flashing “STOP” symbol (12) will appear at a residual battery capacity of
- 20% in the case of standard batteries and
- 40% in the case of maintenance-free batteries.
After a period of 5 minutes, the “STOP” symbol (12) will remain permanently lit. Battery recharging is now required.
Battery discharge monitor: As soon as the “STOP” symbol (12) is permanently displayed, the lifting function of the truck will be automatically switched off.
A
Lifting will only become possible again after the battery has been recharged to at least 70%.
Hour meter: The hour meter (14) integrated into the battery discharge indicator shows the total operating time of the travelling and lifting movements.
A
In the operative condition, the digit after the comma will flash.
h
h
h
STOP
T
T
T
10
11
12
13
14
Page 23
D 6
0499.GB
7
o
Battery discharge indicator, battery discharge monitor, operating hour meter
Battery discharge indicator: The loading status of the battery (15) is indicated in
steps of 10% on the information and service indicator.
m
The manufacturer setting of the battery discharge indicator / discharge monitor is standard batteries. If maintenance-free batteries are used, the indicator must be adjusted in such a way that the "T" symbol appears behind the percent specification. If this setting is not selected the battery may be dama- ged due to a complete discharge. Contact the JUNGHEINRICH customer service for setting the instrument.
If the remaining battery capacity falls below 30%, it is required to recharge the battery.
Battery discharge monitor: If the residual capacity falls below the specified mini- mum value, the lifting function is switched off. A corresponding message is displayed in the information and service indicator.
A
The lifting function will only then be released, if the connected battery is reloaded by min. 70%.
Operating hour meter: The operating hours (17) are indicated next to the loading status of the battery. The operating hour meter indicates the total time of all riding and lifting movements.
BATT T:0 0%4471h
15 16 17
D 6
0499.GB
7
o
Battery discharge indicator, battery discharge monitor, operating hour meter
Battery discharge indicator: The loading status of the battery (15) is indicated in
steps of 10% on the information and service indicator.
m
The manufacturer setting of the battery discharge indicator / discharge monitor is standard batteries. If maintenance-free batteries are used, the indicator must be adjusted in such a way that the "T" symbol appears behind the percent specification. If this setting is not selected the battery may be dama- ged due to a complete discharge. Contact the JUNGHEINRICH customer service for setting the instrument.
If the remaining battery capacity falls below 30%, it is required to recharge the battery.
Battery discharge monitor: If the residual capacity falls below the specified mini- mum value, the lifting function is switched off. A corresponding message is displayed in the information and service indicator.
A
The lifting function will only then be released, if the connected battery is reloaded by min. 70%.
Operating hour meter: The operating hours (17) are indicated next to the loading status of the battery. The operating hour meter indicates the total time of all riding and lifting movements.
BATT T:0 0%4471h
15 16 17
D 6
0499.GB
7
o
Battery discharge indicator, battery discharge monitor, operating hour meter
Battery discharge indicator: The loading status of the battery (15) is indicated in
steps of 10% on the information and service indicator.
m
The manufacturer setting of the battery discharge indicator / discharge monitor is standard batteries. If maintenance-free batteries are used, the indicator must be adjusted in such a way that the "T" symbol appears behind the percent specification. If this setting is not selected the battery may be dama- ged due to a complete discharge. Contact the JUNGHEINRICH customer service for setting the instrument.
If the remaining battery capacity falls below 30%, it is required to recharge the battery.
Battery discharge monitor: If the residual capacity falls below the specified mini- mum value, the lifting function is switched off. A corresponding message is displayed in the information and service indicator.
A
The lifting function will only then be released, if the connected battery is reloaded by min. 70%.
Operating hour meter: The operating hours (17) are indicated next to the loading status of the battery. The operating hour meter indicates the total time of all riding and lifting movements.
BATT T:0 0%4471h
15 16 17
Page 24
E 1
0799.GB
E Operation
1 Safety regulations governing the operation of the fork-lift truck
Driving permission: The fork-lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork-lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork-lift truck during working time. He must forbid unauthorised persons to drive or operate the fork- lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork-lift truck or on the attachments must immediately be brought to the notice of the person in charge. Fork- lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork-lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork-lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling/lowering truck attachments.
f
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork-lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
E 1
0799.GB
E Operation
1 Safety regulations governing the operation of the fork-lift truck
Driving permission: The fork-lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork-lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork-lift truck during working time. He must forbid unauthorised persons to drive or operate the fork- lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork-lift truck or on the attachments must immediately be brought to the notice of the person in charge. Fork- lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork-lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork-lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling/lowering truck attachments.
f
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork-lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
E 1
0799.GB
E Operation
1 Safety regulations governing the operation of the fork-lift truck
Driving permission: The fork-lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork-lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork-lift truck during working time. He must forbid unauthorised persons to drive or operate the fork- lift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork-lift truck or on the attachments must immediately be brought to the notice of the person in charge. Fork- lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork-lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork-lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling/lowering truck attachments.
f
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork-lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
Page 25
E 2
0799.GB
2 Description of the operating controls and indicators
Pos.
Bedien- bzw. Anzeigeelement
Funktion
1 Controller
t
Controls the direction of travel as well as the travelling speed.
2 Operating key “Lifting”
t
Lifts the lifting device.
3 Operating key “Lowering”
t
Lowers the lifting device.
4 Operating key “Horn”
t
Gives an audible warning signal.
5 Combined instrument
Information and service indicator
o
o
Indicates the remaining capacity of the battery and the hours of operation that the truck has already performed (see chapter D, section 6). Indicates important driving and lifting para- meters, warning messages, notes on operation faults and service information (see chapter E, section 5).
6Steering
t
Steering the truck.
7 Key switch
t
Switches the control current on and off. When the key is removed from the key switch, the truck cannot be operated by unauthorised persons.
8 Master switch
(emergency stop)
t
The circuit is interrupted, all electrical functions are switched off and the truck is automatically braked.
9 Dead man's switch
t
- released: Driving function blocked or truck is slowing down
- operated: Driving function released
10 Sitting aid adjusting screw
t
Adjusting the inclination angle of the sitting aid.
t
= Standard equipment
o
= Optional equipment
E 2
0799.GB
2 Description of the operating controls and indicators
Pos.
Bedien- bzw. Anzeigeelement
Funktion
1 Controller
t
Controls the direction of travel as well as the travelling speed.
2 Operating key “Lifting”
t
Lifts the lifting device.
3 Operating key “Lowering”
t
Lowers the lifting device.
4 Operating key “Horn”
t
Gives an audible warning signal.
5 Combined instrument
Information and service indicator
o
o
Indicates the remaining capacity of the battery and the hours of operation that the truck has already performed (see chapter D, section 6). Indicates important driving and lifting para- meters, warning messages, notes on operation faults and service information (see chapter E, section 5).
6Steering
t
Steering the truck.
7 Key switch
t
Switches the control current on and off. When the key is removed from the key switch, the truck cannot be operated by unauthorised persons.
8 Master switch
(emergency stop)
t
The circuit is interrupted, all electrical functions are switched off and the truck is automatically braked.
9 Dead man's switch
t
- released: Driving function blocked or truck is slowing down
- operated: Driving function released
10 Sitting aid adjusting screw
t
Adjusting the inclination angle of the sitting aid.
t
= Standard equipment
o
= Optional equipment
E 2
0799.GB
2 Description of the operating controls and indicators
Pos.
Bedien- bzw. Anzeigeelement
Funktion
1 Controller
t
Controls the direction of travel as well as the travelling speed.
2 Operating key “Lifting”
t
Lifts the lifting device.
3 Operating key “Lowering”
t
Lowers the lifting device.
4 Operating key “Horn”
t
Gives an audible warning signal.
5 Combined instrument
Information and service indicator
o
o
Indicates the remaining capacity of the battery and the hours of operation that the truck has already performed (see chapter D, section 6). Indicates important driving and lifting para- meters, warning messages, notes on operation faults and service information (see chapter E, section 5).
6Steering
t
Steering the truck.
7 Key switch
t
Switches the control current on and off. When the key is removed from the key switch, the truck cannot be operated by unauthorised persons.
8 Master switch
(emergency stop)
t
The circuit is interrupted, all electrical functions are switched off and the truck is automatically braked.
9 Dead man's switch
t
- released: Driving function blocked or truck is slowing down
- operated: Driving function released
10 Sitting aid adjusting screw
t
Adjusting the inclination angle of the sitting aid.
t
= Standard equipment
o
= Optional equipment
Page 26
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0799.GB
2 31
5106 7 8
9
4
E 3
0799.GB
2 31
5106 7 8
9
4
E 3
0799.GB
2 31
5106 7 8
9
4
Page 27
E 4
0799.GB
3 Starting up the truck
f
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
The electronic driving and steering systems automatically control their functions. If an error or fault occurs, the driving and steering functions are stopped.
f
Before the truck is restarted, it is required to perform the relevant troubleshooting actions.
