V2500 GB - Jungheinrich

Operating instructions

50052734

ETVC 16/20

G

05.99-

12.07

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0903

.GBImportant notes on transporting and mounting load lifting devicesto reach trucks

Transport

Depending on the overall height of the lifting mast and the local conditions transportcan be performed in three different ways

– Standing, with the lifting mast mounted (for trucks with low overall height)– Standing, with martially mounted lifting mast tilted towards the overhead guard (for

trucks with medium overall height). Hydraulic line for the lifting function is interrup-ted.

– Standing, with the lifting mast dismounted (for trucks with large overall height)

Safety Instructions for Assembly and Commissioning

f The assembly of the truck on site, commissioning the truck and instructing the drivermust be carried out by personnel trained and authorised by the manufacturer

Connect the hydraulic lines to the basic machine / mast interface and commission thetruck only after having installed the mast as per the instructions.

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Important notes on transporting and mounting load lifting devicesto reach trucks

Transport

Depending on the overall height of the lifting mast and the local conditions transportcan be performed in three different ways

– Standing, with the lifting mast mounted (for trucks with low overall height)– Standing, with martially mounted lifting mast tilted towards the overhead guard (for

trucks with medium overall height). Hydraulic line for the lifting function is interrup-ted.

– Standing, with the lifting mast dismounted (for trucks with large overall height)

Safety Instructions for Assembly and Commissioning

f The assembly of the truck on site, commissioning the truck and instructing the drivermust be carried out by personnel trained and authorised by the manufacturer

Connect the hydraulic lines to the basic machine / mast interface and commission thetruck only after having installed the mast as per the instructions.

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ForewordThe present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter. Each chapterstarts with page 1. The page identification consists of a chapter letter and a pagenumber.For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicingthe truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the followinggraphics:

F Used before safety instructions which must be observed to avoid danger topersonnel.

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 toalter the design, equipment and technical features of the truck. No guarantee ofparticular features of the truck should therefore be inferred from the present operatinginstructions.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0

www.jungheinrich.com

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.GB

ForewordThe present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter. Each chapterstarts with page 1. The page identification consists of a chapter letter and a pagenumber.For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicingthe truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the followinggraphics:

F Used before safety instructions which must be observed to avoid danger topersonnel.

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 toalter the design, equipment and technical features of the truck. No guarantee ofparticular features of the truck should therefore be inferred from the present operatinginstructions.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0

www.jungheinrich.com

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Table of contentsA Correct use and application of the truck

B Description of the truck

1 Application ........................................................................................ B 12 Assembly description and functional description ............................ B 22.1 Truck ................................................................................................ B 32.2 Load lifting system ........................................................................... B 53 Technical data - Standard version ................................................... B 63.1 Output data for standard truck version ............................................. B 63.2 Standard hoist frame versions ......................................................... B 63.3 Dimensions ...................................................................................... B 73.4 EN standards ................................................................................... B 83.5 Conditions for application ................................................................. B 84 Location of instruction labels and identification plates .................... B 94.1 Truck identification plate ................................................................ B 104.2 Load diagram / capacity / load centre / lifting height ...................... B 104.3 Load diagram, capacity / lateral traversing device ......................... B 114.4 Pick-up points for lifting jack ........................................................... B 11

C Transportation and commissioning

1 Loading and unloading of trucks by crane ....................................... C 12 Commissioning ................................................................................. C 13 Moving a defective truck .................................................................. C 2

D Battery - servicing, recharging, replacement

1 Safety regulations governing the handling of lead-acid batteries ..... D 12 Battery type ...................................................................................... D 13 Exposing the battery ........................................................................ D 23.1 Bypassing the drive current interruption ........................................... D 33.2 Battery trolley emergency unlocking system .................................... D 34 Charging the battery ......................................................................... D 35 Removing and installing the battery ................................................. D 46 Battery discharge indicator, battery discharge monitor and

hour meter ..................................................................................... D 5

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Table of contentsA Correct use and application of the truck

B Description of the truck

1 Application ........................................................................................ B 12 Assembly description and functional description ............................ B 22.1 Truck ................................................................................................ B 32.2 Load lifting system ........................................................................... B 53 Technical data - Standard version ................................................... B 63.1 Output data for standard truck version ............................................. B 63.2 Standard hoist frame versions ......................................................... B 63.3 Dimensions ...................................................................................... B 73.4 EN standards ................................................................................... B 83.5 Conditions for application ................................................................. B 84 Location of instruction labels and identification plates .................... B 94.1 Truck identification plate ................................................................ B 104.2 Load diagram / capacity / load centre / lifting height ...................... B 104.3 Load diagram, capacity / lateral traversing device ......................... B 114.4 Pick-up points for lifting jack ........................................................... B 11

C Transportation and commissioning

1 Loading and unloading of trucks by crane ....................................... C 12 Commissioning ................................................................................. C 13 Moving a defective truck .................................................................. C 2


1 Safety regulations governing the handling of lead-acid batteries ..... D 12 Battery type ...................................................................................... D 13 Exposing the battery ........................................................................ D 23.1 Bypassing the drive current interruption ........................................... D 33.2 Battery trolley emergency unlocking system .................................... D 34 Charging the battery ......................................................................... D 35 Removing and installing the battery ................................................. D 46 Battery discharge indicator, battery discharge monitor and

hour meter ..................................................................................... D 5

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E Operation

1 Safety regulations governing the operation of the truck ................... E 12 Description of the operating controls and indicators ........................ E 23 Start-up of truck ................................................................................ E 63.1 How to use the safety belt o ........................................................... E 74 Truck operation ................................................................................ E 94.1 Safety regulations applicable when operating the truck ................... E 94.2 Driving, steering, braking ............................................................... E 104.3 Adjusting the fork tines ................................................................... E 124.4 Picking up and setting down loads ................................................. E 124.5 Picking up, lifting and transporting of loads .................................... E 144.6 Operating an attachment ................................................................ E 154.7 Rendering truck safe when parking ................................................ E 165 Information and service display (LISA) .......................................... E 175.1 LED warning lamps ........................................................................ E 185.2 Key assignment .............................................................................. E 185.3 Displays .......................................................................................... E 195.4 Changing truck parameters ............................................................ E 206 Fault locating operations ................................................................ E 217 Auxiliary electrical systems ............................................................ E 227.1 Seat heating ................................................................................... E 227.2 Floodlight ....................................................................................... E 227.3 360° warning light .......................................................................... E 237.4 Flash lamp ...................................................................................... E 237.5 DC/DC transformer on/off switch ................................................... E 237.6 Override switch (ESA / Electrical lifting limitation) .......................... E 247.7 LED Lateral traversing device in centre position ............................ E 24

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E Operation

1 Safety regulations governing the operation of the truck ................... E 12 Description of the operating controls and indicators ........................ E 23 Start-up of truck ................................................................................ E 63.1 How to use the safety belt o ........................................................... E 74 Truck operation ................................................................................ E 94.1 Safety regulations applicable when operating the truck ................... E 94.2 Driving, steering, braking ............................................................... E 104.3 Adjusting the fork tines ................................................................... E 124.4 Picking up and setting down loads ................................................. E 124.5 Picking up, lifting and transporting of loads .................................... E 144.6 Operating an attachment ................................................................ E 154.7 Rendering truck safe when parking ................................................ E 165 Information and service display (LISA) .......................................... E 175.1 LED warning lamps ........................................................................ E 185.2 Key assignment .............................................................................. E 185.3 Displays .......................................................................................... E 195.4 Changing truck parameters ............................................................ E 206 Fault locating operations ................................................................ E 217 Auxiliary electrical systems ............................................................ E 227.1 Seat heating ................................................................................... E 227.2 Floodlight ....................................................................................... E 227.3 360° warning light .......................................................................... E 237.4 Flash lamp ...................................................................................... E 237.5 DC/DC transformer on/off switch ................................................... E 237.6 Override switch (ESA / Electrical lifting limitation) .......................... E 247.7 LED Lateral traversing device in centre position ............................ E 24

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.GBF Maintenance of the fork-lift truck

1 Operational safety and environmental protection ..............................F 12 Safety regulations applicable to truck maintenance ..........................F 13 Servicing and inspection ...................................................................F 34 Maintenance Check .........................................................................F 45 Lubrication Schedule .........................................................................F 65.1 Fuels, coolants and lubricants ...........................................................F 75.2 Reservoir filling level .........................................................................F 76 Instructions for the servicing operations ............................................F 86.1 Preparing the truck for the performance of servicing and

maintenance operations ....................................................................F 86.2 Opening the arm rest ........................................................................F 86.3 Opening the hood ..............................................................................F 96.4 Opening the battery doors and the seat hood ...................................F 96.5 Checking the hydraulic oil level .......................................................F 106.6 Checking the brake fluid level .........................................................F 106.7 Check fixing of the wheels ..............................................................F 106.8 Safety belt maintenance o .............................................................F 116.9 Checking electrical fuses ................................................................F 126.10 Recommissioning the truck .............................................................F 137 Decommissioning the truck .............................................................F 137.1 Operations to be performed prior to decommissioning ...................F 137.2 Measures to be taken during decommissioning ..............................F 137.3 Recommissioning the truck .............................................................F 148 Safety checks to be performed at regular intervals and following

any untoward incidents (D: Accident prevention check according to BGV D27) ...................................................................F 14

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F Maintenance of the fork-lift truck

1 Operational safety and environmental protection ..............................F 12 Safety regulations applicable to truck maintenance ..........................F 13 Servicing and inspection ...................................................................F 34 Maintenance Check .........................................................................F 45 Lubrication Schedule .........................................................................F 65.1 Fuels, coolants and lubricants ...........................................................F 75.2 Reservoir filling level .........................................................................F 76 Instructions for the servicing operations ............................................F 86.1 Preparing the truck for the performance of servicing and

maintenance operations ....................................................................F 86.2 Opening the arm rest ........................................................................F 86.3 Opening the hood ..............................................................................F 96.4 Opening the battery doors and the seat hood ...................................F 96.5 Checking the hydraulic oil level .......................................................F 106.6 Checking the brake fluid level .........................................................F 106.7 Check fixing of the wheels ..............................................................F 106.8 Safety belt maintenance o .............................................................F 116.9 Checking electrical fuses ................................................................F 126.10 Recommissioning the truck .............................................................F 137 Decommissioning the truck .............................................................F 137.1 Operations to be performed prior to decommissioning ...................F 137.2 Measures to be taken during decommissioning ..............................F 137.3 Recommissioning the truck .............................................................F 148 Safety checks to be performed at regular intervals and following

any untoward incidents (D: Accident prevention check according to BGV D27) ...................................................................F 14

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Appendix

JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If usinganother brand, refer to the manufacturer's operating instructions.

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Appendix

JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If usinganother brand, refer to the manufacturer's operating instructions.

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A Correct use and application of the truck

Z The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) areincluded in the scope of delivery for this truck. The guidelines are part of these ope-rating instructions and must always be heeded. National regulations are fully applica-ble.

The fork-lift truck described in these operating instructions is a truck that is suitablefor lifting and transporting loads.

It must be used, operated and maintained according to the information in these ope-rating instructions. Any other uses are outside the design envelope and can lead toinjury to persons or damage to equipment and property. Above all, overloadingcaused by excessively heavy or unbalanced loads must be avoided. The max. admis-sible load to be picked up is indicated on the identification plate or load diagram labelshown on the truck. The fork-lift truck must not be operated in spaces subject to fireor explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-vail.

Duties of the user: A „user“ within the meaning of these operating instructions is de-fined as any natural or legal person who either uses the fork-lift truck himself, or onwhose behalf it is used. In special cases (e.g. leasing or renting), the user is conside-red the person, who, in accordance with existing contractual agreements between theowner and the user of the fork-lift truck, is charged with the observance of the opera-ting duties.The user must ensure that the truck is not abused and only used within its design li-mits and that all danger to life and limb of the operator, or third parties, is avoided. Inaddition to this, it must be ensured that the relevant accident prevention regulationsand other safety-related provisions, as well as the operating, servicing and mainte-nance guidelines, are observed. The user must also ensure that all persons operatingthe truck have read and understood these operating instructions.

M If these Operating Instruction are not observed the warranty becomes void. The sameapplies if improper works are carried out at the device by the customer and/or thirdparties without permission of our Customer Service.

Mounting of attachments: The mounting or installation of any attachments whichwill interfere with, or supplement, the functions of the truck is permitted only after writ-ten approval by the manufacturer has been obtained. If necessary, the approval oflocal authorities has to be obtained. Any approval obtained from local authorities doesnot, however, make the approval by the manufacturer unnecessary.

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A Correct use and application of the truck

Z The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) areincluded in the scope of delivery for this truck. The guidelines are part of these ope-rating instructions and must always be heeded. National regulations are fully applica-ble.

The fork-lift truck described in these operating instructions is a truck that is suitablefor lifting and transporting loads.

It must be used, operated and maintained according to the information in these ope-rating instructions. Any other uses are outside the design envelope and can lead toinjury to persons or damage to equipment and property. Above all, overloadingcaused by excessively heavy or unbalanced loads must be avoided. The max. admis-sible load to be picked up is indicated on the identification plate or load diagram labelshown on the truck. The fork-lift truck must not be operated in spaces subject to fireor explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-vail.

Duties of the user: A „user“ within the meaning of these operating instructions is de-fined as any natural or legal person who either uses the fork-lift truck himself, or onwhose behalf it is used. In special cases (e.g. leasing or renting), the user is conside-red the person, who, in accordance with existing contractual agreements between theowner and the user of the fork-lift truck, is charged with the observance of the opera-ting duties.The user must ensure that the truck is not abused and only used within its design li-mits and that all danger to life and limb of the operator, or third parties, is avoided. Inaddition to this, it must be ensured that the relevant accident prevention regulationsand other safety-related provisions, as well as the operating, servicing and mainte-nance guidelines, are observed. The user must also ensure that all persons operatingthe truck have read and understood these operating instructions.

M If these Operating Instruction are not observed the warranty becomes void. The sameapplies if improper works are carried out at the device by the customer and/or thirdparties without permission of our Customer Service.

Mounting of attachments: The mounting or installation of any attachments whichwill interfere with, or supplement, the functions of the truck is permitted only after writ-ten approval by the manufacturer has been obtained. If necessary, the approval oflocal authorities has to be obtained. Any approval obtained from local authorities doesnot, however, make the approval by the manufacturer unnecessary.

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B Description of the truck1 Application

The ETVC 16/20 is an electrically driven three-wheel truck incorporating a traversingmast and a lateral seat. Used inside and outside for lifting and transporting goods. Itcan pick up pallets of open ground support, pallets provided with lateral boards arran-ged outside or inside the range of the load-bearing wheels, or trolleys. Loads can bestacked in and out and transported across greater distances.Its capacity is shown on the identification label.

Type Capacity Load centre distanceETVC 16 1600 kg 600 mmETVC 20 2000 kg 600 mm

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B Description of the truck1 Application

The ETVC 16/20 is an electrically driven three-wheel truck incorporating a traversingmast and a lateral seat. Used inside and outside for lifting and transporting goods. Itcan pick up pallets of open ground support, pallets provided with lateral boards arran-ged outside or inside the range of the load-bearing wheels, or trolleys. Loads can bestacked in and out and transported across greater distances.Its capacity is shown on the identification label.

Type Capacity Load centre distanceETVC 16 1600 kg 600 mmETVC 20 2000 kg 600 mm

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2 Assembly description and functional description

Item Designation Item Designation1 t Clear-view lifting mast 10 t Drive wheel2 t Overhead guard 11 t Footstep3 t Free-lift cylinder 12 t Foot switch4 o Auxiliary hydraulics (ZH2) 13 t Battery trolley unlocking

system5 t Control lever „Mast tilting“ 14 t Parking brake6 t Control lever „Traversing of

Mast“15 t Key switch

7 t Solo-pilot 16 t Master switch (emergency stop)

8 t Load-bearing wheels 17 t Information and service display (LISA)

9 t Wheel arm 18 o Safety belt

t = Standard equipment o = Optional equipment

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2.1 Truck

Safety installations: The enclosed truck contour featuring rounded edges ensuressafe handling of the ETVC 16/20 truck. The driver is protected by the overhead guard(2). The drive wheel (10) and the load-bearing wheels (8) are enclosed by a sturdycollision guard.The master switch (16) ensures instant cut-out of all electrical functions in an emer-gency. Six red LED warning lights in the information and service display (17) indicatethe following states:

– Direction of motion Forward (V), „Drive direction“– Parking brake applied– Direction of motion Backward (R), „Load direction“– Lack of brake liquid– Center position of lateral traversing device (option)– Battery locking In case of malfunctions within the hydraulic system, line break safety devices limit thespeed at which the load is lowered.

Indicating instruments: Information and Service Display (LISA) (17) with large-areadisplay in LCD technology as well as with integrated operating hour meter and batterycharge indicator with lift shut-off function, switchable to time display.

Drive system: The complete drive unit is screwed into the vehicle chassis. A 6 kWfixed threephase motor drives the drive wheel (10) via a bevel spur gearbox.The electronic drive current control system provides variable speed to the drive mo-tor, thus allowing smooth starting without jerks, vigorous accelerating and electroni-cally controlled regenerative braking. The rate of energy regeneration can be set with the LISA system.

Brake system: The truck is equipped with two independent brake systems. The ope-rating brake is designed as hydraulic drum brake with asbestos-free brake linings andis actuated by the foot pedal and acts on the drive wheel and the load-bearing wheels. The parking brake of the drive wheel (10) mechanically (compression spring) acts viaa cable on the brake drums. The brake fluid level is monitored by the LISA system. Awarning light shows when the parking brake is applied.

Steering system: Chain-operated steering using a steering gear and, as standard,hydraulic steering. The pivoted drive unit can be swivelled by 90° to both sides.The steering wheel is horizontally adjustable.

Driver position: The driver position is built ergonomically, equipped with a footstep(11) and ample foot space. Driver’s seat and steering wheel are individually adjusta-ble to the driver’s physique.Accelerator and brake pedals are arranged as found in normal vehicles.

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2.1 Truck

Safety installations: The enclosed truck contour featuring rounded edges ensuressafe handling of the ETVC 16/20 truck. The driver is protected by the overhead guard(2). The drive wheel (10) and the load-bearing wheels (8) are enclosed by a sturdycollision guard.The master switch (16) ensures instant cut-out of all electrical functions in an emer-gency. Six red LED warning lights in the information and service display (17) indicatethe following states:

– Direction of motion Forward (V), „Drive direction“– Parking brake applied– Direction of motion Backward (R), „Load direction“– Lack of brake liquid– Center position of lateral traversing device (option)– Battery locking In case of malfunctions within the hydraulic system, line break safety devices limit thespeed at which the load is lowered.

