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
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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
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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
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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
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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
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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
0406.GB
D 6
0406.GB
D 6
E 1
0406.GB
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation The forklift truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they
can drive and handle loads and have been authorised to operate the truck by the
proprietor or his representative.
Driver’s rights, obligations and responsibilities: The driver must be informed of
his duties and responsibilities and be instructed in the operation of the truck and shall
be familiar with the operator manual. The driver shall be afforded all due rights.
Safety shoes must be worn for pedestrian operated trucks.
Unauthorised Use of Truck: The driver is responsible for the truck during the time
it is in use. The drive must prevent unauthorised persons from driving or operating the
truck. Do not carry passengers.
Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the forklift truck or attachment. Trucks which are unsafe for operation (e.g.
wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the forklift truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
Hazardous area: A hazardous area is defined as the area in which people are at risk
from the truck movement, the load handler (e.g. attachments) or the load itself. This
also includes areas which can be reached by falling loads or by the trailer veering.
F
Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, a warning must be sounded with sufficient notice. If
unauthorised personnel are still within the hazardous area the truck shall be brought
to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
E 1
0406.GB
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation The forklift truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they
can drive and handle loads and have been authorised to operate the truck by the
proprietor or his representative.
Driver’s rights, obligations and responsibilities: The driver must be informed of
his duties and responsibilities and be instructed in the operation of the truck and shall
be familiar with the operator manual. The driver shall be afforded all due rights.
Safety shoes must be worn for pedestrian operated trucks.
Unauthorised Use of Truck: The driver is responsible for the truck during the time
it is in use. The drive must prevent unauthorised persons from driving or operating the
truck. Do not carry passengers.
Damage and Faults: The supervisor must be immediately informed of any damage
or faults to the forklift truck or attachment. Trucks which are unsafe for operation (e.g.
wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the forklift truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
Hazardous area: A hazardous area is defined as the area in which people are at risk
from the truck movement, the load handler (e.g. attachments) or the load itself. This
also includes areas which can be reached by falling loads or by the trailer veering.
F
Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, a warning must be sounded with sufficient notice. If
unauthorised personnel are still within the hazardous area the truck shall be brought
to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
0406.GB
E 2
2 Controls and Displays
Item Control / Display Function
1Jet Pilot t Steers the truck.
2 Brake button t The truck brakes at the maximum possible
deceleration rate until it comes to a halt.
3 “Horn” button t Triggers a warning signal.
4 Controller t Controls the direction of travel as well as
the travel speed.
5 Forward “pedestrian / walk-
along operation” button
o Travel starts in pedestrian mode in the
forward direction (V)
(slow travel).
6 Stop button o The electrical functions are cut out and the
truck automatically brakes.
7 Reverse “pedestrian
operation” button
o Travel starts in pedestrian mode in the
reverse direction (R)
(slow travel).
8 Display instrument
(CANDIS)
o Hourmeter.
Displays battery capacity.
Displays travel parameters and service
indicators.
Shows the service hours completed by the
truck.
9 CANCODE
keypad
o Code settings.
Release and select the travel programs.
Enter travel parameters.
Code Lock o Replaces the key switch.
Switches control voltage on and off.
Releases the truck functions.
10 Key switch t Switches the truck on and off.
Removing the key prevents the truck from
being switched on by unauthorised
personnel.
11 Tiller adjustment t The tiller can be set to the required
position.
12 Trailer coupling o For towed load
13 Platform t – released (without load): Travel inhibited,
or truck decelerates.
– actuated (with load): Travel released.
14 Main switch / isolator
(emergency disconnect)
t The circuit is interrupted, all electrical
functions are cut out and the truck
automatically brakes.
t = Standard equipment o = Optional Equipment
0406.GB
E 2
2 Controls and Displays
Item Control / Display Function
1Jet Pilot t Steers the truck.
2 Brake button t The truck brakes at the maximum possible
deceleration rate until it comes to a halt.
3 “Horn” button t Triggers a warning signal.
4 Controller t Controls the direction of travel as well as
the travel speed.
5 Forward “pedestrian / walk-
along operation” button
o Travel starts in pedestrian mode in the
forward direction (V)
(slow travel).
6 Stop button o The electrical functions are cut out and the
truck automatically brakes.
7 Reverse “pedestrian
operation” button
o Travel starts in pedestrian mode in the
reverse direction (R)
(slow travel).
8 Display instrument
(CANDIS)
o Hourmeter.
Displays battery capacity.
Displays travel parameters and service
indicators.
Shows the service hours completed by the
truck.
9 CANCODE
keypad
o Code settings.
Release and select the travel programs.
Enter travel parameters.
Code Lock o Replaces the key switch.
Switches control voltage on and off.
Releases the truck functions.
10 Key switch t Switches the truck on and off.
Removing the key prevents the truck from
being switched on by unauthorised
personnel.
11 Tiller adjustment t The tiller can be set to the required
position.
12 Trailer coupling o For towed load
13 Platform t – released (without load): Travel inhibited,
or truck decelerates.
– actuated (with load): Travel released.
14 Main switch / isolator
(emergency disconnect)
t The circuit is interrupted, all electrical
functions are cut out and the truck
automatically brakes.
t = Standard equipment o = Optional Equipment
E 3
0406.GB
1
2
3
4567 8910
11
12
5
6
7
13
14
E 3
0406.GB
1
2
3
4567 8910
11
12
5
6
7
13
14
0406.GB
E 4
3 Starting up the truck
F
Before the truck can be commissioned or operated, the driver must ensure that there
is nobody within the hazardous area.
The electronic traction controller and optionally the steering controller monitor their
own operation. In the event of an error, travel and steering are interrupted.
F
The error that has occurred must be eliminated by the manufacturer's service
department.
Checks and operations to be performed before starting daily work
– Inspect the entire truck (especially the wheels) for visible signs of damage.
– Visually inspect the battery attachment and cable connections
M
When entering the truck, take care not to activate the controller or the
“pedestrian” (o) button.
Switching on the truck
– Step onto the operator platform (20).
– After relaxing the tiller adjustment device, set the tiller to the required position and
then release the tiller adjustment device.
– Pull out the main switch / isolator (19).
– Insert the key in the key switch (18) and turn it clockwise as far as it will go to the
“I” position.
– Test the horn (15).
– Test the controller (16) (see section 4.2).
The truck is now operational.
Z
The display instrument (CANDIS (17/(o)) shows the available battery capacity.
15
16 17 18
19
20
0406.GB
E 4
3 Starting up the truck
F
Before the truck can be commissioned or operated, the driver must ensure that there
is nobody within the hazardous area.
The electronic traction controller and optionally the steering controller monitor their
own operation. In the event of an error, travel and steering are interrupted.
F
The error that has occurred must be eliminated by the manufacturer's service
department.
Checks and operations to be performed before starting daily work
– Inspect the entire truck (especially the wheels) for visible signs of damage.
– Visually inspect the battery attachment and cable connections
M
When entering the truck, take care not to activate the controller or the
“pedestrian” (o) button.
Switching on the truck
– Step onto the operator platform (20).
– After relaxing the tiller adjustment device, set the tiller to the required position and
then release the tiller adjustment device.
– Pull out the main switch / isolator (19).
– Insert the key in the key switch (18) and turn it clockwise as far as it will go to the
“I” position.
– Test the horn (15).
– Test the controller (16) (see section 4.2).
The truck is now operational.
Z
The display instrument (CANDIS (17/(o)) shows the available battery capacity.
15
16 17 18
19
20
E 5
0406.GB
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must
only be stored in places specially designated for this purpose.
Travel conduct: The driver must adapt the travel speed to local conditions. The truck
must be driven at slow speed when negotiating bends or narrow passageways, when
passing through swing doors and at blind spots. The driver must always observe an
adequate braking distance between the forklift truck and the vehicle in front and must
be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid
U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden
to lean out of or reach beyond the working and operating area.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. The truck must travel with the load at the rear. If this
is not possible, e.g. when shunting, the driver must ensure that the shunting area is
free. If the driver does not have a clear view, a second person must act as a lookout
for the shunting area.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The industrial truck must not be turned, operated at an angle or parked on
inclines or slopes. Inclines must only be negotiated at slow speed, with the driver
ready to brake at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the owner. The
driver must satisfy himself of the above before entering these areas. The truck must
enter lifts with the load in front and must take up a position which does not allow it to
come into contact with the walls of the lift shaft. .
People travelling in the lift with the forklift truck must only enter the lift after the truck
has come to a halt and must exit the lift before the truck.
Towing trailers: Do not exceed the maximum trailer load specified for the forklift
truck for trailers with or without brakes. The trailer load must be secured in
accordance with regulations and must not exceed the dimensions permitted for that
roadway. After coupling and before starting the driver shall ensure that the trailer
coupling cannot become detached. Forklift trucks pulling a load must be driven such
that the trailing vehicle is driven safely and can be stopped under any conditions.
E 5
0406.GB
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must
only be stored in places specially designated for this purpose.