Checks and operations to be performed before starting daily work
- Visually check the entire truck (especially the wheels and the lifting device) for visible damage.
- Visually check the battery attachment and the cable connections.
f
Do not operate the driving switch while mounting the truck.
Switching on the truck
- Step on to the standing platform.
- Pull up the master switch (8).
- Insert the key in the key switch (7) and turn the key clockwise towards the ”I” position until reaching the stop.
- Check the horn (4) for correct functioning.
- Check whether the deadman key (9) and driving switch (1) are properly functioning (see Deadman key E, driving switch 4.5).
The truck is now ready for operation.
o
Combined instrument
A
The combined instrument (5) shows the remaining battery capacity.
o
Information and service indicator
A
The information and service indicator (5) briefly displays the vehicle code, followed by the current steering position of the drive wheel, the available battery capacity and the hours of operation.
JUNGHEINRICH
ESE
BATT: 100% 20 h
E 4
0799.GB
3 Starting up the truck
f
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
The electronic driving and steering systems automatically control their functions. If an error or fault occurs, the driving and steering functions are stopped.
f
Before the truck is restarted, it is required to perform the relevant troubleshooting actions.
Checks and operations to be performed before starting daily work
- Visually check the entire truck (especially the wheels and the lifting device) for visible damage.
- Visually check the battery attachment and the cable connections.
f
Do not operate the driving switch while mounting the truck.
Switching on the truck
- Step on to the standing platform.
- Pull up the master switch (8).
- Insert the key in the key switch (7) and turn the key clockwise towards the ”I” position until reaching the stop.
- Check the horn (4) for correct functioning.
- Check whether the deadman key (9) and driving switch (1) are properly functioning (see Deadman key E, driving switch 4.5).
The truck is now ready for operation.
o
Combined instrument
A
The combined instrument (5) shows the remaining battery capacity.
o
Information and service indicator
A
The information and service indicator (5) briefly displays the vehicle code, followed by the current steering position of the drive wheel, the available battery capacity and the hours of operation.
JUNGHEINRICH
ESE
BATT: 100% 20 h
E 4
0799.GB
3 Starting up the truck
f
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
The electronic driving and steering systems automatically control their functions. If an error or fault occurs, the driving and steering functions are stopped.
f
Before the truck is restarted, it is required to perform the relevant troubleshooting actions.
Checks and operations to be performed before starting daily work
- Visually check the entire truck (especially the wheels and the lifting device) for visible damage.
- Visually check the battery attachment and the cable connections.
f
Do not operate the driving switch while mounting the truck.
Switching on the truck
- Step on to the standing platform.
- Pull up the master switch (8).
- Insert the key in the key switch (7) and turn the key clockwise towards the ”I” position until reaching the stop.
- Check the horn (4) for correct functioning.
- Check whether the deadman key (9) and driving switch (1) are properly functioning (see Deadman key E, driving switch 4.5).
The truck is now ready for operation.
o
Combined instrument
A
The combined instrument (5) shows the remaining battery capacity.
o
Information and service indicator
A
The information and service indicator (5) briefly displays the vehicle code, followed by the current steering position of the drive wheel, the available battery capacity and the hours of operation.
JUNGHEINRICH
ESE
BATT: 100% 20 h
Page 28
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0799.GB
7 8
9
4
1
E 5
0799.GB
7 8
9
4
1
E 5
0799.GB
7 8
9
4
1
Page 29
E 6
0799.GB
4 Operation of the fork-lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially
allocated for truck traffic must be used. Unauthorised persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork-lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork-lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork-lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork-lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork-lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. 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 together with the fork-lift truck must only enter the lift after the fork-lift truck has come safely to a standstill, and must leave the lift before the fork-lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork-lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
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4 Operation of the fork-lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially
allocated for truck traffic must be used. Unauthorised persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork-lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork-lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork-lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork-lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork-lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. 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 together with the fork-lift truck must only enter the lift after the fork-lift truck has come safely to a standstill, and must leave the lift before the fork-lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork-lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
.
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4 Operation of the fork-lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially
allocated for truck traffic must be used. Unauthorised persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork-lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork-lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork-lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork-lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork-lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. 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 together with the fork-lift truck must only enter the lift after the fork-lift truck has come safely to a standstill, and must leave the lift before the fork-lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork-lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
.
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4.2 Adjusting the sitting aid
The truck is provided with a sitting aid with adjustable angle. Folded up = backrest Folded down = sitting aid
m
Adjusting the sitting aid to the operator requirements.
- Fold down the sitting aid.
- Use the adjusting screw (10) to incline it in the desired position: Turning left = down, turning right = up.
f
The truck may only be operated and driven if the sitting aid is properly adjusted.
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4.2 Adjusting the sitting aid
The truck is provided with a sitting aid with adjustable angle. Folded up = backrest Folded down = sitting aid
m
Adjusting the sitting aid to the operator requirements.
- Fold down the sitting aid.
- Use the adjusting screw (10) to incline it in the desired position: Turning left = down, turning right = up.
f
The truck may only be operated and driven if the sitting aid is properly adjusted.
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4.2 Adjusting the sitting aid
The truck is provided with a sitting aid with adjustable angle. Folded up = backrest Folded down = sitting aid
m
Adjusting the sitting aid to the operator requirements.
- Fold down the sitting aid.
- Use the adjusting screw (10) to incline it in the desired position: Turning left = down, turning right = up.
f
The truck may only be operated and driven if the sitting aid is properly adjusted.
10
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4.3 Driving, steering, braking
f
Increased attention has to be paid during driving and steering the truck. The steering system is not automatically set to straight-through driving - thus be care- fully when starting to drive. If required, check the steering position on the information and service indicator (5) (o).
The electric steering system is self-monitoring.
The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switching the truck off and on again. This method prevents the cancellation of a fault without eliminating the fault.
f
As the steering system is a safety-relevant component, the fault must be eliminated by trained service personnel.
Emergency stop
- Depress the master switch (8).
This will switch off all electric functions.
Deadman key
The deadman key (9) has to be operated for all driving functions. If it is not operated, all functions are deactivated and the brake is actuated
o
The optionally available combined instrument (5) remains fully functioning as well as the information and service indicator (5).
8
9
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R
R
V
V
5
6
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4.3 Driving, steering, braking
f
Increased attention has to be paid during driving and steering the truck. The steering system is not automatically set to straight-through driving - thus be care- fully when starting to drive. If required, check the steering position on the information and service indicator (5) (o).
The electric steering system is self-monitoring.
The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switching the truck off and on again. This method prevents the cancellation of a fault without eliminating the fault.
f
As the steering system is a safety-relevant component, the fault must be eliminated by trained service personnel.
Emergency stop
- Depress the master switch (8).
This will switch off all electric functions.
Deadman key
The deadman key (9) has to be operated for all driving functions. If it is not operated, all functions are deactivated and the brake is actuated
o
The optionally available combined instrument (5) remains fully functioning as well as the information and service indicator (5).
8
9
1
R
R
V
V
5
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4.3 Driving, steering, braking
f
Increased attention has to be paid during driving and steering the truck. The steering system is not automatically set to straight-through driving - thus be care- fully when starting to drive. If required, check the steering position on the information and service indicator (5) (o).
The electric steering system is self-monitoring.
The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switching the truck off and on again. This method prevents the cancellation of a fault without eliminating the fault.
f
As the steering system is a safety-relevant component, the fault must be eliminated by trained service personnel.
Emergency stop
- Depress the master switch (8).
This will switch off all electric functions.
Deadman key
The deadman key (9) has to be operated for all driving functions. If it is not operated, all functions are deactivated and the brake is actuated
o
The optionally available combined instrument (5) remains fully functioning as well as the information and service indicator (5).
8
9
1
R
R
V
V
5
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Driving
f
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
- Start up the truck (refer to chapter E, section 3).
- Operate the deadman key (9).
f
The steering system is not automatically set to straight-through driving - thus be care- fully when starting to drive.
o
If required, check the steering position on the information and service indicator (5).
- Set the controller (1) to the required travelling direction: forwards (V) or reverse (R).
The truck will move in the selected direction.
A
The travelling speed is controlled by means of the controller.
Driving on inclines
m
Loads must always be carried at that end of the truck facing uphill.