Indicating instruments: Information and Service Display (LISA) (17) with large-areadisplay in LCD technology as well as with integrated operating hour meter and batterycharge indicator with lift shut-off function, switchable to time display.

Drive system: The complete drive unit is screwed into the vehicle chassis. A 6 kWfixed threephase motor drives the drive wheel (10) via a bevel spur gearbox.The electronic drive current control system provides variable speed to the drive mo-tor, thus allowing smooth starting without jerks, vigorous accelerating and electroni-cally controlled regenerative braking. The rate of energy regeneration can be set with the LISA system.

Brake system: The truck is equipped with two independent brake systems. The ope-rating brake is designed as hydraulic drum brake with asbestos-free brake linings andis actuated by the foot pedal and acts on the drive wheel and the load-bearing wheels. The parking brake of the drive wheel (10) mechanically (compression spring) acts viaa cable on the brake drums. The brake fluid level is monitored by the LISA system. Awarning light shows when the parking brake is applied.

Steering system: Chain-operated steering using a steering gear and, as standard,hydraulic steering. The pivoted drive unit can be swivelled by 90° to both sides.The steering wheel is horizontally adjustable.

Driver position: The driver position is built ergonomically, equipped with a footstep(11) and ample foot space. Driver’s seat and steering wheel are individually adjusta-ble to the driver’s physique.Accelerator and brake pedals are arranged as found in normal vehicles.

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Operating controls and indicators: The operating controls and indicators are clear-ly laid out and arranged at the driver position.

Control lever (5) is used to operate the “Mast tilting” function, control lever (6) to ope-rate the “Forward/backward traversing of mast” function. The following functions areoperated with the Solo Pilot (7):

– lifting/lowering– driving direction– lateral lift (o) left/right in side shifting operation (auxiliary hydraulics ZH1)– horn

As an option, an auxiliary hydraulic system ZH2 can be operated via control lever (4).

Hydraulic system: Pump unit with independent air cooled motor and low-noise pre-cision high-pressure pump. The system is controlled using the individual levers (5-7)and the optional auxiliary hydraulics (4).

Electric system: 48 V two-wire system. As a standard feature, the truck is equippedwith an electronic drive and lifting control system. The electronic drive control system variably controls the travelling speed and allowscounter-current braking when switching the direction of travel.The information and service display (LISA) (17) allows a adjustment of the driving andlifting parameters according to the current requirements. Warning indications, opera-ting error indications and service functions are also shown on the LISA.(For possible drive batteries, see chapter D).

2.2 Load lifting system

Mast holder: The mast holder is borne by supporting rollers. The protracting andretracting movements are carried out directly by a simply telescoping traversingcylinder. The guide rails for the mast holder are screwed onto the wheel arms (9).

Hoist frame: The trucks are equipped with tiltable, telescoping free-vision hoistframes (1) supported by the mast holder. Adjustable lateral rollers and guide piecesabsorb the lateral pressure acting on the fork carrier when transporting unbalancedloads. The mounting of the fork to the fork carrier permits adjustments to be made tothe tines. In the case of the double-lift triplex mast (DZ), the initial lifting sequence ofthe load carriage (free lift), which does not change the total height, is effected by ashort free-lift cylinder (3) arranged off-centre. In the case of the telescopic mast (ZT),the free-lift sequence is limited to 80 mm due to the construction of the truck.

Attachments: Mechanical and hydraulic attachments are available as optionalequipment.

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Operating controls and indicators: The operating controls and indicators are clear-ly laid out and arranged at the driver position.

Control lever (5) is used to operate the “Mast tilting” function, control lever (6) to ope-rate the “Forward/backward traversing of mast” function. The following functions areoperated with the Solo Pilot (7):

– lifting/lowering– driving direction– lateral lift (o) left/right in side shifting operation (auxiliary hydraulics ZH1)– horn

As an option, an auxiliary hydraulic system ZH2 can be operated via control lever (4).

Hydraulic system: Pump unit with independent air cooled motor and low-noise pre-cision high-pressure pump. The system is controlled using the individual levers (5-7)and the optional auxiliary hydraulics (4).

Electric system: 48 V two-wire system. As a standard feature, the truck is equippedwith an electronic drive and lifting control system. The electronic drive control system variably controls the travelling speed and allowscounter-current braking when switching the direction of travel.The information and service display (LISA) (17) allows a adjustment of the driving andlifting parameters according to the current requirements. Warning indications, opera-ting error indications and service functions are also shown on the LISA.(For possible drive batteries, see chapter D).

2.2 Load lifting system

Mast holder: The mast holder is borne by supporting rollers. The protracting andretracting movements are carried out directly by a simply telescoping traversingcylinder. The guide rails for the mast holder are screwed onto the wheel arms (9).

Hoist frame: The trucks are equipped with tiltable, telescoping free-vision hoistframes (1) supported by the mast holder. Adjustable lateral rollers and guide piecesabsorb the lateral pressure acting on the fork carrier when transporting unbalancedloads. The mounting of the fork to the fork carrier permits adjustments to be made tothe tines. In the case of the double-lift triplex mast (DZ), the initial lifting sequence ofthe load carriage (free lift), which does not change the total height, is effected by ashort free-lift cylinder (3) arranged off-centre. In the case of the telescopic mast (ZT),the free-lift sequence is limited to 80 mm due to the construction of the truck.

Attachments: Mechanical and hydraulic attachments are available as optionalequipment.

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3 Technical data - Standard version

Z Technical data to VDI 2198.Technical data are subject to alteration and extension in scope.

3.1 Output data for standard truck version

3.2 Standard hoist frame versions

Description ETVC 16 ETVC 20Q Capacity (where C = 600 mm) 1600 2000 kgC Load centre of gravity 600 600 mm

Travel speed w / w.o. loadin drive direction / fork direction 11,8 / 11 11,8 / 11

Lift speed (lift) w / w.o. load 0,34 / 0,64 0,28 / 0,52 m/s(±10%)

Lift speed (lower) w / w.o. load 0,50 0,50 m/s (±15%)

Reach speed w / w.o. load 0,2 0,12 m/sGradeability w / w.o. load 8 / 12 6 / 10

%Max. gradeability (5 min. rating)w / w.o. load 10 / 15 10 / 15

Description Telescopic mast (ZT) 1.6 t

Triplex Mast (DZ) 1.6 t

Triplex Mast (DZ) 2 t

h1 Height 1950-2700 1950-2700 2200-3100 mm h2 Free lift 80 1306-2056 1470-2370 mm h3 Lift 2900-4400 4250-6500 4700-7400 mm h4 Max. height 3544-5044 4894-7144 5446-8146 mm

s

h2

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h1 h6h3

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3 Technical data - Standard version

Z Technical data to VDI 2198.Technical data are subject to alteration and extension in scope.

3.1 Output data for standard truck version

3.2 Standard hoist frame versions

Description ETVC 16 ETVC 20Q Capacity (where C = 600 mm) 1600 2000 kgC Load centre of gravity 600 600 mm

Travel speed w / w.o. loadin drive direction / fork direction 11,8 / 11 11,8 / 11

Lift speed (lift) w / w.o. load 0,34 / 0,64 0,28 / 0,52 m/s(±10%)

Lift speed (lower) w / w.o. load 0,50 0,50 m/s (±15%)

Reach speed w / w.o. load 0,2 0,12 m/sGradeability w / w.o. load 8 / 12 6 / 10

%Max. gradeability (5 min. rating)w / w.o. load 10 / 15 10 / 15

Description Telescopic mast (ZT) 1.6 t

Triplex Mast (DZ) 1.6 t

Triplex Mast (DZ) 2 t

h1 Height 1950-2700 1950-2700 2200-3100 mm h2 Free lift 80 1306-2056 1470-2370 mm h3 Lift 2900-4400 4250-6500 4700-7400 mm h4 Max. height 3544-5044 4894-7144 5446-8146 mm

s

h2

l4

l7l1

h1 h6h3

h4

Q

c

B 7

0205

.GB

3.3 Dimensions

a) G; Fork length 800 mm; 560 Ah battery: ± 0 mm; 700 Ah battery: +90 mmb) G; 560 Ah battery: ± 0 mm; 700 Ah battery: - 90 mmc) G; 560 Ah battery: ± 0 mm

Description ETVC 16(ZT/DZ)

ETVC 20(DZ)

s Lowered fork height 40 50 mmh6 Height above overhead guard 2155 / 2270 2295 mml1 Overall length 2132 / 2154 a) 2195,5 a) mml4 Reach 717 / 695 b) 687,5 b) mml7 Length over outriggers 1953 2060 mmb1 Max. width 1340 1438 mmb2 Width on drive side 1238 1238 mmWa Turning radius 1705 1810 mmAst Working aisle width for pallets

800 x 1200 longit.2836 / 2856 c) 2916 c) mm

Ast Aisle width for pallets 1000x1200 traverse

2783 / 2799 c) 2867 c) mm

Net weight see truck data plate

Ast

b1b2

Wa

B 7

0205

.GB

3.3 Dimensions

a) G; Fork length 800 mm; 560 Ah battery: ± 0 mm; 700 Ah battery: +90 mmb) G; 560 Ah battery: ± 0 mm; 700 Ah battery: - 90 mmc) G; 560 Ah battery: ± 0 mm

Description ETVC 16(ZT/DZ)

ETVC 20(DZ)

s Lowered fork height 40 50 mmh6 Height above overhead guard 2155 / 2270 2295 mml1 Overall length 2132 / 2154 a) 2195,5 a) mml4 Reach 717 / 695 b) 687,5 b) mml7 Length over outriggers 1953 2060 mmb1 Max. width 1340 1438 mmb2 Width on drive side 1238 1238 mmWa Turning radius 1705 1810 mmAst Working aisle width for pallets

800 x 1200 longit.2836 / 2856 c) 2916 c) mm

Ast Aisle width for pallets 1000x1200 traverse

2783 / 2799 c) 2867 c) mm

Net weight see truck data plate

Ast

b1b2

Wa

0205

.GB

B 8

3.4 EN standards

Continuous sound level: 67 dB(A)

according to EN 12053 as stipulated in ISO 4871.

Z The continuous sound level is a value averaged according to standard regulations,taking the sound pressure level into account when driving, lifting and idling. Thesound pressure level is measured at the ear.

Vibration: 0.30 m/s2

according to EN 13059

Z The swinging acceleration acting on the body in its operating position is, according tostandard regulations, the linear integrated, weighted acceleration in the vertical pla-ne. It is determined by driving over bumps with a constant speed.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limitvalues for electromagnetic emission and interferenceimmunity as well as testing of static electricity dischargeaccording to EN 12895 and the references to other stan-dards contained therein.

Z Electrical or electronic components and their arrangement may only be modified afterwritten approval by the manufacturer has been obtained.

3.5 Conditions for application

Ambient temperature:

- during operation: 5°C to 40°C

Z Industrial trucks must be specially equipped and approved for continuous use inenvironments with temperatures below 5°C or in cold stores respectively with extre-me temperatures or humidity changes.

0205

.GB

B 8

3.4 EN standards

Continuous sound level: 67 dB(A)

according to EN 12053 as stipulated in ISO 4871.

Z The continuous sound level is a value averaged according to standard regulations,taking the sound pressure level into account when driving, lifting and idling. Thesound pressure level is measured at the ear.

Vibration: 0.30 m/s2

according to EN 13059

Z The swinging acceleration acting on the body in its operating position is, according tostandard regulations, the linear integrated, weighted acceleration in the vertical pla-ne. It is determined by driving over bumps with a constant speed.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limitvalues for electromagnetic emission and interferenceimmunity as well as testing of static electricity dischargeaccording to EN 12895 and the references to other stan-dards contained therein.

Z Electrical or electronic components and their arrangement may only be modified afterwritten approval by the manufacturer has been obtained.

3.5 Conditions for application

Ambient temperature:

- during operation: 5°C to 40°C

Z Industrial trucks must be specially equipped and approved for continuous use inenvironments with temperatures below 5°C or in cold stores respectively with extre-me temperatures or humidity changes.

B 9

0205

.GB

4 Location of instruction labels and identification plates

Item Designation19 Drive direction when locking the steering wheel (option)20 Load diagram, capacity / lateral traversing device21 Load diagram, capacity / load centre / lifting height22 Sign „Put on safety belt“23 Prohibitive sign „Do not reach through the hoist frame“24 Prohibitive sign „Keep away from under the load lifting device“25 Pick-up points for crane transportation26 Warning sign „Low voltage electronics“27 Truck identification plate28 Plaque confirming accident prevention checks (only D)29 Pick-up points for lifting jack

27

20

21

24

25

26

19

29

25

mV1,5 V

29

28

26

23

121110

98

7

65 4

32

11996

Regelmäßige Prüfungnach UVV VBG 36 §37durch Sachkundigen

Nächste Prüfung

Ihr Kundendienst-Partner

KundendienstJUNGHEINRICHV

JUNGHE

INRICH

V

22

B 9

0205

.GB

4 Location of instruction labels and identification plates

Item Designation19 Drive direction when locking the steering wheel (option)20 Load diagram, capacity / lateral traversing device21 Load diagram, capacity / load centre / lifting height22 Sign „Put on safety belt“23 Prohibitive sign „Do not reach through the hoist frame“24 Prohibitive sign „Keep away from under the load lifting device“25 Pick-up points for crane transportation26 Warning sign „Low voltage electronics“27 Truck identification plate28 Plaque confirming accident prevention checks (only D)29 Pick-up points for lifting jack

27

20

21

24

25

26

19

29

25

mV1,5 V

29

28

26

23

121110

98

7

65 4

32

11996

Regelmäßige Prüfungnach UVV VBG 36 §37durch Sachkundigen

Nächste Prüfung

Ihr Kundendienst-Partner

KundendienstJUNGHEINRICHV

JUNGHE

INRICH

V

22

0205

.GB

B 10

4.1 Truck identification plate

Z In event of queries relating to the truck or spare part orders, please state the serialno. (31) of the truck.

4.2 Load diagram / capacity / load centre / lifting height

The load diagram (21) shows the capacity of the truck in Q kg with the hoist frame invertical position. The diagram indicates the maximum capacity at a standard loadcentre* C (in mm) and at the desired lifting height H (in mm) in the form of a table.

*) Apart from the height of the load, the standard load centre also includes the widthof the load.

Example showing the determination of the max. capacity:

At a load centre C of 600 mm and a max. lifting height H of 3600 mm, the max. capa-city Qkg is 1105 kg.

Item Designation Item Designation30 Type 36 Manufacturer31 Serial No. 37 Min./max. battery weight in kg32 Rated capacity in kg 38 Drive power in kW33 Battery: Voltage V 39 Load centre distance in mm34 Empty weight without battery in kg 40 Year of manufacture35 Manufacturer logo 41 Option

36

35

3734

3833

3932

4031

4130

21

500 600 700

850850600

X.XXXX.XX.XX

12501105850

12501105850

290036004250

0205

.GB

B 10

4.1 Truck identification plate

Z In event of queries relating to the truck or spare part orders, please state the serialno. (31) of the truck.

4.2 Load diagram / capacity / load centre / lifting height

The load diagram (21) shows the capacity of the truck in Q kg with the hoist frame invertical position. The diagram indicates the maximum capacity at a standard loadcentre* C (in mm) and at the desired lifting height H (in mm) in the form of a table.

*) Apart from the height of the load, the standard load centre also includes the widthof the load.

Example showing the determination of the max. capacity:

At a load centre C of 600 mm and a max. lifting height H of 3600 mm, the max. capa-city Qkg is 1105 kg.

Item Designation Item Designation30 Type 36 Manufacturer31 Serial No. 37 Min./max. battery weight in kg32 Rated capacity in kg 38 Drive power in kW33 Battery: Voltage V 39 Load centre distance in mm34 Empty weight without battery in kg 40 Year of manufacture35 Manufacturer logo 41 Option

36

35

3734

3833

3932

4031

4130

21

500 600 700

850850600

X.XXXX.XX.XX

12501105850

12501105850

290036004250

B 11

0205

.GB

4.3 Load diagram, capacity / lateral traversing device

The load diagram (20) shows the redu-ced capacity Q in kg with the lateral tra-versing device extended.

4.4 Pick-up points for lifting jack

The "Jack contact point" decal (29) indi-cates where the truck may be lifted andjacked up (refer to chapter F).

X

20

29

B 11

0205

.GB

4.3 Load diagram, capacity / lateral traversing device

The load diagram (20) shows the redu-ced capacity Q in kg with the lateral tra-versing device extended.

4.4 Pick-up points for lifting jack

The "Jack contact point" decal (29) indi-cates where the truck may be lifted andjacked up (refer to chapter F).

X

20

29

0205

.GB

B 12

0205

.GB

B 12

C 1

0205

.GB

C Transportation and commissioning1 Loading and unloading of trucks by crane

F Ensure that the lifting gear is of adequate capacity.(Transportation weight = net weight + battery weight; see truck identification plate)

– To load the truck with lifting gear, lay the loop of the rope around the strut of theoverhead guard (1). Two lifting points (2) are provided on the wheel arms.

– Park the truck and render it safe (refer to chapter E).– Use chocks to prevent the truck from moving!

M The lilting gear must be secured to the lifting points in such a way that it does notcome into contact with any attachments when the truck is lifted.

2 Commissioning

M The truck must only be operated on battery current. Rectified alternate current will da-mage the electronics. Cables connected to the battery (towing cable) must be lessthan 6 meters in length.

To prepare the truck for work following delivery or transportation, the following ope-rations must be performed:

– Check that the equipment is complete.– If necessary, install the battery. Do not damage the battery cable (refer to chapter

D).– Charge the battery (refer to chapter D).– Commission the truck as prescribed (refer to chapter E).

1

2

C 1

0205

.GB

C Transportation and commissioning1 Loading and unloading of trucks by crane

F Ensure that the lifting gear is of adequate capacity.(Transportation weight = net weight + battery weight; see truck identification plate)

– To load the truck with lifting gear, lay the loop of the rope around the strut of theoverhead guard (1). Two lifting points (2) are provided on the wheel arms.

– Park the truck and render it safe (refer to chapter E).– Use chocks to prevent the truck from moving!

