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Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 HamburgManufacturer or agent acting in the European Union
Additional information
On behalf of
Date
G EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below indetail complies with the European Directives 2006/42/EC (Machinery Directive) and2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as wellas the legislative decree to incorporate the directives in national law. The signatoriesare in each case individually authorized to compile the technical documents.
Type Option Serial no. Year of manufacture
ECE 310ECE 310 HPECE 310 LJ
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Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 HamburgManufacturer or agent acting in the European Union
Additional information
On behalf of
Date
G EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below indetail complies with the European Directives 2006/42/EC (Machinery Directive) and2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as wellas the legislative decree to incorporate the directives in national law. The signatoriesare in each case individually authorized to compile the technical documents.
Type Option Serial no. Year of manufacture
ECE 310ECE 310 HPECE 310 LJ
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Foreword
Notes on the operating instructions
The 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 and the pages arenumbered continuously.
The operator manual details different industrial truck models. When operating andservicing the industrial truck, make sure that the particular section applies to yourtruck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right toalter the design, equipment and technical features of the system. No guarantee ofparticular features of the truck should therefore be assumed from the presentoperating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the followinggraphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction willresult in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instructionmay result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result inslight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result inmaterial damage.
Z Used before notices and explanations.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
t Indicates standard equipmento Indicates optional equipment
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Foreword
Notes on the operating instructions
The 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 and the pages arenumbered continuously.
The operator manual details different industrial truck models. When operating andservicing the industrial truck, make sure that the particular section applies to yourtruck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right toalter the design, equipment and technical features of the system. No guarantee ofparticular features of the truck should therefore be assumed from the presentoperating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the followinggraphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction willresult in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instructionmay result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result inslight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result inmaterial damage.
Z Used before notices and explanations.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
t Indicates standard equipmento Indicates optional equipment
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Jungheinrich Aktiengesellschaft
Am Stadtrand 3522047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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Jungheinrich Aktiengesellschaft
Am Stadtrand 3522047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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Table of contents
A Correct Use and Application ................................................... 11
1 General.................................................................................................... 112 Correct application................................................................................... 113 Approved application conditions.............................................................. 114 Proprietor responsibilities ........................................................................ 125 Adding attachments and/or accessories.................................................. 12
B Truck Description .................................................................... 13
1 Application ............................................................................................... 131.1 Truck models and rated capacity............................................................. 132 Assemblies and Functional Description................................................... 142.1 Assembly Overview ................................................................................. 142.2 Functional Description ............................................................................. 163 Technical Specifications .......................................................................... 183.1 Performance data .................................................................................... 183.2 Dimensions.............................................................................................. 193.3 Weights.................................................................................................... 223.4 Tyre type.................................................................................................. 223.5 EN norms................................................................................................. 233.6 Conditions of use..................................................................................... 243.7 Electrical requirements ............................................................................ 243.8 Identification points and data plates ........................................................ 25
C Transport and Commissioning ................................................ 27
1 Lifting by crane ........................................................................................ 272 Transport ................................................................................................. 283 Using the Truck for the First Time ........................................................... 29
D Battery - Servicing, Recharging, Replacement ....................... 31
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 312 Battery types............................................................................................ 323 Exposing the battery................................................................................ 334 Charging the battery ................................................................................ 355 Battery removal and installation .............................................................. 37
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Table of contents
A Correct Use and Application ................................................... 11
1 General.................................................................................................... 112 Correct application................................................................................... 113 Approved application conditions.............................................................. 114 Proprietor responsibilities ........................................................................ 125 Adding attachments and/or accessories.................................................. 12
B Truck Description .................................................................... 13
1 Application ............................................................................................... 131.1 Truck models and rated capacity............................................................. 132 Assemblies and Functional Description................................................... 142.1 Assembly Overview ................................................................................. 142.2 Functional Description ............................................................................. 163 Technical Specifications .......................................................................... 183.1 Performance data .................................................................................... 183.2 Dimensions.............................................................................................. 193.3 Weights.................................................................................................... 223.4 Tyre type.................................................................................................. 223.5 EN norms................................................................................................. 233.6 Conditions of use..................................................................................... 243.7 Electrical requirements ............................................................................ 243.8 Identification points and data plates ........................................................ 25
C Transport and Commissioning ................................................ 27
1 Lifting by crane ........................................................................................ 272 Transport ................................................................................................. 283 Using the Truck for the First Time ........................................................... 29
D Battery - Servicing, Recharging, Replacement ....................... 31
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 312 Battery types............................................................................................ 323 Exposing the battery................................................................................ 334 Charging the battery ................................................................................ 355 Battery removal and installation .............................................................. 37
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E Operation ................................................................................ 41
1 Safety Regulations for the Operation of the Forklift Truck....................... 412 Displays and Controls.............................................................................. 432.1 Battery discharge indicator ...................................................................... 463 Starting up the truck ................................................................................ 473.1 Checks and operations to be performed before starting daily operation . 473.2 Preparing the truck for operation ............................................................. 483.3 Parking the truck securely ....................................................................... 503.4 Battery discharge monitor........................................................................ 504 Industrial Truck Operation ....................................................................... 514.1 Safety regulations for truck operation...................................................... 514.2 Emergency Disconnect, Travel, Steering, Braking .................................. 534.3 Lifting, transporting and depositing loads ................................................ 585 Troubleshooting....................................................................................... 605.1 Truck does not start ................................................................................. 605.2 Load cannot be lifted ............................................................................... 606 Operating the truck without its own drive system .................................... 627 Optional equipment ................................................................................. 647.1 Pedestrian mode ..................................................................................... 647.2 Stockpicking up to the second level ........................................................ 667.3 CanCode keypad..................................................................................... 697.4 Setting the truck parameters with CanCode............................................ 747.5 Parameter................................................................................................ 767.6 CanDis display instrument....................................................................... 847.7 ISM access module (o)........................................................................... 85
F Industrial Truck Maintenance .................................................. 87
1 Operational Safety and Environmental Protection................................... 872 Maintenance Safety Regulations............................................................. 873 Servicing and Inspection ......................................................................... 914 Maintenance checklist ............................................................................. 924.1 Owner ...................................................................................................... 924.2 Customer Service .................................................................................... 945 Lubricants and Lubrication Schedule ...................................................... 985.1 Handling consumables safely.................................................................. 985.2 Lubrication Schedule ............................................................................... 1005.3 Consumables........................................................................................... 1026 Maintenance and repairs ......................................................................... 1036.1 Preparing the truck for maintenance and repairs .................................... 1036.2 Tightening the wheel nuts........................................................................ 1046.3 Removing the front panel ........................................................................ 1056.4 Flipping the JetPilot back for maintenance purposes (o) ....................... 1066.5 Checking electrical fuses......................................................................... 1076.6 Restoring the truck to service after maintenance and repairs ................. 1097 Decommissioning the industrial truck ...................................................... 1107.1 Before taking the truck out of service ...................................................... 110
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E Operation ................................................................................ 41
1 Safety Regulations for the Operation of the Forklift Truck....................... 412 Displays and Controls.............................................................................. 432.1 Battery discharge indicator ...................................................................... 463 Starting up the truck ................................................................................ 473.1 Checks and operations to be performed before starting daily operation . 473.2 Preparing the truck for operation ............................................................. 483.3 Parking the truck securely ....................................................................... 503.4 Battery discharge monitor........................................................................ 504 Industrial Truck Operation ....................................................................... 514.1 Safety regulations for truck operation...................................................... 514.2 Emergency Disconnect, Travel, Steering, Braking .................................. 534.3 Lifting, transporting and depositing loads ................................................ 585 Troubleshooting....................................................................................... 605.1 Truck does not start ................................................................................. 605.2 Load cannot be lifted ............................................................................... 606 Operating the truck without its own drive system .................................... 627 Optional equipment ................................................................................. 647.1 Pedestrian mode ..................................................................................... 647.2 Stockpicking up to the second level ........................................................ 667.3 CanCode keypad..................................................................................... 697.4 Setting the truck parameters with CanCode............................................ 747.5 Parameter................................................................................................ 767.6 CanDis display instrument....................................................................... 847.7 ISM access module (o)........................................................................... 85
F Industrial Truck Maintenance .................................................. 87
1 Operational Safety and Environmental Protection................................... 872 Maintenance Safety Regulations............................................................. 873 Servicing and Inspection ......................................................................... 914 Maintenance checklist ............................................................................. 924.1 Owner ...................................................................................................... 924.2 Customer Service .................................................................................... 945 Lubricants and Lubrication Schedule ...................................................... 985.1 Handling consumables safely.................................................................. 985.2 Lubrication Schedule ............................................................................... 1005.3 Consumables........................................................................................... 1026 Maintenance and repairs ......................................................................... 1036.1 Preparing the truck for maintenance and repairs .................................... 1036.2 Tightening the wheel nuts........................................................................ 1046.3 Removing the front panel ........................................................................ 1056.4 Flipping the JetPilot back for maintenance purposes (o) ....................... 1066.5 Checking electrical fuses......................................................................... 1076.6 Restoring the truck to service after maintenance and repairs ................. 1097 Decommissioning the industrial truck ...................................................... 1107.1 Before taking the truck out of service ...................................................... 110
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7.2 Action to be taken during decommissioning ............................................ 1117.3 Restoring the truck to service after decommissioning ............................. 1128 Safety tests to be performed at intervals and after unusual incidents ..... 1139 Final de-commissioning, disposal............................................................ 11310 Human vibration measurement ............................................................... 113
1
0506
.GB
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.
1
0506
.GB
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
1 General
The industrial truck described in the present operating instructions is designed forlifting, lowering and transporting load units.It must be used, operated and serviced in accordance with the present instructions.Any other type of use is beyond the scope of application and can result in damage topersonnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the load chart and must not beexceeded.The load must rest on the load handler or be lifted by an attachment approved by themanufacturer.The load must rest on the back of the fork carriage and centrally between the forks.
– Lifting and lowering of loads.– Transporting lowered loads.– Do not travel with a raised load (>500 mm).– Do not carry or lift passengers.– Do push or pull load units.
3 Approved application conditions
– Operation in industrial and commercial environments.– Permissible temperature range 5°C to 40°C.– Operation only on secure, level surfaces with sufficient capacity.– Operation only on routes that are visible and approved by the proprietor.– Negotiating inclines up to a maximum of 15 %.– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.– Operation in partially public traffic.
Z Special equipment and authorisation are required if the truck is to be used inextreme conditions.The truck is not authorised for use in areas at risk of explosion.
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A Correct Use and Application
1 General
The industrial truck described in the present operating instructions is designed forlifting, lowering and transporting load units.It must be used, operated and serviced in accordance with the present instructions.Any other type of use is beyond the scope of application and can result in damage topersonnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the load chart and must not beexceeded.The load must rest on the load handler or be lifted by an attachment approved by themanufacturer.The load must rest on the back of the fork carriage and centrally between the forks.
– Lifting and lowering of loads.– Transporting lowered loads.– Do not travel with a raised load (>500 mm).– Do not carry or lift passengers.– Do push or pull load units.
3 Approved application conditions
– Operation in industrial and commercial environments.– Permissible temperature range 5°C to 40°C.– Operation only on secure, level surfaces with sufficient capacity.– Operation only on routes that are visible and approved by the proprietor.– Negotiating inclines up to a maximum of 15 %.– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.– Operation in partially public traffic.
Z Special equipment and authorisation are required if the truck is to be used inextreme conditions.The truck is not authorised for use in areas at risk of explosion.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined asany natural or legal person who either uses the industrial truck himself, or on whosebehalf it is used. In special cases (e.g. leasing or renting) the proprietor is consideredthe person who, in accordance with existing contractual agreements between theowner and user of the industrial truck, is charged with operational duties.The proprietor must ensure that the industrial truck is used only for the purpose forwhich it is intended and that there is no danger to life and limb of the user and thirdparties. Furthermore, accident prevention regulations, safety regulations andoperating, servicing and repair guidelines must be followed. The proprietor mustensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. Thesame applies if improper work is carried out on the truck by the customer or thirdparties without the permission of the manufacturer.
5 Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances theperformance of the forklift truck requires the written permission of the manufacturer.Local authority approval may also need to be obtained.Local authority approval does not however constitute the manufacturer’s approval.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined asany natural or legal person who either uses the industrial truck himself, or on whosebehalf it is used. In special cases (e.g. leasing or renting) the proprietor is consideredthe person who, in accordance with existing contractual agreements between theowner and user of the industrial truck, is charged with operational duties.The proprietor must ensure that the industrial truck is used only for the purpose forwhich it is intended and that there is no danger to life and limb of the user and thirdparties. Furthermore, accident prevention regulations, safety regulations andoperating, servicing and repair guidelines must be followed. The proprietor mustensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. Thesame applies if improper work is carried out on the truck by the customer or thirdparties without the permission of the manufacturer.
5 Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances theperformance of the forklift truck requires the written permission of the manufacturer.Local authority approval may also need to be obtained.Local authority approval does not however constitute the manufacturer’s approval.
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B Truck Description
1 Application
The truck is a four-wheel electric pallet truck with an operator position, equippedeither with a Jet Pilot or electric tiller steering (o). It is designed for use on levelsurfaces for transporting and picking goods. Roll cages and open bottom pallets orpallets with transverse boards (provided that the boards are outside the range of theload wheels) can be collected.The rated capacity of the truck is shown on the data plate or capacity plate Qmax.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived fromthe model name.
The rated capacity does not generally match the permissible capacity. The capacitycan be found on the load chart attached to the rack.
ECE310
ECE 310
Model name
3 Series10 Rated capacity x 100 kg
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B Truck Description
1 Application
The truck is a four-wheel electric pallet truck with an operator position, equippedeither with a Jet Pilot or electric tiller steering (o). It is designed for use on levelsurfaces for transporting and picking goods. Roll cages and open bottom pallets orpallets with transverse boards (provided that the boards are outside the range of theload wheels) can be collected.The rated capacity of the truck is shown on the data plate or capacity plate Qmax.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived fromthe model name.
The rated capacity does not generally match the permissible capacity. The capacitycan be found on the load chart attached to the rack.