Securing the truck against “rolling downhill”:
With the controller (1) set to “0”, the service brake is automatically applied after a short jerk (the control system detects rolling downhill on an incline). The service brake is released again via the controller (1), which is also used to select the speed and the travelling direction.
Steering
- Turn the steering wheel (6) to the left or to the right.
o
If necessary, the position of the steered wheel is indicated on the information and ser- vice indicator (5).
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Driving
f
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
- Start up the truck (refer to chapter E, section 3).
- Operate the deadman key (9).
f
The steering system is not automatically set to straight-through driving - thus be care- fully when starting to drive.
o
If required, check the steering position on the information and service indicator (5).
- Set the controller (1) to the required travelling direction: forwards (V) or reverse (R).
The truck will move in the selected direction.
A
The travelling speed is controlled by means of the controller.
Driving on inclines
m
Loads must always be carried at that end of the truck facing uphill.
Securing the truck against “rolling downhill”:
With the controller (1) set to “0”, the service brake is automatically applied after a short jerk (the control system detects rolling downhill on an incline). The service brake is released again via the controller (1), which is also used to select the speed and the travelling direction.
Steering
- Turn the steering wheel (6) to the left or to the right.
o
If necessary, the position of the steered wheel is indicated on the information and ser- vice indicator (5).
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Driving
f
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
- Start up the truck (refer to chapter E, section 3).
- Operate the deadman key (9).
f
The steering system is not automatically set to straight-through driving - thus be care- fully when starting to drive.
o
If required, check the steering position on the information and service indicator (5).
- Set the controller (1) to the required travelling direction: forwards (V) or reverse (R).
The truck will move in the selected direction.
A
The travelling speed is controlled by means of the controller.
Driving on inclines
m
Loads must always be carried at that end of the truck facing uphill.
Securing the truck against “rolling downhill”:
With the controller (1) set to “0”, the service brake is automatically applied after a short jerk (the control system detects rolling downhill on an incline). The service brake is released again via the controller (1), which is also used to select the speed and the travelling direction.
Steering
- Turn the steering wheel (6) to the left or to the right.
o
If necessary, the position of the steered wheel is indicated on the information and ser- vice indicator (5).
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Braking
f
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The truck may be braked in three ways:
- using the service brake (deadman key (9))
- using the generator brake (coasting)
- by counter-current braking (controller (1))
f
In case of emergencies, the truck must only be braked using the service brake (deadman key (9)).
A
During normal operation, the generator brake and counter-current braking should be applied. These methods of braking reduce wear and require less energy (energy recovery.
Braking by means of the service brake:
- Release the deadman key (9).
The truck is braked at the maximum possible deceleration rate until it stands still.
Braking by means of the generator brake (coasting):
- Release the controller (1) - the controller assumes the zero position.
Depending on the setting, the truck is braked by the generator braked, coasting to a stop.
A
The deceleration rate can be adjusted by the JUNGHEINRICH service organization.
8
9
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R
R
V
V
5
6
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Braking
f
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The truck may be braked in three ways:
- using the service brake (deadman key (9))
- using the generator brake (coasting)
- by counter-current braking (controller (1))
f
In case of emergencies, the truck must only be braked using the service brake (deadman key (9)).
A
During normal operation, the generator brake and counter-current braking should be applied. These methods of braking reduce wear and require less energy (energy recovery.
Braking by means of the service brake:
- Release the deadman key (9).
The truck is braked at the maximum possible deceleration rate until it stands still.
Braking by means of the generator brake (coasting):
- Release the controller (1) - the controller assumes the zero position.
Depending on the setting, the truck is braked by the generator braked, coasting to a stop.
A
The deceleration rate can be adjusted by the JUNGHEINRICH service organization.
8
9
1
R
R
V
V
5
6
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Braking
f
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The truck may be braked in three ways:
- using the service brake (deadman key (9))
- using the generator brake (coasting)
- by counter-current braking (controller (1))
f
In case of emergencies, the truck must only be braked using the service brake (deadman key (9)).
A
During normal operation, the generator brake and counter-current braking should be applied. These methods of braking reduce wear and require less energy (energy recovery.
Braking by means of the service brake:
- Release the deadman key (9).
The truck is braked at the maximum possible deceleration rate until it stands still.
Braking by means of the generator brake (coasting):
- Release the controller (1) - the controller assumes the zero position.
Depending on the setting, the truck is braked by the generator braked, coasting to a stop.
A
The deceleration rate can be adjusted by the JUNGHEINRICH service organization.
8
9
1
R
R
V
V
5
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Counter-current braking
- While travelling, turn the controller (1) to the opposite direction.
The truck is braked by counter-current until it starts moving into the opposite direction.
A
The braking effect depends on the position of the controller.
4.4 Picking up and setting down loads
m
Before picking up a load, the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded.
- Pass the lifting device as far as possible under the load. Picking up long loads crosswise is not permitted.
m
Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm).
Lifting and lowering
A
When operating the keys “Lifting” or “Lowering”, the lifting or lowering movement will be at a fixed speed.
Lifting
- Depress operating key “Lifting” (2) until the required lifting height has been reached.
Lowering
- Depress operating key “Lowering” (3); the fork is lowered.
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Counter-current braking
- While travelling, turn the controller (1) to the opposite direction.
The truck is braked by counter-current until it starts moving into the opposite direction.
A
The braking effect depends on the position of the controller.
4.4 Picking up and setting down loads
m
Before picking up a load, the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded.
- Pass the lifting device as far as possible under the load. Picking up long loads crosswise is not permitted.
m
Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm).
Lifting and lowering
A
When operating the keys “Lifting” or “Lowering”, the lifting or lowering movement will be at a fixed speed.
Lifting
- Depress operating key “Lifting” (2) until the required lifting height has been reached.
Lowering
- Depress operating key “Lowering” (3); the fork is lowered.
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Counter-current braking
- While travelling, turn the controller (1) to the opposite direction.
The truck is braked by counter-current until it starts moving into the opposite direction.
A
The braking effect depends on the position of the controller.
4.4 Picking up and setting down loads
m
Before picking up a load, the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded.
- Pass the lifting device as far as possible under the load. Picking up long loads crosswise is not permitted.
m
Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm).
Lifting and lowering
A
When operating the keys “Lifting” or “Lowering”, the lifting or lowering movement will be at a fixed speed.
Lifting
- Depress operating key “Lifting” (2) until the required lifting height has been reached.
Lowering
- Depress operating key “Lowering” (3); the fork is lowered.
32
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4.5 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
f
Never park the truck on a slope or incline. The lifting device must always be completely lowered.
- Lower the lifting device.
- Set the drive wheel to the "straight ahead position". Turn the steering wheel (6) until the drive wheel is set to its straight ahead position.
o
If required, check the steering angle indica- tion on the information and service indicator (5).
- Switch the key switch (7) to position “OFF” (“0”) and remove the key.
- Depress the master switch (emergency cut-out) (8) to the “OFF” position.
8
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6
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4.5 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
f
Never park the truck on a slope or incline. The lifting device must always be completely lowered.
- Lower the lifting device.
- Set the drive wheel to the "straight ahead position". Turn the steering wheel (6) until the drive wheel is set to its straight ahead position.
o
If required, check the steering angle indica- tion on the information and service indicator (5).
- Switch the key switch (7) to position “OFF” (“0”) and remove the key.
- Depress the master switch (emergency cut-out) (8) to the “OFF” position.
8
5
6
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4.5 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
f
Never park the truck on a slope or incline. The lifting device must always be completely lowered.
- Lower the lifting device.
- Set the drive wheel to the "straight ahead position". Turn the steering wheel (6) until the drive wheel is set to its straight ahead position.
o
If required, check the steering angle indica- tion on the information and service indicator (5).
- Switch the key switch (7) to position “OFF” (“0”) and remove the key.
- Depress the master switch (emergency cut-out) (8) to the “OFF” position.
8
5
6
7
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5
o
Information and service indicator (LISA)
The LCD display (12) of the LISA information and service indicator indi- cates the battery charge status (11), the operating hours (14) and the posi- tion of the steered wheel (13). The operating data is shown in the service and diagnosis mode (see chapter E, chapter 2.3). Two light-emitting diodes (LED (15) - (16)) below the display are used as indicators. The keyboard, four keys, (17) to (20), is needed to select, read or modify truck parameters.
m
In the service mode, only authorised personnel of the JUNGHEINRICH service may perform modifications!
