Jungheinrich EZS 350 XL, EZS 330 XL Operating instruction
Operating instructions
50468397
EZS 330/350 / XL
G
04.06 -
04.06
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
F
Used before safety instructions which must be observed to avoid danger to
personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
F
Used before safety instructions which must be observed to avoid danger to
personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
0108.GB
I 1
0205.GB
Table of Contents
A Correct use and application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
2.1 EN norms ............................................................................................ B 3
2.2 Conditions of use ................................................................................ B 3
3 Standard Version Specifications ......................................................... B 4
3.1 Performance data for standard trucks ................................................. B 4
3.2 Dimensions ......................................................................................... B 4
4 Identification points and data plates .................................................... B 6
4.1 Truck data plate .................................................................................. B 7
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Securing the truck during transport ..................................................... C 1
3 Using the truck for the first time .......................................................... C 2
4 Operating the truck without its own drive system ................................ C 3
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 3
4 Charge the battery .............................................................................. D 4
5 Battery removal and installation .......................................................... D 5
I 1
0205.GB
Table of Contents
A Correct use and application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
2.1 EN norms ............................................................................................ B 3
2.2 Conditions of use ................................................................................ B 3
3 Standard Version Specifications ......................................................... B 4
3.1 Performance data for standard trucks ................................................. B 4
3.2 Dimensions ......................................................................................... B 4
4 Identification points and data plates .................................................... B 6
4.1 Truck data plate .................................................................................. B 7
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Securing the truck during transport ..................................................... C 1
3 Using the truck for the first time .......................................................... C 2
4 Operating the truck without its own drive system ................................ C 3
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 3
4 Charge the battery .............................................................................. D 4
5 Battery removal and installation .......................................................... D 5
0205.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
3 Starting up the truck ............................................................................ E 4
4 Industrial Truck Operation ................................................................... E 5
4.1 Safety regulations for truck operation ................................................. E 5
4.2 Travel, Steering, Braking ..................................................................... E 6
4.3 Pedestrian operation (o) .................................................................... E 9
4.4 Coupling Types ................................................................................... E 10
4.5 Travelling with trailers ......................................................................... E 11
4.6 Seat o (XL only) ................................................................................. E 12
4.7 Parking the truck securely ................................................................... E 12
5 Display instrument (CANDIS) (o) ....................................................... E 13
5.1 Operating hours display ...................................................................... E 13
5.2 Power up test ...................................................................................... E 14
6 Keypad (CANCODE) (o) .................................................................... E 15
6.1 Code Lock ........................................................................................... E 15
6.2 Travel programs .................................................................................. E 17
6.3 Parameters .......................................................................................... E 17
6.4 Parameter Settings ............................................................................. E 18
6.5 Travel parameters ............................................................................... E 22
7 Troubleshooting .................................................................................. E 27
F Industrial Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance Safety Regulations ........................................................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ......................................................................... F 4
5 Lubrication Schedule ........................................................................... F 6
5.1 Consumables ...................................................................................... F 7
6 Maintenance Instructions .................................................................... F 8
6.1 Preparing the truck for maintenance and repairs ................................ F 8
6.2 Tightening the wheel nuts ................................................................... F 8
6.3 Remove the front panel ....................................................................... F 9
6.4 Checking electrical fuses .................................................................... F 10
6.5 Recommissioning ................................................................................ F 11
7 Decommissioning the industrial truck .................................................. F 11
7.1 Prior to decommissioning: ................................................................... F 11
7.2 During decommissioning: .................................................................... F 11
7.3 Returning the truck to operation after decommissioning ..................... F 12
8 Safety checks to be performed at regular intervals and following
any unusual incidents (D: Accident prevention check according
to BGV D27 ......................................................................................... F 12
9 Final de-commissioning, disposal ....................................................... F 12
0205.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
3 Starting up the truck ............................................................................ E 4
4 Industrial Truck Operation ................................................................... E 5