Travel conduct: The driver must adapt the travel speed to local conditions. The truck
must be driven at slow speed when negotiating bends or narrow passageways, when
passing through swing doors and at blind spots. The driver must always observe an
adequate braking distance between the forklift truck and the vehicle in front and must
be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid
U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden
to lean out of or reach beyond the working and operating area.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. The truck must travel with the load at the rear. If this
is not possible, e.g. when shunting, the driver must ensure that the shunting area is
free. If the driver does not have a clear view, a second person must act as a lookout
for the shunting area.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The industrial truck must not be turned, operated at an angle or parked on
inclines or slopes. Inclines must only be negotiated at slow speed, with the driver
ready to brake at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the owner. The
driver must satisfy himself of the above before entering these areas. The truck must
enter lifts with the load in front and must take up a position which does not allow it to
come into contact with the walls of the lift shaft. .
People travelling in the lift with the forklift truck must only enter the lift after the truck
has come to a halt and must exit the lift before the truck.
Towing trailers: Do not exceed the maximum trailer load specified for the forklift
truck for trailers with or without brakes. The trailer load must be secured in
accordance with regulations and must not exceed the dimensions permitted for that
roadway. After coupling and before starting the driver shall ensure that the trailer
coupling cannot become detached. Forklift trucks pulling a load must be driven such
that the trailing vehicle is driven safely and can be stopped under any conditions.
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E 6
4.2 Travel, Steering, Braking
F
Be extremely careful when driving and steering, especially when operating outside
the geometry of the truck.
The electric steering system is self-monitoring.
The steering controller monitors the fault frequency over a certain period. If the same
fault is detected several times during this period, the steering controller reduces the
travel speed of the truck to slow travel. If such a fault occurs, the travel speed is not
reset to normal travel by switching the truck off and on again. This prevents a fault
being cancelled without being rectified.
F
As the steering system is a safety-critical component, the fault must be rectified by
the manufacturer's service department.
Emergency Disconnect
– Press the isolator (21) down.
All electrical functions are deactivated.
21
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E 6
4.2 Travel, Steering, Braking
F
Be extremely careful when driving and steering, especially when operating outside
the geometry of the truck.
The electric steering system is self-monitoring.
The steering controller monitors the fault frequency over a certain period. If the same
fault is detected several times during this period, the steering controller reduces the
travel speed of the truck to slow travel. If such a fault occurs, the travel speed is not
reset to normal travel by switching the truck off and on again. This prevents a fault
being cancelled without being rectified.
F
As the steering system is a safety-critical component, the fault must be rectified by
the manufacturer's service department.
Emergency Disconnect
– Press the isolator (21) down.
All electrical functions are deactivated.
21
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Travel
F
Do not drive the truck unless the panels are closed and properly locked.
– Start up the truck (refer to section 3).
– Set the controller (22) to the desired travel direction: forward (V) or reverse (R).
Z
The truck starts to travel in the direction selected.
The travel speed is governed by the controller (22).
For trucks with “pedestrian operation” (o) the truck can be operated at reduced
speed without having to stand on the platform.
Travelling on inclines
Preventing the truck from rolling back:
With the controller (22) set to neutral, the service brake automatically applies after a
short jerk (the controller detects downhill motion on an incline). The service brake is
released again via the controller (22) which is also used to select the speed and the
travel direction.
Steering
– Turn the steering arm to the left or right.
R
R
V
V
22
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0406.GB
Travel
F
Do not drive the truck unless the panels are closed and properly locked.
– Start up the truck (refer to section 3).
– Set the controller (22) to the desired travel direction: forward (V) or reverse (R).
Z
The truck starts to travel in the direction selected.
The travel speed is governed by the controller (22).
For trucks with “pedestrian operation” (o) the truck can be operated at reduced
speed without having to stand on the platform.
Travelling on inclines
Preventing the truck from rolling back:
With the controller (22) set to neutral, the service brake automatically applies after a
short jerk (the controller detects downhill motion on an incline). The service brake is
released again via the controller (22) which is also used to select the speed and the
travel direction.
Steering
– Turn the steering arm to the left or right.
R
R
V
V
22
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E 8
Brakes
F
The brake pattern of the truck depends largely on the state of the ground. The driver
must take this into account when operating the truck.
M
The driver must be looking ahead when travelling. If there is no hazard, brake
moderately to avoid moving the load and to prevent the trailer from veering out.
The truck can be braked in three different ways:
– using the service brake
– using the generator brake (coasting)
– by plugging (controller)
F
In emergencies, the truck must only be braked with the service brake.
Z
During normal operation, the generator brake and plugging can be applied. These
methods of braking reduce wear and require less energy (energy recovery).
Braking with the service brake:
– Apply the brake button (23).
The truck brakes at the maximum possible deceleration rate until it comes to a halt.
Z
The truck can only start again when the controller has been set to “0”.
Braking via the generator brake (coasting):
– Release the controller (25) - the controller assumes the zero position.
Depending on the setting, the truck is braked by the generator brake, coasting to a
stop.
Z
For the standard truck, the rate of deceleration can be adjusted by the manufacturer’s
service department. For trucks with CANCODE and CANDIS it can be adjusted by
entering the appropriate setting.
Plugging:
– When travelling, set the controller (25) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z
The braking intensity depends on the
position of the controller.
23
24
25
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E 8
Brakes
F
The brake pattern of the truck depends largely on the state of the ground. The driver
must take this into account when operating the truck.
M
The driver must be looking ahead when travelling. If there is no hazard, brake
moderately to avoid moving the load and to prevent the trailer from veering out.
The truck can be braked in three different ways:
– using the service brake
– using the generator brake (coasting)
– by plugging (controller)
F
In emergencies, the truck must only be braked with the service brake.
Z
During normal operation, the generator brake and plugging can be applied. These
methods of braking reduce wear and require less energy (energy recovery).
Braking with the service brake:
– Apply the brake button (23).
The truck brakes at the maximum possible deceleration rate until it comes to a halt.
Z
The truck can only start again when the controller has been set to “0”.
Braking via the generator brake (coasting):
– Release the controller (25) - the controller assumes the zero position.
Depending on the setting, the truck is braked by the generator brake, coasting to a
stop.
Z
For the standard truck, the rate of deceleration can be adjusted by the manufacturer’s
service department. For trucks with CANCODE and CANDIS it can be adjusted by
entering the appropriate setting.
Plugging:
– When travelling, set the controller (25) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z
The braking intensity depends on the
position of the controller.
23
24
25
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4.3 Pedestrian operation (o)
F
When travelling in pedestrian mode you must make sure – while walking alongside –
that the steering system is set to straight ahead travel and that the operator cannot
be trapped between the truck and an obstacle.
Z
In pedestrian mode the truck can be operated by the operator from all sides while
walking alongside. In this case, the truck travels at a significantly reduced speed.
Pedestrian mode is achieved by pressing the “pedestrian” buttons (27, 28) on the
backrest.
Travelling with the “pedestrian” button (o)
– Press the “pedestrian” buttons (27, 28).
The truck travels at a fixed speed of approximately 2km/h (slow travel).
R
R
V
V
26
27
28
28R
27V
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0406.GB
4.3 Pedestrian operation (o)
F
When travelling in pedestrian mode you must make sure – while walking alongside –
that the steering system is set to straight ahead travel and that the operator cannot
be trapped between the truck and an obstacle.
Z
In pedestrian mode the truck can be operated by the operator from all sides while
walking alongside. In this case, the truck travels at a significantly reduced speed.
Pedestrian mode is achieved by pressing the “pedestrian” buttons (27, 28) on the
backrest.
Travelling with the “pedestrian” button (o)
– Press the “pedestrian” buttons (27, 28).
The truck travels at a fixed speed of approximately 2km/h (slow travel).
R
R
V
V
26
27
28
28R
27V
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E 10
4.4 Coupling Types
F
When attaching and uncoupling trailers the tow truck and trailer must be on level
ground. All controls must be set to neutral. The tow truck and trailer must be secured
to prevent any accidental movement.
F
Risk of trapping! When coupling a trailer do not trap your hands between any truck
components.
4.4.1 Plug connection (o)
Coupling the trailer
– Pull the bolt (29) up fully out of the trailer
coupling.
– Push the tow eye of the trailer into the
trailer coupling, from the top push the bolt
of the trailer coupling through the holes of
the trailer coupling and through the tow
eye.
– To lock: push the retaining needle (30;
secured by a chain to prevent it from
being lost) through the hole at the end of
the bolt.
Uncoupling the trailer
– Make sure that the trailer cannot move accidentally.
– Pull the retaining needle (30) out from the side of the bolt (29). Pull the bolt out of
the coupling from the top. Bring the tow eye out from the side of the coupling.
Reinsert the bolt into the coupling and secure it.
4.4.2 Double decker plug coupling (o)
Two trailers can be coupled a separate
heights.
Coupling the trailer
– Pull the bolt (31) up fully out of the trailer
coupling.
– Push the tow eye of the trailer into the
trailer coupling, from the top push the bolt
of the trailer coupling through the holes of
the trailer coupling and through the tow
eye.
– To lock: push the retaining needle (32;
secured by a chain to prevent it from
being lost) through the hole at the end of
the bolt.