5.1oLED indicators
Two lit LED indicators show the following states:
5.2oKeyboard assignment
Pos. Function
15 Driving direction forward (direction of the drive) (green LED)
16 Driving direction backwards (direction of the load) (green LED)
Pos. Function
17 Double function
– increase of the selected parameter in steps – Selection of the individual menu items in upward direction
18 Double function
– decrease of the selected parameter in steps – Selection of the individual menu items in downward direction
19 Double function
– Release of a selection menu from the main menu – Confirmation of a question with "NO" -> "x"
20 Quadruple function
– Quitting a selected menu item – Saving a modified parameter – Confirmation of a question with "YES" -> "q" – Change between "operating hours" and "time" indication
BAT T : 1 0%020h
12
13
14
11
18
1615 1917 20
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5
o
Information and service indicator (LISA)
The LCD display (12) of the LISA information and service indicator indi- cates the battery charge status (11), the operating hours (14) and the posi- tion of the steered wheel (13). The operating data is shown in the service and diagnosis mode (see chapter E, chapter 2.3). Two light-emitting diodes (LED (15) - (16)) below the display are used as indicators. The keyboard, four keys, (17) to (20), is needed to select, read or modify truck parameters.
m
In the service mode, only authorised personnel of the JUNGHEINRICH service may perform modifications!
5.1oLED indicators
Two lit LED indicators show the following states:
5.2oKeyboard assignment
Pos. Function
15 Driving direction forward (direction of the drive) (green LED)
16 Driving direction backwards (direction of the load) (green LED)
Pos. Function
17 Double function
– increase of the selected parameter in steps – Selection of the individual menu items in upward direction
18 Double function
– decrease of the selected parameter in steps – Selection of the individual menu items in downward direction
19 Double function
– Release of a selection menu from the main menu – Confirmation of a question with "NO" -> "x"
20 Quadruple function
– Quitting a selected menu item – Saving a modified parameter – Confirmation of a question with "YES" -> "q" – Change between "operating hours" and "time" indication
BAT T : 1 0%020h
12
13
14
11
18
1615 1917 20
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5
o
Information and service indicator (LISA)
The LCD display (12) of the LISA information and service indicator indi- cates the battery charge status (11), the operating hours (14) and the posi- tion of the steered wheel (13). The operating data is shown in the service and diagnosis mode (see chapter E, chapter 2.3). Two light-emitting diodes (LED (15) - (16)) below the display are used as indicators. The keyboard, four keys, (17) to (20), is needed to select, read or modify truck parameters.
m
In the service mode, only authorised personnel of the JUNGHEINRICH service may perform modifications!
5.1oLED indicators
Two lit LED indicators show the following states:
5.2oKeyboard assignment
Pos. Function
15 Driving direction forward (direction of the drive) (green LED)
16 Driving direction backwards (direction of the load) (green LED)
Pos. Function
17 Double function
– increase of the selected parameter in steps – Selection of the individual menu items in upward direction
18 Double function
– decrease of the selected parameter in steps – Selection of the individual menu items in downward direction
19 Double function
– Release of a selection menu from the main menu – Confirmation of a question with "NO" -> "x"
20 Quadruple function
– Quitting a selected menu item – Saving a modified parameter – Confirmation of a question with "YES" -> "q" – Change between "operating hours" and "time" indication
BAT T : 1 0%020h
12
13
14
11
18
1615 1917 20
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5.3oIndicators
Operating data and error messages are displayed on the indicator. The operator menu can be used to set the following truck parameters:
ACCELERATION
L
Here, the interval between maximum controller actuation and 100% adjustment of the electronics is set.
This driving parameter has no function.
DYNAMIC BRAKE (ROLL- OFF BRAKE)
REVERSING BRAKE
L
SPEED DRIVE
L
LOW-SPEED DRIVE
L
SPEED OF FORK
L
SLOW FORK
L
BUZZER ON/OFF
OFF L
BASIC SETTING
L
Issues an audible alarm in case of an operating fault.
This setting has no function.
This driving parameter may only be adjusted by the JUNGHEINRICH service.
This driving parameter has no function.
This driving parameter may only be adjusted by the JUNGHEINRICH service.
This driving parameter has no function.
his driving parameter may only be adjusted by the
UNGHEINRICH service.
SETTING THE TIME
12 :22L
Setting the time: Select the required hours and minutes with key (19). Use keys (17) and (18) to correct the entered values.
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5.3oIndicators
Operating data and error messages are displayed on the indicator. The operator menu can be used to set the following truck parameters:
ACCELERATION
L
Here, the interval between maximum controller actuation and 100% adjustment of the electronics is set.
This driving parameter has no function.
DYNAMIC BRAKE (ROLL- OFF BRAKE)
REVERSING BRAKE
L
SPEED DRIVE
L
LOW-SPEED DRIVE
L
SPEED OF FORK
L
SLOW FORK
L
BUZZER ON/OFF
OFF L
BASIC SETTING
L
Issues an audible alarm in case of an operating fault.
This setting has no function.
This driving parameter may only be adjusted by the JUNGHEINRICH service.
This driving parameter has no function.
This driving parameter may only be adjusted by the JUNGHEINRICH service.
This driving parameter has no function.
his driving parameter may only be adjusted by the
UNGHEINRICH service.
SETTING THE TIME
12 :22L
Setting the time: Select the required hours and minutes with key (19). Use keys (17) and (18) to correct the entered values.
E 14
0799.GB
5.3oIndicators
Operating data and error messages are displayed on the indicator. The operator menu can be used to set the following truck parameters:
ACCELERATION
L
Here, the interval between maximum controller actuation and 100% adjustment of the electronics is set.
This driving parameter has no function.
DYNAMIC BRAKE (ROLL- OFF BRAKE)
REVERSING BRAKE
L
SPEED DRIVE
L
LOW-SPEED DRIVE
L
SPEED OF FORK
L
SLOW FORK
L
BUZZER ON/OFF
OFF L
BASIC SETTING
L
Issues an audible alarm in case of an operating fault.
This setting has no function.
This driving parameter may only be adjusted by the JUNGHEINRICH service.
This driving parameter has no function.
This driving parameter may only be adjusted by the JUNGHEINRICH service.
This driving parameter has no function.
his driving parameter may only be adjusted by the
UNGHEINRICH service.
SETTING THE TIME
12 :22L
Setting the time: Select the required hours and minutes with key (19). Use keys (17) and (18) to correct the entered values.
Page 38
E 15
0799.GB
5.4oChanging driving parameters
f
The driving behaviour of the truck is changed if the truck parameters are modified. This is to be taken into consideration during start-up! Parameters may only be modified with the truck parked and while it is not performing any lifting movements.
- Commissioning the truck (see chapter E, section 3).
- Put the key into the key switch and turn it right until stop.
The operator menu is displayed for approx. 3 sec., indicating the truck designation. Then, the current steering angle, the battery charging status and the operating hours are indicated.
- Key Press selection menu key (19).
The indicator displays "acceleration" with the corresponding parameter.
- Proceed as indicated in the following diagram, if you want to check or modify any truck parameters.
- Use the following keys to change between the adjustment parameters: (17) and (18).
Acceleration
L
1)
Setting the time
XX:XX L
1)
Buzzer on/off
OFF L
1)
Low-speed ride
Load direction L
1)
Speed
Load direction L
1)
Low-speed ride
Direction of the driveL
1)
Speed
Direction of the driveL
1)
Reverse brake
L
3)
Coasting brake
L
1)
Acceleration
S
2)
Setting the time
XX:XX S
2)
Buzzer on/off
ON/OFF S
2
)
Low-speed ride
Load direction S
3)
Speed
Load direction S
2)
Low-speed ride
Direction of the drive
Speed
Direction of the drive
Reverse brake
S
3)
Coasting brake
S
2)
yes
Change?
no
BATT xxx% xx h
4)
1)
L = Read operating parameters (Read mode).
2)
S = Change operating parameters (Write mode) using the keys .
3)
no function
4)
"Operating hours
6)
Parameter selection" indicator
5)
"Time
7)
Parameter selection" indicator
BATT xxx% xx:xx
5)
Basic setting
Default values for "driving"
Basic setting
Default values for "driving"
6)
7)
E 15
0799.GB
5.4oChanging driving parameters
f
The driving behaviour of the truck is changed if the truck parameters are modified. This is to be taken into consideration during start-up! Parameters may only be modified with the truck parked and while it is not performing any lifting movements.
- Commissioning the truck (see chapter E, section 3).
- Put the key into the key switch and turn it right until stop.
The operator menu is displayed for approx. 3 sec., indicating the truck designation. Then, the current steering angle, the battery charging status and the operating hours are indicated.
- Key Press selection menu key (19).
The indicator displays "acceleration" with the corresponding parameter.
- Proceed as indicated in the following diagram, if you want to check or modify any truck parameters.