4.1 Safety regulations for truck operation ................................................. E 5
4.2 Travel, Steering, Braking ..................................................................... E 6
4.3 Pedestrian operation (o) .................................................................... E 9
4.4 Coupling Types ................................................................................... E 10
4.5 Travelling with trailers ......................................................................... E 11
4.6 Seat o (XL only) ................................................................................. E 12
4.7 Parking the truck securely ................................................................... E 12
5 Display instrument (CANDIS) (o) ....................................................... E 13
5.1 Operating hours display ...................................................................... E 13
5.2 Power up test ...................................................................................... E 14
6 Keypad (CANCODE) (o) .................................................................... E 15
6.1 Code Lock ........................................................................................... E 15
6.2 Travel programs .................................................................................. E 17
6.3 Parameters .......................................................................................... E 17
6.4 Parameter Settings ............................................................................. E 18
6.5 Travel parameters ............................................................................... E 22
7 Troubleshooting .................................................................................. E 27
F Industrial Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance Safety Regulations ........................................................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ......................................................................... F 4
5 Lubrication Schedule ........................................................................... F 6
5.1 Consumables ...................................................................................... F 7
6 Maintenance Instructions .................................................................... F 8
6.1 Preparing the truck for maintenance and repairs ................................ F 8
6.2 Tightening the wheel nuts ................................................................... F 8
6.3 Remove the front panel ....................................................................... F 9
6.4 Checking electrical fuses .................................................................... F 10
6.5 Recommissioning ................................................................................ F 11
7 Decommissioning the industrial truck .................................................. F 11
7.1 Prior to decommissioning: ................................................................... F 11
7.2 During decommissioning: .................................................................... F 11
7.3 Returning the truck to operation after decommissioning ..................... F 12
8 Safety checks to be performed at regular intervals and following
any unusual incidents (D: Accident prevention check according
to BGV D27 ......................................................................................... F 12
9 Final de-commissioning, disposal ....................................................... F 12
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB 20506.GB
2
A 1
0406.GB
A Correct use and application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be applied, operated and serviced in accordance with the instructions
contained in the present manual. Any other type of use is beyond the scope of
application and can result in damage to personnel, the truck or property. In particular,
avoid overloading the truck with loads that are too heavy. The data plate attached to
the truck or the load diagram are binding for the maximum load capacity. The
industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the
“proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
M
Failure to comply with the operator manual shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which
affects or supplements the performance of the industrial truck requires the written
permission of the manufacturer. In some cases, local authority approval shall be
required.
Approval of the local authorities however does not constitute the manufacturer’s
approval.
A 1
0406.GB
A Correct use and application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be applied, operated and serviced in accordance with the instructions
contained in the present manual. Any other type of use is beyond the scope of
application and can result in damage to personnel, the truck or property. In particular,
avoid overloading the truck with loads that are too heavy. The data plate attached to
the truck or the load diagram are binding for the maximum load capacity. The
industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the
“proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is
intended for and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
M
Failure to comply with the operator manual shall invalidate the warranty. The same
applies if improper work is carried out on the truck by the customer or third parties
without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which
affects or supplements the performance of the industrial truck requires the written
permission of the manufacturer. In some cases, local authority approval shall be
required.
Approval of the local authorities however does not constitute the manufacturer’s
approval.
B 1
0406.GB
B Truck Description
1 Application
The truck is a three-wheel electric tow truck with a driver’s platform, equipped with a
Jet Pilot. It is designed for transporting goods on level surfaces in buildings.
The tow force is shown on the data plate.
B 1
0406.GB
B Truck Description
1 Application
The truck is a three-wheel electric tow truck with a driver’s platform, equipped with a
Jet Pilot. It is designed for transporting goods on level surfaces in buildings.
The tow force is shown on the data plate.
0406.GB
B 2
2 Assemblies
Item Description Item Description
1 t Front panel 8 o Reverse “pedestrian
operation” switch
2 t Battery panel 9 o Stop button
3 t Jet Pilot 10 o Forward “pedestrian / walk-
along operation” button
4 t Main switch / isolator
(emergency disconnect)
11 o Trailer coupling
5 t Controller 12 t Storage compartment
6 o CANCODE
keypad
13 t Drive wheel
7 t Key switch o Headlight (not shown)
o Strobe (not shown)
t = Standard equipment o = Optional Equipment
1234 567
8
9
10
11
12
13
0406.GB
B 2
2 Assemblies
Item Description Item Description
1 t Front panel 8 o Reverse “pedestrian
operation” switch
2 t Battery panel 9 o Stop button
3 t Jet Pilot 10 o Forward “pedestrian / walk-
along operation” button
4 t Main switch / isolator
(emergency disconnect)
11 o Trailer coupling
5 t Controller 12 t Storage compartment
6 o CANCODE
keypad
13 t Drive wheel
7 t Key switch o Headlight (not shown)
o Strobe (not shown)
t = Standard equipment o = Optional Equipment
1234 567
8
9
10
11
12
13
B 3
0406.GB
2.1 EN norms
Noise level: 66 dB(A)
in accordance with EN 12053 as harmonized with
ISO 4871.