ECE310
ECE 310
Model name
3 Series10 Rated capacity x 100 kg
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2 Assemblies and Functional Description
2.1 Assembly Overview
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1311
22
3, 4 5
8
2
6
19
16
10
9
21
7
18
14
17
20
1
12
2
2
1
1
10
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2 Assemblies and Functional Description
2.1 Assembly Overview
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22
3, 4 5
8
2
6
19
16
10
9
21
7
18
14
17
20
1
12
2
2
1
1
10
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Item Component Item Component
1 t “Lower” button 12 t Emergency Disconnect (main switch)
2 t “Lift” button 13 t Battery cover
3 o CanCode 14 t Lift mechanism
4 o CanDis 15 t Front panel
5 t Key switch 16 t Drive wheel
6 o Load direction “pedestrian” button
17 t Castor wheel
7 o "Pedestrian" stop button 19 o JetPilot LJ (can be raised)
8 o Drive direction “pedestrian” button
18 o Tiller
9 t Travel switch 20 o Lift standing platform
10 t STOP button 21 o Lower standing platform
11 t JetPilot 22 o Lifting standing platform
t = Standard version o = Option
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Item Component Item Component
1 t “Lower” button 12 t Emergency Disconnect (main switch)
2 t “Lift” button 13 t Battery cover
3 o CanCode 14 t Lift mechanism
4 o CanDis 15 t Front panel
5 t Key switch 16 t Drive wheel
6 o Load direction “pedestrian” button
17 t Castor wheel
7 o "Pedestrian" stop button 19 o JetPilot LJ (can be raised)
8 o Drive direction “pedestrian” button
18 o Tiller
9 t Travel switch 20 o Lift standing platform
10 t STOP button 21 o Lower standing platform
11 t JetPilot 22 o Lifting standing platform
t = Standard version o = Option
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2.2 Functional Description
Safety Mechanisms
– An enclosed, smooth truck geometry with rounded edges ensures safe handling ofthe truck.
– The wheels are surrounded by a solid skirt. – Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations.
Hydraulic system
– Lifting and lowering are activated via the lift and lower buttons.– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder.
Emergency Stop safety feature
– The emergency stop is activated by the traction controller. – The steering controller sends a system status signal which is monitored by the
traction controller. If the signal fails to appear or a fault is identified the truckautomatically brakes to a halt. Control displays on the driver’s display indicate theemergency stop.
– Each time the truck is switched on the system performed an automatic diagnosis.
Operator Position
– All travel and lift operations can be performed sensitively without having to reach.– JetPilot or tiller (o) for reliable control of the industrial truck.
Order picking on the second level
– The second picking level can be reached via a step board (o) in the backrest andby climbing onto the battery cover.
– The industrial truck is optionally available with a height-adjustable operator position(o) for order picking on the 2nd level.
– Driving on the 2nd level is possible at reduced speed for industrial trucks withheight-adjustable JetPilot (o).
Operator platform
– Travel functions are only released when the driver stands on the operator platform.
Drive system
– A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox.– The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking withenergy regeneration.
– The driver can choose from 3 travel programs, depending on the load and theenvironment. from maximum performance to energy saving.
Steering
– The driver steers with a JetPilot or a tiller (o).– The steering motion is transmitted directly from the steering controller via a steer
motor directly to the ring gear of the pivoted drive system. – The drive system can be pivoted +/- 90°.
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2.2 Functional Description
Safety Mechanisms
– An enclosed, smooth truck geometry with rounded edges ensures safe handling ofthe truck.
– The wheels are surrounded by a solid skirt. – Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations.
Hydraulic system
– Lifting and lowering are activated via the lift and lower buttons.– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder.
Emergency Stop safety feature
– The emergency stop is activated by the traction controller. – The steering controller sends a system status signal which is monitored by the
traction controller. If the signal fails to appear or a fault is identified the truckautomatically brakes to a halt. Control displays on the driver’s display indicate theemergency stop.
– Each time the truck is switched on the system performed an automatic diagnosis.
Operator Position
– All travel and lift operations can be performed sensitively without having to reach.– JetPilot or tiller (o) for reliable control of the industrial truck.
Order picking on the second level
– The second picking level can be reached via a step board (o) in the backrest andby climbing onto the battery cover.
– The industrial truck is optionally available with a height-adjustable operator position(o) for order picking on the 2nd level.
– Driving on the 2nd level is possible at reduced speed for industrial trucks withheight-adjustable JetPilot (o).
Operator platform
– Travel functions are only released when the driver stands on the operator platform.
Drive system
– A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox.– The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking withenergy regeneration.
– The driver can choose from 3 travel programs, depending on the load and theenvironment. from maximum performance to energy saving.
Steering
– The driver steers with a JetPilot or a tiller (o).– The steering motion is transmitted directly from the steering controller via a steer
motor directly to the ring gear of the pivoted drive system. – The drive system can be pivoted +/- 90°.
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NElectric steering (o)
– The electric steering system is self-monitoring.The steering controller permanently monitors the entire steering system. If an erroris detected the traction controller interrupts travel, brakes regeneratively and themagnetic brake is applied.
Electrical System
– 24 volt system. – Standard electronic traction, lift and steering control are standard.
Controls and Displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of thetravel operations.
– The battery discharge indicator shows the available battery capacity.– The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and event messages.
2.2.1 Hourmeter
Z Prepare the truck for operation, (see "Preparing the truck for operation" onpage 48) or (see "CanCode keypad" on page 69).
Service hours are counted while the truck is operational and the operator is standingon the platform.
2.2.2 Hourmeter in Pedestrian Mode
Z Prepare the truck for operation, (see "Preparing the truck for operation" onpage 48) or (see "CanCode keypad" on page 69).
Service hours are counted while the truck is operational and one of the followingcontrols is applied:– "Pedestrian - drive direction" button, see page 54.– "Pedestrian - load direction" button, see page 54.– "Pedestrian - lift" button, see page 58. – "Pedestrian - lower" button, see page 59.
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Electric steering (o)
– The electric steering system is self-monitoring.The steering controller permanently monitors the entire steering system. If an erroris detected the traction controller interrupts travel, brakes regeneratively and themagnetic brake is applied.
Electrical System
– 24 volt system. – Standard electronic traction, lift and steering control are standard.
Controls and Displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of thetravel operations.
– The battery discharge indicator shows the available battery capacity.– The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and event messages.
2.2.1 Hourmeter
Z Prepare the truck for operation, (see "Preparing the truck for operation" onpage 48) or (see "CanCode keypad" on page 69).
Service hours are counted while the truck is operational and the operator is standingon the platform.
2.2.2 Hourmeter in Pedestrian Mode
Z Prepare the truck for operation, (see "Preparing the truck for operation" onpage 48) or (see "CanCode keypad" on page 69).
Service hours are counted while the truck is operational and one of the followingcontrols is applied:– "Pedestrian - drive direction" button, see page 54.– "Pedestrian - load direction" button, see page 54.– "Pedestrian - lift" button, see page 58. – "Pedestrian - lower" button, see page 59.
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3 Technical Specifications
Z Technical specification details in accordance with VDI 2198. Technicalmodifications and additions reserved.
3.1 Performance data
ECE 310 / 310 HP
Q Rated capacity 1000 kg
c Load centre distance for standard fork length *) 600 mm
Travel speed w / w.o. rated load 9,5 / 12,0 km/h
Lift speed with / without rated load 0,08 / 0,11 m/s
Hydraulic platform lift speed 0,29 m/s
Lower speed with / without load 0,12 / 0,05 m/s
Max. gradeability (5 min) w / w.o. load 6 / 15 %
Drive motor, output S2 60 min 2,8 kW
Lift motor, output S3 (on time) 15% 1,5 kW
*) For trucks with longer forks the load centre is at the centre of the fork.
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3 Technical Specifications
Z Technical specification details in accordance with VDI 2198. Technicalmodifications and additions reserved.
3.1 Performance data
ECE 310 / 310 HP
Q Rated capacity 1000 kg
c Load centre distance for standard fork length *) 600 mm
Travel speed w / w.o. rated load 9,5 / 12,0 km/h
Lift speed with / without rated load 0,08 / 0,11 m/s
Hydraulic platform lift speed 0,29 m/s
Lower speed with / without load 0,12 / 0,05 m/s
Max. gradeability (5 min) w / w.o. load 6 / 15 %
Drive motor, output S2 60 min 2,8 kW
Lift motor, output S3 (on time) 15% 1,5 kW
*) For trucks with longer forks the load centre is at the centre of the fork.
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N3.2 Dimensions
h13m2
Q
50
s1009
1399
474
218 257380 412 xy
c
l
h3
1635
e
a2
a2
132175
b1
Wal2
Ast
l1
b11 b5
19
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3.2 Dimensions
h13m2
Q
50
s1009
1399
474
218 257380 412 xy
c
l
h3
1635
e
a2
a2
132175
b1
Wal2
Ast
l1
b11 b5
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20
218y
l
h13
h3
c
445 390 437
15017550474
1010
1399
Q
x
s
1434
b1 b5
e
Wa
Ast
a2
a2
l2l1
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20
218y
l
h13
h3
c
445 390 437
15017550474
1010
1399
Q
x
s
1434
b1 b5
e
Wa
Ast
a2
a2
l2l1
21
11.1
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N
ECE 310 aisle widths
(all dimensions in mm)
1) HP + 150 mm
ECE 310 ECE 310 HP
l2 Headlength 1341 1491 mm
h13 Lowered fork height 90 mm
h14 Tiller height in travel position 1399
h3 Rated lift 700 mm
h1 Backrest height 1635 1434 mm
hb Battery cover height 1009 1010 mm
hf Standing platform height 132 150 mm
b1 Truck width 810 mm
m2 Ground clearance centre wheelbase
25 mm
b10 Track width, front 500 mm
b11 Track width, rear 380 mm
b5 Outside straddle 560 mm
s/e/l Fork dimensions 60 / 180 / 1150 mm
a Safety distance 200 mm
Wa Turning radius 2145 2300 mm
Net weight: See truck data plate
l l1 1) y 1) x l6 Wa 1) Ast3 1)
1150 2491 1920 800 1200 2145 2911
1400 2741 1920 800 1400 2145 3061
21
11.1
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N
ECE 310 aisle widths
(all dimensions in mm)
1) HP + 150 mm
ECE 310 ECE 310 HP
l2 Headlength 1341 1491 mm
h13 Lowered fork height 90 mm
h14 Tiller height in travel position 1399
h3 Rated lift 700 mm
h1 Backrest height 1635 1434 mm
hb Battery cover height 1009 1010 mm
hf Standing platform height 132 150 mm
b1 Truck width 810 mm
m2 Ground clearance centre wheelbase
25 mm
b10 Track width, front 500 mm
b11 Track width, rear 380 mm
b5 Outside straddle 560 mm
s/e/l Fork dimensions 60 / 180 / 1150 mm
a Safety distance 200 mm
Wa Turning radius 2145 2300 mm
Net weight: See truck data plate
l l1 1) y 1) x l6 Wa 1) Ast3 1)
1150 2491 1920 800 1200 2145 2911
1400 2741 1920 800 1400 2145 3061
11.1
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22
3.3 Weights
3.4 Tyre type
ECE 310 ECE 310 HP
Net weight excl. battery 1244 1346 kg
Axle load, w. loadfront / rear
1296/956 1324/1020 kg
Axle load, w.o. loadfront / rear
372/872 420/926 kg
Battery weight 370 kg
ECE 310
Tyre size, drive 230x78
Tyre size, load section 85x95
Castor wheel (twin wheel) 180x65
Wheels, number front/rear(x = driven)
2 - 1x / 2
11.1
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22
3.3 Weights
3.4 Tyre type
ECE 310 ECE 310 HP
Net weight excl. battery 1244 1346 kg
Axle load, w. loadfront / rear
1296/956 1324/1020 kg
Axle load, w.o. loadfront / rear
372/872 420/926 kg
Battery weight 370 kg
ECE 310
Tyre size, drive 230x78
Tyre size, load section 85x95
Castor wheel (twin wheel) 180x65
Wheels, number front/rear(x = driven)
2 - 1x / 2
23
11.1
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N3.5 EN norms
Noise emission level
– ECE 310: 67 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the level of the driver's ear.
Vibration
– ECE 310: 0,85 m/s² – ECE 220 XL: 0,92 m/s²
in accordance with EN 13059
Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weightedacceleration in the vertical direction. It is calculated when travelling over bumps atconstant speed. These recordings were taken on a single occasion and must notbe confused with the human vibrations of the "2002/44/EC/Vibrations" operatordirective. The manufacturer offers a special service to measure these humanvibrations, (see "Human vibration measurement" on page 113).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagneticemissions and resistance as well as the static electricity discharge test in accordancewith EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may bemade without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiationElectrical equipment on the truck emitting non-ionised radiation (e.g. wireless datatransmission) can affect operators' medical equipment (pacemakers, hearing aidsetc.) and result in malfunctions. Consult with a doctor or the medical equipmentmanufacturer to clarify whether it can be used near the industrial truck.
23
11.1
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3.5 EN norms
Noise emission level
– ECE 310: 67 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the level of the driver's ear.
Vibration
– ECE 310: 0,85 m/s² – ECE 220 XL: 0,92 m/s²
in accordance with EN 13059
Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weightedacceleration in the vertical direction. It is calculated when travelling over bumps atconstant speed. These recordings were taken on a single occasion and must notbe confused with the human vibrations of the "2002/44/EC/Vibrations" operatordirective. The manufacturer offers a special service to measure these humanvibrations, (see "Human vibration measurement" on page 113).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagneticemissions and resistance as well as the static electricity discharge test in accordancewith EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may bemade without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiationElectrical equipment on the truck emitting non-ionised radiation (e.g. wireless datatransmission) can affect operators' medical equipment (pacemakers, hearing aidsetc.) and result in malfunctions. Consult with a doctor or the medical equipmentmanufacturer to clarify whether it can be used near the industrial truck.
11.1
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24
3.6 Conditions of use
Ambient temperature
– operating at 5°C to 40°C
Z Special equipment and authorisation are required if the truck is to be constantlyused in conditions of extreme temperature or air humidity fluctuations.
3.7 Electrical requirements
The manufacturer certifies compliance with the requirements for the design andmanufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -Electrical Requirements", provided the truck is used according to its purpose.
11.1
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N
24
3.6 Conditions of use
Ambient temperature
– operating at 5°C to 40°C
Z Special equipment and authorisation are required if the truck is to be constantlyused in conditions of extreme temperature or air humidity fluctuations.
3.7 Electrical requirements
The manufacturer certifies compliance with the requirements for the design andmanufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -Electrical Requirements", provided the truck is used according to its purpose.
25
11.1
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N3.8 Identification points and data plates
Item Description23 Data plate24 Warning: “Caution, pushbutton operation”25 Load chart26 Test plaque27 Truck designation28 Serial number29 Capacity Qmax30 Strap points for crane lifting
Qmax 2000kg
Qmax XXX kg
*)
*)
24
23
30
28
26
29
2424
24
25
27
25
11.1
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N
3.8 Identification points and data plates
Item Description23 Data plate24 Warning: “Caution, pushbutton operation”25 Load chart26 Test plaque27 Truck designation28 Serial number29 Capacity Qmax30 Strap points for crane lifting
Qmax 2000kg
Qmax XXX kg
*)
*)
24
23
30
28
26
29
2424
24
25
27
11.1
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26
3.8.1 Data plate
Z For queries regarding the truck or ordering spare parts always quote the truck serialnumber (32).