M The lilting gear must be secured to the lifting points in such a way that it does notcome into contact with any attachments when the truck is lifted.

2 Commissioning

M The truck must only be operated on battery current. Rectified alternate current will da-mage the electronics. Cables connected to the battery (towing cable) must be lessthan 6 meters in length.

To prepare the truck for work following delivery or transportation, the following ope-rations must be performed:

– Check that the equipment is complete.– If necessary, install the battery. Do not damage the battery cable (refer to chapter

D).– Charge the battery (refer to chapter D).– Commission the truck as prescribed (refer to chapter E).

1

2

0205

.GB

C 2

3 Moving a defective truck

– Secure the towing device to the recovery vehicle and to the truck to be towed away.– Disconnect the battery connector.– Release the parking brake.

F The towed truck must be steered by a person seated on the truck seat. Tow the truckat a walking pace.

Z As the power steering is not operative, the truck can only be steered with increasedeffort.

0205

.GB

C 2

3 Moving a defective truck

– Secure the towing device to the recovery vehicle and to the truck to be towed away.– Disconnect the battery connector.– Release the parking brake.

F The towed truck must be steered by a person seated on the truck seat. Tow the truckat a walking pace.

Z As the power steering is not operative, the truck can only be steered with increasedeffort.

D 1

0205

.GB


1 Safety regulations governing the handling of lead-acid batteries

The truck must be parked and rendered safe, before any operations on batteries areto be undertaken (refer to chapter E).

Servicing staff: Recharging, servicing and replacing of batteries must only be per-formed by qualified personnel. The instructions contained in this operating manual,and the instructions as prepared by the battery supplier and as available at the batteryrecharging station must be observed, when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted whenhandling batteries. No inflammable substances or spark-generating materials mustbe present or stored within a distance of 2 meters of the truck parked for battery re-charging. The location must be well ventilated and fire fighting equipment must bekept ready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-minals and cable shoes must be clean, lightly greased with pole grease and must besecurely tightened.

Disposal of the battery: Batteries must only be disposed of as stipulated in the na-tional environmental protection regulations or waste disposal provisions. The manu-facturer’s specifications for the disposal must be heeded.

M Before closing the battery hood, make sure that the battery cable cannot be dama-ged.

F Batteries contain dissolved acid, which is toxic and caustic. For this reason protectiveclothing and goggles must be worn whenever work is undertaken on batteries. Avoidphysical contact with battery acid. If clothing, skin or eyes have accidentally come intocontact with battery acid, liberally flush the affected parts with clean water. Consult adoctor, when skin or eyes have come into contact with battery acid. Spilled batteryacid must be immediately neutralized.

2 Battery type

The battery types correspond to IEC 254 / EN 60254.Depending on use, the ETVC 16/20 can be equipped with different types of batteries.The following table shows the capacity and battery types provided:

The battery weights can be seen on the battery identification plate. Batteries with noninsulated terminals must be covered with a non slip insulation mat.

F When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck. Battery weight and battery dimensions have aconsiderable effect on the stability of the truck. Battery type changes are thereforepermitted only after obtaining approval from the manufacturer.

Capacity Designation48 V - 4PzS - Battery 560 Ah 560L48 V - 5PzS - Battery 700 Ah 700L

D 1

0205

.GB


1 Safety regulations governing the handling of lead-acid batteries

The truck must be parked and rendered safe, before any operations on batteries areto be undertaken (refer to chapter E).

Servicing staff: Recharging, servicing and replacing of batteries must only be per-formed by qualified personnel. The instructions contained in this operating manual,and the instructions as prepared by the battery supplier and as available at the batteryrecharging station must be observed, when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted whenhandling batteries. No inflammable substances or spark-generating materials mustbe present or stored within a distance of 2 meters of the truck parked for battery re-charging. The location must be well ventilated and fire fighting equipment must bekept ready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-minals and cable shoes must be clean, lightly greased with pole grease and must besecurely tightened.

Disposal of the battery: Batteries must only be disposed of as stipulated in the na-tional environmental protection regulations or waste disposal provisions. The manu-facturer’s specifications for the disposal must be heeded.

M Before closing the battery hood, make sure that the battery cable cannot be dama-ged.

F Batteries contain dissolved acid, which is toxic and caustic. For this reason protectiveclothing and goggles must be worn whenever work is undertaken on batteries. Avoidphysical contact with battery acid. If clothing, skin or eyes have accidentally come intocontact with battery acid, liberally flush the affected parts with clean water. Consult adoctor, when skin or eyes have come into contact with battery acid. Spilled batteryacid must be immediately neutralized.

2 Battery type

The battery types correspond to IEC 254 / EN 60254.Depending on use, the ETVC 16/20 can be equipped with different types of batteries.The following table shows the capacity and battery types provided:

The battery weights can be seen on the battery identification plate. Batteries with noninsulated terminals must be covered with a non slip insulation mat.

F When replacing or installing batteries, ensure that the battery is correctly secured inthe battery compartment of the truck. Battery weight and battery dimensions have aconsiderable effect on the stability of the truck. Battery type changes are thereforepermitted only after obtaining approval from the manufacturer.

Capacity Designation48 V - 4PzS - Battery 560 Ah 560L48 V - 5PzS - Battery 700 Ah 700L

0205

.GB

D 2

3 Exposing the battery

– Sit on the driver´s seat.– Render the truck ready for operation (refer to chapter E).– Tilt the control lever (1) in direction of arrow (U), drive mast holder to its limit stop

position towards the battery and release control lever (1) (mast is in final position).– Tilt the control lever (1) once again in direction of arrow (U) and go on driving mast

holder to its limit stop position towards the battery (preparation of battery unlok-king).

– Actuate the battery trolley unlocking system (4). The LED (2) lights up.– Tilt the control lever (1) in the T direction and push the mast holder with the coupled

battery trolley forward until the battery is exposed for servicing.– Switch off the master switch and the key switch.

F Connecting and disconnecting of battery connector and socket is permitted only withthe master switch and battery charger switched off.

– Withdraw the battery connector (5) from the socket.– Remove any insulating matting from the batteries.

Z The safety switch of the battery unlocking system interrupts the driving function aslong as the battery trolley is unlocked and the LED (2) is lit. Before commissioning thetruck again, the battery trolley must be returned to the original position to uncouplethe battery trolley and the mast holder. The LED (2) must have gone out.

1

2

5

43

0205

.GB

D 2

3 Exposing the battery

– Sit on the driver´s seat.– Render the truck ready for operation (refer to chapter E).– Tilt the control lever (1) in direction of arrow (U), drive mast holder to its limit stop

position towards the battery and release control lever (1) (mast is in final position).– Tilt the control lever (1) once again in direction of arrow (U) and go on driving mast

holder to its limit stop position towards the battery (preparation of battery unlok-king).

– Actuate the battery trolley unlocking system (4). The LED (2) lights up.– Tilt the control lever (1) in the T direction and push the mast holder with the coupled

battery trolley forward until the battery is exposed for servicing.– Switch off the master switch and the key switch.

F Connecting and disconnecting of battery connector and socket is permitted only withthe master switch and battery charger switched off.

– Withdraw the battery connector (5) from the socket.– Remove any insulating matting from the batteries.


1

2

5

43

D 3

0205

.GB

3.1 Bypassing the drive current interruption

– Switch on the switch “Cut-back speed” (3).

F If the battery is protruding, the truck may only be driven at cut-back speed in the bat-tery charging station!

3.2 Battery trolley emergency unlockingsystem

– Render the truck ready for operation(refer to chapter E).

– Tilt control lever (1) in direction ofarrow (U), drive mast holder to its limitstop position towards the battery andrelease control lever (1).

– Tilt control lever (1) once again in di-rection of arrow (U) and go on drivingmast holder to its limit stop position to-wards the battery.

– Switch off the master switch and the key switch.– Open seat hood (see chapter F)– Loosen screws (6) of the battery lokking system and pull out locking system (7). – Close seat hood.– Connect master switch and key switch.– Tilt the control lever (1) in the T direction and push the mast holder with the coupled

battery trolley forward until the battery is exposed for servicing.– LED (2) lights up. – Disconnect main switch and key switch.

Z Eliminate the malfunction of the battery unlocking system before mounting the batterylocking system.


4 Charging the battery

– Expose the battery (refer to section 3).

F During the recharging operation the tops of the battery cells must be exposed to en-sure adequate ventilation. No metal objects must be placed on the battery. Prior tostarting the recharging operation, check all cable connections and plugged connec-tions for visible damage.

– Remove any insulating mats from the battery.– Connect the charging cable of the battery charger to the battery connector (5).– Recharge the battery observing the instructions provided by the battery supplier

and by the battery charger supplier.

F All safety instructions as provided by the battery supplier and battery charger suppliermust be strictly observed.

6

7

D 3

0205

.GB

3.1 Bypassing the drive current interruption

– Switch on the switch “Cut-back speed” (3).

F If the battery is protruding, the truck may only be driven at cut-back speed in the bat-tery charging station!

3.2 Battery trolley emergency unlockingsystem

– Render the truck ready for operation(refer to chapter E).

– Tilt control lever (1) in direction ofarrow (U), drive mast holder to its limitstop position towards the battery andrelease control lever (1).

– Tilt control lever (1) once again in di-rection of arrow (U) and go on drivingmast holder to its limit stop position to-wards the battery.

– Switch off the master switch and the key switch.– Open seat hood (see chapter F)– Loosen screws (6) of the battery lokking system and pull out locking system (7). – Close seat hood.– Connect master switch and key switch.– Tilt the control lever (1) in the T direction and push the mast holder with the coupled

battery trolley forward until the battery is exposed for servicing.– LED (2) lights up. – Disconnect main switch and key switch.

Z Eliminate the malfunction of the battery unlocking system before mounting the batterylocking system.


4 Charging the battery


F During the recharging operation the tops of the battery cells must be exposed to en-sure adequate ventilation. No metal objects must be placed on the battery. Prior tostarting the recharging operation, check all cable connections and plugged connec-tions for visible damage.

– Remove any insulating mats from the battery.– Connect the charging cable of the battery charger to the battery connector (5).– Recharge the battery observing the instructions provided by the battery supplier

and by the battery charger supplier.

F All safety instructions as provided by the battery supplier and battery charger suppliermust be strictly observed.

6

7

0205

.GB

D 4

5 Removing and installing the battery


F Batteries with open poles, or open cell bridges, must be covered with a rubber mat toprevent short-circuiting. When using a crane in battery replacing operations, ensurethat the crane is of adequate capacity (refer to the battery weight indicated on the bat-tery identification plate located at the battery trough). The battery must be lifted verti-cally to prevent crushing of the battery trough. Lifting hooks must be applied in sucha way that, with the lifting gear slack, they will not drop on to the battery cells.

Removing and installing the battery using lifting gear

– Secure the lifting gear to the battery trough (8).– Loosen counternut (10) and screw (11) at the red battery lock (9).– Pull out the red battery lock (9).– With the lifting gear attached, lift out the battery and move it to one side.

Installation is in the reverse order of operations.

Removing and installing the battery using a battery trolley

F The truck must stand horizontally so that the battery does not automatically roll outwhen the battery safety device is removed.

– Use the service key to open the side door (12).– Loosen counternut (10) and screw (11) at the red battery lock (9).– Pull out the red battery lock (9).– Pull the battery laterally onto the battery transport trolley.


F When replacing batteries, ensure that a battery of the same type is fitted. Upon com-pletion of the battery refitting operations, check all cable connections and pluggedconnections for any visible damage. Covers and side doors must be safely locked.

10

11

9

8

12

0205

.GB

D 4

5 Removing and installing the battery


F Batteries with open poles, or open cell bridges, must be covered with a rubber mat toprevent short-circuiting. When using a crane in battery replacing operations, ensurethat the crane is of adequate capacity (refer to the battery weight indicated on the bat-tery identification plate located at the battery trough). The battery must be lifted verti-cally to prevent crushing of the battery trough. Lifting hooks must be applied in sucha way that, with the lifting gear slack, they will not drop on to the battery cells.

Removing and installing the battery using lifting gear

– Secure the lifting gear to the battery trough (8).– Loosen counternut (10) and screw (11) at the red battery lock (9).– Pull out the red battery lock (9).– With the lifting gear attached, lift out the battery and move it to one side.


Removing and installing the battery using a battery trolley

F The truck must stand horizontally so that the battery does not automatically roll outwhen the battery safety device is removed.

– Use the service key to open the side door (12).– Loosen counternut (10) and screw (11) at the red battery lock (9).– Pull out the red battery lock (9).– Pull the battery laterally onto the battery transport trolley.


F When replacing batteries, ensure that a battery of the same type is fitted. Upon com-pletion of the battery refitting operations, check all cable connections and pluggedconnections for any visible damage. Covers and side doors must be safely locked.

10

11

9

8

12

D 5

0205

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6 Battery discharge indicator, battery discharge monitor and hour meter

Battery discharge indicator: The charging state of the battery (13) is indicated in10% steps in the LISA display.

M The standard setting of the batterydischarge indicator / discharge monitoris made using standard batteries.When using maintenance-free batteries,the indication has to be adjusted in away that the symbol (T) (14) comes upbehind the percent indication. When thissetting is not performed, the batterymight suffer damage caused by exhau-stive discharge. Setting of the instrument should be per-formed by service staff from the manu-facturer of the truck.

In case of a rest capacity of the battery of 20% for standard batteries or 40% for maintenance-free batteries, abattery charge is necessary.

Battery discharge monitor: In case of undershooting the rest capacity the liftingfunction is disconnected. LISA indicates a corresponding message.

Z Lifting will only become possible again, after the battery has been recharged to atleast 70 per cent.

Hour meter: The service hours (15) are indicated besides the charging state of thebattery. The hour meter indicates the overall time of the driving and the lifting move-ments.

BATT T: 0 0 %4 4 71 h

13 14 15

D 5

0205

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6 Battery discharge indicator, battery discharge monitor and hour meter

Battery discharge indicator: The charging state of the battery (13) is indicated in10% steps in the LISA display.

M The standard setting of the batterydischarge indicator / discharge monitoris made using standard batteries.When using maintenance-free batteries,the indication has to be adjusted in away that the symbol (T) (14) comes upbehind the percent indication. When thissetting is not performed, the batterymight suffer damage caused by exhau-stive discharge. Setting of the instrument should be per-formed by service staff from the manu-facturer of the truck.

In case of a rest capacity of the battery of 20% for standard batteries or 40% for maintenance-free batteries, abattery charge is necessary.

Battery discharge monitor: In case of undershooting the rest capacity the liftingfunction is disconnected. LISA indicates a corresponding message.

Z Lifting will only become possible again, after the battery has been recharged to atleast 70 per cent.

Hour meter: The service hours (15) are indicated besides the charging state of thebattery. The hour meter indicates the overall time of the driving and the lifting move-ments.

BATT T: 0 0 %4 4 71 h

13 14 15

0205

.GB

D 6

0205

.GB

D 6

E 1

1005

.GB

E Operation1 Safety regulations governing the operation of the truck

Driving permission: The truck must only be operated by persons who have beentrained in the operation of trucks, who have demonstrated to the user or his represen-tative their capability of moving and handling loads, and who have expressly beencharged by the user or his representative with the operation of the truck.

Rights, duties and conduct of the driver: The driver must be: informed of his rightsand duties; trained in the operation of the fork-lift truck; and familiar with the contentsof these operating instructions. All necessary rights must be granted to him. If thefork-lift truck can be used in the pedestrian-controlled mode, the driver must wearsafety boots when operating the truck.

Prohibition of unauthorized use: The driver is responsible for his truck during wor-king time. He must forbid unauthorized persons to drive or operate the truck. Thetransport or lifting of persons is forbidden.

Damage and defects: Damage or defects noted on the truck or on the attachmentsmust immediately be brought to the notice of the person in charge. Trucks that cannotbe safely operated (e.g. due to worn tyres or defective brakes) must not be used untilthey have been properly repaired.

Repairs: Without specific training and express authorization the driver is not allowedto perform any repairs or modifications on the truck. Under no circumstances mustthe driver change the setting of switches or safety installations, or render them inef-fective.

Danger area: As danger area is considered the area within which persons are endan-gered by the travelling or lifting movements of the truck or its load lifting devices (e.g.fork or attachments), or by the loads being transported. This includes also the areawithin reach of dropping loads or dropping truck attachments.

F Unauthorized persons must be asked to leave the danger area. The driver must givea warning signal, whenever a situation presenting danger to persons might develop.The truck must immediately be brought to a standstill, if persons, although asked, donot leave the danger area.

Safety devices and warning labels: The safety devices, warning labels and warningnotes described in the present operating instructions must always be heeded.

E 1

1005

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E Operation1 Safety regulations governing the operation of the truck

Driving permission: The truck must only be operated by persons who have beentrained in the operation of trucks, who have demonstrated to the user or his represen-tative their capability of moving and handling loads, and who have expressly beencharged by the user or his representative with the operation of the truck.

Rights, duties and conduct of the driver: The driver must be: informed of his rightsand duties; trained in the operation of the fork-lift truck; and familiar with the contentsof these operating instructions. All necessary rights must be granted to him. If thefork-lift truck can be used in the pedestrian-controlled mode, the driver must wearsafety boots when operating the truck.

Prohibition of unauthorized use: The driver is responsible for his truck during wor-king time. He must forbid unauthorized persons to drive or operate the truck. Thetransport or lifting of persons is forbidden.

Damage and defects: Damage or defects noted on the truck or on the attachmentsmust immediately be brought to the notice of the person in charge. Trucks that cannotbe safely operated (e.g. due to worn tyres or defective brakes) must not be used untilthey have been properly repaired.

Repairs: Without specific training and express authorization the driver is not allowedto perform any repairs or modifications on the truck. Under no circumstances mustthe driver change the setting of switches or safety installations, or render them inef-fective.

Danger area: As danger area is considered the area within which persons are endan-gered by the travelling or lifting movements of the truck or its load lifting devices (e.g.fork or attachments), or by the loads being transported. This includes also the areawithin reach of dropping loads or dropping truck attachments.

F Unauthorized persons must be asked to leave the danger area. The driver must givea warning signal, whenever a situation presenting danger to persons might develop.The truck must immediately be brought to a standstill, if persons, although asked, donot leave the danger area.

Safety devices and warning labels: The safety devices, warning labels and warningnotes described in the present operating instructions must always be heeded.