Z
The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the driver’s ear.
Vibration: 0.94 m/s
2
in accordance with EN 13059
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over bumps at constant speed.
Electromagnetic Compatibility (
The manufacturer confirms that equipment complies with
tolerance levels for electromagnetic emissions and
resistance as well as static electricity discharge testing in
accordance with EN 12895 including the normative
procedures contained therein.
Z
No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
2.2 Conditions of use
Ambient temperature
- during operation -10°C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
B 3
0406.GB
2.1 EN norms
Noise level: 66 dB(A)
in accordance with EN 12053 as harmonized with
ISO 4871.
Z
The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the driver’s ear.
Vibration: 0.94 m/s
2
in accordance with EN 13059
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over bumps at constant speed.
Electromagnetic Compatibility (
The manufacturer confirms that equipment complies with
tolerance levels for electromagnetic emissions and
resistance as well as static electricity discharge testing in
accordance with EN 12895 including the normative
procedures contained therein.
Z
No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
2.2 Conditions of use
Ambient temperature
- during operation -10°C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
0406.GB
B 4
3 Standard Version Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.
3.1 Performance data for standard trucks
3.2 Dimensions
1) Level, rolling resistance 200N/t
2) JetPilot height
3) Total length excluding coupling, as different coupling versions are available
Description EZS 330 EZS 350 EZS 330 XL EZS 350 XL
Q Tow capacity
1)
3000 5000 3000 5000 kg
F Rated tow force 600 1000 600 1000 N
Description EZS 330 EZS 350 EZS 330 XL EZS 350 XL
Net weight 1066 1066 1201 1201 kg
Axle load w.o. load
front/rear
514/552 514/552 635/566 635/566 kg
h
7
Height 132 132 142 142 mm
h
14
Tiller height in travel
position
2)
1342 1342 1387 1387 mm
h
10
Coupling height 158 158 158 158 mm
l
1
Overall length
3)
1260 1260 1427 1427 mm
b
1
Overall width 810 810 810 810 mm
b
11
Track width, rear 490 490 490 490 mm
y Wheel base 920 920 1087 1087 mm
m
2
Centre wheelbase
ground clearance
45 45 45 45 mm
W
a
Turning radius 1160 1160 1320 1320 mm
Travel speed w / w.o.
load
8,5/12,5 5,0/8,0 8,5/12,5 5,0/8,0 km/h
Tow force without
load s
2
60 min
600 1000 600 1000 N
Max. tow force
without load s
2
5 min
3000 3500 3000 3500 N
Drive motor, output at
s
2
60 min
2.5 2.5 2.5 2.5 kW
Battery voltage, rated
capacity k
5
24/420
(450)
24/420
(450)
24/560
(600)
24/560
(600)
V/Ah
Battery weight 370 370 370/450 370/450 kg
0406.GB
B 4
3 Standard Version Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.
3.1 Performance data for standard trucks
3.2 Dimensions
1) Level, rolling resistance 200N/t
2) JetPilot height
3) Total length excluding coupling, as different coupling versions are available
Description EZS 330 EZS 350 EZS 330 XL EZS 350 XL
Q Tow capacity
1)
3000 5000 3000 5000 kg
F Rated tow force 600 1000 600 1000 N
Description EZS 330 EZS 350 EZS 330 XL EZS 350 XL
Net weight 1066 1066 1201 1201 kg
Axle load w.o. load
front/rear
514/552 514/552 635/566 635/566 kg
h
7
Height 132 132 142 142 mm
h
14
Tiller height in travel
position
2)
1342 1342 1387 1387 mm
h
10
Coupling height 158 158 158 158 mm
l
1
Overall length
3)
1260 1260 1427 1427 mm
b
1
Overall width 810 810 810 810 mm
b
11
Track width, rear 490 490 490 490 mm
y Wheel base 920 920 1087 1087 mm
m
2
Centre wheelbase
ground clearance
45 45 45 45 mm
W
a
Turning radius 1160 1160 1320 1320 mm
Travel speed w / w.o.