29
30
31
32
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E 10
4.4 Coupling Types
F
When attaching and uncoupling trailers the tow truck and trailer must be on level
ground. All controls must be set to neutral. The tow truck and trailer must be secured
to prevent any accidental movement.
F
Risk of trapping! When coupling a trailer do not trap your hands between any truck
components.
4.4.1 Plug connection (o)
Coupling the trailer
– Pull the bolt (29) up fully out of the trailer
coupling.
– Push the tow eye of the trailer into the
trailer coupling, from the top push the bolt
of the trailer coupling through the holes of
the trailer coupling and through the tow
eye.
– To lock: push the retaining needle (30;
secured by a chain to prevent it from
being lost) through the hole at the end of
the bolt.
Uncoupling the trailer
– Make sure that the trailer cannot move accidentally.
– Pull the retaining needle (30) out from the side of the bolt (29). Pull the bolt out of
the coupling from the top. Bring the tow eye out from the side of the coupling.
Reinsert the bolt into the coupling and secure it.
4.4.2 Double decker plug coupling (o)
Two trailers can be coupled a separate
heights.
Coupling the trailer
– Pull the bolt (31) up fully out of the trailer
coupling.
– Push the tow eye of the trailer into the
trailer coupling, from the top push the bolt
of the trailer coupling through the holes of
the trailer coupling and through the tow
eye.
– To lock: push the retaining needle (32;
secured by a chain to prevent it from
being lost) through the hole at the end of
the bolt.
29
30
31
32
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0406.GB
Uncoupling the trailer
– Make sure that the trailer cannot move accidentally.
– Pull the retaining needle (32) out from the side of the bolt (31). Pull the bolt out of
the coupling from the top. Bring the tow eye out from the side of the coupling.
Reinsert the bolt into the coupling and secure it.
4.4.3 Rockinger coupling with hand lever or Bowden cable (o)
The Rockinger coupling comes either with
or without remote locking (Bowden cable).
The Rockinger coupling with remote locking
allows trailers to be coupled and uncoupled
from the platform via a Bowden cable.
Coupling the trailer
– Push the tow eye of the trailer into the
trailer coupling, the bolt of the trailer
coupling closes automatically.
Uncoupling the trailer
– Open the tow eye lock by applying the lever (33) or Bowden cable handgrip (34).
4.5 Travelling with trailers
F
In difficult application conditions (inclines, smooth or slippery travel routes) the tow
load must have to be reduced to ensure braking without risk of accidents. The max.
permissible load indicated applies only when towing on level surfaces on a good
bearing, non-slip surface.
For tow loads in excess of 2000 kg and on inclines, the use of braked trailers is
recommended.
M
Always pull, never push a trailer.
Z
Familiarise yourself with the brake and steering systems of the trailer when you start
to travel.
M
On cornering with long trailers and trailer trains, note how the angle is reduced.
1. Start the truck slowly until the trailer coupling has become taut. Then gradually
increase the travel speed.
2. To stop, reduce the speed so that both tow truck and trailer gradually slow down.
Brake with care!
Z
Trailer trains are difficult to shunt. For this reason make sure the angle is correct when
cornerning.
33
34
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Uncoupling the trailer
– Make sure that the trailer cannot move accidentally.
– Pull the retaining needle (32) out from the side of the bolt (31). Pull the bolt out of
the coupling from the top. Bring the tow eye out from the side of the coupling.
Reinsert the bolt into the coupling and secure it.
4.4.3 Rockinger coupling with hand lever or Bowden cable (o)
The Rockinger coupling comes either with
or without remote locking (Bowden cable).
The Rockinger coupling with remote locking
allows trailers to be coupled and uncoupled
from the platform via a Bowden cable.
Coupling the trailer
– Push the tow eye of the trailer into the
trailer coupling, the bolt of the trailer
coupling closes automatically.
Uncoupling the trailer
– Open the tow eye lock by applying the lever (33) or Bowden cable handgrip (34).
4.5 Travelling with trailers
F
In difficult application conditions (inclines, smooth or slippery travel routes) the tow
load must have to be reduced to ensure braking without risk of accidents. The max.
permissible load indicated applies only when towing on level surfaces on a good
bearing, non-slip surface.
For tow loads in excess of 2000 kg and on inclines, the use of braked trailers is
recommended.
M
Always pull, never push a trailer.
Z
Familiarise yourself with the brake and steering systems of the trailer when you start
to travel.
M
On cornering with long trailers and trailer trains, note how the angle is reduced.
1. Start the truck slowly until the trailer coupling has become taut. Then gradually
increase the travel speed.
2. To stop, reduce the speed so that both tow truck and trailer gradually slow down.
Brake with care!
Z
Trailer trains are difficult to shunt. For this reason make sure the angle is correct when
cornerning.
33
34
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4.6 Seat o (XL only)
The seat (35) is incorporated into the backrest when folded up. When unfolded, the
seat allows the operator to take up a comfortable position for driving and operating.
The height of the seat is adjustable and can be locked into one of four positions.
– Unfold the seat (35), pull it towards you and push it into the desired height. Lock the
seat at the desired height.
– To set a higher position, push the seat up and release it in the desired position.
– To fold it in, push the seat into the highest position and fold it back.
4.7 Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.
F
Do not park the truck on a slope.
– Set the drive wheel to “Straight ahead”.
– Set the key switch to the “OFF” position (“0”) and remove the key.
– Press the isolator (EMERGENCY DISCONNECT) "Off".
35
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4.6 Seat o (XL only)
The seat (35) is incorporated into the backrest when folded up. When unfolded, the
seat allows the operator to take up a comfortable position for driving and operating.
The height of the seat is adjustable and can be locked into one of four positions.
– Unfold the seat (35), pull it towards you and push it into the desired height. Lock the
seat at the desired height.
– To set a higher position, push the seat up and release it in the desired position.
– To fold it in, push the seat into the highest position and fold it back.
4.7 Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.
F
Do not park the truck on a slope.
– Set the drive wheel to “Straight ahead”.
– Set the key switch to the “OFF” position (“0”) and remove the key.
– Press the isolator (EMERGENCY DISCONNECT) "Off".
35
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0406.GB
5 Display instrument (CANDIS) (o)
The instrument indicates:
– Remaining battery charge
(LED bars (36)),
– Service hours
(LCD display (38)).
It also displays error messages for the
electronic components and
parameter changes.
Discharge status display
Setting limits for the additional “Warning” (39) and “Stop” (37)displays will depend on
the battery type.
5.1 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel movements are collated. This
is a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours display
(38).
Error messages
The operating hours display is also used for indicating errors. The error is displayed
in two parts, starting with a “C” for component and a three-digit component number,
followed by an “E” for error with alternating three-digit error number.
If several errors occurs at the same time, they are displayed one after the other. The
errors are displayed for as long as they remain (always in combination Cxxx / Exxx).
Error messages overwrite the service hour display. Most errors cause the Emergency
Stop to be triggered. Errors remain displayed until the control circuit is switched off
(Code lock).
Z
The manufacturer’s service department has detailed component descriptions with
error codes.
Num-
ber
of bars
Charge
status
Wet battery Maintenance-free battery
LED (yellow)
Warning
LED (red)
Stop
LED (yellow)
Warning
LED (red)
Stop
10 90.1- 100% Off Off Off Off
9 80.1 - 90% Off Off Off Off
8 70.1 - 80% Off Off Off Off
7 60.1 - 70% Off Off Off Off
6 50.1 - 60% Off Off Off Off
5 40.1 - 50% Off Off On Off
4 30.1 - 40% Off Off On On
3 20.1 - 30% On Off On On
2 10.1 - 20% On On On On
Avoid falling below the 20% limit for wet batteries or the 40% limit
for maintenance-free batteries.
36
37
38
39
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5 Display instrument (CANDIS) (o)
The instrument indicates:
– Remaining battery charge
(LED bars (36)),
– Service hours
(LCD display (38)).
It also displays error messages for the
electronic components and
parameter changes.
Discharge status display
Setting limits for the additional “Warning” (39) and “Stop” (37)displays will depend on
the battery type.
5.1 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel movements are collated. This
is a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours display
(38).
Error messages
The operating hours display is also used for indicating errors. The error is displayed
in two parts, starting with a “C” for component and a three-digit component number,
followed by an “E” for error with alternating three-digit error number.
If several errors occurs at the same time, they are displayed one after the other. The
errors are displayed for as long as they remain (always in combination Cxxx / Exxx).
Error messages overwrite the service hour display. Most errors cause the Emergency
Stop to be triggered. Errors remain displayed until the control circuit is switched off
(Code lock).
Z
The manufacturer’s service department has detailed component descriptions with
error codes.
Num-
ber
of bars
Charge
status
Wet battery Maintenance-free battery
LED (yellow)
Warning
LED (red)
Stop
LED (yellow)
Warning
LED (red)
Stop
10 90.1- 100% Off Off Off Off
9 80.1 - 90% Off Off Off Off
8 70.1 - 80% Off Off Off Off
7 60.1 - 70% Off Off Off Off
6 50.1 - 60% Off Off Off Off
5 40.1 - 50% Off Off On Off
4 30.1 - 40% Off Off On On
3 20.1 - 30% On Off On On
2 10.1 - 20% On On On On
Avoid falling below the 20% limit for wet batteries or the 40% limit
for maintenance-free batteries.