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2 Description of the operating controls and indicators

Item Operating control /indicator

Function

1 Control lever„Inclining of mast“

t Operates the following function:– Tilting the hoist frame forward / backward

2 Control lever„Inclining of fork“

t Operates the following function:– Pushing forward / retracting the mast holder

3 Solo-pilot t Operates the following functions:– Forward / reverse drive direction– Lifting / lowering the load lifting device– Moving the lateral traversing device to the left /

right (o)– Horn key

4 Accelerator t Stepless control of the truck travelling speed.5 Brake pedal t Braking of the truck.6 Foot key t – not pressed:

The driving and lifting functions, as well as the auxiliary functions, are locked. The lowering function remains functional. The truck rolls to a stop.

– pressed:The driving and lifting functions, as well as the auxiliary functions, are released.

7 Driver seat lock t Horizontal adjustment of the driver seat.8 Driver seat weight

adjustmentt Setting of driver weight for optimum seat damping.

9 Backrest adjustment t Adjustment of the driver seat backrest.10 Steering column adju-

sting mechanismt Steering column is adjusted to distance.

11 Parking brake t Prevents the truck from moving when parked.12 Battery trolley unlok-

king systemt Unlocks the battery trolley.

13 Key switch with key t For connection and disconnection of the battery voltage to the truck.– Red key (No. 702):

for the user– Grey key (No. 738):

for service and workshop14 Switch -

cut-back speedt Switches cut-back speed on and off.


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2 Description of the operating controls and indicators


Function

1 Control lever„Inclining of mast“

t Operates the following function:– Tilting the hoist frame forward / backward

2 Control lever„Inclining of fork“

t Operates the following function:– Pushing forward / retracting the mast holder

3 Solo-pilot t Operates the following functions:– Forward / reverse drive direction– Lifting / lowering the load lifting device– Moving the lateral traversing device to the left /

right (o)– Horn key

4 Accelerator t Stepless control of the truck travelling speed.5 Brake pedal t Braking of the truck.6 Foot key t – not pressed:

The driving and lifting functions, as well as the auxiliary functions, are locked. The lowering function remains functional. The truck rolls to a stop.

– pressed:The driving and lifting functions, as well as the auxiliary functions, are released.

7 Driver seat lock t Horizontal adjustment of the driver seat.8 Driver seat weight

adjustmentt Setting of driver weight for optimum seat damping.

9 Backrest adjustment t Adjustment of the driver seat backrest.10 Steering column adju-

sting mechanismt Steering column is adjusted to distance.

11 Parking brake t Prevents the truck from moving when parked.12 Battery trolley unlok-

king systemt Unlocks the battery trolley.

13 Key switch with key t For connection and disconnection of the battery voltage to the truck.– Red key (No. 702):

for the user– Grey key (No. 738):

for service and workshop14 Switch -

cut-back speedt Switches cut-back speed on and off.


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Function

15 Master switch (emergency stop)

t The power circuit is interrupted and all electrical functions are switched off.

16 Information and ser-vice display (LISA)

t Display of essential driving parameters, lifting para-meters, warning signals, operating error indications and service indications (refer to section 5).

17 Control lever ZH 2 o Controls the second auxiliary hydraulic system.


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Function

15 Master switch (emergency stop)

t The power circuit is interrupted and all electrical functions are switched off.

16 Information and ser-vice display (LISA)

t Display of essential driving parameters, lifting para-meters, warning signals, operating error indications and service indications (refer to section 5).

17 Control lever ZH 2 o Controls the second auxiliary hydraulic system.


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3 Start-up of truck

F The driver must make sure that nobody is within the danger area of the truck, beforethe truck is switched on or operated, or before a load is lifted.

Checks and operations to be performed before starting daily work

– Visually check the entire truck (especially the wheels and load devices) for dama-ges and wear.

– Check the load chains for uniform tension.– Visually check the security of the battery and the cable connections.

Adjusting the driver seat

Z To ensure optimum shock absorption, the driver seat must be adjusted to the weightof the driver.The driver seat must not be occupied while being adjusted to the driver weight.

Setting the driver weight:

– Pull the lever (8) in the direction indi-cated by the arrow and release itagain.

Z The previously set driver weight is resetto the minimum value. Setting range for the shock absorption:50 kg to 130 kg.

– Pull the lever (8) again in the directionindicated indicated by the arrow untilreaching the appropriate weight markon the scale (18). Then release thelever again.

– Sit down on the driver seat.

F Do not reach between the seat and the chassis wall/overhead guard.

Adjusting the backrest:

– Pull the locking lever (9) upward and adjust the inclination of the backrest (19).– Release the locking lever again, the backrest is locked in position.

Adjusting the seat position:

– Pull the locking lever (7) of the driver’s seat adjustment up in direction of the arrowand slide the seat backwards or forwards into the desired seating position.

– Let the locking lever (7) engage again.

F The driver seat locking system must be properly engaged in the set position. Theposition of the seat must not be changed while driving!

Z The driver seat adjusting mechanism shown relates to the standard version. For alldifferent designs the adjusting instructions as supplied by the manufacturer apply.When performing the seat adjustments, ensure that all operating controls are withineasy reach.

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3 Start-up of truck

F The driver must make sure that nobody is within the danger area of the truck, beforethe truck is switched on or operated, or before a load is lifted.

Checks and operations to be performed before starting daily work

– Visually check the entire truck (especially the wheels and load devices) for dama-ges and wear.

– Check the load chains for uniform tension.– Visually check the security of the battery and the cable connections.

Adjusting the driver seat

Z To ensure optimum shock absorption, the driver seat must be adjusted to the weightof the driver.The driver seat must not be occupied while being adjusted to the driver weight.

Setting the driver weight:

– Pull the lever (8) in the direction indi-cated by the arrow and release itagain.

Z The previously set driver weight is resetto the minimum value. Setting range for the shock absorption:50 kg to 130 kg.

– Pull the lever (8) again in the directionindicated indicated by the arrow untilreaching the appropriate weight markon the scale (18). Then release thelever again.

– Sit down on the driver seat.

F Do not reach between the seat and the chassis wall/overhead guard.

Adjusting the backrest:

– Pull the locking lever (9) upward and adjust the inclination of the backrest (19).– Release the locking lever again, the backrest is locked in position.

Adjusting the seat position:

– Pull the locking lever (7) of the driver’s seat adjustment up in direction of the arrowand slide the seat backwards or forwards into the desired seating position.

– Let the locking lever (7) engage again.

F The driver seat locking system must be properly engaged in the set position. Theposition of the seat must not be changed while driving!

Z The driver seat adjusting mechanism shown relates to the standard version. For alldifferent designs the adjusting instructions as supplied by the manufacturer apply.When performing the seat adjustments, ensure that all operating controls are withineasy reach.

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– Loosen the steering column locking(10) and adjust steering wheel (20) todesired position.

– Tighten steering column locking me-chanism.

Switching on the truck

– Pull up the master switch (15).– Insert the key in the key switch (13)

and turn clockwise against the stop toposition "I".

– Check the horn for proper function.– Check the brake pedal and the par-

king brake for correct functioning(refer to section 4.2).

The truck is now ready for operation.The battery discharge monitor shows the current battery capacity.

3.1 How to use the safety belt o

– Read this section completely beforestarting up the floor conveyor.

– Fasten the belt before performing anymovement of the floor conveyor.

– Adjust the belt height setting (49)according to your size.

F The belt protects you against severeinjuries.

– If the belt buckle (47) or the belt reel-up device is frozen in, let it thaw anddry.

M The temperature of the warm air-streammust not exceed +60°C.

F Do not modify the safety belt.

– After an accident has occurred, checkthe safety belt and the seating coverfor damages. Exchange them, if requi-red.

– Damaged or not fully functioning safe-ty belts may only be exchanged bycontract dealers or branches.

– Only original spare parts may be usedfor upgrading or repairs.

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Adjusting the steering column

– Loosen the steering column locking(10) and adjust steering wheel (20) todesired position.

– Tighten steering column locking me-chanism.

Switching on the truck

– Pull up the master switch (15).– Insert the key in the key switch (13)

and turn clockwise against the stop toposition "I".

– Check the horn for proper function.– Check the brake pedal and the par-

king brake for correct functioning(refer to section 4.2).

The truck is now ready for operation.The battery discharge monitor shows the current battery capacity.

3.1 How to use the safety belt o

– Read this section completely beforestarting up the floor conveyor.

– Fasten the belt before performing anymovement of the floor conveyor.

– Adjust the belt height setting (49)according to your size.

F The belt protects you against severeinjuries.

– If the belt buckle (47) or the belt reel-up device is frozen in, let it thaw anddry.

M The temperature of the warm air-streammust not exceed +60°C.

F Do not modify the safety belt.

– After an accident has occurred, checkthe safety belt and the seating coverfor damages. Exchange them, if requi-red.

– Damaged or not fully functioning safe-ty belts may only be exchanged bycontract dealers or branches.

– Only original spare parts may be usedfor upgrading or repairs.

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Behaviour in unusual situations

M Proceed as follows, if there is danger of the floor conveyor tipping over.

– Press the upper part of your body against the the backrest.

– Keep both hands at the steering wheel and use your feed foradditional support.

– Bend your body against the falling direction.

Operating instruction of the safety belt

Before starting up the floor conveyor, pull the belt continuously out of the reel-updevice and let it catch in with the belt fitting tight to your body.

F The belt must not be twisted when being fastened.

When operating the floor conveyor (e.g. driving, lifting, lowering,etc.) always try to sit with your back having contact with thebackrest.

The locking mechanism of the reel-up device permits enoughfreedom of motion when sitting.

F If you are sitting on the front edge of the seat, protecton willdecrease due to the belt band being too loose.

Z Use the belt only for protecting one person.

– After using the belt, press the red button and direct the beltlocking tongue back to the reel-up device with your hand.

Behaviour for starting up the floor conveyor on steep slopes

The locking mechanism blocks the belt drawing mechanism if the floor conveyor isparked on a steep slope. The belt can no longer be pulled out of the reel-up device.

Z Drive the floor conveyor carefully out of its slope position and fasten the belt.

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Behaviour in unusual situations

M Proceed as follows, if there is danger of the floor conveyor tipping over.

– Press the upper part of your body against the the backrest.

– Keep both hands at the steering wheel and use your feed foradditional support.

– Bend your body against the falling direction.

Operating instruction of the safety belt

Before starting up the floor conveyor, pull the belt continuously out of the reel-updevice and let it catch in with the belt fitting tight to your body.

F The belt must not be twisted when being fastened.

When operating the floor conveyor (e.g. driving, lifting, lowering,etc.) always try to sit with your back having contact with thebackrest.

The locking mechanism of the reel-up device permits enoughfreedom of motion when sitting.

F If you are sitting on the front edge of the seat, protecton willdecrease due to the belt band being too loose.

Z Use the belt only for protecting one person.

– After using the belt, press the red button and direct the beltlocking tongue back to the reel-up device with your hand.

Behaviour for starting up the floor conveyor on steep slopes

The locking mechanism blocks the belt drawing mechanism if the floor conveyor isparked on a steep slope. The belt can no longer be pulled out of the reel-up device.

Z Drive the floor conveyor carefully out of its slope position and fasten the belt.

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4 Truck operation

4.1 Safety regulations applicable when operating the truck

Driving lanes and work areas: Only such lanes and routes that are specially alloca-ted for truck traffic must be used. Unauthorized persons must stay away from workareas. Loads must only be stored at places specially provided for this purpose.

Driving conduct: The travelling speed must be adapted to the prevailing local con-ditions. The truck must be driven at slow speed when negotiating bends or narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways observe an adequate braking distance between his truck and the vehicle in frontand he must be in control of his truck at all times. Sudden stopping (except in emer-gencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. Itis forbidden to lean out of or reach beyond the working and operating area. It is for-bidden to carry passengers or lift personnel.

Visibility: The driver must look in the direction of travel and must always have a clearview of the route ahead. When loads blocking the view are carried, the must be drivenwith the load at the rear. If this is not possible, a second person must walk in front ofthe truck to give suitable warnings.

Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted on-ly, when they are recognized lanes, when they are clean and non-slipping, and whenthe technical specification of the truck permits safe driving on such slopes or inclines.Loads must always be carried at that end of the truck facing uphill. U-turns, cuttingobliquely over slopes or inclines and parking of the truck on slopes or inclines is notpermitted. Inclines must only be negotiated at slow speed with the driver ready to bra-ke at any moment.

Use of lifts and driving on loading platforms: Lifts and loading platforms must onlybe used, if they are of adequate load bearing capacity, if suitable for driving on, andif authorized by the user of the truck for truck traffic. The truck driver has to satisfyhimself accordingly before driving into lifts or on to loading platforms. The truck mustenter lifts with the load in front and must take up a position which does not allow it tocome into contact with the walls of the lift shaft. Persons riding in the lift together withthe truck must only enter the lift after the truck has come safely to a standstill, andmust leave the lift before the truck.

Nature of the loads carried: Only loads that have been safely and correctly securedmust be carried. Never transport loads stacked higher than the top of the fork carria-ge, or stacked higher than the guard grille.

Towing trailers: Do not exceed the maximum trailer load specified for the forklifttruck for trailers with or without brakes. The trailer load must be properly secured andmust not exceed the dimensions permitted for the driveway. After attaching the trailerand before driving, the driver must check that the attachment coupling cannotbecome detached. Towing forklift trucks must be operated in such a manner that thesafe driving and braking of the truck and trailer can be guaranteed at all times.

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4 Truck operation

4.1 Safety regulations applicable when operating the truck

Driving lanes and work areas: Only such lanes and routes that are specially alloca-ted for truck traffic must be used. Unauthorized persons must stay away from workareas. Loads must only be stored at places specially provided for this purpose.

Driving conduct: The travelling speed must be adapted to the prevailing local con-ditions. The truck must be driven at slow speed when negotiating bends or narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways observe an adequate braking distance between his truck and the vehicle in frontand he must be in control of his truck at all times. Sudden stopping (except in emer-gencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. Itis forbidden to lean out of or reach beyond the working and operating area. It is for-bidden to carry passengers or lift personnel.

Visibility: The driver must look in the direction of travel and must always have a clearview of the route ahead. When loads blocking the view are carried, the must be drivenwith the load at the rear. If this is not possible, a second person must walk in front ofthe truck to give suitable warnings.

Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted on-ly, when they are recognized lanes, when they are clean and non-slipping, and whenthe technical specification of the truck permits safe driving on such slopes or inclines.Loads must always be carried at that end of the truck facing uphill. U-turns, cuttingobliquely over slopes or inclines and parking of the truck on slopes or inclines is notpermitted. Inclines must only be negotiated at slow speed with the driver ready to bra-ke at any moment.

Use of lifts and driving on loading platforms: Lifts and loading platforms must onlybe used, if they are of adequate load bearing capacity, if suitable for driving on, andif authorized by the user of the truck for truck traffic. The truck driver has to satisfyhimself accordingly before driving into lifts or on to loading platforms. The truck mustenter lifts with the load in front and must take up a position which does not allow it tocome into contact with the walls of the lift shaft. Persons riding in the lift together withthe truck must only enter the lift after the truck has come safely to a standstill, andmust leave the lift before the truck.

Nature of the loads carried: Only loads that have been safely and correctly securedmust be carried. Never transport loads stacked higher than the top of the fork carria-ge, or stacked higher than the guard grille.

Towing trailers: Do not exceed the maximum trailer load specified for the forklifttruck for trailers with or without brakes. The trailer load must be properly secured andmust not exceed the dimensions permitted for the driveway. After attaching the trailerand before driving, the driver must check that the attachment coupling cannotbecome detached. Towing forklift trucks must be operated in such a manner that thesafe driving and braking of the truck and trailer can be guaranteed at all times.

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4.2 Driving, steering, brakingEmergency cut-out

– Depress the master switch (15).

This will switch off all electric functions.Functioning of the switch must not be af-fected by object placed on it.

Driving

F Do not drive the truck unless the hoodsare closed and locked in the stipulatedmanner.The main direction of travel is in the di-rection of the drive (V). Be especially ca-reful when driving in the direction of theload (R).

Z The truck should only be driven in the direction of the load (R) for positioning purpo-ses and for picking up or depositing loads.

– Render truck ready for operation (refer to section 3).– Release the parking brake (11).– Set the travel direction switch (21) to the desired travelling direction (V) or (R).– Press the accelerator pedal (4) and the foot key (6).

The truck will now move in the selected direction.

F The foot key (6) prevents the operator's foot from protuding beyond the truck's con-tour while driving. If it is not pressed, all electrical functions except for the steering,the information and service display (LISA), the horn and the battery discharge indica-tor are deactivated. The truck coasts to a stop in accordance with the parameter setfor the “coasting brake”. The lowering function remains functional.

Z The travelling speed is controlled by means of the accelerator (4).

o Douple-pedal version

Driving

Floor conveyors from the double-pedalseries are provided with two pedalswhich can be used for selecting the dri-ving direction. They can also be used forregulating the driving speed.

Driving pedal 47: Driving in fork direc-tion.

Driving pedal 48: Driving in actuation di-rection.

When driving, both feet are to kept onthe pedals.

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4.2 Driving, steering, brakingEmergency cut-out

– Depress the master switch (15).

This will switch off all electric functions.Functioning of the switch must not be af-fected by object placed on it.

Driving

F Do not drive the truck unless the hoodsare closed and locked in the stipulatedmanner.The main direction of travel is in the di-rection of the drive (V). Be especially ca-reful when driving in the direction of theload (R).

Z The truck should only be driven in the direction of the load (R) for positioning purpo-ses and for picking up or depositing loads.

– Render truck ready for operation (refer to section 3).– Release the parking brake (11).– Set the travel direction switch (21) to the desired travelling direction (V) or (R).– Press the accelerator pedal (4) and the foot key (6).

The truck will now move in the selected direction.

F The foot key (6) prevents the operator's foot from protuding beyond the truck's con-tour while driving. If it is not pressed, all electrical functions except for the steering,the information and service display (LISA), the horn and the battery discharge indica-tor are deactivated. The truck coasts to a stop in accordance with the parameter setfor the “coasting brake”. The lowering function remains functional.

Z The travelling speed is controlled by means of the accelerator (4).

o Douple-pedal version

Driving

Floor conveyors from the double-pedalseries are provided with two pedalswhich can be used for selecting the dri-ving direction. They can also be used forregulating the driving speed.

Driving pedal 47: Driving in fork direc-tion.

Driving pedal 48: Driving in actuation di-rection.

When driving, both feet are to kept onthe pedals.