load
8,5/12,5 5,0/8,0 8,5/12,5 5,0/8,0 km/h
Tow force without
load s
2
60 min
600 1000 600 1000 N
Max. tow force
without load s
2
5 min
3000 3500 3000 3500 N
Drive motor, output at
s
2
60 min
2.5 2.5 2.5 2.5 kW
Battery voltage, rated
capacity k
5
24/420
(450)
24/420
(450)
24/560
(600)
24/560
(600)
V/Ah
Battery weight 370 370 370/450 370/450 kg
B 5
0406.GB
4) Rated tow force
a
2
a
2
Wa
y
1335
l
1
b
11
b
1
h
14
m2h
10
h
7
B 5
0406.GB
4) Rated tow force
a
2
a
2
Wa
y
1335
l
1
b
11
b
1
h
14
m2h
10
h
7
0406.GB
B 6
4 Identification points and data plates
Item Description
14 Truck data plate
15 “Caution, pushbutton operation” warning
16 Accident prevention inspection label (Donly)
17 Warning: Risk of trapping when reversing
18 Attachment point of hooks for transportation by crane (inside)
“Read operating instructions” warning
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXX
XXXXXXX
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
14
15
16
18
17
0406.GB
B 6
4 Identification points and data plates
Item Description
14 Truck data plate
15 “Caution, pushbutton operation” warning
16 Accident prevention inspection label (Donly)
17 Warning: Risk of trapping when reversing
18 Attachment point of hooks for transportation by crane (inside)
“Read operating instructions” warning
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXX
XXXXXXX
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2000
14
15
16
18
17
B 7
0406.GB
4.1 Truck data plate
Z
For any queries relating to the truck or spare part orders, please state the truck serial
no. (22).
Item Description
19 Max. supporting force (kg)
20 Net weight w.o. battery (kg)
21 Min./max. battery weight (kg)
22 Manufacturer
23 Customer no.
24 Year of manufacture
25 Rated tow force 5 min. in N
26 Output (kW)
27 Order no.
28 Battery: Voltage (V)
29 Rated tow force 60 min. in N
30 Serial no.
31 Type
32 Manufacturer’s logo
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXX
XXXXXXX
XXXXXXXXX
XXXXXXXXX
19
20
21
22
23
24
25
26
27
28
29
30
31
32
B 7
0406.GB
4.1 Truck data plate
Z
For any queries relating to the truck or spare part orders, please state the truck serial
no. (22).
Item Description
19 Max. supporting force (kg)
20 Net weight w.o. battery (kg)
21 Min./max. battery weight (kg)
22 Manufacturer
23 Customer no.
24 Year of manufacture
25 Rated tow force 5 min. in N
26 Output (kW)
27 Order no.
28 Battery: Voltage (V)
29 Rated tow force 60 min. in N
30 Serial no.
31 Type
32 Manufacturer’s logo
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXXXX
XXXXXXX
XXXXXXX
XXXXXXXXX
XXXXXXXXX
19
20
21
22
23
24
25
26
27
28
29
30
31
32
0406.GB
B 8
0406.GB
B 8
C 1
0406.GB
C Transport and Commissioning
1 Lifting by crane
F
Only use lifting gear with
sufficient capacity
(for transport weight see truck
data plate).
Z
Lifting gear attachment points
are provided on the chassis (3)
and the back wall (1) in case the
truck is to be lifted or transported
by crane.
– Park the truck securely (see
Chapter E).
– Open the front cover (2) and
put it to one side (refer to
chapter F).
– Secure the lifting slings to the
attachment points (1) and (3).
M
The lifting gear must be
attached to the attachment
points in such a manner that it
cannot slip under any circumstances and cannot come into contact with any
attachments when the truck is lifted.
2 Securing the truck during transport
The truck must be securely fastened when transported on a lorry or a trailer. The lorry
/ trailer must have fastening rings.
To fasten the truck pull the tensioning belt (5) over the truck (4) and attach it to the
fastening rings.
Tighten the tensioning belt with
the tensioner (6).
Loading must be carried out by
specially trained staff in
accordance with recommendations contained in Guidelines
VDI 2700 and VDI 2703. In each
case correct measurements shall
be determined and appropriate
safety measures adopted.