- Use the following keys to change between the adjustment parameters: (17) and (18).
Acceleration
L
1)
Setting the time
XX:XX L
1)
Buzzer on/off
OFF L
1)
Low-speed ride
Load direction L
1)
Speed
Load direction L
1)
Low-speed ride
Direction of the driveL
1)
Speed
Direction of the driveL
1)
Reverse brake
L
3)
Coasting brake
L
1)
Acceleration
S
2)
Setting the time
XX:XX S
2)
Buzzer on/off
ON/OFF S
2
)
Low-speed ride
Load direction S
3)
Speed
Load direction S
2)
Low-speed ride
Direction of the drive
Speed
Direction of the drive
Reverse brake
S
3)
Coasting brake
S
2)
yes
Change?
no
BATT xxx% xx h
4)
1)
L = Read operating parameters (Read mode).
2)
S = Change operating parameters (Write mode) using the keys .
3)
no function
4)
"Operating hours
6)
Parameter selection" indicator
5)
"Time
7)
Parameter selection" indicator
BATT xxx% xx:xx
5)
Basic setting
Default values for "driving"
Basic setting
Default values for "driving"
6)
7)
E 15
0799.GB
5.4oChanging driving parameters
f
The driving behaviour of the truck is changed if the truck parameters are modified. This is to be taken into consideration during start-up! Parameters may only be modified with the truck parked and while it is not performing any lifting movements.
- Commissioning the truck (see chapter E, section 3).
- Put the key into the key switch and turn it right until stop.
The operator menu is displayed for approx. 3 sec., indicating the truck designation. Then, the current steering angle, the battery charging status and the operating hours are indicated.
- Key Press selection menu key (19).
The indicator displays "acceleration" with the corresponding parameter.
- Proceed as indicated in the following diagram, if you want to check or modify any truck parameters.
- Use the following keys to change between the adjustment parameters: (17) and (18).
Acceleration
L
1)
Setting the time
XX:XX L
1)
Buzzer on/off
OFF L
1)
Low-speed ride
Load direction L
1)
Speed
Load direction L
1)
Low-speed ride
Direction of the driveL
1)
Speed
Direction of the driveL
1)
Reverse brake
L
3)
Coasting brake
L
1)
Acceleration
S
2)
Setting the time
XX:XX S
2)
Buzzer on/off
ON/OFF S
2
)
Low-speed ride
Load direction S
3)
Speed
Load direction S
2)
Low-speed ride
Direction of the drive
Speed
Direction of the drive
Reverse brake
S
3)
Coasting brake
S
2)
yes
Change?
no
BATT xxx% xx h
4)
1)
L = Read operating parameters (Read mode).
2)
S = Change operating parameters (Write mode) using the keys .
3)
no function
4)
"Operating hours
6)
Parameter selection" indicator
5)
"Time
7)
Parameter selection" indicator
BATT xxx% xx:xx
5)
Basic setting
Default values for "driving"
Basic setting
Default values for "driving"
6)
7)
Page 39
E 16
0799.GB
6 Fault location
This chapter enables the operator to locate and rectify minor faults and malfunctions, or the effects of operating errors. When trying to locate a fault, proceed in the order shown in the table.
A
If it is not possible to rectify the fault by performing the indicated remedial actions, please contact the JUNGHEINRICH Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
Fault Possible cause Remedial action
Truck does not move
- Battery connector not connected.
- Master switch (emergency stop) depressed.
- Key switch in position ”0”.
- Battery exhausted.
- Platform switch not operated.
- Fuse defective.
- Check the battery connector and connect if necessary.
- Release the master switch.
- Set the key switch to position ”I”.
- Check the charging condition of the battery and recharge if necessary.
- Operate platform switch.
- Check fuses F1 and 1F1.
Load cannot be lifted
- Truck not operative.
- Hydraulic oil level too low.
- Battery discharge monitor has switched off the lifting function and indicates “STOP”.
- Fuse defective.
- Load is too heavy.
- Perform all remedial actions listed under the fault “Truck does not move”.
- Check the hydraulic oil level.
- Recharge the battery.
- Check fuse 2F1.
- Heed the maximum capacity (see the identification plate).
E 16
0799.GB
6 Fault location
This chapter enables the operator to locate and rectify minor faults and malfunctions, or the effects of operating errors. When trying to locate a fault, proceed in the order shown in the table.
A
If it is not possible to rectify the fault by performing the indicated remedial actions, please contact the JUNGHEINRICH Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
Fault Possible cause Remedial action
Truck does not move
- Battery connector not connected.
- Master switch (emergency stop) depressed.
- Key switch in position ”0”.
- Battery exhausted.
- Platform switch not operated.
- Fuse defective.
- Check the battery connector and connect if necessary.
- Release the master switch.
- Set the key switch to position ”I”.
- Check the charging condition of the battery and recharge if necessary.
- Operate platform switch.
- Check fuses F1 and 1F1.
Load cannot be lifted
- Truck not operative.
- Hydraulic oil level too low.
- Battery discharge monitor has switched off the lifting function and indicates “STOP”.
- Fuse defective.
- Load is too heavy.
- Perform all remedial actions listed under the fault “Truck does not move”.
- Check the hydraulic oil level.
- Recharge the battery.
- Check fuse 2F1.
- Heed the maximum capacity (see the identification plate).
E 16
0799.GB
6 Fault location
This chapter enables the operator to locate and rectify minor faults and malfunctions, or the effects of operating errors. When trying to locate a fault, proceed in the order shown in the table.
A
If it is not possible to rectify the fault by performing the indicated remedial actions, please contact the JUNGHEINRICH Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
Fault Possible cause Remedial action
Truck does not move
- Battery connector not connected.
- Master switch (emergency stop) depressed.
- Key switch in position ”0”.
- Battery exhausted.
- Platform switch not operated.
- Fuse defective.
- Check the battery connector and connect if necessary.
- Release the master switch.
- Set the key switch to position ”I”.
- Check the charging condition of the battery and recharge if necessary.
- Operate platform switch.
- Check fuses F1 and 1F1.
Load cannot be lifted
- Truck not operative.
- Hydraulic oil level too low.
- Battery discharge monitor has switched off the lifting function and indicates “STOP”.
- Fuse defective.
- Load is too heavy.
- Perform all remedial actions listed under the fault “Truck does not move”.
- Check the hydraulic oil level.
- Recharge the battery.
- Check fuse 2F1.
- Heed the maximum capacity (see the identification plate).
Page 40
F 1
0499.GB
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork-lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced
and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork- lift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery- operated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
m
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed.
F 1
0499.GB
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork-lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced
and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork- lift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery- operated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
m
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed.
F 1
0499.GB
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
f
Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
m
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork-lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced
and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork- lift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery- operated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
m
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed.
Page 41
F 2
0499.GB
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic com-ponents, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic compo-nents or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. Changes must only be made following consultations with the manufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
F 2
0499.GB
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic com-ponents, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic compo-nents or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. Changes must only be made following consultations with the manufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
F 2
0499.GB
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic com-ponents, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic compo-nents or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. Changes must only be made following consultations with the manufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
Page 42
F 3
0499.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork-lift truck. The neglect of regular servicing intervals can lead to fork-lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week M3 = every 500 operating hours, but at least every 3 months M6 = every 1000 operating hours, but at least every 6 months M12 = every 2000 operating hours, but at least every 12 months
In the running-in phase of the truck, the following additional operations have to be carried out:
After the first 100 operating hours:
- Check the wheel nuts for security and retighten if required.
- Check the hydraulic connections for leaks and retighten if required.
After the first 500 operating hours:
- Replace the hydraulic oil and the filter cartridge.
F 3
0499.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork-lift truck. The neglect of regular servicing intervals can lead to fork-lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week M3 = every 500 operating hours, but at least every 3 months M6 = every 1000 operating hours, but at least every 6 months M12 = every 2000 operating hours, but at least every 12 months
In the running-in phase of the truck, the following additional operations have to be carried out:
After the first 100 operating hours:
- Check the wheel nuts for security and retighten if required.
- Check the hydraulic connections for leaks and retighten if required.
After the first 500 operating hours:
- Replace the hydraulic oil and the filter cartridge.
F 3
0499.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork-lift truck. The neglect of regular servicing intervals can lead to fork-lift truck failure and constitutes a potential hazard to personnel and equipment.
m
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
W1 = every 50 operating hours, but at least once per week M3 = every 500 operating hours, but at least every 3 months M6 = every 1000 operating hours, but at least every 6 months M12 = every 2000 operating hours, but at least every 12 months
In the running-in phase of the truck, the following additional operations have to be carried out:
After the first 100 operating hours:
- Check the wheel nuts for security and retighten if required.