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When the steering wheel is actuated, the steering booster is automatically switchedon and the position of the drive wheel is set accordingly.

t Contradirectional steering (standard version)When travelling forward (travel direction switch (21) set to V = drive direction), turningthe steering wheel to the left results in a left turn and turning the wheel to the right ina right turn.

o Synchronized steeringWhen travelling forward (travel direction switch (21) set to V = drive direction), turningthe steering wheel to the left results in a right turn and turning the wheel to the rightto a left turn.

Braking

Z The braking behaviour of the truck strongly depends on the state of the floor. Thismust be taken into account by the driver for his driving behaviour.

The truck can be braked in three ways:

– by counter-current braking,– by coasting, or by– using the service brake.

F If the truck is operated by several drivers(for instance in multi-shift operations),the braking and travelling behaviour ofthe truck must be checked, when the pa-rameters are individually set. Check thetruck reactions when taking over thetruck.

Counter-current braking:

– Change over the travelling directionswitch (21) during travel to the opposi-te driving direction. The truck is thenbraked by the drive current control sy-stem until movement in the oppositedirection commences.

Z This mode of braking reduces energy consumption, as it involves energy recovery viathe drive current control system.

Braking by coasting:

– Slowly release the accelerator pedal while driving. The truck is braked by the drivecurrent control according to the position of the accelerator pedal.

Braking using the service brake:

– Depress the brake pedal (5).

Z The truck is hydraulically braked by means of a drum brake and two load-bearingwheel brakes.

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Steering

When the steering wheel is actuated, the steering booster is automatically switchedon and the position of the drive wheel is set accordingly.

t Contradirectional steering (standard version)When travelling forward (travel direction switch (21) set to V = drive direction), turningthe steering wheel to the left results in a left turn and turning the wheel to the right ina right turn.

o Synchronized steeringWhen travelling forward (travel direction switch (21) set to V = drive direction), turningthe steering wheel to the left results in a right turn and turning the wheel to the rightto a left turn.

Braking

Z The braking behaviour of the truck strongly depends on the state of the floor. Thismust be taken into account by the driver for his driving behaviour.

The truck can be braked in three ways:

– by counter-current braking,– by coasting, or by– using the service brake.

F If the truck is operated by several drivers(for instance in multi-shift operations),the braking and travelling behaviour ofthe truck must be checked, when the pa-rameters are individually set. Check thetruck reactions when taking over thetruck.

Counter-current braking:

– Change over the travelling directionswitch (21) during travel to the opposi-te driving direction. The truck is thenbraked by the drive current control sy-stem until movement in the oppositedirection commences.

Z This mode of braking reduces energy consumption, as it involves energy recovery viathe drive current control system.

Braking by coasting:

– Slowly release the accelerator pedal while driving. The truck is braked by the drivecurrent control according to the position of the accelerator pedal.

Braking using the service brake:

– Depress the brake pedal (5).

Z The truck is hydraulically braked by means of a drum brake and two load-bearingwheel brakes.

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4.3 Adjusting the fork tines

F To ensure safe picking up of loads, thetines should be apart as far as possibleand set centrally to the truck. The loadcentre must be located centrally bet-ween the fork tines.

– Swivel the locking lever (22) upwards.– Push the fork tines (23) along the fork

carrier (24) to the required position.– Swivel the locking lever downwards

and deplace the fork until it engages agroove.

4.4 Picking up and setting down loads

M Before picking up a load, the driver hasto check that the load rests properly onits pallet and that it does not exceed thecapacity of his truck.

– Pass the fork tines as far as possibleunder the load.

Lifting

F Persons must not be allowed to standunder raised forks.

– Pull the solo-pilot (3) in the H direction.

Z The inclination angle of the control levercontrols the lifting speed.

– Do not release the solo-pilot until thedesired lifting height has been rea-ched.

Z If the fork moves against the end stop(audible noise emitted by the pressurelimiting valve), the multi-pilot stick mustimmediately be returned to its neutralposition.

Lowering

– Push the solo-pilot (3) in the S direction.

Z The inclination angle of the solo-pilot controls the lowering speed.

M Avoid impacting of the load to prevent damage to the load and to the racking.

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4.3 Adjusting the fork tines

F To ensure safe picking up of loads, thetines should be apart as far as possibleand set centrally to the truck. The loadcentre must be located centrally bet-ween the fork tines.

– Swivel the locking lever (22) upwards.– Push the fork tines (23) along the fork

carrier (24) to the required position.– Swivel the locking lever downwards

and deplace the fork until it engages agroove.

4.4 Picking up and setting down loads

M Before picking up a load, the driver hasto check that the load rests properly onits pallet and that it does not exceed thecapacity of his truck.

– Pass the fork tines as far as possibleunder the load.

Lifting

F Persons must not be allowed to standunder raised forks.

– Pull the solo-pilot (3) in the H direction.

Z The inclination angle of the control levercontrols the lifting speed.

– Do not release the solo-pilot until thedesired lifting height has been rea-ched.

Z If the fork moves against the end stop(audible noise emitted by the pressurelimiting valve), the multi-pilot stick mustimmediately be returned to its neutralposition.

Lowering

– Push the solo-pilot (3) in the S direction.

Z The inclination angle of the solo-pilot controls the lowering speed.

M Avoid impacting of the load to prevent damage to the load and to the racking.

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F The fork must be free before they can be lowered from the rack.Do not start before the fork is completely lowered.

Pushing the mast holder forward

F Do not reach between the mast and thebattery hood.

– Tilt the control lever (2) in the T direc-tion to push the mast holder forwardand in the U direction to retract it.

Z The inclination angle of the control levercontrols the traversing speed.

F Transport runs with or without load mustonly be performed with the mast holderretracted, the hoist frame tilted back-wards and the load lifting device lowe-red.

Mast tilting

– Move control lever (1) in direction (V)for front inclining and in direction (R)for back inclining.

U

T

2

R

V

1

E 13

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F The fork must be free before they can be lowered from the rack.Do not start before the fork is completely lowered.

Pushing the mast holder forward

F Do not reach between the mast and thebattery hood.

– Tilt the control lever (2) in the T direc-tion to push the mast holder forwardand in the U direction to retract it.

Z The inclination angle of the control levercontrols the traversing speed.

F Transport runs with or without load mustonly be performed with the mast holderretracted, the hoist frame tilted back-wards and the load lifting device lowe-red.

Mast tilting

– Move control lever (1) in direction (V)for front inclining and in direction (R)for back inclining.

U

T

2

R

V

1

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4.5 Picking up, lifting and transporting of loads

– Tilt the control lever (1) in the V or the R direction to bring the fork tines into a hori-zontal position.

– Move the truck up to the load.– Tilt the control lever (2) in the T direction to push the mast holder forward.– Pull the solo-pilot (3) in the H direction to lift the fork tines to the appropriate height.– Move the fork tines under the load.– Pull the solo-pilot (3) in the H direction to lift the load clear.– Tilt the control lever (2) in the U direction to retract the mast holder.

F Transport runs with or without load must only be performed with the mast holder re-tracted, the hoist frame tilted backwards and the load lifting device lowered.

– Press the solo-pilot (3) in the S dir. to lower the load to the transport position. – Pull the control lever in the R direction to tilt the load backward.– Transport the load to the required location.– Press the control lever (1) in the V direction to bring the load into the horizontal po-

sition.– Bring load to the desired height: Pull the solo-pilot (3) the H direction, if necessary,

tilt the control lever (2) the T direction in order to extraxt the mast holder. – Press the solo-pilot (3) in the S direction to set down the load.– Pull the control lever (2) in the U direction to retract the mast holder.

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4.5 Picking up, lifting and transporting of loads

– Tilt the control lever (1) in the V or the R direction to bring the fork tines into a hori-zontal position.

– Move the truck up to the load.– Tilt the control lever (2) in the T direction to push the mast holder forward.– Pull the solo-pilot (3) in the H direction to lift the fork tines to the appropriate height.– Move the fork tines under the load.– Pull the solo-pilot (3) in the H direction to lift the load clear.– Tilt the control lever (2) in the U direction to retract the mast holder.

F Transport runs with or without load must only be performed with the mast holder re-tracted, the hoist frame tilted backwards and the load lifting device lowered.

– Press the solo-pilot (3) in the S dir. to lower the load to the transport position. – Pull the control lever in the R direction to tilt the load backward.– Transport the load to the required location.– Press the control lever (1) in the V direction to bring the load into the horizontal po-

sition.– Bring load to the desired height: Pull the solo-pilot (3) the H direction, if necessary,

tilt the control lever (2) the T direction in order to extraxt the mast holder. – Press the solo-pilot (3) in the S direction to set down the load.– Pull the control lever (2) in the U direction to retract the mast holder.

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4.6 Operating an attachment

o Lateral traversing device

Z The directions „to the left“ and „to theright“ refer to the load lifting device asseen from the operator’s position.

Moving the lateral traversing device tothe left:

– Press the switch (21) in the X1 direc-tion.

Moving the lateral traversing device tothe right:

– Press the switch (21) in the Y1 direc-tion.

F Reduced capacity must be taken into ac-count when traversing of load is required(refer to chapter B).

o Hydraulic attachments

The control lever (17) controlling the functions (X2) and (Y2) is provided for the ope-ration of a hydraulic attachment.(Refer to the operating instructions provided by the manufacturer).

F Check the capacity of the respective attachment.

F Observe load chart for the truck with attachment and the truck and attachment ope-rator manuals.

– The attachment must only be operated by trained and authorised personnel.– Any operation that could affect safety must be prohibited.– The attachment must only be operated when fully functional.– Check the attachment for visible signs of damage at least once a shift.– Report any signs of damage immediately.

21 17

Y1

Y2

X1

X2

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4.6 Operating an attachment

o Lateral traversing device

Z The directions „to the left“ and „to theright“ refer to the load lifting device asseen from the operator’s position.

Moving the lateral traversing device tothe left:

– Press the switch (21) in the X1 direc-tion.

Moving the lateral traversing device tothe right:

– Press the switch (21) in the Y1 direc-tion.

F Reduced capacity must be taken into ac-count when traversing of load is required(refer to chapter B).

o Hydraulic attachments

The control lever (17) controlling the functions (X2) and (Y2) is provided for the ope-ration of a hydraulic attachment.(Refer to the operating instructions provided by the manufacturer).

F Check the capacity of the respective attachment.

F Observe load chart for the truck with attachment and the truck and attachment ope-rator manuals.

– The attachment must only be operated by trained and authorised personnel.– Any operation that could affect safety must be prohibited.– The attachment must only be operated when fully functional.– Check the attachment for visible signs of damage at least once a shift.– Report any signs of damage immediately.

21 17

Y1

Y2

X1

X2

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4.7 Rendering truck safe when parking

When the truck is parked and left unattended, it has to be rendered safe, even if it isleft unattended for only a short period of time.

F Never park the truck on a slope or incline. The load lifting device must always be com-pletely lowered.

– Press the parking brake switch (11).– Completely lower the load lifting

device and move it to a horizontalposition.

– Completely retract the mast holder.– Depress the master switch (15) to the

position „OFF“.– Switch the key switch (13) to the posi-

tion „0“ and remove the key from thekey switch.

1513

11

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4.7 Rendering truck safe when parking

When the truck is parked and left unattended, it has to be rendered safe, even if it isleft unattended for only a short period of time.

F Never park the truck on a slope or incline. The load lifting device must always be com-pletely lowered.

– Press the parking brake switch (11).– Completely lower the load lifting

device and move it to a horizontalposition.

– Completely retract the mast holder.– Depress the master switch (15) to the

position „OFF“.– Switch the key switch (13) to the posi-

tion „0“ and remove the key from thekey switch.

1513

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5 Information and service display (LISA)

The display (25) of the LCD information and service display (LISA) shows the opera-tion data, the battery charge, the service hours as well as service data and diagnosti-cal data. Below the display there are six LEDs (26) - (31). The keyboard (four keys(32) - (35) serves for the selection, the reading and the modification of vehicle para-meters.

Z The vehicle is delivered with two different keys:for the user Key code: 702 (red):

Use of vehicle possible,LISA only displays current driving data.

for service / workshop Key code: 738 (grey):Use of vehicle possible,LISA allows modifications of vehicleparameters in the user mode(see section 5.4).

M Modifications in the service mode must only be performed by authorized service per-sonnel of the manufacturer!

26 27 28 29 30 31 32 33 34 35

25

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5 Information and service display (LISA)

The display (25) of the LCD information and service display (LISA) shows the opera-tion data, the battery charge, the service hours as well as service data and diagnosti-cal data. Below the display there are six LEDs (26) - (31). The keyboard (four keys(32) - (35) serves for the selection, the reading and the modification of vehicle para-meters.

Z The vehicle is delivered with two different keys:for the user Key code: 702 (red):

Use of vehicle possible,LISA only displays current driving data.

for service / workshop Key code: 738 (grey):Use of vehicle possible,LISA allows modifications of vehicleparameters in the user mode(see section 5.4).

M Modifications in the service mode must only be performed by authorized service per-sonnel of the manufacturer!

26 27 28 29 30 31 32 33 34 35

25

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5.1 LED warning lamps

Six red light-emitting diodes indicate the following states:

5.2 Key assignment

Item Function

26 Direction of motion forward (drive direction) (green LED)

27 Parking brake applied (red LED)

28 Direction of motion backward (load direction) (green LED)

29 Brake liquid level too low (red LED)

30 Lateral traversing device in center position (green LED)

31 Battery unlocked (red LED)

Item Function

32Double function- incremental increase of the selected parameter- selection of the individual menu items in ascending order

33Double function - incremental decrease of the selected parameter- selection of the individual menu items in descending order

34Double function - release of a selection menu from the main menu - acknowledging a query with "NO" -> "x"

35

Quadruple function– exiting from a selected menu point – storing of modified parameters – acknowledging a query with "YES" -> "q"– display change between „service hours“ / „time“

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5.1 LED warning lamps

Six red light-emitting diodes indicate the following states:

5.2 Key assignment

Item Function

26 Direction of motion forward (drive direction) (green LED)

27 Parking brake applied (red LED)

28 Direction of motion backward (load direction) (green LED)

29 Brake liquid level too low (red LED)

30 Lateral traversing device in center position (green LED)

31 Battery unlocked (red LED)

Item Function

32Double function- incremental increase of the selected parameter- selection of the individual menu items in ascending order

33Double function - incremental decrease of the selected parameter- selection of the individual menu items in descending order

34Double function - release of a selection menu from the main menu - acknowledging a query with "NO" -> "x"

35

Quadruple function– exiting from a selected menu point – storing of modified parameters – acknowledging a query with "YES" -> "q"– display change between „service hours“ / „time“

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5.3 Displays

The display shows operating data and fault messages. The user menu permits thesetting of the following driving parameters:

Here the time between maximum actua-tion of the driving pedal and 100% com-pensation of the electronics is set.

When releasing the driving pedal thebraking process is initiated by the drivecurrent control system. The value is bet-ween 0% (rolling to a standstill) and amax. value, which is equal to the mini-mum value for counter-current braking.

The setting of the counter-current brakeaffects braking when changing direction.Actual braking when changing directionis also a function of the accelerator posi-tion.

Adjustment of maximum speed in drivewheel direction af motion.

Adjustment of maximum speed in drivewheel direction af motion when actua-ting the slow speed switch.

Adjustment of maximum speed in loadpart direction af motion.

Adjustment of maximum speed in loadpart direction af motion when actuatingthe slow speed switch.

Issues an acoustic alarm in case of ope-rating errors.

Preset values can be called up and adju-sted.

Time adjustment.Select hour or minute with key 34.Modify adjustment with keys 32 and 33.

A C C E L E R A T I O NL

R E L E A S E B R A K EL

I N V E R S I O N B R A K EL

M A X . S P E E D F O R W .L

C U T B A C K F O R W .L

M A X R E V E R S . S P E E DL

C U T B A C K R E V E R S .L

B U Z Z E R O N / O F FO F F L

R E L O A DL

C H A N G E T I M E1 2 : 2 2

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5.3 Displays

The display shows operating data and fault messages. The user menu permits thesetting of the following driving parameters:

Here the time between maximum actua-tion of the driving pedal and 100% com-pensation of the electronics is set.

When releasing the driving pedal thebraking process is initiated by the drivecurrent control system. The value is bet-ween 0% (rolling to a standstill) and amax. value, which is equal to the mini-mum value for counter-current braking.

The setting of the counter-current brakeaffects braking when changing direction.Actual braking when changing directionis also a function of the accelerator posi-tion.

Adjustment of maximum speed in drivewheel direction af motion.

Adjustment of maximum speed in drivewheel direction af motion when actua-ting the slow speed switch.

Adjustment of maximum speed in loadpart direction af motion.

Adjustment of maximum speed in loadpart direction af motion when actuatingthe slow speed switch.

Issues an acoustic alarm in case of ope-rating errors.

Preset values can be called up and adju-sted.

Time adjustment.Select hour or minute with key 34.Modify adjustment with keys 32 and 33.

A C C E L E R A T I O NL

R E L E A S E B R A K EL

I N V E R S I O N B R A K EL

M A X . S P E E D F O R W .L

C U T B A C K F O R W .L

M A X R E V E R S . S P E E DL

C U T B A C K R E V E R S .L

B U Z Z E R O N / O F FO F F L

R E L O A DL

C H A N G E T I M E1 2 : 2 2

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5.4 Changing truck parameters

F Changing of truck parameters will also change the driving behaviour of the truck. Thismust be taken into account when commissioning the truck! Parameters may only be changed while the truck is at a standstill and no liftingmovements are performed.

– Commission the truck (refer to section 3).Insert key (738) into key switch and turn to the right until reaching the limit stop.

The display shows the user menu with vehicle name for about three seconds, afterthat the battery charge and the service hours are indicated.

– Press the selection menu key (34).

The display shows „acceleration“ with the corresponding parameter.

– To view or change the truck parameters, proceed in accordance with the followingdiagram.

– Moving between the 10 setting parameters is effected by means of the keys (32)and (33).

1) L = Operating parameters are read out (Reading mode)2) S = The chosen operational parameter can be modified (Writing mode)3) Service hours display4) Time display5) Selection of parameters6) Changing parameters

no

AccelerationL1)

Release brake

Change timeXX:XX

Inversion brake

Maximum speedforward

Cut-back speedforward

Maximum reversingspeed

Cut-back speedreversing

Buzzer on/offOFF

AccelerationS2)

Release brake

Change timeXX:XX

Inversion brake





Buzzer on/offON/OFF

Are yousure?

yes

BATT xxx % xxh 3) BATT xxx % xx:xx 4)

Default setting“Travel” default values


5) 6)

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5.4 Changing truck parameters

F Changing of truck parameters will also change the driving behaviour of the truck. Thismust be taken into account when commissioning the truck! Parameters may only be changed while the truck is at a standstill and no liftingmovements are performed.