1
2
3
4
5 6
C 1
0406.GB
C Transport and Commissioning
1 Lifting by crane
F
Only use lifting gear with
sufficient capacity
(for transport weight see truck
data plate).
Z
Lifting gear attachment points
are provided on the chassis (3)
and the back wall (1) in case the
truck is to be lifted or transported
by crane.
– Park the truck securely (see
Chapter E).
– Open the front cover (2) and
put it to one side (refer to
chapter F).
– Secure the lifting slings to the
attachment points (1) and (3).
M
The lifting gear must be
attached to the attachment
points in such a manner that it
cannot slip under any circumstances and cannot come into contact with any
attachments when the truck is lifted.
2 Securing the truck during transport
The truck must be securely fastened when transported on a lorry or a trailer. The lorry
/ trailer must have fastening rings.
To fasten the truck pull the tensioning belt (5) over the truck (4) and attach it to the
fastening rings.
Tighten the tensioning belt with
the tensioner (6).
Loading must be carried out by
specially trained staff in
accordance with recommen-
dations contained in Guidelines
VDI 2700 and VDI 2703. In each
case correct measurements shall
be determined and appropriate
safety measures adopted.
1
2
3
4
5 6
0406.GB
C 2
3 Using the truck for the first time
M
Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cables connected to the battery (trailing cables) must be less
than 6 meters in length.
To prepare the truck after delivery or after transport, proceed as follows:
– Check the truck for completion and satisfactory condition of the equipment.
– Install battery (where required). Do not damage battery cables (see Chapter D).
– Charge the battery (see Chapter D).
– Commission the truck in accordance with instructions (see Chapter E).
Z
When the truck is parked, the running surface of the tyres will flatten. The flattening
will disappear after a short period of operation.
0406.GB
C 2
3 Using the truck for the first time
M
Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cables connected to the battery (trailing cables) must be less
than 6 meters in length.
To prepare the truck after delivery or after transport, proceed as follows:
– Check the truck for completion and satisfactory condition of the equipment.
– Install battery (where required). Do not damage battery cables (see Chapter D).
– Charge the battery (see Chapter D).
– Commission the truck in accordance with instructions (see Chapter E).
Z
When the truck is parked, the running surface of the tyres will flatten. The flattening
will disappear after a short period of operation.
C 3
0406.GB
4 Operating the truck without its own drive system
F
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as
follows:
– Set the master switch to position “OFF”.
– Set the key switch to position “OFF” (“0”) and remove the key.
– Prevent the truck from rolling away.
– Open battery cover (refer to chapter D).
– Open the front cover (7) and put it to one side (see chapter F).
– Slacken the lock nuts (8) and tighten the screws (9).
The brake is now released and the truck can move.
F
On reaching your destination, ensure that the brake is restored to its initial state. The
truck must never be parked with the brakes released.
– Loosen the screws (9) by approx. 5 mm and lock by tightening the lock nuts (8).
The brake is now applied again.
– Refit the front cover (7).
7
8
9
C 3
0406.GB
4 Operating the truck without its own drive system
F
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as
follows:
– Set the master switch to position “OFF”.
– Set the key switch to position “OFF” (“0”) and remove the key.
– Prevent the truck from rolling away.
– Open battery cover (refer to chapter D).
– Open the front cover (7) and put it to one side (see chapter F).
– Slacken the lock nuts (8) and tighten the screws (9).
The brake is now released and the truck can move.
F
On reaching your destination, ensure that the brake is restored to its initial state. The
truck must never be parked with the brakes released.
– Loosen the screws (9) by approx. 5 mm and lock by tightening the lock nuts (8).
The brake is now applied again.
– Refit the front cover (7).
7
8
9
0406.GB
C 4
0406.GB
C 4
D 1
0406.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection: Smoking and naked flames must be avoided when working with
batteries Wherever a truck is parked for charging there shall be no inflammable
material or operating fluids capable of creating sparks within 2 metres around the
truck. The area must be well ventilated. Fire protection equipment must be provided.
Battery maintenance: The battery cell covers must be kept dry and clean. The
terminals and cable shoes must be clean, secure and have a light coating of dielectric
grease. Batteries with non insulated terminals must be covered with a non slip
insulation mat.
Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Avoid all contact with battery acide.
Should however clothing, skin or eyes come in contact with acid the affected parts
should be rinsed with plenty of clean water - where the skin or eyes are affected call
a doctor immediately. Immediately neutralise any spilled battery acid.
M
Only batteries with a sealed battery container may be used.
F
The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.
D 1
0406.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection: Smoking and naked flames must be avoided when working with
batteries Wherever a truck is parked for charging there shall be no inflammable
material or operating fluids capable of creating sparks within 2 metres around the
truck. The area must be well ventilated. Fire protection equipment must be provided.
Battery maintenance: The battery cell covers must be kept dry and clean. The
terminals and cable shoes must be clean, secure and have a light coating of dielectric
grease. Batteries with non insulated terminals must be covered with a non slip
insulation mat.
Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Avoid all contact with battery acide.
Should however clothing, skin or eyes come in contact with acid the affected parts
should be rinsed with plenty of clean water - where the skin or eyes are affected call
a doctor immediately. Immediately neutralise any spilled battery acid.
M
Only batteries with a sealed battery container may be used.
F
The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.
0406.GB
D 2
2Battery types
The truck will be equipped with different battery types, depending on the application.
The following table shows which combinations can be included as standard:
1)
partially maintenance-free with electrolytic recirculation
2) XL only
The battery weight is indicated on the battery data 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/installing the battery make sure the battery is securely located in the
battery compartment of the truck.
LxWxH 798x212x784 mm; 370 kg
24 V EPzS battery 3 EPzS 420 Ah
24 volt EPzS battery
enhanced
3 EPzS 450 Ah
24 volt EPzV battery
maintenance free
3 EPzV 360 Ah
24 volt PzW battery
wf 200
1)
3 PzW 420 Ah
LxWxH 798x330x784 mm; 450 kg
2)
24 V EPzS battery 4 EPzS 560 Ah
24 volt EPzS battery
enhanced
4 EPzS 620 Ah
24 volt EPzV battery
maintenance free
4 EPzV 480 Ah
24 volt PzW battery
wf 200
1)
4 PzW 560 Ah
0406.GB
D 2
2Battery types
The truck will be equipped with different battery types, depending on the application.
The following table shows which combinations can be included as standard:
1)
partially maintenance-free with electrolytic recirculation
2) XL only
The battery weight is indicated on the battery data 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/installing the battery make sure the battery is securely located in the
battery compartment of the truck.
LxWxH 798x212x784 mm; 370 kg
24 V EPzS battery 3 EPzS 420 Ah
24 volt EPzS battery
enhanced
3 EPzS 450 Ah
24 volt EPzV battery
maintenance free
3 EPzV 360 Ah
24 volt PzW battery
wf 200
1)
3 PzW 420 Ah
LxWxH 798x330x784 mm; 450 kg
2)
24 V EPzS battery 4 EPzS 560 Ah
24 volt EPzS battery
enhanced
4 EPzS 620 Ah
24 volt EPzV battery
maintenance free
4 EPzV 480 Ah
24 volt PzW battery
wf 200
1)
4 PzW 560 Ah
D 3
0406.GB
3 Exposing the battery
F
Park the truck securely (see Chapter E).
– Pull lever (1) upward while at the same time setting the tiller vertical.
– Release the lever (1) again.
– Flip up the battery latch (3) and open the battery cover (2).
F
All covers and connections must be restored to the normal operating condition before
the truck can operate again.
123
D 3
0406.GB
3 Exposing the battery
F
Park the truck securely (see Chapter E).
– Pull lever (1) upward while at the same time setting the tiller vertical.
– Release the lever (1) again.
– Flip up the battery latch (3) and open the battery cover (2).
F
All covers and connections must be restored to the normal operating condition before
the truck can operate again.
123
0406.GB
D 4
4 Charge the battery
F
To charge the battery, the truck must be parked in a closed and properly ventilated
room.
– Expose the battery (see Section 3).
M
The battery connector (5) and the charging cable (4) of the battery charging station
must only be connected or disconnected with the truck and the battery charger
switched off. The main switch (7) must also only be pressed when the truck and the
battery charger are switched off.
F
When charging, the tops of the battery cells must be exposed to provide sufficient
ventilation. Do not place any metal objects on the battery. Before charging, check all
cables and plug connections for visible signs of damage.