3.8.2 Truck load chart
The load chart (29) gives the capacity (Q) of the truck in kg assuming the load on theload handler is evenly distributed.
31 32 3433 35
42
38
41
40
39
3736
Item Description Item Description31 Type 37 Year of manufacture32 Serial number 38 Load centre (mm)33 Rated capacity (kg) 39 Output34 Battery voltage (V) 40 Min./max. battery weight (kg)35 Net weight w.o. battery (kg) 41 Manufacturer36 Option 42 Manufacturer’s logo
Qmax XXX kg 29
11.1
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26
3.8.1 Data plate
Z For queries regarding the truck or ordering spare parts always quote the truck serialnumber (32).
3.8.2 Truck load chart
The load chart (29) gives the capacity (Q) of the truck in kg assuming the load on theload handler is evenly distributed.
31 32 3433 35
42
38
41
40
39
3736
Item Description Item Description31 Type 37 Year of manufacture32 Serial number 38 Load centre (mm)33 Rated capacity (kg) 39 Output34 Battery voltage (V) 40 Min./max. battery weight (kg)35 Net weight w.o. battery (kg) 41 Manufacturer36 Option 42 Manufacturer’s logo
Qmax XXX kg 29
27
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C Transport and Commissioning
1 Lifting by crane
WARNING!
Improper lifting by crane can result in accidentsThe use of unsuitable lifting gear can cause the truck to crash when being lifted bycrane.Prevent the truck from striking other objects when it is being raised, and avoid anyinvoluntary movements. If necessary secure the truck with guide ropes.The truck should only be handled by people who are trained in using lifting slings
and tools.Wear safety shoes when lifting the truck by crane.Do not stand under a swaying load.Do not walk into or stand in a hazardous area.Always use lifting gear with sufficient capacity (for truck weight see truck data
plate).Always attach the crane slings to the prescribed strap points and prevent them from
slipping.Use the lifting gear only in the prescribed load direction.Crane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
Lifting the truck by crane
Requirements– Park the truck securely, (see
"Parking the truck securely" onpage 50).
Tools and Material Required– Lifting gear– Crane lifting gear
Procedure• Open the front panel (15) and put it to
one side.• Secure the lifting slings to the strap
points (30).
The truck can now be lifted by crane.
3030
27
11.1
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N
C Transport and Commissioning
1 Lifting by crane
WARNING!
Improper lifting by crane can result in accidentsThe use of unsuitable lifting gear can cause the truck to crash when being lifted bycrane.Prevent the truck from striking other objects when it is being raised, and avoid anyinvoluntary movements. If necessary secure the truck with guide ropes.The truck should only be handled by people who are trained in using lifting slings
and tools.Wear safety shoes when lifting the truck by crane.Do not stand under a swaying load.Do not walk into or stand in a hazardous area.Always use lifting gear with sufficient capacity (for truck weight see truck data
plate).Always attach the crane slings to the prescribed strap points and prevent them from
slipping.Use the lifting gear only in the prescribed load direction.Crane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
Lifting the truck by crane
Requirements– Park the truck securely, (see
"Parking the truck securely" onpage 50).
Tools and Material Required– Lifting gear– Crane lifting gear
Procedure• Open the front panel (15) and put it to
one side.• Secure the lifting slings to the strap
points (30).
The truck can now be lifted by crane.
3030
11.1
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28
2 Transport
WARNING!
Accidental movement during transportImproper fastening of the truck and mast during transport can result in seriousaccidents.Loading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each casecorrect measurements must be made and appropriate safety measures adopted.
The truck must be securely fastened when transported on a lorry or a trailer.The lorry / trailer must have fastening rings.Use wedges to prevent the truck from moving.Use only tension belts or tie-down straps or with sufficient strength.
Securing the truck for transport
Tools and Material Required– Tension belts/tie down straps
Procedure• Move the truck onto the transporting
truck.• Park the truck securely, (see
"Parking the truck securely" onpage 50).
• Strap the belts (43) around the truckand tension them sufficiently.
The truck can now be transported.
43
11.1
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28
2 Transport
WARNING!
Accidental movement during transportImproper fastening of the truck and mast during transport can result in seriousaccidents.Loading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each casecorrect measurements must be made and appropriate safety measures adopted.
The truck must be securely fastened when transported on a lorry or a trailer.The lorry / trailer must have fastening rings.Use wedges to prevent the truck from moving.Use only tension belts or tie-down straps or with sufficient strength.
Securing the truck for transport
Tools and Material Required– Tension belts/tie down straps
Procedure• Move the truck onto the transporting
truck.• Park the truck securely, (see
"Parking the truck securely" onpage 50).
• Strap the belts (43) around the truckand tension them sufficiently.
The truck can now be transported.
43
29
11.1
4 E
N3 Using the Truck for the First Time
CAUTION!
Only operate the truck with battery current. Rectified AC current will damage theelectronic components. Cable connections to the battery (tow leads) must be lessthan 6 m long and have a minimum cross-section of 50 mm².
Procedure• Check the equipment is complete.• If necessary install the battery, (see "Battery removal and installation" on page 37)• Charge the battery, (see "Charging the battery" on page 35).
The truck can now be started, (see "Starting up the truck" on page 47)
NOTE
Cold store trucksTrucks designed for use in cold stores have a cold store hydraulic oil and a
protective frame instead of a mast guard on the mast.If a truck with cold store oil is used outside the cold store, the lowering speeds may
increase.
29
11.1
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3 Using the Truck for the First Time
CAUTION!
Only operate the truck with battery current. Rectified AC current will damage theelectronic components. Cable connections to the battery (tow leads) must be lessthan 6 m long and have a minimum cross-section of 50 mm².
Procedure• Check the equipment is complete.• If necessary install the battery, (see "Battery removal and installation" on page 37)• Charge the battery, (see "Charging the battery" on page 35).
The truck can now be started, (see "Starting up the truck" on page 47)
NOTE
Cold store trucksTrucks designed for use in cold stores have a cold store hydraulic oil and a
protective frame instead of a mast guard on the mast.If a truck with cold store oil is used outside the cold store, the lowering speeds may
increase.
31
11.1
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D Battery - Servicing, Recharging,Replacement
1 Safety Regulations Governing the Handling of Lead-AcidBatteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. Thisoperator manual and the manufacturer’s instructions concerning batteries andcharging stations must be observed when carrying out the work.
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever anindustrial truck is parked for charging there shall be no inflammable material orlubricants capable of creating sparks within 2 m around the truck. The room must beventilated. Fire protection equipment must be on hand.
Battery maintenance
The battery cell covers must be kept dry and clean. The terminals and cable shoesmust be clean, secure and have a light coating of dielectric grease.
CAUTION!
Before closing the battery panel make sure that the battery cable cannot bedamaged. There is a risk of short circuits with damaged cables.
Battery disposal
Batteries may only be disposed of in accordance with national environmentalprotection regulations or disposal laws. The manufacturer’s disposal instructionsmust be followed.
31
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D Battery - Servicing, Recharging,Replacement
1 Safety Regulations Governing the Handling of Lead-AcidBatteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. Thisoperator manual and the manufacturer’s instructions concerning batteries andcharging stations must be observed when carrying out the work.
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever anindustrial truck is parked for charging there shall be no inflammable material orlubricants capable of creating sparks within 2 m around the truck. The room must beventilated. Fire protection equipment must be on hand.
Battery maintenance
The battery cell covers must be kept dry and clean. The terminals and cable shoesmust be clean, secure and have a light coating of dielectric grease.
CAUTION!
Before closing the battery panel make sure that the battery cable cannot bedamaged. There is a risk of short circuits with damaged cables.
Battery disposal
Batteries may only be disposed of in accordance with national environmentalprotection regulations or disposal laws. The manufacturer’s disposal instructionsmust be followed.
11.1
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32
WARNING!
Batteries can be hazardousBatteries contain an acid solution which is poisonous and corrosive. Above all avoidany contact with battery acid.Dispose of used battery acid in accordance with regulations.Always wear protective clothing and goggles when working with batteries.Do not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.In the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.Spilled battery acid should be neutralised immediately with plenty of water.Only batteries with a sealed battery container may be used.Follow national guidelines and legislation.
WARNING!
Using unsuitable batteries can cause accidentsThe weight and dimensions of the battery have a considerable effect on theoperational safety and capacity of the industrial truck. Changing the battery featuresrequires the manufacturer’s approval, as compensating weights are required ifsmaller batteries are fitted. When replacing/installing the battery make sure thebattery is securely located in the battery compartment of the truck.
Park the truck securely before carrying out any work on the batteries ((see "Parkingthe truck securely" on page 50)).
2 Battery types
Depending on the model, the truck will be supplied with different battery types. Thefollowing table shows which combinations are included as standard:
The battery weights can be taken from the battery data plate. Batteries with noninsulated terminals must be covered with a non slip insulating mat.
Battery type Capacity Weight
24 V - Battery 798X212X784 mm (LXWXH)
3 PzS 420 Ah L 370 kg
24 V - Battery 798X212X784 mm (LXWXH)
Enhanced capacity
3 PzS 450 Ah HX 370 kg
11.1
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32
WARNING!
Batteries can be hazardousBatteries contain an acid solution which is poisonous and corrosive. Above all avoidany contact with battery acid.Dispose of used battery acid in accordance with regulations.Always wear protective clothing and goggles when working with batteries.Do not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.In the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.Spilled battery acid should be neutralised immediately with plenty of water.Only batteries with a sealed battery container may be used.Follow national guidelines and legislation.
WARNING!
Using unsuitable batteries can cause accidentsThe weight and dimensions of the battery have a considerable effect on theoperational safety and capacity of the industrial truck. Changing the battery featuresrequires the manufacturer’s approval, as compensating weights are required ifsmaller batteries are fitted. When replacing/installing the battery make sure thebattery is securely located in the battery compartment of the truck.
Park the truck securely before carrying out any work on the batteries ((see "Parkingthe truck securely" on page 50)).
2 Battery types
Depending on the model, the truck will be supplied with different battery types. Thefollowing table shows which combinations are included as standard:
The battery weights can be taken from the battery data plate. Batteries with noninsulated terminals must be covered with a non slip insulating mat.
Battery type Capacity Weight
24 V - Battery 798X212X784 mm (LXWXH)
3 PzS 420 Ah L 370 kg
24 V - Battery 798X212X784 mm (LXWXH)
Enhanced capacity
3 PzS 450 Ah HX 370 kg
33
11.1
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N3 Exposing the battery
CAUTION!
Trapping hazardMake sure there is nothing between the battery cover and the truck when you fit the
battery cover.
WARNING!
An unsecured truck can cause accidentsParking the truck on an incline or with a raised load handler is dangerous and isstrictly prohibited.Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges.Always fully lower the mast and forks.Select a place to park where no other people are at risk of injury from lowering
forks.
Requirements– Park the truck on a level surface.– Park the truck securely, (see
"Parking the truck securely" onpage 50).
Procedure• Pull the lever (44) upward while at
the same time setting the JetPilotvertical.
• Flip the battery latch (45) up, pull upthe lock and open the battery cover(13).
The battery connector (46) andbattery retainer (38) can be accessed
44
1345
33
11.1
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3 Exposing the battery
CAUTION!
Trapping hazardMake sure there is nothing between the battery cover and the truck when you fit the
battery cover.
WARNING!
An unsecured truck can cause accidentsParking the truck on an incline or with a raised load handler is dangerous and isstrictly prohibited.Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges.Always fully lower the mast and forks.Select a place to park where no other people are at risk of injury from lowering
forks.
Requirements– Park the truck on a level surface.– Park the truck securely, (see
"Parking the truck securely" onpage 50).
Procedure• Pull the lever (44) upward while at
the same time setting the JetPilotvertical.
• Flip the battery latch (45) up, pull upthe lock and open the battery cover(13).
The battery connector (46) andbattery retainer (38) can be accessed
44
1345
11.1
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34
Exposing the battery with JetPilot LJoption
Procedure• Loosen and flip back the JetPilot, (see
"Flipping the JetPilot back formaintenance purposes (o)" onpage 106).
The battery cover can be opened.
13
11.1
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34
Exposing the battery with JetPilot LJoption
Procedure• Loosen and flip back the JetPilot, (see
"Flipping the JetPilot back formaintenance purposes (o)" onpage 106).
The battery cover can be opened.
13
35
11.1
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N4 Charging the battery
WARNING!
The gases produced during charging can cause explosionsThe battery produces a mixture of nitrogen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Switch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.The charger must be adapted to the battery in terms of voltage and charge
capacity.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.The battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.Fire protection equipment must be on hand.Do not lay any metallic objects on battery.It is essential to follow the safety regulations of the battery and charger station
manufacturers.
Charging the battery
Requirements– Park the truck on a level surface.– Expose the battery, (see "Exposing the battery" on page 33).– Disconnect the battery
Procedure• Pull the battery connector (46) from out of the bracket (48).• Remove any insulating mats from the battery.• Connect the charger lead (47) of the battery charger station with the battery
connector (46).• Switch on the charger / charging begins automatically.
The battery is now charged.
35
11.1
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4 Charging the battery
WARNING!
The gases produced during charging can cause explosionsThe battery produces a mixture of nitrogen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Switch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.The charger must be adapted to the battery in terms of voltage and charge
capacity.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.The battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.Fire protection equipment must be on hand.Do not lay any metallic objects on battery.It is essential to follow the safety regulations of the battery and charger station
manufacturers.
Charging the battery
Requirements– Park the truck on a level surface.– Expose the battery, (see "Exposing the battery" on page 33).– Disconnect the battery
Procedure• Pull the battery connector (46) from out of the bracket (48).• Remove any insulating mats from the battery.• Connect the charger lead (47) of the battery charger station with the battery
connector (46).• Switch on the charger / charging begins automatically.
The battery is now charged.
11.1
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36
Completing the battery charge, restoring the truck to operation
NOTE
If charging has been interrupted, the full battery capacity will not be available
Requirements– Battery charging is complete.
Procedure• Switch off the charger.• Disconnect the battery from the charger.• Connect the battery to the truck.
The truck is operational again
47 4846
11.1
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36
Completing the battery charge, restoring the truck to operation
NOTE
If charging has been interrupted, the full battery capacity will not be available
Requirements– Battery charging is complete.
Procedure• Switch off the charger.• Disconnect the battery from the charger.• Connect the battery to the truck.
The truck is operational again
47 4846
37
11.1
4 E
N5 Battery removal and installation
WARNING!