– Commission the truck (refer to section 3).Insert key (738) into key switch and turn to the right until reaching the limit stop.

The display shows the user menu with vehicle name for about three seconds, afterthat the battery charge and the service hours are indicated.

– Press the selection menu key (34).

The display shows „acceleration“ with the corresponding parameter.

– To view or change the truck parameters, proceed in accordance with the followingdiagram.

– Moving between the 10 setting parameters is effected by means of the keys (32)and (33).

1) L = Operating parameters are read out (Reading mode)2) S = The chosen operational parameter can be modified (Writing mode)3) Service hours display4) Time display5) Selection of parameters6) Changing parameters

no

AccelerationL1)

Release brake

Change timeXX:XX

Inversion brake





Buzzer on/offOFF

AccelerationS2)

Release brake

Change timeXX:XX

Inversion brake





Buzzer on/offON/OFF

Are yousure?

yes

BATT xxx % xxh 3) BATT xxx % xx:xx 4)



5) 6)

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6 Fault locating operations

This chapter enables the user to locate and to remedy simple faults or the conse-quences of operating errors. Fault locating operations should be performed in the or-der as set out in the table below.

Z If the fault could not be eliminated after performing the „troubleshooting procedures"„,contact the customer service of the manufacturer since all follow-up troubleshootingcan only be performed by specially trained and qualified service staff.

Fault Possible cause RemedyTruck does not move

Battery connector not connected

Check the battery connector, or con-nect, if required

Master switch depressed Release the master switchKey switch in position „0“ Switch the key switch to position „I“Battery charge too low Check the charge condition of the

battery and recharge if requiredDefective fuse Check fusesParking brake applied Release the parking brakeFoot switch not pressed Press foot switch

Load cannot be raised

Truck not operative Perform all remedial actions indica-ted under fault „Truck does not mo-ve“

Hydraulic oil level too low

Check the hydraulic oil level

Battery charge too low,lift cut-out active

Check the charge condition of the battery and recharge if required

Defective fuse Check fusesLoad too high Comply with maximum load

(see nameplate)

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6 Fault locating operations

This chapter enables the user to locate and to remedy simple faults or the conse-quences of operating errors. Fault locating operations should be performed in the or-der as set out in the table below.

Z If the fault could not be eliminated after performing the „troubleshooting procedures"„,contact the customer service of the manufacturer since all follow-up troubleshootingcan only be performed by specially trained and qualified service staff.

Fault Possible cause RemedyTruck does not move

Battery connector not connected

Check the battery connector, or con-nect, if required

Master switch depressed Release the master switchKey switch in position „0“ Switch the key switch to position „I“Battery charge too low Check the charge condition of the

battery and recharge if requiredDefective fuse Check fusesParking brake applied Release the parking brakeFoot switch not pressed Press foot switch

Load cannot be raised

Truck not operative Perform all remedial actions indica-ted under fault „Truck does not mo-ve“

Hydraulic oil level too low

Check the hydraulic oil level

Battery charge too low,lift cut-out active

Check the charge condition of the battery and recharge if required

Defective fuse Check fusesLoad too high Comply with maximum load

(see nameplate)

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7 Auxiliary electrical systems

7.1 Seat heating

Z All auxiliary electrical systems are activated regardless of the key switch position. Thebattery master switch must have been switched on (see section 3, “Switching on thetruck”). To prevent discharge of the battery after the truck has been parked, always heed sec-tion 4.7, “Rendering vehicle safe when parking”.

7.2 Floodlight

Z The floodlight is equipped with a joint that can be swivelled in all directions.

Item Designation36 o Heatable seat surface37 o Control lamp - seat heating38 o Switch - seat heating ON/OFF

Item Designation39 o Floodlight40 o Switch - floodlight ON/OFF

36

37 38

39 40

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7 Auxiliary electrical systems

7.1 Seat heating

Z All auxiliary electrical systems are activated regardless of the key switch position. Thebattery master switch must have been switched on (see section 3, “Switching on thetruck”). To prevent discharge of the battery after the truck has been parked, always heed sec-tion 4.7, “Rendering vehicle safe when parking”.

7.2 Floodlight

Z The floodlight is equipped with a joint that can be swivelled in all directions.

Item Designation36 o Heatable seat surface37 o Control lamp - seat heating38 o Switch - seat heating ON/OFF

Item Designation39 o Floodlight40 o Switch - floodlight ON/OFF

36

37 38

39 40

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7.3 360° warning light

7.4 Flash lamp

7.5 DC/DC transformer on/off switch

Switches the DC/DC transformer 48/24Vor 48/12V respectively on or off.

Item Designation41 o 360° warning light42 o Switch - 360° warning light ON/OFF

Item Designation43 o Flash lamp44 o Switch - flash lamp ON/OFF

Item Designation45 o Switch DC/DC transformer.

4344

45

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7.3 360° warning light

7.4 Flash lamp

7.5 DC/DC transformer on/off switch

Switches the DC/DC transformer 48/24Vor 48/12V respectively on or off.

Item Designation41 o 360° warning light42 o Switch - 360° warning light ON/OFF

Item Designation43 o Flash lamp44 o Switch - flash lamp ON/OFF

Item Designation45 o Switch DC/DC transformer.

4344

45

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E 24

7.6 Override switch (ESA / Electrical lifting limitation)

o Bridge switch

Lateral traversing device

If the load carriage is below the safety height in front of the wheel arms, the mast hol-der retraction motion is blocked by the limit switches.

When the lateral traversing device is between the wheel arms and below the safetyheight, the lateral traversing movement is blocked by limit switches.

The blocking of the mast holder retraction movement and the lateral traversing devicemovement, respectively, performed by the safety switch (ESA), can be bridged bypressing the bridge switch (46) and simultaneous use of the control lever (2) or thepushbutton (21), respectively.

Lifting limitation

If the load carriage reaches the set switch-off height, further lifting motion is blocked.It is possible to surpass the disconnection height by pressing the bridging switch (46)and simultaneous use of the control lever (3).

7.7 LED Lateral traversing device in centre position

If the side shifting device is off centre and the load carriage is below the safety heightin front of the wheel arms, the mast holder retraction motion is blocked by limit swit-ches. The mast slide retraction movement is unblocked when the green LED (30)lights up.

When the lateral traversing device is between the wheel arms and below the safetyheight, the lateral traversing movement is blocked by limit switches. The block isreleased, when the load carriage is lifted above the safety height.

Item Designation46 o Override switch

46 230

21

3

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E 24

7.6 Override switch (ESA / Electrical lifting limitation)

o Bridge switch

Lateral traversing device

If the load carriage is below the safety height in front of the wheel arms, the mast hol-der retraction motion is blocked by the limit switches.

When the lateral traversing device is between the wheel arms and below the safetyheight, the lateral traversing movement is blocked by limit switches.

The blocking of the mast holder retraction movement and the lateral traversing devicemovement, respectively, performed by the safety switch (ESA), can be bridged bypressing the bridge switch (46) and simultaneous use of the control lever (2) or thepushbutton (21), respectively.

Lifting limitation

If the load carriage reaches the set switch-off height, further lifting motion is blocked.It is possible to surpass the disconnection height by pressing the bridging switch (46)and simultaneous use of the control lever (3).

7.7 LED Lateral traversing device in centre position

If the side shifting device is off centre and the load carriage is below the safety heightin front of the wheel arms, the mast holder retraction motion is blocked by limit swit-ches. The mast slide retraction movement is unblocked when the green LED (30)lights up.

When the lateral traversing device is between the wheel arms and below the safetyheight, the lateral traversing movement is blocked by limit switches. The block isreleased, when the load carriage is lifted above the safety height.

Item Designation46 o Override switch

46 230

21

3

F 1

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.GB

F Maintenance of the fork-lift truck1 Operational safety and environmental protection

The checks and servicing operations contained in this chapter must be performed inaccordance with the intervals as indicated in the servicing checklists.

F Modifications of fork-lift truck assemblies, especially of the safety installations, are notpermitted. On no account must the operational speeds of the truck be changed.

M Only original spare parts have been certified by our quality assurance service. Toensure safe and reliable operation of the fork-lift truck, only spare parts of the manu-facturer must be used. Used parts, oils and fuels must be disposed of in accordancewith the applicable environmental protection regulations. For oil changes, the oilservice of the manufacturer is available to you.

Upon completion of any checking and servicing activities, the operations contained inthe section „Recommissioning“ must be performed (refer to chapter F).

2 Safety regulations applicable to truck maintenance

Servicing and maintenance personnel: The fork-lift truck must only be servicedand maintained by trained personnel of the manufacturer. The service organizationof the manufacturer has external technicians trained especially for these assign-ments. We thus recommend signing a maintenance contract with the relevant servicelocation of the manufacturer.

Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must onlybe secured to the points specially provided for this purpose. When the truck is to bejacked up, suitable measures must be taken to prevent the truck from slipping or tip-ping over (use of wedges, wooden blocks). Work underneath the raised load liftingdevice must only be carried out when the fork is immobilised and supported by achain of adequate strength.

Z Jacking point see chapter B.

Cleaning operations: No inflammable liquids must be used when cleaning the fork-lift truck. Prior to commencing cleaning operations, all safety measures that arerequired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope-rated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak com-pressed air and non-conducting, antistatic brushes must be used for the cleaning ofelectric or electronic assemblies.

M If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, allelectric and electronic components must be carefully covered beforehand becausemoisture can lead to incorrect functioning.Cleaning by means of a steam jet is not permitted.

Upon completion of cleaning work, the operations detailed in the section „Recommis-sioning“ must be performed.

F 1

1207

.GB

F Maintenance of the fork-lift truck1 Operational safety and environmental protection

The checks and servicing operations contained in this chapter must be performed inaccordance with the intervals as indicated in the servicing checklists.

F Modifications of fork-lift truck assemblies, especially of the safety installations, are notpermitted. On no account must the operational speeds of the truck be changed.

M Only original spare parts have been certified by our quality assurance service. Toensure safe and reliable operation of the fork-lift truck, only spare parts of the manu-facturer must be used. Used parts, oils and fuels must be disposed of in accordancewith the applicable environmental protection regulations. For oil changes, the oilservice of the manufacturer is available to you.

Upon completion of any checking and servicing activities, the operations contained inthe section „Recommissioning“ must be performed (refer to chapter F).

2 Safety regulations applicable to truck maintenance

Servicing and maintenance personnel: The fork-lift truck must only be servicedand maintained by trained personnel of the manufacturer. The service organizationof the manufacturer has external technicians trained especially for these assign-ments. We thus recommend signing a maintenance contract with the relevant servicelocation of the manufacturer.

Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must onlybe secured to the points specially provided for this purpose. When the truck is to bejacked up, suitable measures must be taken to prevent the truck from slipping or tip-ping over (use of wedges, wooden blocks). Work underneath the raised load liftingdevice must only be carried out when the fork is immobilised and supported by achain of adequate strength.

Z Jacking point see chapter B.

Cleaning operations: No inflammable liquids must be used when cleaning the fork-lift truck. Prior to commencing cleaning operations, all safety measures that arerequired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-ope-rated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak com-pressed air and non-conducting, antistatic brushes must be used for the cleaning ofelectric or electronic assemblies.

M If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, allelectric and electronic components must be carefully covered beforehand becausemoisture can lead to incorrect functioning.Cleaning by means of a steam jet is not permitted.

Upon completion of cleaning work, the operations detailed in the section „Recommis-sioning“ must be performed.

1207

.GB

F 2

Work on the electric system: Work on the electric system of the truck must only beperformed by personnel specially trained for such operations. Before commencingany work on the electric system, all measures required to prevent electric shockshave to be taken. For battery-operated fork-lift trucks, the truck must also be depowe-red by removing the battery plug.

Welding operations: To prevent any damage to electric or electronic components,these have to be removed from the fork-lift truck before any welding operations areundertaken.

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, all truck-specific settings have to be retained.

Tyres: The quality of the tyres greatly affects the stability and the driving behaviourof the fork-lift truck. The factory-mounted tyres must only be replaced by original spare parts of themanufacturer, since otherwise the specification of the data sheet cannot be met.When replacing wheels or tyres, it must be ensured that the fork-lift truck remainslevel (tyres and wheels must always be replaced in pairs, i.e. left and right together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the servicechecklist apply to normal duty. If requirements are higher (dust, temperature), lubri-cation is required more often. The specified chain spray must be used as specified.The external application of grease does not provide sufficient lubrication.

Hydraulic hoses: The hoses must be renewed every six years. When replacinghydraulic components, also renew the hoses in this hydraulic system.

1207

.GB

F 2

Work on the electric system: Work on the electric system of the truck must only beperformed by personnel specially trained for such operations. Before commencingany work on the electric system, all measures required to prevent electric shockshave to be taken. For battery-operated fork-lift trucks, the truck must also be depowe-red by removing the battery plug.

Welding operations: To prevent any damage to electric or electronic components,these have to be removed from the fork-lift truck before any welding operations areundertaken.

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, all truck-specific settings have to be retained.

Tyres: The quality of the tyres greatly affects the stability and the driving behaviourof the fork-lift truck. The factory-mounted tyres must only be replaced by original spare parts of themanufacturer, since otherwise the specification of the data sheet cannot be met.When replacing wheels or tyres, it must be ensured that the fork-lift truck remainslevel (tyres and wheels must always be replaced in pairs, i.e. left and right together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the servicechecklist apply to normal duty. If requirements are higher (dust, temperature), lubri-cation is required more often. The specified chain spray must be used as specified.The external application of grease does not provide sufficient lubrication.

Hydraulic hoses: The hoses must be renewed every six years. When replacinghydraulic components, also renew the hoses in this hydraulic system.

F 3

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3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safeoperation of the industrial truck. Failure to perform regular servicing can lead to truckfailure and poses a potential hazard to personnel and equipment.

M The service intervals stated are based on single shift operation under normal opera-ting conditions. They must be reduced accordingly if the truck is to be used in condi-tions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which theyshould be carried out. Maintenance intervals are defined as:

W = Every 50 service hours, at least weeklyA = Every 500 operating hoursB = Every 1000 operating hours, or at least annuallyC = Every 2000 operating hours, or at least annually

Z W service intervals are to be performed by the customer.

– In the run-in period - after approx. 100 service hours - or after repair work, the own-er must check the wheel nuts/bolts and re-tighten if necessary.

F 3

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3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safeoperation of the industrial truck. Failure to perform regular servicing can lead to truckfailure and poses a potential hazard to personnel and equipment.

M The service intervals stated are based on single shift operation under normal opera-ting conditions. They must be reduced accordingly if the truck is to be used in condi-tions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which theyshould be carried out. Maintenance intervals are defined as:

W = Every 50 service hours, at least weeklyA = Every 500 operating hoursB = Every 1000 operating hours, or at least annuallyC = Every 2000 operating hours, or at least annually

Z W service intervals are to be performed by the customer.

– In the run-in period - after approx. 100 service hours - or after repair work, the own-er must check the wheel nuts/bolts and re-tighten if necessary.

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4 Maintenance Check Maintenance intervals

standard = t W A B Ccold store = k

Chassis and superstruct.:

1.1 Check all load bearing elements for damage t1.2 Check all bolted connections t1.3 Check driver’s protective roof and load guard for secure

fasteningk t

Drive unit: 2.1 Check the transmission for noises and leakage t2.2 Check whether the drive support plate and screws are fit-

ted tightlyt

2.3 Check the transmission oil level t2.4 Check the mechanical pedal linkage; adjust, if necessary t2.5 Change the transmission oil k t

Wheels: 3.1 Check for wear and damage t3.2 Check the wheel bearings and ensure secure fastening of

wheelsk t

Steering: 4.1 Check the steering chain and chain sprocket for wear, adjust and grease

k t

4.2 Check mechanical parts of the steering head t4.3 Check the steering for correct function and adjustment t4.4 Check the hydraulic assemblies for correct functioning

and leakaget

Brake system:

5.1 Check the brake linings for wear t5.2 Performance and adjustment check k t5.3 Check the brake linkage, adjust and grease, if necessary k t5.4 Check the brake lines and connections t5.5 Change the brake fluid k t5.6 Check brake cable of the parking brake and replace it, if

necessaryt

Hydraulic system:

6.1 Performance check t6.2 Check all connections for leakage and damage t6.3 Check hydraulic cylinders for leakage, damage and

secure attachmentk t

6.4 Check the oil level k t6.5 Replace the hydraulic oil, the filter cartridge and the vent

filterk t

6.6 Check the hose run for correct functioning and damage k t6.7 Check the pressure relief valves for correct functioning k t6.8 Replace the pressure filter cartridge t

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F 4

4 Maintenance Check Maintenance intervals

standard = t W A B Ccold store = k

Chassis and superstruct.:

1.1 Check all load bearing elements for damage t1.2 Check all bolted connections t1.3 Check driver’s protective roof and load guard for secure

fasteningk t

Drive unit: 2.1 Check the transmission for noises and leakage t2.2 Check whether the drive support plate and screws are fit-

ted tightlyt

2.3 Check the transmission oil level t2.4 Check the mechanical pedal linkage; adjust, if necessary t2.5 Change the transmission oil k t

Wheels: 3.1 Check for wear and damage t3.2 Check the wheel bearings and ensure secure fastening of

wheelsk t

Steering: 4.1 Check the steering chain and chain sprocket for wear, adjust and grease

k t

4.2 Check mechanical parts of the steering head t4.3 Check the steering for correct function and adjustment t4.4 Check the hydraulic assemblies for correct functioning

and leakaget

Brake system:

5.1 Check the brake linings for wear t5.2 Performance and adjustment check k t5.3 Check the brake linkage, adjust and grease, if necessary k t5.4 Check the brake lines and connections t5.5 Change the brake fluid k t5.6 Check brake cable of the parking brake and replace it, if

necessaryt

Hydraulic system:

6.1 Performance check t6.2 Check all connections for leakage and damage t6.3 Check hydraulic cylinders for leakage, damage and

secure attachmentk t

6.4 Check the oil level k t6.5 Replace the hydraulic oil, the filter cartridge and the vent

filterk t

6.6 Check the hose run for correct functioning and damage k t6.7 Check the pressure relief valves for correct functioning k t6.8 Replace the pressure filter cartridge t