- Check the hydraulic connections for leaks and retighten if required.
After the first 500 operating hours:
- Replace the hydraulic oil and the filter cartridge.
Page 43
F 4
0499.GB
4 Maintenance checklist ESE 20
Maintenance intervals:
W 1= 50 operating hours, once per week min. M 3 = 500 operating hours, every 3 months min M 6 = 1000 operating hours, every 6 months min standard =
t
M12 = 2000 operating hours, every 12 months min cold store=
l
Maintenance
intervals
W1M3M6M
12
Chassis and superstruct.
1.1 Check all load bearing elements for damage
t
1.2 Check all bolted connections
t
1.3 Check platform for correct functioning and damage
t
Drive unit
2.1 Check the transmission for noises and leakage
t
2.2 Check the transmission oil level
t
2.3 Change the transmission oil
lt
Wheels
3.1 Check for wear and damage
t
3.2 Check the wheel bearings for correct fastening a)
lt
Steering
4.1 Check the steering wheel play
t
4.2 Check the steering chain and chain sprocket for wear, adjust and grease
lt
Brake system
5.1 Performance and adjustment check
lt
5.2 Check the brake linings for wear
t
5.3 Check reset function of the deadman key
t
5.4 Check the brake linkage; adjust if necessary
lt
Hydraulic system
6.1 Performance check
lt
6.2 Check all connections for leakage and damage b)
lt
6.3 Check hydraulic cylinders for leakage, damage and secure attachment
lt
6.4 Clean filter
t
6.5 Check the oil level
lt
6.6 Change hydraulic oil c)
lt
6.7 Check the pressure relief valves for correct functioning
lt
Electrical system
7.1 Performance check
t
7.2 Check all cables for secure connection and damage
t
7.3 Check the fuses for correct amperage
t
7.4 Check switches and trip cams for secure attachment and correct functioning
t
7.5 Check the warning installation for correct functioning
lt
7.6 Check contactors, replace wearing parts if necessary
t
Electric motors
8.1 Check the carbon brushes for wear
t
8.2 Check the motor for secure attachment
t
8.3 Clean motor housing by means of a vacuum cleaner and check the commutator for wear
lt
8.4 Check whether the cover of the steering-engine potentiometer is present.
t
F 4
0499.GB
4 Maintenance checklist ESE 20
Maintenance intervals:
W 1= 50 operating hours, once per week min. M 3 = 500 operating hours, every 3 months min M 6 = 1000 operating hours, every 6 months min standard =
t
M12 = 2000 operating hours, every 12 months min cold store=
l
Maintenance
intervals
W1M3M6M
12
Chassis and superstruct.
1.1 Check all load bearing elements for damage
t
1.2 Check all bolted connections
t
1.3 Check platform for correct functioning and damage
t
Drive unit
2.1 Check the transmission for noises and leakage
t
2.2 Check the transmission oil level
t
2.3 Change the transmission oil
lt
Wheels
3.1 Check for wear and damage
t
3.2 Check the wheel bearings for correct fastening a)
lt
Steering
4.1 Check the steering wheel play
t
4.2 Check the steering chain and chain sprocket for wear, adjust and grease
lt
Brake system
5.1 Performance and adjustment check
lt
5.2 Check the brake linings for wear
t
5.3 Check reset function of the deadman key
t
5.4 Check the brake linkage; adjust if necessary
lt
Hydraulic system
6.1 Performance check
lt
6.2 Check all connections for leakage and damage b)
lt
6.3 Check hydraulic cylinders for leakage, damage and secure attachment
lt
6.4 Clean filter
t
6.5 Check the oil level
lt
6.6 Change hydraulic oil c)
lt
6.7 Check the pressure relief valves for correct functioning
lt
Electrical system
7.1 Performance check
t
7.2 Check all cables for secure connection and damage
t
7.3 Check the fuses for correct amperage
t
7.4 Check switches and trip cams for secure attachment and correct functioning
t
7.5 Check the warning installation for correct functioning
lt
7.6 Check contactors, replace wearing parts if necessary
t
Electric motors
8.1 Check the carbon brushes for wear
t
8.2 Check the motor for secure attachment
t
8.3 Clean motor housing by means of a vacuum cleaner and check the commutator for wear
lt
8.4 Check whether the cover of the steering-engine potentiometer is present.
t
F 4
0499.GB
4 Maintenance checklist ESE 20
Maintenance intervals:
W 1= 50 operating hours, once per week min. M 3 = 500 operating hours, every 3 months min M 6 = 1000 operating hours, every 6 months min standard =
t
M12 = 2000 operating hours, every 12 months min cold store=
l
Maintenance
intervals
W1M3M6M
12
Chassis and superstruct.
1.1 Check all load bearing elements for damage
t
1.2 Check all bolted connections
t
1.3 Check platform for correct functioning and damage
t
Drive unit
2.1 Check the transmission for noises and leakage
t
2.2 Check the transmission oil level
t
2.3 Change the transmission oil
lt
Wheels
3.1 Check for wear and damage
t
3.2 Check the wheel bearings for correct fastening a)
lt
Steering
4.1 Check the steering wheel play
t
4.2 Check the steering chain and chain sprocket for wear, adjust and grease
lt
Brake system
5.1 Performance and adjustment check
lt
5.2 Check the brake linings for wear
t
5.3 Check reset function of the deadman key
t
5.4 Check the brake linkage; adjust if necessary
lt
Hydraulic system
6.1 Performance check
lt
6.2 Check all connections for leakage and damage b)
lt
6.3 Check hydraulic cylinders for leakage, damage and secure attachment
lt
6.4 Clean filter
t
6.5 Check the oil level
lt
6.6 Change hydraulic oil c)
lt
6.7 Check the pressure relief valves for correct functioning
lt
Electrical system
7.1 Performance check
t
7.2 Check all cables for secure connection and damage
t
7.3 Check the fuses for correct amperage
t
7.4 Check switches and trip cams for secure attachment and correct functioning
t
7.5 Check the warning installation for correct functioning
lt
7.6 Check contactors, replace wearing parts if necessary
t
Electric motors
8.1 Check the carbon brushes for wear
t
8.2 Check the motor for secure attachment
t
8.3 Clean motor housing by means of a vacuum cleaner and check the commutator for wear
lt
8.4 Check whether the cover of the steering-engine potentiometer is present.
t
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a) Wheel bolts to be first checked for tightness after approx. 100 operating hours, tighten, if necessary. b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours; tighten, if necessary. d) First change after 500 operating hours.
A
The maintenance intervals refer to normal service conditions. In case of aggravated conditions, the intervals must be reduced as required.
Battery
9.1 Check acid density, acid level and cell voltage
lt
9.2 Check the terminals for secure attachment and apply grease
lt
9.3 Clean battery connections, check for tight seat
lt
9.4 Check the battery cables for damage, renew, if necessary
t
9.5 Check whether the battery lock is fully functioning
t
Lifting device
10.1 Performance and adjustment check
t
10.2 Perform sight check of rollers, sliding elements, and stops
lt
10.3 Check fork tines and fork carrier for wear and damage
lt
Lubrication
11.1 Grease the vehicle in accordance with the lubrication schedule
lt
General measurements
12.1 Check the electrical system for a grounding fault
t
12.2 Check the driving speed and braking distance
t
12.3 Check the lifting and lowering speed
t
12.4 Check safety and shutdown devices
t
Demonstration
13.1 Perform a trial run under a nominal load
t
13.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible
lt
Maintenance intervals:
W 1= 50 operating hours, once per week min. M 3 = 500 operating hours, every 3 months min M 6 = 1000 operating hours, every 6 months min standard =
t
M12 = 2000 operating hours, every 12 months min cold store=
l
Maintenance
intervals
W1M3M6M
12
F 5
0499.GB
a) Wheel bolts to be first checked for tightness after approx. 100 operating hours, tighten, if necessary. b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours; tighten, if necessary. d) First change after 500 operating hours.
A
The maintenance intervals refer to normal service conditions. In case of aggravated conditions, the intervals must be reduced as required.