36
37
38
39
0406.GB
E 14
Display for parameter changes (travel programs)
The LC display (38) is used in conjunction with the operator keyboard (CANCODE
(o)) to display the setting parameters. The first three digits of the display show the
parameter numbers, the last three digits indicate the parameter value.
Z
Settings of parameter group 0XX (code lock) are not displayed.
5.2 Power up test
On power up the display shows:
– the software version of the display instrument (briefly),
– the operating hours
– the charge status
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Display for parameter changes (travel programs)
The LC display (38) is used in conjunction with the operator keyboard (CANCODE
(o)) to display the setting parameters. The first three digits of the display show the
parameter numbers, the last three digits indicate the parameter value.
Z
Settings of parameter group 0XX (code lock) are not displayed.
5.2 Power up test
On power up the display shows:
– the software version of the display instrument (briefly),
– the operating hours
– the charge status
E 15
0406.GB
6 Keypad (CANCODE) (o)
The keypad consists of 10 digit keys, a Set key
and a o key.
Activation of the travel programs is indicated
through green LEDs on keys 1, 2 and 3.
The o key indicates operational status through a
red/green LED.
It contains the following functions:
– Code lock function (commissioning the truck).
– Travel program selection.
– Setting the travel and battery parameters, only in conjunction with the display
instrument (CANDIS (o)).
The o key has top priority and restores the truck from any status to its default status
without modifying any settings.
6.1 Code Lock
When the correct code has been entered, the machine is ready for use. You can
allocate an individual code to each truck, driver or group of drivers.
Z
When supplied from the factory, the operator code (factory setting 2-5-8-0) is
indicated on a removable sticker.
M
When starting the truck for the first time, change the master and operating codes.
(refer to section 6.4)
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0406.GB
6 Keypad (CANCODE) (o)
The keypad consists of 10 digit keys, a Set key
and a o key.
Activation of the travel programs is indicated
through green LEDs on keys 1, 2 and 3.
The o key indicates operational status through a
red/green LED.
It contains the following functions:
– Code lock function (commissioning the truck).
– Travel program selection.
– Setting the travel and battery parameters, only in conjunction with the display
instrument (CANDIS (o)).
The o key has top priority and restores the truck from any status to its default status
without modifying any settings.
6.1 Code Lock
When the correct code has been entered, the machine is ready for use. You can
allocate an individual code to each truck, driver or group of drivers.
Z
When supplied from the factory, the operator code (factory setting 2-5-8-0) is
indicated on a removable sticker.
M
When starting the truck for the first time, change the master and operating codes.
(refer to section 6.4)
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E 16
Starting the truck for the first time
After switching on the isolator and if necessary the key switch, the LED (44) turns red.
When you enter the correct operator code (factory setting 2-5-8-0) the LED (44) turns
green.
If the wrong code is entered LED (44) flashes red for two seconds. The correct code
can then be entered.
Z
The Set key (45) has no function in operating mode
Power Down
The truck is switched off by pressing the
o key (43).
Z
The truck can switch off automatically after a
pre-determined time. To do this the
corresponding code lock parameter must be
set (see section 6.4).
40 41 42
43
4445
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Starting the truck for the first time
After switching on the isolator and if necessary the key switch, the LED (44) turns red.
When you enter the correct operator code (factory setting 2-5-8-0) the LED (44) turns
green.
If the wrong code is entered LED (44) flashes red for two seconds. The correct code
can then be entered.
Z
The Set key (45) has no function in operating mode
Power Down
The truck is switched off by pressing the
o key (43).
Z
The truck can switch off automatically after a
pre-determined time. To do this the
corresponding code lock parameter must be
set (see section 6.4).
40 41 42
43
4445
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6.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated
programme is indicated by the green LEDs (40), (41), (42) in the corresponding key.
Z
The travel programmes differ with respect to travelling speed, acceleration, and
deceleration.
Factory settings:
– Program 1: Soft operation
– Program 2: Normal operation
– Program 3: High performance mode (preset on commissioning)
Z
The travel programs can be adapted individually to the truck (refer to section 6.4).
6.3 Parameters
In programming mode, the operator keypad enables you to set the code lock
functions and adapt travel programs. In addition, the battery parameters can also be
set.
Z
For trucks without display instrument (CANDIS (o)) only the code lock parameters
can be set.
Parameter Groups
The parameter number is composed of three digits. The first digit refers to the
parameter group as shown in Table 1. The second and third digits are numbered in
sequence from 00 to 99.
No. Parameter Group
0xx Code lock settings
((codes, travel program authorisation, automatic cutout, etc.)
1xx Travel program 1 parameters
(acceleration, coasting brake, speed, etc.)
2xx Travel program 2 parameters
(acceleration, coasting brake, speed, etc.)
3xx Travel program 3 parameters
(acceleration, coasting brake, speed, etc.)
4xx Program-independent parameters
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6.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated
programme is indicated by the green LEDs (40), (41), (42) in the corresponding key.
Z
The travel programmes differ with respect to travelling speed, acceleration, and
deceleration.
Factory settings:
– Program 1: Soft operation
– Program 2: Normal operation
– Program 3: High performance mode (preset on commissioning)
Z
The travel programs can be adapted individually to the truck (refer to section 6.4).
6.3 Parameters
In programming mode, the operator keypad enables you to set the code lock
functions and adapt travel programs. In addition, the battery parameters can also be
set.
Z
For trucks without display instrument (CANDIS (o)) only the code lock parameters
can be set.
Parameter Groups
The parameter number is composed of three digits. The first digit refers to the
parameter group as shown in Table 1. The second and third digits are numbered in
sequence from 00 to 99.
No. Parameter Group
0xx Code lock settings
((codes, travel program authorisation, automatic cutout, etc.)
1xx Travel program 1 parameters
(acceleration, coasting brake, speed, etc.)
2xx Travel program 2 parameters
(acceleration, coasting brake, speed, etc.)
3xx Travel program 3 parameters
(acceleration, coasting brake, speed, etc.)
4xx Program-independent parameters
0406.GB
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6.4 Parameter Settings
To change the truck setting you must enter the master code.
Z
The factory setting for the master code is 7-2-9-5.
M
When starting the truck for the first time, change the master code (see Section 6.1).
F
Safety notes for trucks with indicator instrument (CANDIS (o))
– Parameter settings must be made carefully and only by special trained personnel .
If in doubt, consult the manufacturer's service department.
– Every setting procedure must be monitored on the LC display of the display
instrument (o)). If in doubt, the setting procedure must be cancelled by pressing
the o key (43)
– Since changing any parameter will affect the truck's travel pattern, you must carry
out a test run in a specially designated work area.
To enter the master code:
– Press the o key
– Enter master code
Code Lock Parameters
Setting procedure for trucks without display instrument (CANDIS (o)):
– Enter the three digit parameter number and confirm with set key (45).
– Enter the setting according to the parameter list or change and confirm with the Set
key (45).
Z
If the entry is incorrect, the LED (44) of the o key (43) goes red. If you enter the
parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete your entry, press the
o key (43).
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
Service hours
are displayed
284.0
Green
flashing
Off Off Off
0406.GB
E 18
6.4 Parameter Settings
To change the truck setting you must enter the master code.
Z
The factory setting for the master code is 7-2-9-5.
M
When starting the truck for the first time, change the master code (see Section 6.1).
F
Safety notes for trucks with indicator instrument (CANDIS (o))
– Parameter settings must be made carefully and only by special trained personnel .
If in doubt, consult the manufacturer's service department.
– Every setting procedure must be monitored on the LC display of the display
instrument (o)). If in doubt, the setting procedure must be cancelled by pressing
the o key (43)
– Since changing any parameter will affect the truck's travel pattern, you must carry
out a test run in a specially designated work area.
To enter the master code:
– Press the o key
– Enter master code
Code Lock Parameters
Setting procedure for trucks without display instrument (CANDIS (o)):
– Enter the three digit parameter number and confirm with set key (45).
– Enter the setting according to the parameter list or change and confirm with the Set
key (45).
Z
If the entry is incorrect, the LED (44) of the o key (43) goes red. If you enter the
parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete your entry, press the
o key (43).
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
Service hours
are displayed
284.0
Green
flashing
Off Off Off
E 19
0406.GB
Setting procedure for trucks with and without display instrument (CANDIS (o)):
– Enter the three digit parameter number and confirm with set key (45).
– The display instrument (CANDIS (o)) continues to display the operating hours. If
the display changes, cancel the setting procedure with the o key (43) and restart
from the beginning.
– Enter the setting according to the parameter list or change and confirm with the Set
key (45).
Z
If the entry is incorrect, the LED (44) of the o key (43) goes red. If you enter the
parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete your entry, press the
o key (43).
The following parameters may be entered.