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Maintenance intervalsstandard = t W A B C

cold store = kElectrical system:

7.1 Performance check t7.2 Check all cables for secure connection and damage t7.3 Check the fuses for correct amperage t7.4 Check switches and trip cams for secure attachment and

correct functioningt

7.5 Check the warning installation for correct functioning k t7.6 Check contactors, replace wearing parts, if necessary t7.7 Check the electronic boards for tight seat and cleanliness t

Electric motors:

8.1 Check the motor for secure attachment t

Battery: 9.1 Check the battery cables for damage, renew, if necessary t9.2 Check battery trolley locking, performance and

adjustmentt

9.3 Check acid density, acid level and cell voltage k t9.4 Check the terminals for secure attachment and apply

greasek t

9.5 Clean battery connections, check for tight seat k tHoist frame: 10.1 Check the mast anchorage t

10.2 Check lifting chains and chain guides for wear, adjust and grease

t

10.3 Check support and attachment of tilt cylinder t10.4 Check the tilt angle of mast t10.5 Perform sight check of rollers, sliding elements, and stops k t10.6 Check hoist frame bearing t10.7 Check the traversing systems for wear and damage,

adjust lateral play, if necessaryt

10.8 Check fork tines and fork carrier for wear and damage k t10.9 Check mast damping function t

Mounted implement:

11.1 Performance check k t11.2 Check the attachment to the vehicle and all load bearing

elementsk t

11.3 Check bearings, guide elements, and stops for wear and damage, grease

t

General mea-surements:

12.1 Check the electrical system for a grounding fault t12.2 Check the driving speed and braking distance t12.3 Check the lifting and lowering speed t12.4 Check safety and shutdown devices t

Lubrication: 13.1 Grease the vehicle in accordance with the lubrication schedule

k t

Demonstrati-on:

14.1 Perform a trial run under nominal load t14.2 Upon completion of servicing operations, demonstrate

the vehicle to the person responsiblek t

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Maintenance intervalsstandard = t W A B C

cold store = kElectrical system:

7.1 Performance check t7.2 Check all cables for secure connection and damage t7.3 Check the fuses for correct amperage t7.4 Check switches and trip cams for secure attachment and

correct functioningt

7.5 Check the warning installation for correct functioning k t7.6 Check contactors, replace wearing parts, if necessary t7.7 Check the electronic boards for tight seat and cleanliness t

Electric motors:

8.1 Check the motor for secure attachment t

Battery: 9.1 Check the battery cables for damage, renew, if necessary t9.2 Check battery trolley locking, performance and

adjustmentt

9.3 Check acid density, acid level and cell voltage k t9.4 Check the terminals for secure attachment and apply

greasek t

9.5 Clean battery connections, check for tight seat k tHoist frame: 10.1 Check the mast anchorage t

10.2 Check lifting chains and chain guides for wear, adjust and grease

t

10.3 Check support and attachment of tilt cylinder t10.4 Check the tilt angle of mast t10.5 Perform sight check of rollers, sliding elements, and stops k t10.6 Check hoist frame bearing t10.7 Check the traversing systems for wear and damage,

adjust lateral play, if necessaryt

10.8 Check fork tines and fork carrier for wear and damage k t10.9 Check mast damping function t

Mounted implement:

11.1 Performance check k t11.2 Check the attachment to the vehicle and all load bearing

elementsk t

11.3 Check bearings, guide elements, and stops for wear and damage, grease

t

General mea-surements:

12.1 Check the electrical system for a grounding fault t12.2 Check the driving speed and braking distance t12.3 Check the lifting and lowering speed t12.4 Check safety and shutdown devices t

Lubrication: 13.1 Grease the vehicle in accordance with the lubrication schedule

k t

Demonstrati-on:

14.1 Perform a trial run under nominal load t14.2 Upon completion of servicing operations, demonstrate

the vehicle to the person responsiblek t

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F 6

5 Lubrication Schedule

g

Ac

D 0,2 lt

s

G

G

g

EF

EF

J

Min. = 16lMax.= 23l

b

BB+C 1)

ETV-C16 = 4,5lETV-C20 = 5,3l

E F

205 Nm

1

2

3

2)

a 2)

g Gliding surfacess Grease nipples

Filter plug hydraulic oilc Drain plug hydraulik oilb Filter plug gear oila Drain plug gear oilt Filter plug brake fluid

Cold store usage1) Compound cold store 1:12) Filling level: refer to the table on section 5.2

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F 6

5 Lubrication Schedule

g

Ac

D 0,2 lt

s

G

G

g

EF

EF

J

Min. = 16lMax.= 23l

b

BB+C 1)

ETV-C16 = 4,5lETV-C20 = 5,3l

E F

205 Nm

1

2

3

2)

a 2)

g Gliding surfacess Grease nipples

Filter plug hydraulic oilc Drain plug hydraulik oilb Filter plug gear oila Drain plug gear oilt Filter plug brake fluid

Cold store usage1) Compound cold store 1:12) Filling level: refer to the table on section 5.2

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5.1 Fuels, coolants and lubricants

Handling consumption type material: Consumption type material must always behandled properly. Manufacturer's instructions to be observed.

F Improper handling is injurious to health, life, and environment. Consumption type ma-terials must be stored in adequate containers. They might be inflammable and, the-refore, must not come into contact with hot components or open fire.

When filling in consumption type materials use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualitiies resp., except if mi-xing is expressively prescribed in these operating instructions. Avoid spilling. Spilt li-quid must be removed immediately using a suitable binding agent, and the mixture ofconsumption type material and binding agent is to be disposed of according to the re-gulations.

Grease data

5.2 Reservoir filling level

Code Order-no. Supply Qty Designation Used forA 50 449 669 5,0 l HLP-D 46, DIN 51524 Hydraulic systemB 29 200 680 5,0 l CLP 100, DIN 51517 TransmissionC 29 200 810 5,0 l HLP 10, DIN 51524 TransmissionD 29 200 150 1,0 l Brake fluid Brake systemE 29 201 430 1,0 kg Grease, DIN 51825 LubricationF 50 430 702 1,0 kg Grease, TTF52 LubricationG 29 201 280 400 ml Chain spray ChainsJ 29 202 020 5,0 l Aero Shell Fluid 41 Hydraulic system

Code Saponification Dropp. point°C

Worked penetr.at 25 °C

NLG1class

Servicetemperat. °C

E Lithium 185 265-295 2 -35/+120F -- -- 310-340 1 -52/+100

MarkingTop level

Litres Lift heights (h3) in mm

ZT 1,6 t DZ 1,6 t DZ 2,0 t6 Approx. 26,5 - - Up to 74003 Approx. 23 Up to 4400 Up to 6500 Up to 56002 Approx. 20 Up to 3800 Up to 5000 Up to 47001 Approx. 16 - -

F 7

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5.1 Fuels, coolants and lubricants

Handling consumption type material: Consumption type material must always behandled properly. Manufacturer's instructions to be observed.

F Improper handling is injurious to health, life, and environment. Consumption type ma-terials must be stored in adequate containers. They might be inflammable and, the-refore, must not come into contact with hot components or open fire.

When filling in consumption type materials use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualitiies resp., except if mi-xing is expressively prescribed in these operating instructions. Avoid spilling. Spilt li-quid must be removed immediately using a suitable binding agent, and the mixture ofconsumption type material and binding agent is to be disposed of according to the re-gulations.

Grease data

5.2 Reservoir filling level

Code Order-no. Supply Qty Designation Used forA 50 449 669 5,0 l HLP-D 46, DIN 51524 Hydraulic systemB 29 200 680 5,0 l CLP 100, DIN 51517 TransmissionC 29 200 810 5,0 l HLP 10, DIN 51524 TransmissionD 29 200 150 1,0 l Brake fluid Brake systemE 29 201 430 1,0 kg Grease, DIN 51825 LubricationF 50 430 702 1,0 kg Grease, TTF52 LubricationG 29 201 280 400 ml Chain spray ChainsJ 29 202 020 5,0 l Aero Shell Fluid 41 Hydraulic system

Code Saponification Dropp. point°C

Worked penetr.at 25 °C

NLG1class

Servicetemperat. °C

E Lithium 185 265-295 2 -35/+120F -- -- 310-340 1 -52/+100

MarkingTop level

Litres Lift heights (h3) in mm

ZT 1,6 t DZ 1,6 t DZ 2,0 t6 Approx. 26,5 - - Up to 74003 Approx. 23 Up to 4400 Up to 6500 Up to 56002 Approx. 20 Up to 3800 Up to 5000 Up to 47001 Approx. 16 - -

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6 Instructions for the servicing operations

6.1 Preparing the truck for the performance of servicing and maintenance operati-ons

All required safety measures must be taken to prevent any accidents in the course ofthe servicing and maintenance operations. The following preparatory operationsmust be performed:

– Park and secure the truck (refer to chapter E).– Disconnect the battery plug (1) to prevent accidental starting of the truck.

F When work has to be performed under the raised fork or under the jacked up truck,suitable measures must be taken to prevent any dropping, tilting or slipping of the forkor truck. When lifting the truck, the instructions contained in chapter „Transportationand commissioning“ have to be observed. When performing work on the parking brake, the truck must be secured against mo-ving.

6.2 Opening the arm rest

– Swing the arm rest (2) upward.

Z Service key and hood release are accessible.

1

2

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F 8

6 Instructions for the servicing operations

6.1 Preparing the truck for the performance of servicing and maintenance operati-ons

All required safety measures must be taken to prevent any accidents in the course ofthe servicing and maintenance operations. The following preparatory operationsmust be performed:

– Park and secure the truck (refer to chapter E).– Disconnect the battery plug (1) to prevent accidental starting of the truck.

F When work has to be performed under the raised fork or under the jacked up truck,suitable measures must be taken to prevent any dropping, tilting or slipping of the forkor truck. When lifting the truck, the instructions contained in chapter „Transportationand commissioning“ have to be observed. When performing work on the parking brake, the truck must be secured against mo-ving.

6.2 Opening the arm rest

– Swing the arm rest (2) upward.

Z Service key and hood release are accessible.

1

2

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6.3 Opening the hood

– Unlock the hood (4) using the service key (3).– Swing the hood upward.

Z Controls and truck fuses are easily accessible for servicing.

6.4 Opening the battery doors and the seat hood

– Unlock the battery door (5) using the service key and remove it.

– Unlock the seat hood (7) using the service key and screw out the securing screw(6).

– Swing the seat hood sideways in the direction of the arrow.

Z The drive unit and the hydraulic unit are accessible for servicing purposes.

4

3

5

7

6

5

F 9

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6.3 Opening the hood

– Unlock the hood (4) using the service key (3).– Swing the hood upward.

Z Controls and truck fuses are easily accessible for servicing.

6.4 Opening the battery doors and the seat hood

– Unlock the battery door (5) using the service key and remove it.

– Unlock the seat hood (7) using the service key and screw out the securing screw(6).

– Swing the seat hood sideways in the direction of the arrow.

Z The drive unit and the hydraulic unit are accessible for servicing purposes.

4

3

5

7

6

5

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F 10

6.5 Checking the hydraulic oil level

– Prepare the truck for servicing andmaintenance (refer sections 6.1).

– Open the seat hood (see section 6.4).– Check the hydraulic oil level in the

hydraulic reservoir (8)

Z The oil level must be checked at thehydraulic reservoir with the load liftingdevice completely lowered.– If necessary, top up through the filler

neck (9) using oil of the correct speci-fication.For the hydraulic oil specification(refer section 5.1).

– Lock the seat hood again and screw inthe securing screw.Lock the seat hoodagain and screw in the securingscrew.

6.6 Checking the brake fluid level

F Brake fluid is poisonous and must there-fore be stored in the closed original con-tainers.

Z Lack of brake fluid is indicated by a redLED on the information and service dis-play.

– Park and secure the truck (refer tochapter E).

– Visually check the brake fluid level onthe brake fluid reservoir (10); if neces-sary, add brake fluid (refer section5.1).

Z The brake fluid level must be visible bet-ween the “Min.” and “Max.” marks.

M Replaced oils and lubricants must be disposed of as specified by the applicable en-vironment protection laws.

6.7 Check fixing of the wheels

– Park the truck and render it safe (see chapter E).– Tighten wheel bolts cross-wise with a torque wrench.

TorqueDriven wheels MA = 195-10 Nm

Rear wheels MA = 195-10 Nm

8

9

10

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F 10

6.5 Checking the hydraulic oil level

– Prepare the truck for servicing andmaintenance (refer sections 6.1).

– Open the seat hood (see section 6.4).– Check the hydraulic oil level in the

hydraulic reservoir (8)

Z The oil level must be checked at thehydraulic reservoir with the load liftingdevice completely lowered.– If necessary, top up through the filler

neck (9) using oil of the correct speci-fication.For the hydraulic oil specification(refer section 5.1).

– Lock the seat hood again and screw inthe securing screw.Lock the seat hoodagain and screw in the securingscrew.

6.6 Checking the brake fluid level

F Brake fluid is poisonous and must there-fore be stored in the closed original con-tainers.

Z Lack of brake fluid is indicated by a redLED on the information and service dis-play.

– Park and secure the truck (refer tochapter E).

– Visually check the brake fluid level onthe brake fluid reservoir (10); if neces-sary, add brake fluid (refer section5.1).

Z The brake fluid level must be visible bet-ween the “Min.” and “Max.” marks.

M Replaced oils and lubricants must be disposed of as specified by the applicable en-vironment protection laws.

6.7 Check fixing of the wheels

– Park the truck and render it safe (see chapter E).– Tighten wheel bolts cross-wise with a torque wrench.

TorqueDriven wheels MA = 195-10 Nm

Rear wheels MA = 195-10 Nm

8

9

10

F 11

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6.8 Safety belt maintenance o

It is recommended that the driver checks daily condition and function of the safety beltdaily before starting up the floor conveyor. Only regular checks ensure that a fault ordefective is detected in time.

– Pull out the belt completely and check the fibres for wear and tear.– Check the function of the belt buckle and control whether the belt is perfectly

winding up in the reel-up device.

Checking the blocking mechanism:

– Park the floor conveyor in horizontal position.– Pull out the belt jerkily.

M The mechanism must block the pull-out movement.

F Do not operate the floor conveyor with a defective safety belt - have it exchangedimmediately!

F 11

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6.8 Safety belt maintenance o

It is recommended that the driver checks daily condition and function of the safety beltdaily before starting up the floor conveyor. Only regular checks ensure that a fault ordefective is detected in time.

– Pull out the belt completely and check the fibres for wear and tear.– Check the function of the belt buckle and control whether the belt is perfectly

winding up in the reel-up device.

Checking the blocking mechanism:

– Park the floor conveyor in horizontal position.– Pull out the belt jerkily.

M The mechanism must block the pull-out movement.

F Do not operate the floor conveyor with a defective safety belt - have it exchangedimmediately!

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F 12

6.9 Checking electrical fuses

– Prepare the truck for servicing and maintenance (refer section 6.1).– Check all fuses for correct value according to table, replace if necessary.

Item Description Rating / type18 9F4 Fuse Options 10 A19 4F10 Fan fuse 10 A20 1F9 Travel and lift electronics control fuse 3 A21 1F8 Interface control fuse 3 A22 F1 Overall control fuse 30 A23 F8 Main fuse 355 A

22

23

21

20

19

18

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F 12

6.9 Checking electrical fuses

– Prepare the truck for servicing and maintenance (refer section 6.1).– Check all fuses for correct value according to table, replace if necessary.

Item Description Rating / type18 9F4 Fuse Options 10 A19 4F10 Fan fuse 10 A20 1F9 Travel and lift electronics control fuse 3 A21 1F8 Interface control fuse 3 A22 F1 Overall control fuse 30 A23 F8 Main fuse 355 A

22

23

21

20

19

18

F 13

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6.10 Recommissioning the truck

Recommissioning of the truck following the performance of cleaning or maintenancework is permitted only, after the following operations have been performed:

– Check the horn for proper functioning.– Check the master switch for correct function.– Check the brake for correct function.– Lubricate truck according to lubrication schedule.

7 Decommissioning the truck

If the truck is to be decommissioned for more than two months, it must be parked ina frost-free and dry location and all measures to be taken before, during and followingdecommissioning must be performed as detailed below.

M During decommissioning the truck must be jacked up ensuring that the wheels areclear of the ground. Only this measure will ensure that wheels and wheel bearings donot suffer damage.

If the fork-lift truck is to be decommissioned for more than 6 months, additional mea-sures must be discussed with the Service Department of the manufacturer.

7.1 Operations to be performed prior to decommissioning

– Thoroughly clean the truck.– Check the brakes for correct function.– Check the hydraulic oil level and top up, if required (refer section 6.4).– Apply a thin film of oil or grease to all parts not protected by a paint coating.– Grease the truck as detailed in the lubrication chart (refer section 5).– Recharge the battery (refer to chapter D).– Disconnect and clean the battery. Apply pole grease to the battery poles.

Z In addition to this, all instructions as given by the battery supplier have to be obser-ved.

– Spray all exposed electrical contacts with a suitable contact spray.

7.2 Measures to be taken during decommissioning

Every 2 months:

– Recharge the battery (refer to chapter D).

M Regular recharging of the battery is very important, as otherwise, caused by self-di-scharging, excessive depletion of the battery would occur, which, owing to sulfatiza-tion, will result in the destruction of the battery.

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Recommissioning of the truck following the performance of cleaning or maintenancework is permitted only, after the following operations have been performed:

– Check the horn for proper functioning.– Check the master switch for correct function.– Check the brake for correct function.– Lubricate truck according to lubrication schedule.

7 Decommissioning the truck

If the truck is to be decommissioned for more than two months, it must be parked ina frost-free and dry location and all measures to be taken before, during and followingdecommissioning must be performed as detailed below.

M During decommissioning the truck must be jacked up ensuring that the wheels areclear of the ground. Only this measure will ensure that wheels and wheel bearings donot suffer damage.

If the fork-lift truck is to be decommissioned for more than 6 months, additional mea-sures must be discussed with the Service Department of the manufacturer.

7.1 Operations to be performed prior to decommissioning

– Thoroughly clean the truck.– Check the brakes for correct function.– Check the hydraulic oil level and top up, if required (refer section 6.4).– Apply a thin film of oil or grease to all parts not protected by a paint coating.– Grease the truck as detailed in the lubrication chart (refer section 5).– Recharge the battery (refer to chapter D).– Disconnect and clean the battery. Apply pole grease to the battery poles.