Battery
9.1 Check acid density, acid level and cell voltage
lt
9.2 Check the terminals for secure attachment and apply grease
lt
9.3 Clean battery connections, check for tight seat
lt
9.4 Check the battery cables for damage, renew, if necessary
t
9.5 Check whether the battery lock is fully functioning
t
Lifting device
10.1 Performance and adjustment check
t
10.2 Perform sight check of rollers, sliding elements, and stops
lt
10.3 Check fork tines and fork carrier for wear and damage
lt
Lubrication
11.1 Grease the vehicle in accordance with the lubrication schedule
lt
General measurements
12.1 Check the electrical system for a grounding fault
t
12.2 Check the driving speed and braking distance
t
12.3 Check the lifting and lowering speed
t
12.4 Check safety and shutdown devices
t
Demonstration
13.1 Perform a trial run under a nominal load
t
13.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible
lt
Maintenance intervals:
W 1= 50 operating hours, once per week min. M 3 = 500 operating hours, every 3 months min M 6 = 1000 operating hours, every 6 months min standard =
t
M12 = 2000 operating hours, every 12 months min cold store=
l
Maintenance
intervals
W1M3M6M
12
F 5
0499.GB
a) Wheel bolts to be first checked for tightness after approx. 100 operating hours, tighten, if necessary. b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours; tighten, if necessary. d) First change after 500 operating hours.
A
The maintenance intervals refer to normal service conditions. In case of aggravated conditions, the intervals must be reduced as required.
Battery
9.1 Check acid density, acid level and cell voltage
lt
9.2 Check the terminals for secure attachment and apply grease
lt
9.3 Clean battery connections, check for tight seat
lt
9.4 Check the battery cables for damage, renew, if necessary
t
9.5 Check whether the battery lock is fully functioning
t
Lifting device
10.1 Performance and adjustment check
t
10.2 Perform sight check of rollers, sliding elements, and stops
lt
10.3 Check fork tines and fork carrier for wear and damage
lt
Lubrication
11.1 Grease the vehicle in accordance with the lubrication schedule
lt
General measurements
12.1 Check the electrical system for a grounding fault
t
12.2 Check the driving speed and braking distance
t
12.3 Check the lifting and lowering speed
t
12.4 Check safety and shutdown devices
t
Demonstration
13.1 Perform a trial run under a nominal load
t
13.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible
lt
Maintenance intervals:
W 1= 50 operating hours, once per week min. M 3 = 500 operating hours, every 3 months min M 6 = 1000 operating hours, every 6 months min standard =
t
M12 = 2000 operating hours, every 12 months min cold store=
l
Maintenance
intervals
W1M3M6M
12
Page 45
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5 Lubrication schedule ESE 20
g
Gliding surfaces
s
Grease nipples Filler plug for hydraulic oil
b
Filler plug for gear oil
a
Drain plug for gear oil Cold store usage
1)
Compound for cold store usage 1:1
2)
1.25l - 1.3 l; depending on the drive type (always up to the lower edge of the filler neck).
B
1,25 - 1,3 l
B + C
1)
2)
E
F
G
0,7 l
AA+C
1)
F 6
0499.GB
5 Lubrication schedule ESE 20
g
Gliding surfaces
s
Grease nipples Filler plug for hydraulic oil
b
Filler plug for gear oil
a
Drain plug for gear oil Cold store usage
1)
Compound for cold store usage 1:1
2)
1.25l - 1.3 l; depending on the drive type (always up to the lower edge of the filler neck).
B
1,25 - 1,3 l
B + C
1)
2)
E
F
G
0,7 l
AA+C
1)
F 6
0499.GB
5 Lubrication schedule ESE 20
g
Gliding surfaces
s
Grease nipples Filler plug for hydraulic oil
b
Filler plug for gear oil
a
Drain plug for gear oil Cold store usage
1)
Compound for cold store usage 1:1
2)
1.25l - 1.3 l; depending on the drive type (always up to the lower edge of the filler neck).
B
1,25 - 1,3 l
B + C
1)
2)
E
F
G
0,7 l
AA+C
1)
Page 46
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5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions are to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Grease data
Code Order No. Supply Qty Designation Used for:
A 29 200 670 5.0 l H-LP 46 DIN 51524 Hydraulic system
B 29 200 680 5.0 l CLP 100 DIN 51517 Transmission
C 29 200 810 5.0 l H-LP 10 DIN 51524
Transmission, hydraulic system
E 29 201 430 1.0 kg Grease DIN 51825 Lubrication
F 29 200 100 1.0 kg Grease TTF52 Lubrication
G 29 201 280 0.51 kg Chain spray Chains
Code Saponification Dropp. point °C
Worked penetr. at
25 °C
NLG1 class
Service temperat.
°C
E Lithium 185 265 - 295 2 -35 / +120
F — — 310 - 340 1 -52 / +100
F 7
0499.GB
5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions are to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Grease data
Code Order No. Supply Qty Designation Used for:
A 29 200 670 5.0 l H-LP 46 DIN 51524 Hydraulic system
B 29 200 680 5.0 l CLP 100 DIN 51517 Transmission
C 29 200 810 5.0 l H-LP 10 DIN 51524
Transmission, hydraulic system
E 29 201 430 1.0 kg Grease DIN 51825 Lubrication
F 29 200 100 1.0 kg Grease TTF52 Lubrication
G 29 201 280 0.51 kg Chain spray Chains
Code Saponification Dropp. point °C
Worked penetr. at
25 °C
NLG1 class
Service temperat.
°C
E Lithium 185 265 - 295 2 -35 / +120
F — — 310 - 340 1 -52 / +100
F 7
0499.GB
5.1 Fuels, coolants and lubricants
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions are to be observed.
f
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Grease data
Code Order No. Supply Qty Designation Used for:
A 29 200 670 5.0 l H-LP 46 DIN 51524 Hydraulic system
B 29 200 680 5.0 l CLP 100 DIN 51517 Transmission
C 29 200 810 5.0 l H-LP 10 DIN 51524
Transmission, hydraulic system
E 29 201 430 1.0 kg Grease DIN 51825 Lubrication
F 29 200 100 1.0 kg Grease TTF52 Lubrication
G 29 201 280 0.51 kg Chain spray Chains
Code Saponification Dropp. point °C
Worked penetr. at
25 °C
NLG1 class
Service temperat.
°C
E Lithium 185 265 - 295 2 -35 / +120
F — — 310 - 340 1 -52 / +100
Page 47
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6 Instructions for the servicing operations
6.1 Preparing the truck for servicing and maintenance operations
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
- Park the truck and render it safe (refer to chapter E, section 4.5).
- Disconnect the battery plug to prevent accidental starting of the truck (refer to chapter D, section 4)
f
When work has to be performed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, the instructions contained in the chapter “Transportation and commissioning” have to be observed.
6.2 Tightening the wheel screws
The wheel screws of the drive wheel must be retightened in accordance with the servicing intervals indicated in the servicing checklist.
- Position the drive wheel (3) at right angles to the longitudinal axis of the truck.
- Tighten all wheel-fixing bolts (1) using a wrench which is to be inserted through the opening (2) of the collision guard (tightening torque 105Nm).
m
Remove the wrench after tightening the wheel-fixing bolts.
32
1
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6 Instructions for the servicing operations
6.1 Preparing the truck for servicing and maintenance operations
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
- Park the truck and render it safe (refer to chapter E, section 4.5).
- Disconnect the battery plug to prevent accidental starting of the truck (refer to chapter D, section 4)
f
When work has to be performed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, the instructions contained in the chapter “Transportation and commissioning” have to be observed.
6.2 Tightening the wheel screws
The wheel screws of the drive wheel must be retightened in accordance with the servicing intervals indicated in the servicing checklist.
- Position the drive wheel (3) at right angles to the longitudinal axis of the truck.
- Tighten all wheel-fixing bolts (1) using a wrench which is to be inserted through the opening (2) of the collision guard (tightening torque 105Nm).
m
Remove the wrench after tightening the wheel-fixing bolts.
32
1
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6 Instructions for the servicing operations
6.1 Preparing the truck for servicing and maintenance operations
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
- Park the truck and render it safe (refer to chapter E, section 4.5).
- Disconnect the battery plug to prevent accidental starting of the truck (refer to chapter D, section 4)
f
When work has to be performed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, the instructions contained in the chapter “Transportation and commissioning” have to be observed.
6.2 Tightening the wheel screws
The wheel screws of the drive wheel must be retightened in accordance with the servicing intervals indicated in the servicing checklist.
- Position the drive wheel (3) at right angles to the longitudinal axis of the truck.
- Tighten all wheel-fixing bolts (1) using a wrench which is to be inserted through the opening (2) of the collision guard (tightening torque 105Nm).
m
Remove the wrench after tightening the wheel-fixing bolts.
32
1
Page 48
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6.3 Removing the drive cover
- If required, fold up the sitting aid (4).
- Carefully open the drive cover (6) above the recessed grip (5); then pull it off and store it in a safe location.
- Installation occurs in the reverse order of steps.
f
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
4
5
6
F 9
0499.GB
6.3 Removing the drive cover
- If required, fold up the sitting aid (4).