Code Lock Parameter List
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
000 Change master code
The length (4-6 digits) of
the master code also predetermines the length of
the operator code (4-6
digits). Provided the
operator codes are
programmed, only news
codes of the same length
can be entered. If the
code length is to be
changed, all operator
codes must first be
deleted.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 40 flashes)
Enter
current code
Confirm (Set)
(LED 41 flashes)
Enter a
new code
Confirm (Set)
(LED 42 flashes)
Repeat new code
Confirm (Set)
001 Add operator code (max.
600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 41 flashes)
Enter a
code
Confirm (Set)
(LED 42 flashes)
Repeat code
entry
Confirm (Set)
E 19
0406.GB
Setting procedure for trucks with and without display instrument (CANDIS (o)):
– Enter the three digit parameter number and confirm with set key (45).
– The display instrument (CANDIS (o)) continues to display the operating hours. If
the display changes, cancel the setting procedure with the o key (43) and restart
from the beginning.
– Enter the setting according to the parameter list or change and confirm with the Set
key (45).
Z
If the entry is incorrect, the LED (44) of the o key (43) goes red. If you enter the
parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete your entry, press the
o key (43).
The following parameters may be entered.
Code Lock Parameter List
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
000 Change master code
The length (4-6 digits) of
the master code also pre-
determines the length of
the operator code (4-6
digits). Provided the
operator codes are
programmed, only news
codes of the same length
can be entered. If the
code length is to be
changed, all operator
codes must first be
deleted.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 40 flashes)
Enter
current code
Confirm (Set)
(LED 41 flashes)
Enter a
new code
Confirm (Set)
(LED 42 flashes)
Repeat new code
Confirm (Set)
001 Add operator code (max.
600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 41 flashes)
Enter a
code
Confirm (Set)
(LED 42 flashes)
Repeat code
entry
Confirm (Set)
0406.GB
E 20
LEDs 23-25 are located in key fields 1-3 (see Section 6.2)
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
002 Change user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 40 flashes)
Enter
current code
Confirm (Set)
(LED 41 flashes)
Enter a
new code
Confirm (Set)
(LED 42 flashes)
Repeat code
entry
Confirm
003 Delete user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 41 flashes)
Enter a
code
Confirm (Set)
(LED 42 flashes)
Repeat
code entry
Confirm (Set)
004 Delete code log
(Deletes all user codes )
3265 3265 = delete
other inputs= do not
delete
010 Automatic time cutout 00 - 31 00 00 = No
cutout
01 to 30 =
Cutout time in
minutes
31 = cutout in 10
seconds
0406.GB
E 20
LEDs 23-25 are located in key fields 1-3 (see Section 6.2)
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
002 Change user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 40 flashes)
Enter
current code
Confirm (Set)
(LED 41 flashes)
Enter a
new code
Confirm (Set)
(LED 42 flashes)
Repeat code
entry
Confirm
003 Delete user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 41 flashes)
Enter a
code
Confirm (Set)
(LED 42 flashes)
Repeat
code entry
Confirm (Set)
004 Delete code log
(Deletes all user codes )
3265 3265 = delete
other inputs= do not
delete
010 Automatic time cutout 00 - 31 00 00 = No
cutout
01 to 30 =
Cutout time in
minutes
31 = cutout in 10
seconds
E 21
0406.GB
*) only in conjunction with display instrument (CANDIS (o))
Error messages on keypad
LED (44) flashes red to indicate the following errors:
– New master code is already operator code.
– New operator code is already master code.
– Operator code to be changed does not exist.
– Tried to change the operator code to an existing code.
– Operator code to be deleted does not exist.
Code memory full
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
020 Start
travel program
0-3 3 0 – There is no start program
1 – Travel program 1 = Start
travel program
2 – Travel program 2 = Start
travel program
3 – Travel program 3 = Start
travel program
021 Travel program 1*
)
release
0 or 1 1 0 = Fahrprogram
not released
1 = travel program released
022 Travel program 2*
)
release
0 or 1 1 0 = Travel program not
released
1 = travel program released
023 Travel program 3*
)
release
0 or 1 1 0 = Travel program not
released
1 = travel program released
030 Log status
display *
)
When the parameter number
is entered the number of user
codes used is shown on the
CANDIS displayinstrument.
E 21
0406.GB
*) only in conjunction with display instrument (CANDIS (o))
Error messages on keypad
LED (44) flashes red to indicate the following errors:
– New master code is already operator code.
– New operator code is already master code.
– Operator code to be changed does not exist.
– Tried to change the operator code to an existing code.
– Operator code to be deleted does not exist.
Code memory full
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
020 Start
travel program
0-3 3 0 – There is no start program
1 – Travel program 1 = Start
travel program
2 – Travel program 2 = Start
travel program
3 – Travel program 3 = Start
travel program
021 Travel program 1*
)
release
0 or 1 1 0 = Fahrprogram
not released
1 = travel program released
022 Travel program 2*
)
release
0 or 1 1 0 = Travel program not
released
1 = travel program released
023 Travel program 3*
)
release
0 or 1 1 0 = Travel program not
released
1 = travel program released
030 Log status
display *
)
When the parameter number
is entered the number of user
codes used is shown on the
CANDIS displayinstrument.
0406.GB
E 22
6.5 Travel parameters
Z
For trucks without a display instrument (CANDIS (o)) the code lock parameters can
only be set by the manufacturer's service department.
The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 101).
Acceleration example
Enter the three-digit parameter number (101) and confirm with the Set key (45).
– Check the LC display of the display instrument (CANDIS (o)) (parameter number
and current parameter value are displayed).
Z
If there is no input for approx. 5 seconds, the display switches back to showing the
operating hours.
F
If you require a different parameter number than the one displayed, you must wait
until the operating hours are displayed again.
Enter or change the parameter value according to the parameter list.
Check the LC display of the indicator instrument (CANDIS (o)), (confirm with the Set
key (45).
– The LED (44) of the o key (43) switches briefly to steady light and start flashing
again after approx. 2 seconds.
Z
If the entry is incorrect, the LED (44) of the o key (43) goes red. If you enter the
parameter number again the setting can be entered or changed.
Repeat the procedure to enter further parameters as soon as the LED (44) of the o
key (43) flashes. To complete your entry, press the o key (43).
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
current setting is
displayed
101 6
Green
flashing
Off Off Off
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
changed setting is
displayed
101 8
Green
flashing
Off Off Off
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
Parameter
number
Parameter
setting
0406.GB
E 22
6.5 Travel parameters
Z
For trucks without a display instrument (CANDIS (o)) the code lock parameters can
only be set by the manufacturer's service department.
The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 101).
Acceleration example
Enter the three-digit parameter number (101) and confirm with the Set key (45).
– Check the LC display of the display instrument (CANDIS (o)) (parameter number
and current parameter value are displayed).
Z
If there is no input for approx. 5 seconds, the display switches back to showing the
operating hours.
F
If you require a different parameter number than the one displayed, you must wait
until the operating hours are displayed again.
Enter or change the parameter value according to the parameter list.
Check the LC display of the indicator instrument (CANDIS (o)), (confirm with the Set
key (45).
– The LED (44) of the o key (43) switches briefly to steady light and start flashing
again after approx. 2 seconds.
Z
If the entry is incorrect, the LED (44) of the o key (43) goes red. If you enter the
parameter number again the setting can be entered or changed.
Repeat the procedure to enter further parameters as soon as the LED (44) of the o
key (43) flashes. To complete your entry, press the o key (43).
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
current setting is
displayed
101 6
Green
flashing
Off Off Off
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
changed setting is
displayed
101 8
Green
flashing
Off Off Off
Display instrument
(CANDIS)
LED (44)
o key
LED (40)
Key 1
LED (41)
Key 2
LED (42)
Key 3
Parameter
number
Parameter
setting
E 23
0406.GB
Z
Travel is disabled while the parameters are being entered. If the setting is to be
checked in programming mode, follow this sequence:
– Select the edited travel program after changing the parameter value, confirm with
the Set key (45).
– The truck is now in travel mode and can be checked.
– To continue setting, confirm with the Set key (45) again.
The following parameters may be entered.
Travel programs
No. Function Setting
range
Standard
setting
Comments
Travel program 1
100 Acceleration in
Pedestrian mode
0 - 9 2 Value of parameter
101 >= Parameter
100
101 Acceleration in
Rider mode
0 - 9 2
102 Coasting brake in
rider mode
0 - 9 2
103 Coasting brake in
Pedestrian mode
0 - 9 2 Value of parameter
103 >= Parameter
102
104 Maximum speed in drive
direction via controller
0 - 9 8 depending on
travel switch
105 Pedestrian speed in drive
direction via controller
0 - 9 5 depending on
travel switch
106 Pedestrian speed in drive
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
108 Maximum speed in fork
direction via controller
0 - 9 8 depending on
travel switch
109 Pedestrian speed in fork
direction via controller
0 - 9 5 depending on
travel switch
110 Pedestrian speed in fork
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
E 23
0406.GB
Z
Travel is disabled while the parameters are being entered. If the setting is to be
checked in programming mode, follow this sequence:
– Select the edited travel program after changing the parameter value, confirm with
the Set key (45).
– The truck is now in travel mode and can be checked.
– To continue setting, confirm with the Set key (45) again.
The following parameters may be entered.