Accident risk during battery removal and installationDue to the battery weight and acid there is a risk of trapping or scalding when thebattery is removed and installed.Note the "Safety regulations for handling acid batteries" section in this chapter.Wear safety shoes when removing and installing the battery.Use only batteries with insulated cells and terminal connectors.Park the truck on a level surface to prevent the battery from sliding out.Make sure the crane slings have sufficient capacity to replace the battery.Use only approved battery replacement devices (battery roller stand, replacement
trolley etc.).Make sure the battery is securely located in the truck's battery compartment.
Removing the battery from the top
Battery removal
Requirements– Park the truck securely, (see "Parking the truck securely" on page 50).– Expose the battery, (see "Exposing the battery" on page 33).
Procedure• Disconnect the battery connector from the truck connector.
Z Place the battery cable on the tray so that it cannot be severed when the battery ispulled out.
• Undo the battery lock (45).• Strap the crane lifting gear to the eyes (49).
Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear mustnever fall into the battery cells.
• Pull the battery (50) up out of the battery compartment.
The battery is now removed.
Z Installation is the reverse order. When reinstalling the battery, note the properinstallation position and make sure the battery is connected correctly.
37
11.1
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N
5 Battery removal and installation
WARNING!
Accident risk during battery removal and installationDue to the battery weight and acid there is a risk of trapping or scalding when thebattery is removed and installed.Note the "Safety regulations for handling acid batteries" section in this chapter.Wear safety shoes when removing and installing the battery.Use only batteries with insulated cells and terminal connectors.Park the truck on a level surface to prevent the battery from sliding out.Make sure the crane slings have sufficient capacity to replace the battery.Use only approved battery replacement devices (battery roller stand, replacement
trolley etc.).Make sure the battery is securely located in the truck's battery compartment.
Removing the battery from the top
Battery removal
Requirements– Park the truck securely, (see "Parking the truck securely" on page 50).– Expose the battery, (see "Exposing the battery" on page 33).
Procedure• Disconnect the battery connector from the truck connector.
Z Place the battery cable on the tray so that it cannot be severed when the battery ispulled out.
• Undo the battery lock (45).• Strap the crane lifting gear to the eyes (49).
Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear mustnever fall into the battery cells.
• Pull the battery (50) up out of the battery compartment.
The battery is now removed.
Z Installation is the reverse order. When reinstalling the battery, note the properinstallation position and make sure the battery is connected correctly.
39
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Removing the battery from the side (o)
CAUTION!
Trapping hazardTrapping hazard when removing and installing the battery.When removing and installing the battery do not put your hands between the
battery and the chassis.
Battery removal
Requirements– Park the truck securely, (see "Parking the truck securely" on page 50).– Expose the battery, (see "Exposing the battery" on page 33).
Tools and Material Required– Battery replacement station / trolley
Procedure• Disconnect the battery connector (46) from the truck connector.• Undo the battery lock (45).• Move the battery replacement station / trolley up to the side of the truck.• Carefully push the battery from off the truck onto the battery replacement station /
trolley.
The battery is now removed.
Battery installation
Requirements– Park the truck securely, (see "Parking the truck securely" on page 50).– Expose the battery, (see "Exposing the battery" on page 33).
ProcedureZ Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly.
39
11.1
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Removing the battery from the side (o)
CAUTION!
Trapping hazardTrapping hazard when removing and installing the battery.When removing and installing the battery do not put your hands between the
battery and the chassis.
Battery removal
Requirements– Park the truck securely, (see "Parking the truck securely" on page 50).– Expose the battery, (see "Exposing the battery" on page 33).
Tools and Material Required– Battery replacement station / trolley
Procedure• Disconnect the battery connector (46) from the truck connector.• Undo the battery lock (45).• Move the battery replacement station / trolley up to the side of the truck.• Carefully push the battery from off the truck onto the battery replacement station /
trolley.
The battery is now removed.
Battery installation
Requirements– Park the truck securely, (see "Parking the truck securely" on page 50).– Expose the battery, (see "Exposing the battery" on page 33).
ProcedureZ Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly.
41
11.1
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NE Operation
1 Safety Regulations for the Operation of theForklift Truck
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated tothe proprietor or his representative that they can drive and handle loads and havebeen authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities
The driver must be informed of his duties and responsibilities and be instructed in theoperation of the truck and shall be familiar with the operating instructions. The drivershall be afforded all due rights. Safety shoes must be worn for pedestrian operatedtrucks.
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver mustprevent unauthorised persons from driving or operating the truck. Do not carrypassengers or lift other people.
Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck orattachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)must not be used until they have been rectified.
Repairs
The driver must not carry out any repairs or alterations to the truck without thenecessary training and authorisation to do so. The driver must never disable or adjustsafety mechanisms or switches.
Hazardous area
WARNING!
Risk of accidents / injury in the hazardous area of the truckThe hazardous area is defined as the area in which a person is at risk due to truckmovement, lifting operations, the load handler (e.g. forks or attachments) or the loaditself. This also includes areas which can be reached by falling loads or loweringoperating equipment.Instruct unauthorised people to leave the hazardous area.Give a warning signal with plenty of time for people to leave.If unauthorised personnel are still within the hazardous area stop the truck
immediately.
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11.1
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E Operation
1 Safety Regulations for the Operation of theForklift Truck
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated tothe proprietor or his representative that they can drive and handle loads and havebeen authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities
The driver must be informed of his duties and responsibilities and be instructed in theoperation of the truck and shall be familiar with the operating instructions. The drivershall be afforded all due rights. Safety shoes must be worn for pedestrian operatedtrucks.
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver mustprevent unauthorised persons from driving or operating the truck. Do not carrypassengers or lift other people.
Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck orattachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)must not be used until they have been rectified.
Repairs
The driver must not carry out any repairs or alterations to the truck without thenecessary training and authorisation to do so. The driver must never disable or adjustsafety mechanisms or switches.
Hazardous area
WARNING!
Risk of accidents / injury in the hazardous area of the truckThe hazardous area is defined as the area in which a person is at risk due to truckmovement, lifting operations, the load handler (e.g. forks or attachments) or the loaditself. This also includes areas which can be reached by falling loads or loweringoperating equipment.Instruct unauthorised people to leave the hazardous area.Give a warning signal with plenty of time for people to leave.If unauthorised personnel are still within the hazardous area stop the truck
immediately.
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42
Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" onpage 25)) and warning instructions in the present operating instructions must bestrictly observed.
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42
Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" onpage 25)) and warning instructions in the present operating instructions must bestrictly observed.
43
11.1
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N2 Displays and Controls
51
1211
53
1
7810
53
2
678
52
9
6 451
21
910
112 2
51
20
9 9
11
54
57 56
55
59
58
12
6566
43
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2 Displays and Controls
51
1211
53
1
7810
53
2
678
52
9
6 451
21
910
112 2
51
20
9 9
11
54
57 56
55
59
58
12
6566
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44
Item Control / Display Function1 “Lower” button t – Lowers the lift mechanism.2 “Lift” button t – Raises the lift mechanism.3 Code lock o Replaces the key switch
– Activates the truck by entering the relevant code
4 CanDis o Display instrument for– Battery charge status– Service hours– Warning messages– Parameter settings
5 Key switch and key t – Activates the truck by applying the control voltage
– Removing the key prevents the truck from being switched on by unauthorised personnel
6 “Pedestrian” reverse button (not for “touch mode only in drive direction” option)
o – Travel starts in pedestrian mode in the reverse direction (R) (slow travel).
7 “Pedestrian" stop button o – The electrical functions are cut out and the truck automatically brakes.
8 Forward “pedestrian” button
o – Travel starts in pedestrian mode in the forward direction (V) (slow travel)
9 Travel switch t – Controls the travel direction and speed.CanCode o Replaces the key switch
– Activates the truck by entering the relevant code
– Travel program selection– Code setting– Parameter setting
ISM o Replaces the key switch– Activates the truck via a card /
transponder– Displays readiness for operation– Operational data acquisition– Data exchange with card / transponder
Charge display t – Battery charge status10 STOP button o – The truck decelerates at the maximum
rate until it comes to a halt.12 Emergency Disconnect
switcht Disconnects the battery supply
– All electric functions are deactivated and the truck decelerates
11 JetPilot t – Steers the truck.Tiller o – Steers the truck.
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44
Item Control / Display Function1 “Lower” button t – Lowers the lift mechanism.2 “Lift” button t – Raises the lift mechanism.3 Code lock o Replaces the key switch
– Activates the truck by entering the relevant code
4 CanDis o Display instrument for– Battery charge status– Service hours– Warning messages– Parameter settings
5 Key switch and key t – Activates the truck by applying the control voltage
– Removing the key prevents the truck from being switched on by unauthorised personnel
6 “Pedestrian” reverse button (not for “touch mode only in drive direction” option)
o – Travel starts in pedestrian mode in the reverse direction (R) (slow travel).
7 “Pedestrian" stop button o – The electrical functions are cut out and the truck automatically brakes.
8 Forward “pedestrian” button
o – Travel starts in pedestrian mode in the forward direction (V) (slow travel)
9 Travel switch t – Controls the travel direction and speed.CanCode o Replaces the key switch
– Activates the truck by entering the relevant code
– Travel program selection– Code setting– Parameter setting
ISM o Replaces the key switch– Activates the truck via a card /
transponder– Displays readiness for operation– Operational data acquisition– Data exchange with card / transponder
Charge display t – Battery charge status10 STOP button o – The truck decelerates at the maximum
rate until it comes to a halt.12 Emergency Disconnect
switcht Disconnects the battery supply
– All electric functions are deactivated and the truck decelerates
11 JetPilot t – Steers the truck.Tiller o – Steers the truck.
45
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20 “Platform raise” switch t Raises the platform at a constant speed.21 “Platform lower” switch t Lowers the platform at a constant speed.51 Warning signal (horn)
buttont – “Warning” button
52 JetPilot adjuster t – The JetPilot can be set to the required position
53 Operator platform t – released (without load): Travel inhibited, or truck brakes.
– pressed (with load):Travel released.
o In conjunction with pedestrian operation– without load:
Travel at reduced speed.– With load:
Travel at full speed.54 Safety bar o Grab bar for the 2nd level with the LJ option55 Safety bar o Additional grab bar for the 2nd level56 Emergency Disconnect
switch (LJ)o The electrical functions are cut out and the
truck automatically brakes. 57 JetPilot adjuster (LJ) o The JetPilot can be moved to the required
position.58 "Lift platform“ button (LJ) o Raises the platform at a constant speed.59 "Lower platform" button
(LJ)o Lowers the platform at a constant speed.
65 "Lift platform" button on Jetpilot (LJ)
o Raises the platform at a constant speed.
66 "Lower platform" button on Jetpilot (LJ)
o Lowers the platform at a constant speed.
t = Standard equipment o = Optional equipment
Item Control / Display Function
45
11.1
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20 “Platform raise” switch t Raises the platform at a constant speed.21 “Platform lower” switch t Lowers the platform at a constant speed.51 Warning signal (horn)
buttont – “Warning” button
52 JetPilot adjuster t – The JetPilot can be set to the required position
53 Operator platform t – released (without load): Travel inhibited, or truck brakes.
– pressed (with load):Travel released.
o In conjunction with pedestrian operation– without load:
Travel at reduced speed.– With load:
Travel at full speed.54 Safety bar o Grab bar for the 2nd level with the LJ option55 Safety bar o Additional grab bar for the 2nd level56 Emergency Disconnect
switch (LJ)o The electrical functions are cut out and the
truck automatically brakes. 57 JetPilot adjuster (LJ) o The JetPilot can be moved to the required
position.58 "Lift platform“ button (LJ) o Raises the platform at a constant speed.59 "Lower platform" button
(LJ)o Lowers the platform at a constant speed.
65 "Lift platform" button on Jetpilot (LJ)
o Raises the platform at a constant speed.
66 "Lower platform" button on Jetpilot (LJ)
o Lowers the platform at a constant speed.
t = Standard equipment o = Optional equipment
Item Control / Display Function
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46
2.1 Battery discharge indicator
When the truck has been released via the keyswitch, code lock or ISM, the battery charge statusis displayed. The LED (60) colours represent thefollowing conditions:
Z If the LED is red, load units can no longer be lifted. Lifting is only enabled againwhen the battery connected is at least 70% charged.
If the LED flashes red and the truck is not ready for operation, inform themanufacturer's service department. Red flashing is a truck controller code. Theflashing sequence indicates the type of fault.
LED colour Residual capacityGreen 40 - 100 %
Orange 30 - 40 %Flashing
green/orange 1Hz20 - 30 %
Red 0 - 20 %
60
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46
2.1 Battery discharge indicator
When the truck has been released via the keyswitch, code lock or ISM, the battery charge statusis displayed. The LED (60) colours represent thefollowing conditions:
Z If the LED is red, load units can no longer be lifted. Lifting is only enabled againwhen the battery connected is at least 70% charged.
If the LED flashes red and the truck is not ready for operation, inform themanufacturer's service department. Red flashing is a truck controller code. Theflashing sequence indicates the type of fault.
LED colour Residual capacityGreen 40 - 100 %
Orange 30 - 40 %Flashing
green/orange 1Hz20 - 30 %
Red 0 - 20 %
60
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11.1
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N3 Starting up the truck
3.1 Checks and operations to be performed before starting dailyoperation
WARNING!
Damage and other truck or attachment (special equipment) defects can resultin accidents.If damage or other truck or attachment (special equipment) defects are discoveredduring the following checks, the truck must be taken out of service until it has beenrepaired.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
Pre-start inspections
Procedure• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.• Check the battery attachment and wire connections for damage and make sure
they are secure.• Check the battery connectors are secure.• Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks.• Check the drive wheel and load wheels for damage.• Check that the markings and labels are present, clean and legible, (see
"Identification points and data plates" on page 25).• Test the Emergency Disconnect switch.• Check the control handle (damper) is restored to its normal position.• Check the controls are automatically restored to zero after being applied.• Test the warning signal.• Test the brakes.• Test the collision safety switch.
47
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3 Starting up the truck
3.1 Checks and operations to be performed before starting dailyoperation
WARNING!
Damage and other truck or attachment (special equipment) defects can resultin accidents.If damage or other truck or attachment (special equipment) defects are discoveredduring the following checks, the truck must be taken out of service until it has beenrepaired.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
Pre-start inspections
Procedure• Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately.• Check the battery attachment and wire connections for damage and make sure
they are secure.• Check the battery connectors are secure.• Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks.• Check the drive wheel and load wheels for damage.• Check that the markings and labels are present, clean and legible, (see
"Identification points and data plates" on page 25).• Test the Emergency Disconnect switch.• Check the control handle (damper) is restored to its normal position.• Check the controls are automatically restored to zero after being applied.• Test the warning signal.• Test the brakes.• Test the collision safety switch.