- Carefully open the drive cover (6) above the recessed grip (5); then pull it off and store it in a safe location.
- Installation occurs in the reverse order of steps.
f
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
4
5
6
F 9
0499.GB
6.3 Removing the drive cover
- If required, fold up the sitting aid (4).
- Carefully open the drive cover (6) above the recessed grip (5); then pull it off and store it in a safe location.
- Installation occurs in the reverse order of steps.
f
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
4
5
6
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6.4 Checking the electric fuses
- Prepare the truck for the servicing and maintenance operations (refer to chapter F, section 6.1).
- Remove the drive cover (see chapter F, section 6.3).
- Referring to the table, check all fuses for correct rating and damage; replace fuses where required.
- Remount the drive cover (see chapter F, section 6.3).
Item Designation Protection of: Value
71F1tDrive motor 150 A
82F1tPump motor 150 A
91F10tField “Driving” 40 A
10 6F2
o
Battery discharge indicator / operating hour meter
10 A
11 F1
t
Entire control circuit 10 A
12 3F9
t
Steering motor 30 A
t
= Standard equipment
o
= Optional equipment
9 10
1112
7
8
F 10
0499.GB
6.4 Checking the electric fuses
- Prepare the truck for the servicing and maintenance operations (refer to chapter F, section 6.1).
- Remove the drive cover (see chapter F, section 6.3).
- Referring to the table, check all fuses for correct rating and damage; replace fuses where required.
- Remount the drive cover (see chapter F, section 6.3).
Item Designation Protection of: Value
71F1tDrive motor 150 A
82F1tPump motor 150 A
91F10tField “Driving” 40 A
10 6F2
o
Battery discharge indicator / operating hour meter
10 A
11 F1
t
Entire control circuit 10 A
12 3F9
t
Steering motor 30 A
t
= Standard equipment
o
= Optional equipment
9 10
1112
7
8
F 10
0499.GB
6.4 Checking the electric fuses
- Prepare the truck for the servicing and maintenance operations (refer to chapter F, section 6.1).
- Remove the drive cover (see chapter F, section 6.3).
- Referring to the table, check all fuses for correct rating and damage; replace fuses where required.
- Remount the drive cover (see chapter F, section 6.3).
Item Designation Protection of: Value
71F1tDrive motor 150 A
82F1tPump motor 150 A
91F10tField “Driving” 40 A
10 6F2
o
Battery discharge indicator / operating hour meter
10 A
11 F1
t
Entire control circuit 10 A
12 3F9
t
Steering motor 30 A
t
= Standard equipment
o
= Optional equipment
9 10
1112
7
8
Page 50
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6.5 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
- Check the brake for correct functioning.
- Check the master switch for correct functioning.
- Check the horn for proper functioning.
7 Decommissioning the fork-lift truck
If the fork-lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
f
During decommissioning, the fork-lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork-lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
- Thoroughly clean the fork-lift truck.
- Check the brakes for correct function.
- Check the hydraulic oil level and top up if required (refer to chapter F).
- Apply a thin film of oil or grease to all parts not protected by a paint coating.
- Grease the fork-lift truck as detailed in the lubrication chart (refer to chapter F, section 5).
- Recharge the battery (refer to chapter D, section 4).
- Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions given by the battery supplier must be observed.
- Spray all exposed electrical contacts with a suitable contact spray.
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6.5 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
- Check the brake for correct functioning.
- Check the master switch for correct functioning.
- Check the horn for proper functioning.
7 Decommissioning the fork-lift truck
If the fork-lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
f
During decommissioning, the fork-lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork-lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
- Thoroughly clean the fork-lift truck.
- Check the brakes for correct function.
- Check the hydraulic oil level and top up if required (refer to chapter F).
- Apply a thin film of oil or grease to all parts not protected by a paint coating.
- Grease the fork-lift truck as detailed in the lubrication chart (refer to chapter F, section 5).
- Recharge the battery (refer to chapter D, section 4).
- Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions given by the battery supplier must be observed.
- Spray all exposed electrical contacts with a suitable contact spray.
F 11
0499.GB
6.5 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
- Check the brake for correct functioning.
- Check the master switch for correct functioning.
- Check the horn for proper functioning.
7 Decommissioning the fork-lift truck
If the fork-lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
f
During decommissioning, the fork-lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork-lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
- Thoroughly clean the fork-lift truck.
- Check the brakes for correct function.
- Check the hydraulic oil level and top up if required (refer to chapter F).
- Apply a thin film of oil or grease to all parts not protected by a paint coating.
- Grease the fork-lift truck as detailed in the lubrication chart (refer to chapter F, section 5).
- Recharge the battery (refer to chapter D, section 4).
- Disconnect and clean the battery. Apply pole grease to the battery poles.
A
In addition to this, all instructions given by the battery supplier must be observed.
- Spray all exposed electrical contacts with a suitable contact spray.
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7.2 Measures to be taken during decommissioning
Every 2 months:
- Recharge the battery (refer to chapter D, section 4).
m
Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
7.3 Recommissioning the truck
- Thoroughly clean the fork-lift truck.
- Lubricate the fork-lift truck according to the lubrication chart (refer to chapter F, section 5).
- Clean the battery. Grease the pole screws using pole grease and reconnect the battery.
- Recharge the battery (refer to chapter D, section 4).
- Check if the gear oil contains condensed water and change if required.
- Check if the hydraulic oil contains condensed water and change if required.
- Start up the fork-lift truck (refer to chapter E, section 3).
A
If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
F 12
0499.GB
7.2 Measures to be taken during decommissioning
Every 2 months:
- Recharge the battery (refer to chapter D, section 4).
m
Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
7.3 Recommissioning the truck
- Thoroughly clean the fork-lift truck.
- Lubricate the fork-lift truck according to the lubrication chart (refer to chapter F, section 5).
- Clean the battery. Grease the pole screws using pole grease and reconnect the battery.
- Recharge the battery (refer to chapter D, section 4).
- Check if the gear oil contains condensed water and change if required.
- Check if the hydraulic oil contains condensed water and change if required.
- Start up the fork-lift truck (refer to chapter E, section 3).
A
If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
F 12
0499.GB
7.2 Measures to be taken during decommissioning
Every 2 months:
- Recharge the battery (refer to chapter D, section 4).
m
Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
7.3 Recommissioning the truck
- Thoroughly clean the fork-lift truck.
- Lubricate the fork-lift truck according to the lubrication chart (refer to chapter F, section 5).
- Clean the battery. Grease the pole screws using pole grease and reconnect the battery.
- Recharge the battery (refer to chapter D, section 4).
- Check if the gear oil contains condensed water and change if required.
- Check if the hydraulic oil contains condensed water and change if required.
- Start up the fork-lift truck (refer to chapter E, section 3).
A
If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
f
Perform several brake tests immediately after recommissioning the truck.
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8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork-lift truck has to be checked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to be able to assess the condition of the fork-lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork-lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork-lift truck with regard to accident prevention aspects. Apart from this, the fork- lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork-lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with spe- cially qualified staff. As visual proof that the fork-lift truck has passed the safety inspection, a plaque is affixed to it. This pla- que indicates in which month of which year the next test will be due.
Example for D:
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
Regelmäßige Prüfung
nach UVV VBG 36 §37 durch Sachkundigen
Nächste Prüfung
Ihr Kundendienst-Partner
Kundendienst
F 13
0499.GB
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork-lift truck has to be checked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to be able to assess the condition of the fork-lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork-lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork-lift truck with regard to accident prevention aspects. Apart from this, the fork- lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork-lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with spe- cially qualified staff. As visual proof that the fork-lift truck has passed the safety inspection, a plaque is affixed to it. This pla- que indicates in which month of which year the next test will be due.
Example for D:
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
Regelmäßige Prüfung
nach UVV VBG 36 §37 durch Sachkundigen
Nächste Prüfung
Ihr Kundendienst-Partner
Kundendienst
F 13
0499.GB
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to VBG 36)
At least once yearly, or after any untoward incident, the fork-lift truck has to be checked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to be able to assess the condition of the fork-lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork-lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork-lift truck with regard to accident prevention aspects. Apart from this, the fork- lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork-lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
A
The manufacturer has set up a special safety service with spe- cially qualified staff. As visual proof that the fork-lift truck has passed the safety inspection, a plaque is affixed to it. This pla- que indicates in which month of which year the next test will be due.
Example for D:
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
Regelmäßige Prüfung
nach UVV VBG 36 §37 durch Sachkundigen
Nächste Prüfung
Ihr Kundendienst-Partner
Kundendienst
Page 53
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