Travel programs
No. Function Setting
range
Standard
setting
Comments
Travel program 1
100 Acceleration in
Pedestrian mode
0 - 9 2 Value of parameter
101 >= Parameter
100
101 Acceleration in
Rider mode
0 - 9 2
102 Coasting brake in
rider mode
0 - 9 2
103 Coasting brake in
Pedestrian mode
0 - 9 2 Value of parameter
103 >= Parameter
102
104 Maximum speed in drive
direction via controller
0 - 9 8 depending on
travel switch
105 Pedestrian speed in drive
direction via controller
0 - 9 5 depending on
travel switch
106 Pedestrian speed in drive
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
108 Maximum speed in fork
direction via controller
0 - 9 8 depending on
travel switch
109 Pedestrian speed in fork
direction via controller
0 - 9 5 depending on
travel switch
110 Pedestrian speed in fork
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
0406.GB
E 24
No. Function Setting
range
Standard
setting
Comments
Travel program 2
200 Acceleration in
Pedestrian mode
0 - 9 5 Value of parameter
201 >= Parameter
200
201 Acceleration in
Rider mode
0 - 9 5
202 Coasting brake in
rider mode
0 - 9 5
203 Coasting brake in
Pedestrian mode
0 - 9 5 Value of parameter
203 >= Parameter
202
204 Maximum speed in drive
direction via controller
0 - 9 8 depending on
travel switch
205 Pedestrian speed in drive
direction via controller
0 - 9 5 depending on
travel switch
206 Pedestrian speed in drive
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
208 Maximum speed in fork
direction via controller
0 - 9 8 depending on
travel switch
209 Pedestrian speed in fork
direction via controller
0 - 9 5 depending on
travel switch
210 Pedestrian speed in fork
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
0406.GB
E 24
No. Function Setting
range
Standard
setting
Comments
Travel program 2
200 Acceleration in
Pedestrian mode
0 - 9 5 Value of parameter
201 >= Parameter
200
201 Acceleration in
Rider mode
0 - 9 5
202 Coasting brake in
rider mode
0 - 9 5
203 Coasting brake in
Pedestrian mode
0 - 9 5 Value of parameter
203 >= Parameter
202
204 Maximum speed in drive
direction via controller
0 - 9 8 depending on
travel switch
205 Pedestrian speed in drive
direction via controller
0 - 9 5 depending on
travel switch
206 Pedestrian speed in drive
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
208 Maximum speed in fork
direction via controller
0 - 9 8 depending on
travel switch
209 Pedestrian speed in fork
direction via controller
0 - 9 5 depending on
travel switch
210 Pedestrian speed in fork
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
E 25
0406.GB
No. Function Setting
range
Standard
setting
Comments
Travel program 3
300 Acceleration in
Pedestrian mode
0 - 9 7 Value of parameter
301 >= Parameter
300
301 Acceleration in
Rider mode
0 - 9 7
302 Coasting brake in
rider mode
0 - 9 7
303 Coasting brake in
Pedestrian mode
0 - 9 7 Value of parameter
303 >= Parameter
302
304 Maximum speed in drive
direction via controller
0 - 9 8 depending on
travel switch
305 Pedestrian speed in drive
direction via controller
0 - 9 5 depending on
travel switch
306 Pedestrian speed in drive
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
308 Maximum speed in fork
direction via controller
0 - 9 8 depending on
travel switch
309 Pedestrian speed in fork
direction via controller
0 - 9 5 depending on
travel switch
310 Pedestrian speed in fork
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
E 25
0406.GB
No. Function Setting
range
Standard
setting
Comments
Travel program 3
300 Acceleration in
Pedestrian mode
0 - 9 7 Value of parameter
301 >= Parameter
300
301 Acceleration in
Rider mode
0 - 9 7
302 Coasting brake in
rider mode
0 - 9 7
303 Coasting brake in
Pedestrian mode
0 - 9 7 Value of parameter
303 >= Parameter
302
304 Maximum speed in drive
direction via controller
0 - 9 8 depending on
travel switch
305 Pedestrian speed in drive
direction via controller
0 - 9 5 depending on
travel switch
306 Pedestrian speed in drive
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
308 Maximum speed in fork
direction via controller
0 - 9 8 depending on
travel switch
309 Pedestrian speed in fork
direction via controller
0 - 9 5 depending on
travel switch
310 Pedestrian speed in fork
direction via pushbutton in
backrest
0 - 9 3 not dependant on
travel switch
(fixed speed)
0406.GB
E 26
Program-independent parameters
Z
For trucks without a display instrument (CANDIS (o)) theBATTERY parameters can
only be set by the manufacturer's service department.
The parameters are set in the same way as for the travel parameters.
The following parameters may be entered.
Setting 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Setting
range
Standard
setting
Comments
Battery parameters
411 Battery type (normal /
high performance / dry)
0 - 2 0 0 = Normal (wet)
1 = enhanced (wet)
2 = Dry
(maintenance-free)
412 Discharge monitor
function
0 / 1 1
0406.GB
E 26
Program-independent parameters
Z
For trucks without a display instrument (CANDIS (o)) theBATTERY parameters can
only be set by the manufacturer's service department.
The parameters are set in the same way as for the travel parameters.
The following parameters may be entered.
Setting 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Setting
range
Standard
setting
Comments
Battery parameters
411 Battery type (normal /
high performance / dry)
0 - 2 0 0 = Normal (wet)
1 = enhanced (wet)
2 = Dry
(maintenance-free)
412 Discharge monitor
function
0 / 1 1
E 27
0406.GB
7 Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table.
Z
If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer’s service department, as any further troubleshooting can only be
performed by specially trained and qualified service personnel.
Fault Possible cause Action
Truck
does not
move
– Battery connector not
connected.
– Isolator (Emergency Stop)
depressed.
– Key switch set to "0"
– Battery charge too low.
– Faulty fuse.
– Check the battery connector and
connect if necessary.
– Release isolator
– Set the key switch to position “I”.
– Check the charging condition of
the battery and recharge if
necessary.
– Check fuses F1 and 1F1.
E 27
0406.GB
7 Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table.
Z
If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer’s service department, as any further troubleshooting can only be
performed by specially trained and qualified service personnel.
Fault Possible cause Action
Truck
does not
move
– Battery connector not
connected.
– Isolator (Emergency Stop)
depressed.
– Key switch set to "0"
– Battery charge too low.
– Faulty fuse.
– Check the battery connector and
connect if necessary.
– Release isolator
– Set the key switch to position “I”.
– Check the charging condition of
the battery and recharge if
necessary.
– Check fuses F1 and 1F1.
0406.GB
E 28
0406.GB
E 28
F 1
0406.GB
F Industrial Truck Maintenance
1 Operational safety and environmental protection
The servicing and inspection duties contained in this chapter must be performed in
accordance with the intervals indicated in the maintenance checklists.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. The operational speeds of the truck must not be changed under any
circumstances.
M
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the forklift truck, use only the manufacturer's
spare parts. Used parts, oils and fuels must be disposed of in accordance with the
relevant environmental protection regulations. For oil changes, contact the
manufacturer’s specialist department.
Upon completion of inspection and servicing, the tasks contained in the
“Recommissioning” section must be performed (see chapter F).
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has
field technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must
only be secured to the points specially provided for this purpose. When jacking up the
truck, take appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks).
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
implement all necessary safety measures to prevent sparking (e.g. through short
circuits). For battery-operated trucks, the battery connector must be removed. Only
weak suction or compressed air and non-conductive antistatic brushes may be used
for cleaning electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions..
Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
F 1
0406.GB
F Industrial Truck Maintenance
1 Operational safety and environmental protection
The servicing and inspection duties contained in this chapter must be performed in
accordance with the intervals indicated in the maintenance checklists.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. The operational speeds of the truck must not be changed under any
circumstances.
M
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the forklift truck, use only the manufacturer's
spare parts. Used parts, oils and fuels must be disposed of in accordance with the
relevant environmental protection regulations. For oil changes, contact the
manufacturer’s specialist department.
Upon completion of inspection and servicing, the tasks contained in the
“Recommissioning” section must be performed (see chapter F).
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has
field technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must
only be secured to the points specially provided for this purpose. When jacking up the
truck, take appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks).
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
implement all necessary safety measures to prevent sparking (e.g. through short
circuits). For battery-operated trucks, the battery connector must be removed. Only
weak suction or compressed air and non-conductive antistatic brushes may be used
for cleaning electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions..
Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
0406.GB
F 2
Electrical System: Only suitably trained personnel may operate on the truck’s
electrical system. Before working on the electrical system, take all precautionary
measures to avoid electric shocks. For battery-operated trucks, also de-energise the
truck by removing the battery connector.
Welding: To avoid damaging electric or electronic components, remove these from
the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare parts.
Otherwise the data sheet specifications of the truck cannot be guaranteed. When
changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing
wheels always left and right simultaneously).
0406.GB
F 2
Electrical System: Only suitably trained personnel may operate on the truck’s
electrical system. Before working on the electrical system, take all precautionary
measures to avoid electric shocks. For battery-operated trucks, also de-energise the
truck by removing the battery connector.
Welding: To avoid damaging electric or electronic components, remove these from
the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare parts.