11.1
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48
3.2 Preparing the truck for operation
Switching on the truck
Requirements– For checks and operations to be performed before starting daily operation, (see
"Checks and operations to be performed before starting daily operation" onpage 47).
Procedure• Step onto the operator platform (54).• Loosen the Jet pilot adjuster and set the Jet pilot to the required position. Now
release the Jet pilot adjuster again.• Pull out the Emergency Disconnect switch (12).• Switch on the truck, to do this:
• Insert the key in the key switch (60) and turn it to the right as far as it will go(position “I”) or for CANCODE (3,o) enter the activation code, (see "CanCodekeypad" on page 69).
• Test the warning signal button (51).• Test the travel switch (9).• Test the steering.
The truck is operational.
WARNING!
Do not press the travel switch or the "pedestrian" button (o) when entering andexiting the truck.
Z The CanDis display instrument (4(o)) indicates the available battery capacity.
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48
3.2 Preparing the truck for operation
Switching on the truck
Requirements– For checks and operations to be performed before starting daily operation, (see
"Checks and operations to be performed before starting daily operation" onpage 47).
Procedure• Step onto the operator platform (54).• Loosen the Jet pilot adjuster and set the Jet pilot to the required position. Now
release the Jet pilot adjuster again.• Pull out the Emergency Disconnect switch (12).• Switch on the truck, to do this:
• Insert the key in the key switch (60) and turn it to the right as far as it will go(position “I”) or for CANCODE (3,o) enter the activation code, (see "CanCodekeypad" on page 69).
• Test the warning signal button (51).• Test the travel switch (9).• Test the steering.
The truck is operational.
WARNING!
Do not press the travel switch or the "pedestrian" button (o) when entering andexiting the truck.
Z The CanDis display instrument (4(o)) indicates the available battery capacity.
11.1
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50
3.3 Parking the truck securely
WARNING!
An unsecured truck can cause accidentsParking the truck on an incline, without the brakes applied or with a raised load / loadhandler is dangerous and is strictly prohibited.Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges.Always fully lower the mast and forks.Select a place to park where no other people are at risk of injury from lowering
forks.
Parking the truck securely
Procedure• Fully lower the load handler.• Set the drive wheel to “Straight ahead”.
Z JetPilot (t): The control arm is set automatically to straight travel.Tiller (o): Set tiller to the forward position.
• Turn off the key switch and remove the key.• For CANCODE, press the O key.• For ISM, press the red button.• Press the Emergency Disconnect.
The truck is parked.
3.4 Battery discharge monitor
Z The standard setting for the battery discharge indicator / discharge monitor isbased on standard batteries. When using maintenance-free or special batteries thedisplay and cutout points of the battery discharge monitor must be set byauthorised specialist personnel. If this adjustment is not made the battery maybecome damaged through excessive depletion.
If the residual capacity falls below the required level, lifting is inhibited. An alternatingdisplay (60) appears. Lifting is only released when the battery connected is at least70% charged.
11.1
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50
3.3 Parking the truck securely
WARNING!
An unsecured truck can cause accidentsParking the truck on an incline, without the brakes applied or with a raised load / loadhandler is dangerous and is strictly prohibited.Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges.Always fully lower the mast and forks.Select a place to park where no other people are at risk of injury from lowering
forks.
Parking the truck securely
Procedure• Fully lower the load handler.• Set the drive wheel to “Straight ahead”.
Z JetPilot (t): The control arm is set automatically to straight travel.Tiller (o): Set tiller to the forward position.
• Turn off the key switch and remove the key.• For CANCODE, press the O key.• For ISM, press the red button.• Press the Emergency Disconnect.
The truck is parked.
3.4 Battery discharge monitor
Z The standard setting for the battery discharge indicator / discharge monitor isbased on standard batteries. When using maintenance-free or special batteries thedisplay and cutout points of the battery discharge monitor must be set byauthorised specialist personnel. If this adjustment is not made the battery maybecome damaged through excessive depletion.
If the residual capacity falls below the required level, lifting is inhibited. An alternatingdisplay (60) appears. Lifting is only released when the battery connected is at least70% charged.
51
11.1
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N4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised thirdparties must stay away from work areas. Loads must only be stored in placesspecially designated for this purpose.The truck must only be operated in work areas with sufficient lighting to avoid dangerto personnel and materials. Additional equipment is necessary to operate the truck inareas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.At blind spots get a second person to assist.The driver must ensure that the loading dock / ramp cannot move or come looseduring loading / unloading.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be drivenat slow speed when negotiating bends or narrow passageways, when passingthrough swing doors and at blind spots. The driver must always observe an adequatebraking distance between the forklift truck and the vehicle in front and must be incontrol of the truck at all times. Abrupt stopping (except in emergencies), rapid U turnsand overtaking at dangerous or blind spots are not permitted. Do not lean out or reachbeyond the working and operating area.
Travel visibility
The driver must look in the direction of travel and must always have a clear view ofthe route ahead. Loads that affect visibility must be positioned at the rear of the truck.If this is not possible, a second person must walk alongside the truck as a lookout toobserve the travel route while maintaining eye contact with the driver. Proceed onlyat walking pace and with particular care. Stop the truck as soon as you lose eyecontact.
Negotiating slopes and inclines
Negotiating slopes or inclines is only permitted if they are specifically designed astravel routes, are clean and have a non-slip surface and providing they can be safelytravelled along in accordance with the truck's technical specifications. The truck mustalways be driven with the load unit facing uphill. The industrial truck must not beturned, operated at an angle or parked on inclines or slopes. Inclines must only benegotiated at slow speed, with the driver ready to brake at any moment.
51
11.1
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4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised thirdparties must stay away from work areas. Loads must only be stored in placesspecially designated for this purpose.The truck must only be operated in work areas with sufficient lighting to avoid dangerto personnel and materials. Additional equipment is necessary to operate the truck inareas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.At blind spots get a second person to assist.The driver must ensure that the loading dock / ramp cannot move or come looseduring loading / unloading.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be drivenat slow speed when negotiating bends or narrow passageways, when passingthrough swing doors and at blind spots. The driver must always observe an adequatebraking distance between the forklift truck and the vehicle in front and must be incontrol of the truck at all times. Abrupt stopping (except in emergencies), rapid U turnsand overtaking at dangerous or blind spots are not permitted. Do not lean out or reachbeyond the working and operating area.
Travel visibility
The driver must look in the direction of travel and must always have a clear view ofthe route ahead. Loads that affect visibility must be positioned at the rear of the truck.If this is not possible, a second person must walk alongside the truck as a lookout toobserve the travel route while maintaining eye contact with the driver. Proceed onlyat walking pace and with particular care. Stop the truck as soon as you lose eyecontact.
Negotiating slopes and inclines
Negotiating slopes or inclines is only permitted if they are specifically designed astravel routes, are clean and have a non-slip surface and providing they can be safelytravelled along in accordance with the truck's technical specifications. The truck mustalways be driven with the load unit facing uphill. The industrial truck must not beturned, operated at an angle or parked on inclines or slopes. Inclines must only benegotiated at slow speed, with the driver ready to brake at any moment.
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52
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving onand authorised for truck traffic by the owner. The driver must satisfy himself of theabove before entering these areas. The truck must enter lifts with the load in front andmust take up a position which does not allow it to come into contact with the walls ofthe lift shaft. People travelling in the lift with the forklift truck must only enter the liftafter the truck has come to a halt and must exit the lift before the truck. The drivermust ensure that the loading ramp / bridge cannot move or come loose during loading/ unloading.
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52
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving onand authorised for truck traffic by the owner. The driver must satisfy himself of theabove before entering these areas. The truck must enter lifts with the load in front andmust take up a position which does not allow it to come into contact with the walls ofthe lift shaft. People travelling in the lift with the forklift truck must only enter the liftafter the truck has come to a halt and must exit the lift before the truck. The drivermust ensure that the loading ramp / bridge cannot move or come loose during loading/ unloading.
53
11.1
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N4.2 Emergency Disconnect, Travel, Steering, Braking
4.2.1 Emergency Disconnect
Applying the Emergency Disconnect
Procedure
CAUTION!Accident riskThe operation of the Emergency Disconnect switch must not be affected by anyobjects placed in its way.
Z Do not use the Emergency Disconnect switch (12) as a service brake. • Press the Emergency Disconnect (12).• If equipped with LJ (o) press Emergency Disconnect switch (LJ) (56).
All electrical functions are deactivated. The truck brakes to a halt.
Releasing the Emergency Disconnect
Procedure• Pull the Emergency Disconnect switch (12) to unlock it.• If equipped with LJ (o) turn to unlock Emergency Disconnect switch (LJ) (56).
All electrical functions are enabled and the industrial truck is operational again(assuming the truck was operational before the Emergency Disconnect waspressed).With CanCode and ISM the vehicle is still turned off.
12
56
53
11.1
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4.2 Emergency Disconnect, Travel, Steering, Braking
4.2.1 Emergency Disconnect
Applying the Emergency Disconnect
Procedure
CAUTION!Accident riskThe operation of the Emergency Disconnect switch must not be affected by anyobjects placed in its way.
Z Do not use the Emergency Disconnect switch (12) as a service brake. • Press the Emergency Disconnect (12).• If equipped with LJ (o) press Emergency Disconnect switch (LJ) (56).
All electrical functions are deactivated. The truck brakes to a halt.
Releasing the Emergency Disconnect
Procedure• Pull the Emergency Disconnect switch (12) to unlock it.• If equipped with LJ (o) turn to unlock Emergency Disconnect switch (LJ) (56).
All electrical functions are enabled and the industrial truck is operational again(assuming the truck was operational before the Emergency Disconnect waspressed).With CanCode and ISM the vehicle is still turned off.
12
56
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54
4.2.2 Operator platform
NOTE
The operator platform (53) must be occupied for all travel functions to work.
Z If the truck is fitted with “pedestrian operation” (o), the following functions can becarried out (depending on the configuration) without standing on the platform (53):
– Travel forward (V) or in reverse (R) at a reduced speed by applying the travel switch(9).
– Travel at slow speed by pressing the “Pedestrian” button (8,6) (o) (optionallyforward travel only).
– (see "Pedestrian mode" on page 64).
R
R
V
V
8 6
99
9
9
10
10
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54
4.2.2 Operator platform
NOTE
The operator platform (53) must be occupied for all travel functions to work.
Z If the truck is fitted with “pedestrian operation” (o), the following functions can becarried out (depending on the configuration) without standing on the platform (53):
– Travel forward (V) or in reverse (R) at a reduced speed by applying the travel switch(9).
– Travel at slow speed by pressing the “Pedestrian” button (8,6) (o) (optionallyforward travel only).
– (see "Pedestrian mode" on page 64).
R
R
V
V
8 6
99
9
9
10
10
55
11.1
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N4.2.3 Steering
Steering with JetPilot (t)
Procedure• Turn the Jet pilot to the left or right.
Steering with the tiller (o)
Procedure• Move the tiller to the left or right.
Z For trucks with tiller steering, the tiller will extend beyond the contour of the truckaround narrow bends
55
11.1
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4.2.3 Steering
Steering with JetPilot (t)
Procedure• Turn the Jet pilot to the left or right.
Steering with the tiller (o)
Procedure• Move the tiller to the left or right.
Z For trucks with tiller steering, the tiller will extend beyond the contour of the truckaround narrow bends
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56
4.2.4 Travel
CAUTION!
Do not drive the truck unless the panels are closed and properly locked.
Requirements– Start up the truck, (see "Starting up the truck" on page 47)
Procedure• Control the travel speed with the travel switch (9).• Set the travel switch (9) to the desired travel direction: forward (V) or reverse (R).
Z When the travel switch is release it automatically returns to its original position.Z For trucks with “pedestrian operation” (o) the truck can be operated at reduced
speed (slow travel) without standing on the platform.
The brakes are released and the truck moves in the selected direction.
Z Preventing the truck from “rolling downhill”:
If the truck rolls backwards on an incline the controller detects the situation and thetravel switch brake applies automatically after a short jerk.
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56
4.2.4 Travel
CAUTION!
Do not drive the truck unless the panels are closed and properly locked.
Requirements– Start up the truck, (see "Starting up the truck" on page 47)
Procedure• Control the travel speed with the travel switch (9).• Set the travel switch (9) to the desired travel direction: forward (V) or reverse (R).
Z When the travel switch is release it automatically returns to its original position.Z For trucks with “pedestrian operation” (o) the truck can be operated at reduced
speed (slow travel) without standing on the platform.
The brakes are released and the truck moves in the selected direction.
Z Preventing the truck from “rolling downhill”:
If the truck rolls backwards on an incline the controller detects the situation and thetravel switch brake applies automatically after a short jerk.
57
11.1
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N4.2.5 Brakes
The brake pattern of the truck depends largely on the travel route conditions. Thedriver must take this into account when travelling.
The truck can brake in three different ways:
– Using the service brake– By inversion braking (controller)– Using the regenerative brake (coasting)
CAUTION!
Use the service brake in emergencies
Braking with the service brake:
Procedure• Press the Stop button (10).
The truck will decelerate at the maximum rate and the service brake will apply.
Z The truck can only start again when the travel switch has been set to neutral.
Regenerative braking
Procedure• Release the travel switch (9) - the travel switch (9) reverts to neutral.
The truck brakes to a halt regeneratively via the coasting brake. The service brakethen applies.
Z With regenerative braking energy is recuperated to the battery, ensuring a longerservice time.
Inversion braking
Procedure• When travelling, set the travel switch (9) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z The braking intensity can be set by the manufacturer’s service department.
9
9
10 910
57
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N
4.2.5 Brakes
The brake pattern of the truck depends largely on the travel route conditions. Thedriver must take this into account when travelling.
The truck can brake in three different ways:
– Using the service brake– By inversion braking (controller)– Using the regenerative brake (coasting)
CAUTION!
Use the service brake in emergencies
Braking with the service brake:
Procedure• Press the Stop button (10).
The truck will decelerate at the maximum rate and the service brake will apply.
Z The truck can only start again when the travel switch has been set to neutral.
Regenerative braking
Procedure• Release the travel switch (9) - the travel switch (9) reverts to neutral.
The truck brakes to a halt regeneratively via the coasting brake. The service brakethen applies.
Z With regenerative braking energy is recuperated to the battery, ensuring a longerservice time.
Inversion braking
Procedure• When travelling, set the travel switch (9) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction.
Z The braking intensity can be set by the manufacturer’s service department.
9
9
10 910
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4.3 Lifting, transporting and depositing loads
WARNING!
Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver must ensure that it has been correctly palletisedand does not exceed the truck’s capacity.Instruct other people to move out of the hazardous area of the industrial truck. Stop
working with the truck if people do not leave the hazardous area.Only carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.Damaged loads must not be transported.Never exceed the maximum loads specified on the capacity chart.Never stand underneath a raised load handler.Do not stand on the load handler.Do not lift other people on the load handler.Insert the load handler as far as possible underneath the load.
NOTE
Adapt a slower speed when stacking and retrieving.
4.3.1 Lifting load units
Requirements– Load unit correctly palletised.– Load unit weight matches the truck's capacity.– Forks evenly loaded for heavy loads.
Procedure• Drive the truck carefully up to the pallet.• Slowly insert the forks into the pallet until the fork shank touches the pallet.
Z The load unit must not extend by more than 50 mm beyond the fork tips.• Press the “Lift” button (2) button until you reach the desired lift height.
The load unit is raised.
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4.3 Lifting, transporting and depositing loads
WARNING!
Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver must ensure that it has been correctly palletisedand does not exceed the truck’s capacity.Instruct other people to move out of the hazardous area of the industrial truck. Stop
working with the truck if people do not leave the hazardous area.Only carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.Damaged loads must not be transported.Never exceed the maximum loads specified on the capacity chart.Never stand underneath a raised load handler.Do not stand on the load handler.Do not lift other people on the load handler.Insert the load handler as far as possible underneath the load.
NOTE
Adapt a slower speed when stacking and retrieving.
4.3.1 Lifting load units
Requirements– Load unit correctly palletised.– Load unit weight matches the truck's capacity.– Forks evenly loaded for heavy loads.
Procedure• Drive the truck carefully up to the pallet.• Slowly insert the forks into the pallet until the fork shank touches the pallet.
Z The load unit must not extend by more than 50 mm beyond the fork tips.• Press the “Lift” button (2) button until you reach the desired lift height.
The load unit is raised.
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Transporting load units
Requirements– Load unit correctly lifted.– Mast lowered for transport (approx. 150 - 200 mm above the ground).– Good ground conditions.
Procedure• Accelerate and decelerate gradually.• Adapt your travel speed to the conditions of the route and the load you are
transporting.• Travel at a constant speed.• Watch out for other traffic at crossings and passageways. • Always travel with a lookout at blind spots.• On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn.
4.3.3 Lowering the load unit
21 2 121
2
1
59
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4.3.2 Transport the load unit.
Transporting load units
Requirements– Load unit correctly lifted.– Mast lowered for transport (approx. 150 - 200 mm above the ground).– Good ground conditions.
Procedure• Accelerate and decelerate gradually.• Adapt your travel speed to the conditions of the route and the load you are
transporting.• Travel at a constant speed.• Watch out for other traffic at crossings and passageways. • Always travel with a lookout at blind spots.• On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn.
4.3.3 Lowering the load unit
21 2 121
2
1
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60
Depositing load units
NOTE
Loads must not be deposited on travel or escape routes, in front of safetymechanisms or operating equipment that must be accessible at all times.
Requirements– Warehouse location suitable for storing the load.
Procedure• Drive carefully up to the storage location.• Press the "Lower load handler" button until the forks are clear of the load.
Z Avoid depositing the load to avoid damaging the load and the load handler.• Carefully remove the forks from the pallet.
The load unit is lowered.
5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects ofincorrect operation. When trying to locate a fault, proceed in the order shown in thetable.
Z If, after carrying out the following remedial action, the truck cannot be restored tooperation or if a fault in the electronics system is displayed with a correspondingerror code, contact the manufacturer’s service department.Additional troubleshooting must only be performed by the manufacturer’s specialistservice engineers. The manufacturer's customer service department is speciallytrained to carry out these operations.In order for customer services to react quickly and specifically to the fault, thefollowing information is essential:- Truck serial number- Error number on the display unit (if applicable)- Error description- Current location of truck
5.1 Truck does not start
5.2 Load cannot be lifted
Possible Cause Action
Battery connector not plugged in Check the battery connector and plug it in if necessary.
Emergency Disconnect pressed. Unlock the Emergency Disconnect
Key switch set to O. Set the key switch to “I”
Battery charge too low Check the battery charge and charge battery if necessary.
Faulty fuse Check fuses
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Depositing load units
NOTE
Loads must not be deposited on travel or escape routes, in front of safetymechanisms or operating equipment that must be accessible at all times.
Requirements– Warehouse location suitable for storing the load.
Procedure• Drive carefully up to the storage location.• Press the "Lower load handler" button until the forks are clear of the load.
Z Avoid depositing the load to avoid damaging the load and the load handler.• Carefully remove the forks from the pallet.
The load unit is lowered.
5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects ofincorrect operation. When trying to locate a fault, proceed in the order shown in thetable.
Z If, after carrying out the following remedial action, the truck cannot be restored tooperation or if a fault in the electronics system is displayed with a correspondingerror code, contact the manufacturer’s service department.Additional troubleshooting must only be performed by the manufacturer’s specialistservice engineers. The manufacturer's customer service department is speciallytrained to carry out these operations.In order for customer services to react quickly and specifically to the fault, thefollowing information is essential:- Truck serial number- Error number on the display unit (if applicable)- Error description- Current location of truck
5.1 Truck does not start
5.2 Load cannot be lifted
Possible Cause Action
Battery connector not plugged in Check the battery connector and plug it in if necessary.
Emergency Disconnect pressed. Unlock the Emergency Disconnect
Key switch set to O. Set the key switch to “I”
Battery charge too low Check the battery charge and charge battery if necessary.
Faulty fuse Check fuses
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Truck not operational Carry out all measures listed under “Truck does not start”.
Hydraulic oil level too low Checking the hydraulic oil level
Battery discharge monitor has switched off
Charge the battery
Faulty fuse Check fuses
Excessive load Note maximum capacity, see data plate.
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Possible Cause Remedy
Truck not operational Carry out all measures listed under “Truck does not start”.
Hydraulic oil level too low Checking the hydraulic oil level
Battery discharge monitor has switched off
Charge the battery
Faulty fuse Check fuses
Excessive load Note maximum capacity, see data plate.
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6 Operating the truck without its own drive system
WARNING!
Uncontrolled truck movementWhen the brakes are de-activated the truck must be parked on a level surface, sincethe brakes are no longer effective.Do not release the brake on slopes or inclines.Apply the brake again when you reach your destination.Do not park the truck with the brake released.
Releasing the brake
Tools and Material Required– Two M5x42 screws– Spanner wrench
Procedure• Turn of the key switch, CanCode (o).• Switch off the Emergency Disconnect button.• Disconnect the battery.• Prevent the truck from rolling away.• Open the battery panel, (see "Exposing the battery" on page 33).• Lift up the front panel (15) and put it to one side, (see "Removing the front panel"
on page 105).• Insert two M5x42 screws (61) as far as the stop and lift up the anchor plate.
The brake is now released and the truck can be moved.
Applying the brake
Procedure• Unscrew the two M5x42 screws again.• Refit the front cover (15).
Braking is now restored again.
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62
6 Operating the truck without its own drive system
WARNING!
Uncontrolled truck movementWhen the brakes are de-activated the truck must be parked on a level surface, sincethe brakes are no longer effective.Do not release the brake on slopes or inclines.Apply the brake again when you reach your destination.Do not park the truck with the brake released.
Releasing the brake
Tools and Material Required– Two M5x42 screws– Spanner wrench
Procedure• Turn of the key switch, CanCode (o).• Switch off the Emergency Disconnect button.• Disconnect the battery.• Prevent the truck from rolling away.• Open the battery panel, (see "Exposing the battery" on page 33).• Lift up the front panel (15) and put it to one side, (see "Removing the front panel"
on page 105).• Insert two M5x42 screws (61) as far as the stop and lift up the anchor plate.
The brake is now released and the truck can be moved.
Applying the brake
Procedure• Unscrew the two M5x42 screws again.• Refit the front cover (15).
Braking is now restored again.
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7 Optional equipment
7.1 Pedestrian mode
CAUTION!
Risk of trappingSteering set straight-ahead.The operator must always stand beside the truck during pedestrian operation.There must be no persons standing between the truck and any obstacles.There must be no persons on the operator platform.
Z In pedestrian mode the truck can be operated by the operator from either side whilewalking alongside. In this case, the truck travels at a significantly reduced speed.
There are two methods of pedestrian operation:
– Via the travel switch (9).– Via the “pedestrian” buttons (6,8) in the backrest
Z For the “touch mode only in drive direction” option, pedestrian mode is onlyavailable for forward travel via button (6).
Travelling via the travel switch
Procedure• Set the travel switch (9) to the desired travel direction: forward (V) or reverse (R).
Z The speed can be set via travel parameters, (see "Parameters" on page 69).
Truck travels at preset reduced speed.
Travel using the “pedestrian” button
Procedure• Press the “pedestrian” button (8,6).
Z The speed can be set via travel parameters, (see "Parameters" on page 69).Z When you travel via the "pedestrian" button (8,6) you can steer between +/- 10° left
and right. If you steer beyond this range the truck will stop.
The truck travels at a preset reduced speed.
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64
7 Optional equipment
7.1 Pedestrian mode
CAUTION!
Risk of trappingSteering set straight-ahead.The operator must always stand beside the truck during pedestrian operation.There must be no persons standing between the truck and any obstacles.There must be no persons on the operator platform.
Z In pedestrian mode the truck can be operated by the operator from either side whilewalking alongside. In this case, the truck travels at a significantly reduced speed.
There are two methods of pedestrian operation:
– Via the travel switch (9).– Via the “pedestrian” buttons (6,8) in the backrest
Z For the “touch mode only in drive direction” option, pedestrian mode is onlyavailable for forward travel via button (6).
Travelling via the travel switch
Procedure• Set the travel switch (9) to the desired travel direction: forward (V) or reverse (R).
Z The speed can be set via travel parameters, (see "Parameters" on page 69).
Truck travels at preset reduced speed.
Travel using the “pedestrian” button
Procedure• Press the “pedestrian” button (8,6).
Z The speed can be set via travel parameters, (see "Parameters" on page 69).Z When you travel via the "pedestrian" button (8,6) you can steer between +/- 10° left
and right. If you steer beyond this range the truck will stop.
The truck travels at a preset reduced speed.
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66
7.2 Stockpicking up to the second level
7.2.1 Order picking up to the 2nd level with railing and grab handle
The operator position is designed so that the driver can climb onto the step (64) usingthe grab handle (62) in order to reach higher objects stored at the first level. Theoperator must only hold onto the grab handles (62) on the raised backrest, not the JetPilot or the tiller (o). The operator must not apply any controls while carrying out thisactivity. The pedestrian mode travel switch option must not be used for this expansionstage.
2nd level picking is only permitted if the truck is equipped with railing (63,o) on thebattery cover. In this case the driver can climb up a step (64) while holding onto therailing (63,o) onto the non-slip surface (15) of the battery cover in order to reachobjects stored at the 2nd level.
WARNING!
Risk of falling when climbing onto the battery cover without railingDo not climb onto the battery cover if there is no railing (63); otherwise, there is a riskof falling from the cover.Only climb on the cover if the railing is fitted.
7.2.2 Order picking up to the 2nd level with height-adjustable standing platform orJetPilot
The operator position is designed so that the driver can be elevated with the standingplatform up to the second level by applying the foot switch (20). The standing platform
64
15
6263
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66
7.2 Stockpicking up to the second level
7.2.1 Order picking up to the 2nd level with railing and grab handle
The operator position is designed so that the driver can climb onto the step (64) usingthe grab handle (62) in order to reach higher objects stored at the first level. Theoperator must only hold onto the grab handles (62) on the raised backrest, not the JetPilot or the tiller (o). The operator must not apply any controls while carrying out thisactivity. The pedestrian mode travel switch option must not be used for this expansionstage.
2nd level picking is only permitted if the truck is equipped with railing (63,o) on thebattery cover. In this case the driver can climb up a step (64) while holding onto therailing (63,o) onto the non-slip surface (15) of the battery cover in order to reachobjects stored at the 2nd level.
WARNING!
Risk of falling when climbing onto the battery cover without railingDo not climb onto the battery cover if there is no railing (63); otherwise, there is a riskof falling from the cover.Only climb on the cover if the railing is fitted.
7.2.2 Order picking up to the 2nd level with height-adjustable standing platform orJetPilot
The operator position is designed so that the driver can be elevated with the standingplatform up to the second level by applying the foot switch (20). The standing platform
64
15
6263
67
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NOTE
On entering the second level all the other controls are automatically deactivated.
Z Industrial trucks with the height-adjustable JetPilot (o) offer reduced speed travel.
Standing platform lift for HP
Procedure• Double click the "Platform raise" button (20)
(click twice within 1 second).• Keep pressing down on the button until you
reach the required lift height.
Raises the standing platform.
Standing platform lower for HP
Procedure• Double click the "Platform lower" button (21) (click twice within 1 second).• Keep the switch depressed until you reach the required lowered height.
Lowers the standing platform.
Z The “Lift standing platform” and “Lower standing platform” buttons can be used tolift/lower at a constant speed.
20
21
55
67
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can then be lowered again by applying the foot switch (21).
NOTE
On entering the second level all the other controls are automatically deactivated.
Z Industrial trucks with the height-adjustable JetPilot (o) offer reduced speed travel.
Standing platform lift for HP
Procedure• Double click the "Platform raise" button (20)
(click twice within 1 second).• Keep pressing down on the button until you
reach the required lift height.
Raises the standing platform.
Standing platform lower for HP
Procedure• Double click the "Platform lower" button (21) (click twice within 1 second).• Keep the switch depressed until you reach the required lowered height.
Lowers the standing platform.
Z The “Lift standing platform” and “Lower standing platform” buttons can be used tolift/lower at a constant speed.
20
21
55
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68
Lift standing platform for LJ
Procedure• Double click the "Platform raise" button
(58) (click twice within 1 second) or press"Lift" (65) on the height-adjustableJetPilot.
• Keep pressing down on the button untilyou reach the required lift height.
Raises the standing platform.
Lower standing platform for LJ
Procedure• Double click the "Platform lower" button (59)
click twice within 1 second or press "Lower" (66) on the height-adjustable JetPilot.• Keep the switch depressed until you reach the required lowered height.
Lowers the standing platform.
Z The “Lift standing platform” and “Lower standing platform” buttons can be used tolift/lower at a constant speed.
59
65
5958
5455
66
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68
Lift standing platform for LJ
Procedure• Double click the "Platform raise" button
(58) (click twice within 1 second) or press"Lift" (65) on the height-adjustableJetPilot.
• Keep pressing down on the button untilyou reach the required lift height.
Raises the standing platform.
Lower standing platform for LJ
Procedure• Double click the "Platform lower" button (59)
click twice within 1 second or press "Lower" (66) on the height-adjustable JetPilot.• Keep the switch depressed until you reach the required lowered height.