Z In addition to this, all instructions as given by the battery supplier have to be obser-ved.

– Spray all exposed electrical contacts with a suitable contact spray.

7.2 Measures to be taken during decommissioning

Every 2 months:

– Recharge the battery (refer to chapter D).

M Regular recharging of the battery is very important, as otherwise, caused by self-di-scharging, excessive depletion of the battery would occur, which, owing to sulfatiza-tion, will result in the destruction of the battery.

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F 14


– Thoroughly clean the truck.– Lubricate the truck according to the lubrication chart (refer section 5).– Clean the battery. Grease the pole screws using pole grease and reconnect the

battery.– Recharge the battery (refer to chapter D).– Check if the gear oil contains condensed water and change, if required.– Check if the hydraulic oil contains condensed water and change, if required.– Start up the truck (refer to chapter E).

Z If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove a possible oxide layer on the contacts of the ope-rating controls by repeated operation.

F Perform several brake tests immediately after recommissioning the truck.

8 Safety checks to be performed at regular intervals and following any untowardincidents (D: Accident prevention check according to BGV D27)

At least once yearly, or after any untoward incident, the truck has to be checked by aqualified inspector. The inspector must assess the condition of the truck from a stand-point purely concerned with safety aspects, uninfluenced by any company or econo-mic circumstances. The inspector must be adequately informed and experienced tobe able to assess the condition of the truck and the effectiveness of the safety instal-lations based on the technical rules and principles governing the inspection of trucks.

The inspection must comprise a comprehensive check of the technical condition ofthe truck with regard to accident prevention aspects. Apart from this, the truck mustbe thoroughly inspected for damage possibly caused by incorrect use of the truck.The inspection results must be recorded in an inspection report which has to be keptavailable for a period spanning at least the next two inspection intervals.The user has to ensure that all defects are eliminated without delay.

Z The manufacturer has set up a special safety service with specially qualified staff. Asvisual proof that the truck has passed the safety inspection, a plaque will be affixedto it. This plaque indicates in which month of which year the next test will be due.

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F 14


– Thoroughly clean the truck.– Lubricate the truck according to the lubrication chart (refer section 5).– Clean the battery. Grease the pole screws using pole grease and reconnect the

battery.– Recharge the battery (refer to chapter D).– Check if the gear oil contains condensed water and change, if required.– Check if the hydraulic oil contains condensed water and change, if required.– Start up the truck (refer to chapter E).

Z If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove a possible oxide layer on the contacts of the ope-rating controls by repeated operation.

F Perform several brake tests immediately after recommissioning the truck.

8 Safety checks to be performed at regular intervals and following any untowardincidents (D: Accident prevention check according to BGV D27)

At least once yearly, or after any untoward incident, the truck has to be checked by aqualified inspector. The inspector must assess the condition of the truck from a stand-point purely concerned with safety aspects, uninfluenced by any company or econo-mic circumstances. The inspector must be adequately informed and experienced tobe able to assess the condition of the truck and the effectiveness of the safety instal-lations based on the technical rules and principles governing the inspection of trucks.

The inspection must comprise a comprehensive check of the technical condition ofthe truck with regard to accident prevention aspects. Apart from this, the truck mustbe thoroughly inspected for damage possibly caused by incorrect use of the truck.The inspection results must be recorded in an inspection report which has to be keptavailable for a period spanning at least the next two inspection intervals.The user has to ensure that all defects are eliminated without delay.

Z The manufacturer has set up a special safety service with specially qualified staff. Asvisual proof that the truck has passed the safety inspection, a plaque will be affixedto it. This plaque indicates in which month of which year the next test will be due.

1

0506

.GB

Instructions for use

Jungheinrich traction battery

Table of contents1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB..........................................2-6

Type plate Jungheinrich traction battery............................................7

Instruction for useAquamatic/BFS III water refilling system ......................................................8-12

2 Jungheinrich traction batteryMaintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17


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Instructions for use

Jungheinrich traction battery

Table of contents1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB..........................................2-6


Instruction for useAquamatic/BFS III water refilling system ......................................................8-12

2 Jungheinrich traction batteryMaintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17


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1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB

Rating Data

1. Nominal capacity C5: See type plate2. Nominal voltage: 2,0 V x No of cells3. Discharge current:: C5/5h4. Nominal S.G. of electrolyte*

Type EPzS: 1,29 kg/lType EPzB: 1,29 kg/l

5. Rated temperature: 30° C6. 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!

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1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB

Rating Data

1. Nominal capacity C5: See type plate2. Nominal voltage: 2,0 V x No of cells3. Discharge current:: C5/5h4. Nominal S.G. of electrolyte*

Type EPzS: 1,29 kg/lType EPzB: 1,29 kg/l

5. Rated temperature: 30° C6. 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

.GBIgnoring the operation instructions, repair with non-original parts or using additives forthe electrolyte will render the warranty void.

For batteries in classes I and II the instructions for maintaining the appropriateprotection class during operation must be complied with (see relevant certificate).

1. Commissioning filled and charged batteries. For commissioning of unfilledbatteries 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 thepolarity is correct. Otherwise battery, vehicle or charger could be damaged.

The specified torque loading for the polscrews of the charger cables and connectorsare:

The level of the electrolyte must be checked. If it is below the antisurge baffle or thetop 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 circuitcondition.

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 leftdischarged. This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. All charging procedures in accordancewith DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned toa charger, suitable for the size of battery, in order to avoid overloading of the electriccables and contacts, unacceptable gassing and the escape of electrolyte from thecells.

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 itssuitability checked by the manufacturers service department. When charging, properprovision must be made for venting of the charging gases.

steel M 10 23 ± 1 Nm

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Ignoring the operation instructions, repair with non-original parts or using additives forthe electrolyte will render the warranty void.


1. Commissioning filled and charged batteries. For commissioning of unfilledbatteries see separate instructions!


The charger cables must be connected to ensure a good contact, taking care that thepolarity is correct. Otherwise battery, vehicle or charger could be damaged.

The specified torque loading for the polscrews of the charger cables and connectorsare:

The level of the electrolyte must be checked. If it is below the antisurge baffle or thetop 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


2.1 Discharging

Be sure that all breather holes are not sealed or covered.



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 leftdischarged. This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. All charging procedures in accordancewith DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned toa charger, suitable for the size of battery, in order to avoid overloading of the electriccables and contacts, unacceptable gassing and the escape of electrolyte from thecells.

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 itssuitability checked by the manufacturers service department. When charging, properprovision must be made for venting of the charging gases.


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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. Whencharging the temperature of the electrolyte rises by about 10°C, so charging shouldonly begin if the electrolyte temperature is below 45°C. The electrolyte temperatureof batteries should be at least +10°C before charging otherwise a full charge will notbe achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltagehave remained constant for two hours. Special instructions for the operation of batte-ries in hazardous areas. This concerns batteries which are used in accordance withEN 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 lidsmust 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 protectionpacks 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 itscapacity. They are necessary after deep discharges, repeated incomplete rechargesand 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°Cand 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 specificgravity 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.

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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. Whencharging the temperature of the electrolyte rises by about 10°C, so charging shouldonly begin if the electrolyte temperature is below 45°C. The electrolyte temperatureof batteries should be at least +10°C before charging otherwise a full charge will notbe achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltagehave remained constant for two hours. Special instructions for the operation of batte-ries in hazardous areas. This concerns batteries which are used in accordance withEN 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 lidsmust 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 protectionpacks must not be closed until at least half an hour after charging has past.


Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. They are necessary after deep discharges, repeated incomplete rechargesand 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).


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°Cand 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 specificgravity 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.

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3.1 Daily

Charge the battery after every discharge. Towards the end of charge the electrolytelevel should be checked and if necessary topped up to the specified level with purifiedwater. The electrolyte level must not fall below the anti-surge baffle or the top of theseparator 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 becarried out (see point 2.3).

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measuredwith the charger switched on, and recorded. After charging has ended the specificgravity 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 orbloc batteries are found further testing and maintenance by the service departmentshould be requested.

3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance ofthe truck and the battery must be checked by an electrical specialist.

The tests on the insulation resistance of the battery must be conducted in accordancewith DIN EN 60254-1.

The insulation resistance of the battery thus determined must not be below a value of50 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 ofVehicle 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 ensurethat the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call in our service department for this.

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3. Maintenance

3.1 Daily

Charge the battery after every discharge. Towards the end of charge the electrolytelevel should be checked and if necessary topped up to the specified level with purifiedwater. The electrolyte level must not fall below the anti-surge baffle or the top of theseparator 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 becarried out (see point 2.3).

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measuredwith the charger switched on, and recorded. After charging has ended the specificgravity 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 orbloc batteries are found further testing and maintenance by the service departmentshould be requested.

3.4 Annually


The tests on the insulation resistance of the battery must be conducted in accordancewith DIN EN 60254-1.





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 ensurethat the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call in our service department for this.

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5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room. To ensure the battery is always readyfor 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 storagetime 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 shouldbe 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 bedisposed of as hazardous waste!

We reserve the right make technical modification.

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5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room. To ensure the battery is always readyfor 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 storagetime 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 shouldbe called in without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.






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* CE mark is only for batteries with a nominal voltage greater than 75 volt.

Item Designation Item Designation1 Logo 8 Recycling symbol2 Battery designation 9 Dustbin/material3 Battery type 10 Nominal battery voltage4 Battery number 11 Nominal battery capacity5 Battery tray number 12 Number of battery cells6 Delivery date 13 Battery weight7 Battery manufacturer's logo 14 Safety instructions and warnings

Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7

Number of CellsBatteriegewicht 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 651113

1

14

41012

7

8

9

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7.Type plate, Jungheinrich traction battery



Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7



Serien-Nr.3


Supplier No.

Baujahr 2

Year of manufacture


5

Pb Pb

2/3 651113

1

14

41012

7

8

9

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Aquamatic/BFS III water refilling system for Jungheinrich traction battery withEPzS 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. columnEPzS. 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-originalspare 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 mm2/160 – 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 mm2/210 – 10/1050 – 61,0 mm 61,0 mm2/230 – 10/1150 – 61,0 mm 61,0 mm2/250 – 10/1250 – 61,0 mm 61,0 mm2/280 – 10/1400 – 72,0 mm 66,0 mm2/310 – 10/1550 – 72,0 mm 66,0 mm

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Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

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Aquamatic/BFS III water refilling system for Jungheinrich traction battery withEPzS 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. columnEPzS. 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-originalspare 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 mm2/160 – 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 mm2/210 – 10/1050 – 61,0 mm 61,0 mm2/230 – 10/1150 – 61,0 mm 61,0 mm2/250 – 10/1250 – 61,0 mm 61,0 mm2/280 – 10/1400 – 72,0 mm 66,0 mm2/310 – 10/1550 – 72,0 mm 66,0 mm

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Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

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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 gaseswhich arise during charging. In addition to the optical level indicator, the plug systemsalso 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 sealingcoupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries forforklift trucks. The water refilling system is provided with a central water connectionfor 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 connectionsleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve locatedin the plug in combination with the float and the float rods. In the Aquamatic Systemthe existing water pressure at the valve turns off the water supply and ensures thatthe 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 timesthe buoyant force and consequently interrupt the water supply reliably.

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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 gaseswhich arise during charging. In addition to the optical level indicator, the plug systemsalso 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 sealingcoupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries forforklift trucks. The water refilling system is provided with a central water connectionfor 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 connectionsleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve locatedin the plug in combination with the float and the float rods. In the Aquamatic Systemthe existing water pressure at the valve turns off the water supply and ensures thatthe 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 timesthe buoyant force and consequently interrupt the water supply reliably.

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4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the batterycharging comes to an end; this ensures that the refilled water quantity is mixed withthe 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 thewater pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operatingpressure range of between 0.2 bars and 0.6 bars. The BFS system has an operatingpressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impairthe 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. Forthe Aquamatic System the installation height is 2 m to 6 m and for the BFS systemthe 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 barsand 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 necessaryfilling pressure. No difference in height is permitted between the standing level of theServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under whichthe battery is used, the ambient temperatures and the type of filling and/or the fillingpressure. 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 fillthe batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kindof dirt which could impair the functional reliability of the Aquamatic/BFS plug. Forsafety 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.

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4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the batterycharging comes to an end; this ensures that the refilled water quantity is mixed withthe 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 thewater pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operatingpressure range of between 0.2 bars and 0.6 bars. The BFS system has an operatingpressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impairthe 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. Forthe Aquamatic System the installation height is 2 m to 6 m and for the BFS systemthe 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 barsand 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 necessaryfilling pressure. No difference in height is permitted between the standing level of theServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under whichthe battery is used, the ambient temperatures and the type of filling and/or the fillingpressure. 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 fillthe batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kindof dirt which could impair the functional reliability of the Aquamatic/BFS plug. Forsafety 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.

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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 temperaturedamages 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 roomswith temperatures > 0° C (as there is otherwise a danger that the systems mayfreeze).

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 a7.5 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 comein 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 pipeon the battery side. During the filling process, the paddlewheel is turned by the flowingwater. When the filling process ends, the wheel stops and this indicates the end ofthe 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 toprevent any damage to the plug systems.

11

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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 temperaturedamages 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 roomswith temperatures > 0° C (as there is otherwise a danger that the systems mayfreeze).

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 a7.5 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 comein 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 pipeon the battery side. During the filling process, the paddlewheel is turned by the flowingwater. When the filling process ends, the wheel stops and this indicates the end ofthe 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 toprevent any damage to the plug systems.

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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 maximumpassage 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 chargingstation 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 couplerconstruction 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 at0.1 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 andoperating pressure range: 0.3 to 1.8 bars in the BFS system.

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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 maximumpassage 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 chargingstation 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 couplerconstruction 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 at0.1 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 andoperating pressure range: 0.3 to 1.8 bars in the BFS system.

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2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular platestype 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 plugthere are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements asfor vented cells apply to protect against hazards from electric current, from explosionof electrolytic gas and in case of the cell container is damaged, from the corrosiveelectrolyte.

• 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!

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2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular platestype 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 plugthere are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements asfor vented cells apply to protect against hazards from electric current, from explosionof electrolytic gas and in case of the cell container is damaged, from the corrosiveelectrolyte.

• 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!

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Ignoring the operation instructions, repair with non-original parts and non authorisedinterventions will render the warranty void.


1. Commissioning


The battery end cables must have a good contact to terminals, check that the polarityis 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 connectorsare:

2. Operation


2.1 Discharging

Ventilation openings must not be sealed or covered.



They reduce the battery life considerable. To measure the state of discharge use onlythe 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 DIN41773 and DIN 41774 must only be applied in the manufacturer approved modifica-tions. Therefore only battery manufacturer approved chargers must be used. Onlyconnect the battery assigned to a charger, suitable for the size of battery, in order toavoid overloading of the electric cables and contacts and unacceptable gassing of thecells. 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.


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14

Ignoring the operation instructions, repair with non-original parts and non authorisedinterventions will render the warranty void.


1. Commissioning


The battery end cables must have a good contact to terminals, check that the polarityis 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 connectorsare:

2. Operation


2.1 Discharging

Ventilation openings must not be sealed or covered.



They reduce the battery life considerable. To measure the state of discharge use onlythe 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 DIN41773 and DIN 41774 must only be applied in the manufacturer approved modifica-tions. Therefore only battery manufacturer approved chargers must be used. Onlyconnect the battery assigned to a charger, suitable for the size of battery, in order toavoid overloading of the electric cables and contacts and unacceptable gassing of thecells. 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.


15

0506

.GBWith 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. Whencharging the temperature of the battery rises by about 15° C, so charging should onlybegin if the battery temperature is below 35° C. The battery temperature should be atleast +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 chargersneed 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.


Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. Equalising charges are carried out following normal charging.

They are necessary after deep discharges and repeated incomplete recharges. Forthe equalising charges has to be used only the battery manufacturer prescribed char-gers.


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 bemeasured.

3. Maintenance

Don’t refill water!

3.1 Daily

Charge the battery immediately after every discharge.

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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. Whencharging the temperature of the battery rises by about 15° C, so charging should onlybegin if the battery temperature is below 35° C. The battery temperature should be atleast +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 chargersneed 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.


Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. Equalising charges are carried out following normal charging.

They are necessary after deep discharges and repeated incomplete recharges. Forthe equalising charges has to be used only the battery manufacturer prescribed char-gers.


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 bemeasured.

3. Maintenance

Don’t refill water!

3.1 Daily

Charge the battery immediately after every discharge.

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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 andrecorded:

• the voltages of the battery

• the voltages of every cells

If significant changes from earlier measurements or differences between the cells orbloc batteries are found, further testing and maintenance by the service departmentshould be requested.

3.4 Annually


The tests on the insulation resistance of the battery must be conducted in accordancewith DIN 43539-1.





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 thatthe insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If itis 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 thefully charged condition in a dry, frost-free room.

To ensure the battery is always ready for use a choice of charging methods can bemade:

1.a quarterly full charging like charge as in point 2.2. If any consumer is connectedwith, e.g. measure or controlling systems, it can be, that this charging is necessaryevery 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.

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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 andrecorded:

• the voltages of the battery

• the voltages of every cells

If significant changes from earlier measurements or differences between the cells orbloc batteries are found, further testing and maintenance by the service departmentshould be requested.

3.4 Annually


The tests on the insulation resistance of the battery must be conducted in accordancewith DIN 43539-1.





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 thatthe insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If itis 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 thefully charged condition in a dry, frost-free room.

To ensure the battery is always ready for use a choice of charging methods can bemade:

1.a quarterly full charging like charge as in point 2.2. If any consumer is connectedwith, e.g. measure or controlling systems, it can be, that this charging is necessaryevery 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.

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If malfunctions are found on the battery or the charger our service department shouldbe called without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.









Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7



Serien-Nr.3


Supplier No.

Baujahr 2

Year of manufacture


5

Pb Pb

2/3 651113

1

14

41012

7

8

9

17

0506

.GB

6. Malfunctions

If malfunctions are found on the battery or the charger our service department shouldbe called without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.









Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7



Serien-Nr.3


Supplier No.

Baujahr 2

Year of manufacture


5

Pb Pb

2/3 651113

1

14

41012

7

8

9

0506

.GB

18

0506

.GB

18

Documents

V2500 GB - Jungheinrich