All safety instructions given by the battery and battery charger manufacturers must
be strictly observed.
– Pull out the battery plug (5) from the bracket (6).
– Remove any insulating mats from the battery.
– Connect the charging cable (4) of the battery charging station to the battery
connector (5) and switch on the charger.
M
Charge the battery in accordance with the battery and charging station
manufacturers’ instructions.
4 5 67
0406.GB
D 4
4 Charge the battery
F
To charge the battery, the truck must be parked in a closed and properly ventilated
room.
– Expose the battery (see Section 3).
M
The battery connector (5) and the charging cable (4) of the battery charging station
must only be connected or disconnected with the truck and the battery charger
switched off. The main switch (7) must also only be pressed when the truck and the
battery charger are switched off.
F
When charging, the tops of the battery cells must be exposed to provide sufficient
ventilation. Do not place any metal objects on the battery. Before charging, check all
cables and plug connections for visible signs of damage.
All safety instructions given by the battery and battery charger manufacturers must
be strictly observed.
– Pull out the battery plug (5) from the bracket (6).
– Remove any insulating mats from the battery.
– Connect the charging cable (4) of the battery charging station to the battery
connector (5) and switch on the charger.
M
Charge the battery in accordance with the battery and charging station
manufacturers’ instructions.
4 5 67
D 5
0406.GB
5 Battery removal and installation
F
The truck must be parked on level ground. To prevent short circuits, batteries with
exposed terminals or connectors must be covered with a rubber mat. Place the
battery connector or the battery cable in such a way that they will not get caught on
the truck when the battery is withdrawn.
M
When transporting batteries using a crane, ensure that the crane is of adequate
capacity (the battery weight is indicated on the battery data plate on the battery
container). The lifting gear must exert a vertical pull so that the battery container is
not compressed. Attach the hooks to the attachment points (8) in such a way that the
lifting gear, when slack, cannot collapse on the battery cells.
– Expose the battery (see Section 3).
– Pull out the battery plug (10) from the bracket.
– Flip back the battery locking mechanism (9).
– Using crane lifting gear, lift the battery (11) slowly and carefully out of the truck.
The battery can optionally be removed from the side. To do this, pull the battery out
at the side onto the battery replacement trolley.
F
Do not put your fingers between the truck frame and the battery.
F
Follow the operating instructions of the battery replacement trolley manufacturer!
Installation is in the reverse order of removal. When reinstalling the battery, note the
required installation position and make sure the battery is connected correctly.
F
After installing the battery check all cables and plug connections for visible signs of
damage.
The battery must be securely fixed in the truck to avoid damage arising from
accidental movement. After each replacement ensure that the battery is prevented
from sliding, by flipping the battery locking mechanism (9) back into the recess.
The battery cover must be firmly closed.
8
910
11
D 5
0406.GB
5 Battery removal and installation
F
The truck must be parked on level ground. To prevent short circuits, batteries with
exposed terminals or connectors must be covered with a rubber mat. Place the
battery connector or the battery cable in such a way that they will not get caught on
the truck when the battery is withdrawn.
M
When transporting batteries using a crane, ensure that the crane is of adequate
capacity (the battery weight is indicated on the battery data plate on the battery
container). The lifting gear must exert a vertical pull so that the battery container is
not compressed. Attach the hooks to the attachment points (8) in such a way that the
lifting gear, when slack, cannot collapse on the battery cells.
– Expose the battery (see Section 3).
– Pull out the battery plug (10) from the bracket.
– Flip back the battery locking mechanism (9).
– Using crane lifting gear, lift the battery (11) slowly and carefully out of the truck.
The battery can optionally be removed from the side. To do this, pull the battery out
at the side onto the battery replacement trolley.
F
Do not put your fingers between the truck frame and the battery.
F
Follow the operating instructions of the battery replacement trolley manufacturer!
Installation is in the reverse order of removal. When reinstalling the battery, note the
required installation position and make sure the battery is connected correctly.
F
After installing the battery check all cables and plug connections for visible signs of
damage.
The battery must be securely fixed in the truck to avoid damage arising from
accidental movement. After each replacement ensure that the battery is prevented
from sliding, by flipping the battery locking mechanism (9) back into the recess.
The battery cover must be firmly closed.
8
910
11
Loading...