Lowers the standing platform.
Z The “Lift standing platform” and “Lower standing platform” buttons can be used tolift/lower at a constant speed.
59
65
5958
5455
66
69
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CanCode keypad
The keypad consists of 10 digit keys, a Set key and a okey.
The O key indicates the follow operating statuses via ared / green LED:– Code lock function (starting up the truck).– Adjusting the travel program depending on the setting
and truck.– Setting and changing parameters.
7.3.1 Keypad
When the correct code is entered, the truck is ready for use. You can allocate anindividual code to each truck, operator or group of operators. When the truck issupplied from the factory, the code is indicated on a sticker. Change the master andoperator codes when you use the truck for the first time.
Z Set different codes for rider and pedestrian trucks.
Starting the truck
Procedure• Switching on the Emergency
Disconnect.LED (71) lights up red.
• Enter the code.When you enter the correct operatorcode the LED (71) turns green. If theLED (71) flashes red this means thewrong code has been entered. Tryagain.
The truck is switched on
Z The Set key (70) has no function in operating mode.
Switching the truck off
Procedure• Press the O key.
The truck is switched off.
Z The truck can switch off automatically after a set time. To do this the relevant codelock parameters must be entered, (see "Parameter Settings" on page 70).
7.3.2 Parameters
The keypad enables parameters to be adjusted in programming mode.
1 2 3
4 5 6
7 8 9
0Set
1 2 3
4 5 6
7 8 9
0Set70
66 67 68
69
71
69
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7.3 CanCode keypad
CanCode keypad
The keypad consists of 10 digit keys, a Set key and a okey.
The O key indicates the follow operating statuses via ared / green LED:– Code lock function (starting up the truck).– Adjusting the travel program depending on the setting
and truck.– Setting and changing parameters.
7.3.1 Keypad
When the correct code is entered, the truck is ready for use. You can allocate anindividual code to each truck, operator or group of operators. When the truck issupplied from the factory, the code is indicated on a sticker. Change the master andoperator codes when you use the truck for the first time.
Z Set different codes for rider and pedestrian trucks.
Starting the truck
Procedure• Switching on the Emergency
Disconnect.LED (71) lights up red.
• Enter the code.When you enter the correct operatorcode the LED (71) turns green. If theLED (71) flashes red this means thewrong code has been entered. Tryagain.
The truck is switched on
Z The Set key (70) has no function in operating mode.
Switching the truck off
Procedure• Press the O key.
The truck is switched off.
Z The truck can switch off automatically after a set time. To do this the relevant codelock parameters must be entered, (see "Parameter Settings" on page 70).
7.3.2 Parameters
The keypad enables parameters to be adjusted in programming mode.
1 2 3
4 5 6
7 8 9
0Set
1 2 3
4 5 6
7 8 9
0Set70
66 67 68
69
71
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70
Parameter Groups
The parameter number is composed of three digits. The first digit refers to theparameter group as shown in Table 1. The second and third digits are numbered insequence from 00 to 99.
7.3.3 Parameter Settings
To change the truck settings you must enter the master code.
Z The master code factory setting is 7-2-9-5. Change the master code the first timeyou use the truck.
Z Set different codes for rider and pedestrian trucks.
Changing the truck settings
Procedure• Press the O key (69).• Enter the master code.• Enter the three-digit parameter number. • Confirm with the SET key (70).• Enter the setting as per parameter list.
Z If the entry is incorrect, the LED (71) of the O key (69) turns red. • Enter the parameter number again.• Enter the setting again or change it.
• Confirm with the SET key (70).• Repeat the procedure for other parameters.• Then press the O key (69).
The settings are now saved.
No. Parameter Groups0XX Code lock settings (codes, travel program release, automatic cutout, etc.)
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70
Parameter Groups
The parameter number is composed of three digits. The first digit refers to theparameter group as shown in Table 1. The second and third digits are numbered insequence from 00 to 99.
7.3.3 Parameter Settings
To change the truck settings you must enter the master code.
Z The master code factory setting is 7-2-9-5. Change the master code the first timeyou use the truck.
Z Set different codes for rider and pedestrian trucks.
Changing the truck settings
Procedure• Press the O key (69).• Enter the master code.• Enter the three-digit parameter number. • Confirm with the SET key (70).• Enter the setting as per parameter list.
Z If the entry is incorrect, the LED (71) of the O key (69) turns red. • Enter the parameter number again.• Enter the setting again or change it.
• Confirm with the SET key (70).• Repeat the procedure for other parameters.• Then press the O key (69).
The settings are now saved.
No. Parameter Groups0XX Code lock settings (codes, travel program release, automatic cutout, etc.)
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No. Function Setting range Standard setting
Procedure
000 Change master code: The length (4-6 digits) of the master code also determines the length of the operator code (4-6 digits). Provided the operator codes are programmed, only new codes of the same length can be entered. If you wish to change the code length, you must first delete all the operator codes.
0000 - 9999 or
00000 - 99999 or
000000 - 999999
7295 – (LED 66 flashes) Confirm current code entry
–(Set 70)
– (LED 67 flashes)Enter a new code
–(Set 70)
– (LED 68 flashes) repeat new code
–(Set 70)
001 Add code (max. 250) 0000 - 9999 or
00000 - 99999 or
000000 - 999999
2580 – (LED 67 flashes)Confirm code entry
–(Set 70)
– (LED 68 flashes) repeat code entry
–(Set 70)
002 Change code 0000 - 9999 or
00000 - 99999 or
000000 - 999999
– (LED 66 flashes)Confirm current code entry
–(Set 70)
– (LED 67 flashes)Confirm new code entry
–(Set 70)
– (LED 68 flashes)Confirm code re-entry
–(Set 70)
LEDs 66-68 are located in keypads 1-3.
71
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Parameter list
No. Function Setting range Standard setting
Procedure
000 Change master code: The length (4-6 digits) of the master code also determines the length of the operator code (4-6 digits). Provided the operator codes are programmed, only new codes of the same length can be entered. If you wish to change the code length, you must first delete all the operator codes.
0000 - 9999 or
00000 - 99999 or
000000 - 999999
7295 – (LED 66 flashes) Confirm current code entry
–(Set 70)
– (LED 67 flashes)Enter a new code
–(Set 70)
– (LED 68 flashes) repeat new code
–(Set 70)
001 Add code (max. 250) 0000 - 9999 or
00000 - 99999 or
000000 - 999999
2580 – (LED 67 flashes)Confirm code entry
–(Set 70)
– (LED 68 flashes) repeat code entry
–(Set 70)
002 Change code 0000 - 9999 or
00000 - 99999 or
000000 - 999999
– (LED 66 flashes)Confirm current code entry
–(Set 70)
– (LED 67 flashes)Confirm new code entry
–(Set 70)
– (LED 68 flashes)Confirm code re-entry
–(Set 70)
LEDs 66-68 are located in keypads 1-3.
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Assigning the starting travel program (depending on the truck)
The travel programs are connected to the code. The travel programs can beindividually released or blocked for each code. A starting travel program can beassigned to each code.
Once a user code has been set up, all travel programs are globally released, the validstart travel program is travel program 2.The code configuration can then be changed with program number 024.
1. digit: travel program 1 release (0 = blocked or 1 = released) 2nd digit: travel program 2 release (0 = blocked or 1 = released) 3rd digit: travel program 3 release (0 = blocked or 1 = released) 4th digit: start travel program (0, 1, 2 or 3)
003 Delete code 0000 - 9999 or
00000 - 99999 or
000000 - 999999
– (LED 67 flashes)Confirm new code entry
–(Set 70)
– (LED 68 flashes) repeat code entry
–(Set 70)
004 Delete code log (deletes all codes)
3265 – 3265 = delete– other inputs = do
not delete
010 Automatic timeout 00-31 00 – 00 = No timeout– 01 - 30 = Timeout
in minutes– 31 = Timeout after
10 seconds
No. Function Setting range Standard setting
Procedure
LEDs 66-68 are located in keypads 1-3.
No. Function Setting range Standard setting
Procedure
024 Code configuration 1112
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72
Assigning the starting travel program (depending on the truck)
The travel programs are connected to the code. The travel programs can beindividually released or blocked for each code. A starting travel program can beassigned to each code.
Once a user code has been set up, all travel programs are globally released, the validstart travel program is travel program 2.The code configuration can then be changed with program number 024.
1. digit: travel program 1 release (0 = blocked or 1 = released) 2nd digit: travel program 2 release (0 = blocked or 1 = released) 3rd digit: travel program 3 release (0 = blocked or 1 = released) 4th digit: start travel program (0, 1, 2 or 3)
003 Delete code 0000 - 9999 or
00000 - 99999 or
000000 - 999999
– (LED 67 flashes)Confirm new code entry
–(Set 70)
– (LED 68 flashes) repeat code entry
–(Set 70)
004 Delete code log (deletes all codes)
3265 – 3265 = delete– other inputs = do
not delete
010 Automatic timeout 00-31 00 – 00 = No timeout– 01 - 30 = Timeout
in minutes– 31 = Timeout after
10 seconds
No. Function Setting range Standard setting
Procedure
LEDs 66-68 are located in keypads 1-3.
No. Function Setting range Standard setting
Procedure
024 Code configuration 1112
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Setting the travel program configuration to a code
Procedure• Press the O key (69).• Enter the master code.• Enter the three-digit parameter number 024. • Confirm with the SET key (70).• Enter the code to be changed and confirm with SET.• Enter the configuration (4 digit) and confirm with SET.• Enter the configuration (4 digit) again and confirm with SET.• Repeat the procedure for other codes.• Then press the O key.
The travel programs are assigned to the codes
Keypad event messages
The LED (71) flashes red to indicate the following events:– New master code is already in use.– New code is already the master code– Code to be changed does not exist– Attempt to change the code to one that already exists.– Attempt to delete a code that does not exist– Code memory full.
73
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Setting the travel program configuration to a code
Procedure• Press the O key (69).• Enter the master code.• Enter the three-digit parameter number 024. • Confirm with the SET key (70).• Enter the code to be changed and confirm with SET.• Enter the configuration (4 digit) and confirm with SET.• Enter the configuration (4 digit) again and confirm with SET.• Repeat the procedure for other codes.• Then press the O key.
The travel programs are assigned to the codes
Keypad event messages
The LED (71) flashes red to indicate the following events:– New master code is already in use.– New code is already the master code– Code to be changed does not exist– Attempt to change the code to one that already exists.– Attempt to delete a code that does not exist– Code memory full.
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7.4 Setting the truck parameters with CanCode
CAUTION!
Faulty entryWithout CanDis only CanCode internal parameters can be changed. Tractioncontroller parameters can only be changed with CanDis, without CanDis the settingsmust be performed by the manufacturer's service department.
CAUTION!
Altering travel parameters can cause accidentsIncreasing the settings for acceleration, steering, travel, lifting and lowering can resultin accidents. Carry out a test run in a secure environment.This requires greater attention on the part of the operator.
Parameter setting example:
The following example shows the parameter setting for the acceleration of travelprogram 1 (parameter 0256).
Acceleration example
Procedure• Enter four-digit parameter number "0256" and confirm with the SET key (70).• Enter sub-index (enter "2") and confirm with the SET key (70).
Z The parameter and sub index are displayed alternately with the current reading(0256-2<->0000-3).
• Enter the parameter according to the parameter list and confirm with the Set key(70).
Z The LED (71) of the O key (69) switches briefly to steady light and start flashingagain after approx. 2 seconds.
Z If the entry is incorrect, the LED (71) of the O key (69) turns red. Enter theparameter number again to repeat the setting.
Z The parameter and sub index are displayed alternately with the current reading(0256-2<->0000-5).
The travel parameter is now set.
Repeat the procedure to enter further parameters as soon as the LED (71) of the Okey (69) flashes.
Z Travel is disabled while the parameters are being entered.
Checking the settings in programming mode
Procedure• Select the travel program to be worked on after changing the parameter value, and
confirm with the Set key (70).
The truck is now in travel mode and can be checked.
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7.4 Setting the truck parameters with CanCode
CAUTION!
Faulty entryWithout CanDis only CanCode internal parameters can be changed. Tractioncontroller parameters can only be changed with CanDis, without CanDis the settingsmust be performed by the manufacturer's service department.
CAUTION!
Altering travel parameters can cause accidentsIncreasing the settings for acceleration, steering, travel, lifting and lowering can resultin accidents. Carry out a test run in a secure environment.This requires greater attention on the part of the operator.
Parameter setting example:
The following example shows the parameter setting for the acceleration of travelprogram 1 (parameter 0256).
Acceleration example
Procedure• Enter four-digit parameter number "0256" and confirm with the SET key (70).• Enter sub-index (enter "2") and confirm with the SET key (70).
Z The parameter and sub index are displayed alternately with the current reading(0256-2<->0000-3).
• Enter the parameter according to the parameter list and confirm with the Set key(70).
Z The LED (71) of the O key (69) switches briefly to steady light and start flashingagain after approx. 2 seconds.
Z If the entry is incorrect, the LED (71) of the O key (69) turns red. Enter theparameter number again to repeat the setting.
Z The parameter and sub index are displayed alternately with the current reading(0256-2<->0000-5).
The travel parameter is now set.
Repeat the procedure to enter further parameters as soon as the LED (71) of the Okey (69) flashes.
Z Travel is disabled while the parameters are being entered.
Checking the settings in programming mode
Procedure• Select the travel program to be worked on after changing the parameter value, and
confirm with the Set key (70).
The truck is now in travel mode and can be checked.
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Saving travel parameters
Requirements– Enter all parameters.
Procedure• Run "SaveParameters" by pressing 1-2-3-Set.• Confirm with the O key (69).
75
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Z To continue setting, confirm with the Set key (70) again.
Saving travel parameters
Requirements– Enter all parameters.
Procedure• Run "SaveParameters" by pressing 1-2-3-Set.• Confirm with the O key (69).