Otherwise the data sheet specifications of the truck cannot be guaranteed. When
changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing
wheels always left and right simultaneously).
F 3
0406.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually.
C = Every 2000 service hours, or at least annually
Z
W service intervals are to be performed by the customer.
During the run-in period – after approx. 100 service hours – the owner must check
the wheel nuts/bolts and re-tighten if necessary.
F 3
0406.GB
3 Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually.
C = Every 2000 service hours, or at least annually
Z
W service intervals are to be performed by the customer.
During the run-in period – after approx. 100 service hours – the owner must check
the wheel nuts/bolts and re-tighten if necessary.
0406.GB
F 4
4 Maintenance checklist
Maintenance intervals
Standard = t WA B C
Cold Store = k
Chassis/
Superstructure:
1.1 Check all load bearing components for damage t
1.2 Check screw connections t
1.3 Test the operator platform and check for damage t
Drive unit: 2.1 Check the transmission for noise and leakage t
Wheels 3.1 Check wheels for wear and damage t
3.2 Check suspension and attachment lt
Steering 4.1 Check the steering play t
4.2 Check the steering chain and the chain sprocket for wear;
adjust and grease
lt
4.3 Check the mechanical parts of the steering column; grease
if necessary
t
Brake
system:
5.1 Test operation and settings lt
5.2 Check the brake lining wear t
5.3 Check the brake linkage; adjust and grease t
Electrical
system:
7.1 Test operation t
7.2 Check all cables for secure connection and
damage
t
7.3 Check fuse ratings t
7.4 Check switches and trip cams are securely attached and
operating
correctly
t
7.5 Check the warning devices and safety circuits
are operating correctly
lt
7.6 Check contactors, replace any worn parts. t
Electric
motors:
8.2 Check motor is attached securely t
0406.GB
F 4
4 Maintenance checklist
Maintenance intervals
Standard = t WA B C
Cold Store = k
Chassis/
Super-
structure:
1.1 Check all load bearing components for damage t
1.2 Check screw connections t
1.3 Test the operator platform and check for damage t
Drive unit: 2.1 Check the transmission for noise and leakage t
Wheels 3.1 Check wheels for wear and damage t
3.2 Check suspension and attachment lt
Steering 4.1 Check the steering play t
4.2 Check the steering chain and the chain sprocket for wear;
adjust and grease
lt
4.3 Check the mechanical parts of the steering column; grease
if necessary
t
Brake
system:
5.1 Test operation and settings lt
5.2 Check the brake lining wear t
5.3 Check the brake linkage; adjust and grease t
Electrical
system:
7.1 Test operation t
7.2 Check all cables for secure connection and
damage
t
7.3 Check fuse ratings t
7.4 Check switches and trip cams are securely attached and
operating
correctly
t
7.5 Check the warning devices and safety circuits
are operating correctly
lt
7.6 Check contactors, replace any worn parts. t
Electric
motors:
8.2 Check motor is attached securely t
F 5
0406.GB
Maintenance intervals
Standard = t WA B C
Cold Store = k
Battery 9.1 Check acid density, acid level and cell voltage lt
9.2 Check terminals are securely attached, and
apply grease
lt
9.3 Clean the battery connections; make sure they
are secure
lt
9.4 Check battery cables for damage, replace if necessary. t
Lubrication 11.1 Lubricate truck in accordance with Lubrication Schedule. lt
General
measurements:
12.1 Check electrical system for frame leakage t
12.2 Test travel speed and braking distance t
12.4 Test safety devices and cutouts t
Demonstration
13.1 Test run with rated load t
13.2 After carrying out maintenance, present the truck to the
supervisor.
lt
F 5
0406.GB
Maintenance intervals
Standard = t WA B C
Cold Store = k
Battery 9.1 Check acid density, acid level and cell voltage lt
9.2 Check terminals are securely attached, and
apply grease
lt
9.3 Clean the battery connections; make sure they
are secure
lt
9.4 Check battery cables for damage, replace if necessary. t
Lubrication 11.1 Lubricate truck in accordance with Lubrication Schedule. lt
General
measure-
ments:
12.1 Check electrical system for frame leakage t
12.2 Test travel speed and braking distance t
12.4 Test safety devices and cutouts t
Demonstra-
tion
13.1 Test run with rated load t
13.2 After carrying out maintenance, present the truck to the
supervisor.
lt
0406.GB
F 6
5 Lubrication Schedule
g Contact surfaces
s Grease nipple
b Transmission oil filler neck
a Transmission oil drain plug
Cold store application
1)
Compound ratio for cold store usage 1:1
G
B b
a
E
B+C
1)
1.4l
0406.GB
F 6
5 Lubrication Schedule
g Contact surfaces
s Grease nipple
b Transmission oil filler neck
a Transmission oil drain plug
Cold store application
1)
Compound ratio for cold store usage 1:1
G
B b
a
E
B+C
1)
1.4l
F 7
0406.GB
5.1 Consumables
Handling consumption type material: Consumables must always be handled
correctly. Follow the manufacturer’s instructions.
F
Improper handling is hazardous to health, life and the environment. Consumables
must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is if mixing is expressively prescribed
in the corresponding operating instructions.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent / consumable mixture must be disposed of in
accordance with regulations.
Grease guidelines
Code Order no. Quantity Description Used for
B 50 380 904 5,0 l Fuchs Titan Gear
HSY 75W-90
Transmission
C 29 200 810 5.0 l H-LP 10, DIN 51524 Transmission
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 0.4 l Chain spray Chains
Code Saponifica-
tion
Dew point
°C
Worked
penetration at
25 °C
NLG1
class
Application
temperature °C
E Lithium 185 265 - 295 2 -35 / +120
F — — 310 - 340 1 -52 / +100
F 7
0406.GB
5.1 Consumables
Handling consumption type material: Consumables must always be handled
correctly. Follow the manufacturer’s instructions.
F
Improper handling is hazardous to health, life and the environment. Consumables
must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is if mixing is expressively prescribed
in the corresponding operating instructions.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent / consumable mixture must be disposed of in
accordance with regulations.
Grease guidelines
Code Order no. Quantity Description Used for
B 50 380 904 5,0 l Fuchs Titan Gear
HSY 75W-90
Transmission
C 29 200 810 5.0 l H-LP 10, DIN 51524 Transmission
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 0.4 l Chain spray Chains
Code Saponifica-
tion
Dew point
°C
Worked
penetration at
25 °C
NLG1
class
Application
temperature °C
E Lithium 185 265 - 295 2 -35 / +120
F — — 310 - 340 1 -52 / +100
0406.GB
F 8
6 Maintenance Instructions
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Park the truck securely (see Chapter E).
– Disconnect the battery so that the truck cannot be started by unauthorised persons
(refer to chapter D).
F
When working on the brake system, prevent the truck from rolling away.
6.2 Tightening the wheel nuts
The wheel nuts on the drive wheel must be retightened in accordance with the
maintenance intervals indicated in the maintenance checklist.
– Position the drive wheel (1) at right angles to the longitudinal axis of the truck.
– Pass the socket wrench through the opening (3) in the collision guard and tighten
all wheel screws (2) applying a torque of 150 Nm.
M
Remove the socket wrench from the opening (3) after the wheel nuts have been
tightened.
1
2
3
0406.GB
F 8
6 Maintenance Instructions
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Park the truck securely (see Chapter E).
– Disconnect the battery so that the truck cannot be started by unauthorised persons
(refer to chapter D).
F
When working on the brake system, prevent the truck from rolling away.
6.2 Tightening the wheel nuts
The wheel nuts on the drive wheel must be retightened in accordance with the
maintenance intervals indicated in the maintenance checklist.
– Position the drive wheel (1) at right angles to the longitudinal axis of the truck.
– Pass the socket wrench through the opening (3) in the collision guard and tighten
all wheel screws (2) applying a torque of 150 Nm.
M
Remove the socket wrench from the opening (3) after the wheel nuts have been
tightened.
1
2
3
F 9
0406.GB
6.3 Remove the front panel
– Open battery cover (refer to chapter D).
– Remove the hex socket screws (5) located under the battery cover using the hex
socket wrench (6).
– Lift up the front panel (4) and put it to one side.
Z
Installation is the reverse order.
F
Do not drive the truck unless the panels are closed and properly locked.
4
5
F 9
0406.GB
6.3 Remove the front panel
– Open battery cover (refer to chapter D).
– Remove the hex socket screws (5) located under the battery cover using the hex
socket wrench (6).
– Lift up the front panel (4) and put it to one side.
Z
Installation is the reverse order.
F
Do not drive the truck unless the panels are closed and properly locked.
4
5
0406.GB
F 10
6.4 Checking electrical fuses
– Prepare the truck for maintenance and repairs
(see Chapter 6.1).
– Remove the front panel (see Section 6.3).
– Referring to the table, check all fuses for correct rating and damage; replace fuses
where required.
– Reinstall the front panel
(see section 6.3).
Item Description To protect: Rating
6 6F1 Battery discharge indicator / battery hourmeter 2 A
7 F1 Overall control circuit fuse 10 A
8 3F6 Steer motor / steering 30 A
9 1F1 Drive motor 300 A
6
7
8
9
0406.GB
F 10
6.4 Checking electrical fuses
– Prepare the truck for maintenance and repairs
(see Chapter 6.1).
– Remove the front panel (see Section 6.3).
– Referring to the table, check all fuses for correct rating and damage; replace fuses
where required.
– Reinstall the front panel
(see section 6.3).
Item Description To protect: Rating
6 6F1 Battery discharge indicator / battery hourmeter 2 A
7 F1 Overall control circuit fuse 10 A
8 3F6 Steer motor / steering 30 A
9 1F1 Drive motor 300 A
6
7
8
9
F 11
0406.GB
6.5 Recommissioning
The truck may only be restored to service after cleaning or repair work, once the
following operations have been performed.
– Test horn.
– Test main switch operation.
– Test brakes.
– Lubricate the truck in accordance with the lubrication schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
7.1 Prior to decommissioning:
– Thoroughly clean the truck.
– Check the brakes.
– Apply a thin layer of oil or grease to any non-painted mechanical components.
– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and grease the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning:
Every 2 months:
– Charge the battery (see Chapter D).
M
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
F 11
0406.GB
6.5 Recommissioning
The truck may only be restored to service after cleaning or repair work, once the
following operations have been performed.
– Test horn.
– Test main switch operation.
– Test brakes.
– Lubricate the truck in accordance with the lubrication schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
7.1 Prior to decommissioning:
– Thoroughly clean the truck.
– Check the brakes.
– Apply a thin layer of oil or grease to any non-painted mechanical components.
– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).
– Charge the battery (see Chapter D).
– Disconnect the battery, clean it and grease the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning:
Every 2 months:
– Charge the battery (see Chapter D).
M
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
0406.GB
F 12
7.3 Returning the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (see Chapter D).
– Check transmission oil for condensed water and replace if necessary.
– Start up the truck (see Chapter E).
Z
Battery powered trucks:
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8 Safety checks to be performed at regular intervals and following any unusual
incidents (D: Accident prevention check according to BGV D27
The truck must be inspected at least annually or after any unusual event by a qualified
inspector. The inspector shall assess the condition of the truck from purely a safety
viewpoint, without regard to operational or economic circumstances. The inspector
shall be sufficiently instructed and experienced to be able to assess the condition of
the truck and the effectiveness of the safety mechanisms based on the technical
regulations and principles governing the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
The manufacturer has a safety department with trained personnel to carry out
inspections. A test plate is attached to the truck as proof that it has passed the safety
inspection. This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z
Final, correct de-commissioning or disposal of the truck must be performed in
accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed..
0406.GB
F 12
7.3 Returning the truck to operation after decommissioning
– Thoroughly clean the truck.
– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).
– Clean the battery, grease the terminals and connect the battery.
– Charge the battery (see Chapter D).
– Check transmission oil for condensed water and replace if necessary.
– Start up the truck (see Chapter E).
Z
Battery powered trucks:
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8 Safety checks to be performed at regular intervals and following any unusual
incidents (D: Accident prevention check according to BGV D27
The truck must be inspected at least annually or after any unusual event by a qualified
inspector. The inspector shall assess the condition of the truck from purely a safety
viewpoint, without regard to operational or economic circumstances. The inspector
shall be sufficiently instructed and experienced to be able to assess the condition of
the truck and the effectiveness of the safety mechanisms based on the technical
regulations and principles governing the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
The manufacturer has a safety department with trained personnel to carry out
inspections. A test plate is attached to the truck as proof that it has passed the safety
inspection. This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z
Final, correct de-commissioning or disposal of the truck must be performed in
accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed..
1
0506.GB
Instructions for use
Jungheinrich traction battery
Table of contents
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB.......................................... 2-6
Type plate Jungheinrich traction battery............................................ 7
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
2 Jungheinrich traction battery
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS
............................................................................................13-17
Type plate Jungheinrich traction battery............................................ 17
1
0506.GB
Instructions for use
Jungheinrich traction battery
Table of contents
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB.......................................... 2-6
Type plate Jungheinrich traction battery............................................ 7
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
2 Jungheinrich traction battery
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS
............................................................................................13-17
Type plate Jungheinrich traction battery............................................ 17
0506.GB
2
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte*
Type EPzS: 1,29 kg/l
Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C
6. Nominal electrolyte level: up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
0506.GB
2
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte*
Type EPzS: 1,29 kg/l
Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C
6. Nominal electrolyte level: up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other me-
tal objects on the battery!
3
0506.GB
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
steel
M 10 23 ± 1 Nm
3
0506.GB
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-
scharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-
ded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
steel
M 10 23 ± 1 Nm
0506.GB
4
Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
0506.GB
4
Battery container lids and the covers of battery compartments must be opened or re-
moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batte-
ries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-
tentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flamma-
bility due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out follo-
wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-
pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-
peratures shorten the life of the battery, lower temperatures reduce the capacity avai-
lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-
perature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher tempe-
ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
5
0506.GB
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and recorded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
5
0506.GB
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-
tery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and re-
corded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
0506.GB
6
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
0506.GB
6
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault fin-
ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
7
0506.GB
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
7
0506.GB
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
0506.GB
8
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (yellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm
2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm
– 2/110 – 12/ 660 50,5 mm 51,0 mm
– 2/130 – 12/ 780 50,5 mm 51,0 mm
– 2/150 – 12/ 900 50,5 mm 51,0 mm
– 2/172 – 12/1032 50,5 mm 51,0 mm
– 2/200 – 12/1200 56,0 mm 56,0 mm
– 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm
2/210 – 10/1050 – 61,0 mm 61,0 mm
2/230 – 10/1150 – 61,0 mm 61,0 mm
2/250 – 10/1250 – 61,0 mm 61,0 mm
2/280 – 10/1400 – 72,0 mm 66,0 mm
2/310 – 10/1550 – 72,0 mm 66,0 mm
stroke
length
stroke
length
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
0506.GB
8
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the in-
structions on maintaining the respective protection class during operation (see asso-
ciated certification).
Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (yellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm
2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm
– 2/110 – 12/ 660 50,5 mm 51,0 mm
– 2/130 – 12/ 780 50,5 mm 51,0 mm
– 2/150 – 12/ 900 50,5 mm 51,0 mm
– 2/172 – 12/1032 50,5 mm 51,0 mm
– 2/200 – 12/1200 56,0 mm 56,0 mm
– 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm
2/210 – 10/1050 – 61,0 mm 61,0 mm
2/230 – 10/1150 – 61,0 mm 61,0 mm
2/250 – 10/1250 – 61,0 mm 61,0 mm
2/280 – 10/1400 – 72,0 mm 66,0 mm
2/310 – 10/1550 – 72,0 mm 66,0 mm
stroke
length
stroke
length
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
9
0506.GB
Diagrammatic view
Equipment for the
water refilling system
1. Water tank
2. Level switch
3. Discharge point with ball
valve
4. Discharge point with solenoid valve
5. Charger
6. Sealing coupler
7. Closing nipple
8. Ion exchange cartridge with
conductance meter and
solenoid valve
9. Connection for untreated
water
10. Charging lead
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
at least 3 m
9
0506.GB
Diagrammatic view
Equipment for the
water refilling system
1. Water tank
2. Level switch
3. Discharge point with ball
valve
4. Discharge point with sole-
noid valve
5. Charger
6. Sealing coupler
7. Closing nipple
8. Ion exchange cartridge with
conductance meter and
solenoid valve
9. Connection for untreated
water
10. Charging lead
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjus-
ting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte den-
sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-
matic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose con-
nections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS sys-
tem, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
at least 3 m
0506.GB
10
4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of filling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
0506.GB
10
4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of fil-
ling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-
ter feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
11
0506.GB
8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
10. Accessories
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
11
0506.GB
8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a tempe-
rature range of > 0° C to a maximum of 55° C.
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling sys-
tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
10. Accessories
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug sys-
tems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
0506.GB
12
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
0506.GB
12
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres-
sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-
ry's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-
tral supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
13
0506.GB
2 Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h
4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire, avoid short circuits!
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
13
0506.GB
2 Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h
4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe-
re a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire, avoid short circuits!
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
0506.GB
14
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors
are:
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left discharged.
This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or removed.
steel
M 10 23 ± 1 Nm
0506.GB
14
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors
are:
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left dischar-
ged.
This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifica-
tions. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or re-
moved.
steel
M 10 23 ± 1 Nm
15
0506.GB
With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed chargers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
15
0506.GB
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the tem-
peratures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed char-
gers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher tempera-
tures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating tempera-
ture.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
0506.GB
16
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
• the voltages of the battery
• the voltages of every cells
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
To ensure the battery is always ready for use a choice of charging methods can be
made:
1.a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
2.float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the battery.
0506.GB
16
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
• the voltages of the battery
• the voltages of every cells
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
To ensure the battery is always ready for use a choice of charging methods can be
made:
1.a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
2.float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the batte-
ry.
17
0506.GB
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
17
0506.GB
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault fin-
ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5
11
13
1
14
4
10
12
7
8
9
0506.GB
18
0506.GB
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