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7.5 Parameter
Travel program 1 (up to 10.11)
No. Function Setting range
Standard setting
Comments
0256 Rider mode acceleration
0 - 9 5
0257 Pedestrian mode acceleration
0 - 9 5
0260 Rider mode coasting brake
0 - 9 5
0261 Pedestrian mode coasting brake
0 - 9 5
0264 Maximum forward speed using travel switch
0 - 9 8depending on travel switch
0265 Maximum reverse speed using travel switch
0 - 9 5depending on travel switch
0266 Maximum pedestrian forward speed using button
0 - 9 3fixed speed
0268 Maximum reverse speed using travel switch
0 - 9 9depending on travel switch
0269 Maximum pedestrian reverse speed using travel switch
0 - 9 5
depending on travel switch
0270 Maximum pedestrian reverse speed using button
0 - 9 3fixed speed
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7.5 Parameter
Travel program 1 (up to 10.11)
No. Function Setting range
Standard setting
Comments
0256 Rider mode acceleration
0 - 9 5
0257 Pedestrian mode acceleration
0 - 9 5
0260 Rider mode coasting brake
0 - 9 5
0261 Pedestrian mode coasting brake
0 - 9 5
0264 Maximum forward speed using travel switch
0 - 9 8depending on travel switch
0265 Maximum reverse speed using travel switch
0 - 9 5depending on travel switch
0266 Maximum pedestrian forward speed using button
0 - 9 3fixed speed
0268 Maximum reverse speed using travel switch
0 - 9 9depending on travel switch
0269 Maximum pedestrian reverse speed using travel switch
0 - 9 5
depending on travel switch
0270 Maximum pedestrian reverse speed using button
0 - 9 3fixed speed
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Travel program 1 (from 11.11)
No. Function Setting range Standard setting Comments0256 Rider mode
acceleration30 - 120 70
0257 Pedestrian mode acceleration
2 - 40 35
0260 Rider mode coasting brake
20 - 250 80
0261 Pedestrian mode coasting brake
20 - 250 80
0264 Maximum forward speed using travel switch
0 - 120(10.50 km/h)
105depending on travel switch
0265 Maximum reverse speed using travel switch
0 - 40(4.0 km/h)
40depending on travel switch
0266 Maximum pedestrian forward speed using button
0 - 40(2.5 km/h)
25
adjustable
0268 Maximum reverse speed using travel switch
0 - 120(10.50 km/h)
105depending on travel switch
0269 Maximum pedestrian reverse speed using travel switch
0 - 40(4.0 km/h)
40
depending on travel switch
0270 Maximum pedestrian reverse speed using button
0 - 40(2.5 km/h)
25
adjustable
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Travel program 1 (from 11.11)
No. Function Setting range Standard setting Comments0256 Rider mode
acceleration30 - 120 70
0257 Pedestrian mode acceleration
2 - 40 35
0260 Rider mode coasting brake
20 - 250 80
0261 Pedestrian mode coasting brake
20 - 250 80
0264 Maximum forward speed using travel switch
0 - 120(10.50 km/h)
105depending on travel switch
0265 Maximum reverse speed using travel switch
0 - 40(4.0 km/h)
40depending on travel switch
0266 Maximum pedestrian forward speed using button
0 - 40(2.5 km/h)
25
adjustable
0268 Maximum reverse speed using travel switch
0 - 120(10.50 km/h)
105depending on travel switch
0269 Maximum pedestrian reverse speed using travel switch
0 - 40(4.0 km/h)
40
depending on travel switch
0270 Maximum pedestrian reverse speed using button
0 - 40(2.5 km/h)
25
adjustable
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Travel program 2 (up to 10.11)
No. Function Setting range
Standard setting
Comments
0272 Rider mode acceleration
0 - 9 6
0273 Pedestrian mode acceleration
0 - 9 6
0276 Rider mode coasting brake
0 - 9 5
0277 Pedestrian mode coasting brake
0 - 9 5
0280 Maximum forward speed using travel switch
0 - 9 8depending on travel switch
0281 Maximum reverse speed using travel switch
0 - 9 5depending on travel switch
0282 Maximum pedestrian forward speed using button
0 - 9 3fixed speed
0284 Maximum reverse speed using travel switch
0 - 9 9depending on travel switch
0285 Maximum pedestrian reverse speed using travel switch
0 - 9 5
depending on travel switch
0286 Maximum pedestrian reverse speed using button
0 - 9 3fixed speed
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Travel program 2 (up to 10.11)
No. Function Setting range
Standard setting
Comments
0272 Rider mode acceleration
0 - 9 6
0273 Pedestrian mode acceleration
0 - 9 6
0276 Rider mode coasting brake
0 - 9 5
0277 Pedestrian mode coasting brake
0 - 9 5
0280 Maximum forward speed using travel switch
0 - 9 8depending on travel switch
0281 Maximum reverse speed using travel switch
0 - 9 5depending on travel switch
0282 Maximum pedestrian forward speed using button
0 - 9 3fixed speed
0284 Maximum reverse speed using travel switch
0 - 9 9depending on travel switch
0285 Maximum pedestrian reverse speed using travel switch
0 - 9 5
depending on travel switch
0286 Maximum pedestrian reverse speed using button
0 - 9 3fixed speed
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Travel program 2 (from 11.11)
No. Function Setting range Standard setting Comments0272 Rider mode
acceleration30 - 120 100
0273 Pedestrian mode acceleration
2 - 40 35
0276 Rider mode coasting brake
20 - 250 130
0277 Pedestrian mode coasting brake
20 - 250 130
0280 Maximum forward speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0281 Maximum reverse speed using travel switch
0 - 40(4.0 km/h)
40depending on travel switch
0282 Maximum pedestrian forward speed using button
0 - 40(2.5 km/h)
25adjustable
0284 Maximum reverse speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0285 Maximum pedestrian reverse speed using travel switch
0 - 40(4.0 km/h)
40
depending on travel switch
0286 Maximum pedestrian reverse speed using button
0 - 40(2.5 km/h)
25adjustable
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Travel program 2 (from 11.11)
No. Function Setting range Standard setting Comments0272 Rider mode
acceleration30 - 120 100
0273 Pedestrian mode acceleration
2 - 40 35
0276 Rider mode coasting brake
20 - 250 130
0277 Pedestrian mode coasting brake
20 - 250 130
0280 Maximum forward speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0281 Maximum reverse speed using travel switch
0 - 40(4.0 km/h)
40depending on travel switch
0282 Maximum pedestrian forward speed using button
0 - 40(2.5 km/h)
25adjustable
0284 Maximum reverse speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0285 Maximum pedestrian reverse speed using travel switch
0 - 40(4.0 km/h)
40
depending on travel switch
0286 Maximum pedestrian reverse speed using button
0 - 40(2.5 km/h)
25adjustable
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Travel program 3 (up to 10.11)
No. Function Setting range
Standard setting
Comments
0288 Rider mode acceleration
0 - 9 8
0289 Pedestrian mode acceleration
0 - 9 8
0292 Rider mode coasting brake
0 - 9 7
0293 Pedestrian mode coasting brake
0 - 9 7
0296 Maximum forward speed using travel switch
0 - 9 8depending on travel switch
0297 Maximum reverse speed using travel switch
0 - 9 5depending on travel switch
0298 Maximum pedestrian forward speed using button
0 - 9 3fixed speed
0300 Maximum reverse speed using travel switch
0 - 9 9depending on travel switch
0301 Maximum pedestrian reverse speed using travel switch
0 - 9 5
depending on travel switch
0302 Maximum pedestrian reverse speed using button
0 - 9 3fixed speed
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Travel program 3 (up to 10.11)
No. Function Setting range
Standard setting
Comments
0288 Rider mode acceleration
0 - 9 8
0289 Pedestrian mode acceleration
0 - 9 8
0292 Rider mode coasting brake
0 - 9 7
0293 Pedestrian mode coasting brake
0 - 9 7
0296 Maximum forward speed using travel switch
0 - 9 8depending on travel switch
0297 Maximum reverse speed using travel switch
0 - 9 5depending on travel switch
0298 Maximum pedestrian forward speed using button
0 - 9 3fixed speed
0300 Maximum reverse speed using travel switch
0 - 9 9depending on travel switch
0301 Maximum pedestrian reverse speed using travel switch
0 - 9 5
depending on travel switch
0302 Maximum pedestrian reverse speed using button
0 - 9 3fixed speed
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Travel program 3 (from 11.11)
No. Function Setting range Standard setting Comments0288 Rider mode
acceleration30 - 120 110
0289 Pedestrian mode acceleration
2 - 40 35
0292 Rider mode coasting brake
20 - 250 145
0293 Pedestrian mode coasting brake
20 - 250 145
0296 Maximum forward speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0297 Maximum reverse speed using travel switch
0 - 40(4.0 km/h)
40depending on travel switch
0298 Maximum pedestrian forward speed using button
0 - 40(2.5 km/h)
25
adjustable
0300 Maximum reverse speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0301 Maximum pedestrian reverse speed using travel switch
0 - 40(4.0 km/h)
40
depending on travel switch
0302 Maximum pedestrian reverse speed using button
0 - 40(2.5 km/h)
25
adjustable
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Travel program 3 (from 11.11)
No. Function Setting range Standard setting Comments0288 Rider mode
acceleration30 - 120 110
0289 Pedestrian mode acceleration
2 - 40 35
0292 Rider mode coasting brake
20 - 250 145
0293 Pedestrian mode coasting brake
20 - 250 145
0296 Maximum forward speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0297 Maximum reverse speed using travel switch
0 - 40(4.0 km/h)
40depending on travel switch
0298 Maximum pedestrian forward speed using button
0 - 40(2.5 km/h)
25
adjustable
0300 Maximum reverse speed using travel switch
0 - 120(12.0 km/h)
120depending on travel switch
0301 Maximum pedestrian reverse speed using travel switch
0 - 40(4.0 km/h)
40
depending on travel switch
0302 Maximum pedestrian reverse speed using button
0 - 40(2.5 km/h)
25
adjustable
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Battery parameters (up to 10.11)
No. Function Setting range
Standard setting
Comments
1377 Battery type (normal / high performance / dry)
0 - 2 1 0 = Normal (wet)
1 = High performance (wet)
2 = Dry (maintenance-free)
1389 Discharge monitor function
0 /1 1 0 = Not active1 = Active
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Battery parameters (up to 10.11)
No. Function Setting range
Standard setting
Comments
1377 Battery type (normal / high performance / dry)
0 - 2 1 0 = Normal (wet)
1 = High performance (wet)
2 = Dry (maintenance-free)
1389 Discharge monitor function
0 /1 1 0 = Not active1 = Active
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Battery parameters (from 11.11)
CAUTION!
Battery type parametersThe battery and charger used must match the battery parameters
No. Function Setting range
Standard setting
Comments
1377 Battery type (normal / high performance / dry)
0 - 7 1 0 = Normal (wet)
1 = High performance (wet)
2 = Dry (maintenance-free)
3 = US type ("Flat Plate")
4 = US type("Pallet Pfro")
5 = US type("Tubular Plate"/dry battery)
7 = Exide GF12 063 Y (dry battery)
1389 Discharge monitor function
0 - 4 1 0 = Not active
1 = Active
2 = Display and lift cutout active (except for digital lift input)
3 = Display and lift cutout active (except for MFC05 lift setpoints)
4 = Display and lift cutout active (except for MFC05 lift setpoints and digital lift input)
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Battery parameters (from 11.11)
CAUTION!
Battery type parametersThe battery and charger used must match the battery parameters
No. Function Setting range
Standard setting
Comments
1377 Battery type (normal / high performance / dry)
0 - 7 1 0 = Normal (wet)
1 = High performance (wet)
2 = Dry (maintenance-free)
3 = US type ("Flat Plate")
4 = US type("Pallet Pfro")
5 = US type("Tubular Plate"/dry battery)
7 = Exide GF12 063 Y (dry battery)
1389 Discharge monitor function
0 - 4 1 0 = Not active
1 = Active
2 = Display and lift cutout active (except for digital lift input)
3 = Display and lift cutout active (except for MFC05 lift setpoints)
4 = Display and lift cutout active (except for MFC05 lift setpoints and digital lift input)
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7.6 CanDis display instrument
The instrument indicates:
Charge status display
The charge status is shown through eight LED bars.
Eight lit LED bars correspond to a fully charged battery. One lit LED bar correspondsto an almost discharged battery.
When the "Attention" symbol (74) starts to flash, it is advisable to charge the battery.
If the "Attention" symbol (74) is lit steadily, the battery must be charged.
If the "Stop" symbol (75) is lit steadily, the battery must be charged immediately. Ifactivated, the discharge monitor function is applied in this case, (see "Dischargemonitor function" on page 85).
Z The point at which the "Attention" (74) and "Stop" (75) symbols start to light updiffers depending on the battery type.
72Battery charge display (on board charger only)
73 LED bars for battery charge status
74"Attention" symbol (yellow)Battery charge recommended
75"Stop" symbol (red); lift cutout,Battery charge essential
76"T" symbol appears during operation when the discharge indicator is set to maintenance-free battery
77
6 digit LCD display;– Service hours– Parameter entry and changes– Event messages
72
74
76
73
75
77
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7.6 CanDis display instrument
The instrument indicates:
Charge status display
The charge status is shown through eight LED bars.
Eight lit LED bars correspond to a fully charged battery. One lit LED bar correspondsto an almost discharged battery.
When the "Attention" symbol (74) starts to flash, it is advisable to charge the battery.
If the "Attention" symbol (74) is lit steadily, the battery must be charged.
If the "Stop" symbol (75) is lit steadily, the battery must be charged immediately. Ifactivated, the discharge monitor function is applied in this case, (see "Dischargemonitor function" on page 85).
Z The point at which the "Attention" (74) and "Stop" (75) symbols start to light updiffers depending on the battery type.
72Battery charge display (on board charger only)
73 LED bars for battery charge status
74"Attention" symbol (yellow)Battery charge recommended
75"Stop" symbol (red); lift cutout,Battery charge essential
76"T" symbol appears during operation when the discharge indicator is set to maintenance-free battery
77
6 digit LCD display;– Service hours– Parameter entry and changes– Event messages
72
74
76
73
75
77
85
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The discharge limit has been reached when the"Stop" symbol (75) lights up. When the dischargemonitor function is activated lifting operations aredisabled. Travel and lowering are still possible.
Lifting is only enabled again when the battery is 70%charged.
7.6.2 Service hour display
The service hour display range is between 0.0 and99,999.0 hours. The display (77) has backgroundlighting.
Z For maintenance-free batteries a "T" (76) symbol is shown in the display.
7.6.3 Event Messages
The service hours display is also used to display event messages. The eventmessages overwrite the service hour display. Event message start with an ”E” forEvent and a four-digit error number.The event message is displayed as long as the fault persists. If there are severalevent messages they are displayed consecutively. Most event messages result in theEmergency Stop being activated.
Z Remedies, (see "Troubleshooting" on page 60).
7.6.4 Power up test
Once the truck has become operational the following displays appear:
– Display unit software version is flashed briefly– Service hours– Battery charge status
7.7 ISM access module (o)
Z If the truck is equipped with an ISM access module or Can Code refer to the “ISMAccess Module” operator manual.
72
74
76
73
75
77
85
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7.6.1 Discharge monitor function
The discharge limit has been reached when the"Stop" symbol (75) lights up. When the dischargemonitor function is activated lifting operations aredisabled. Travel and lowering are still possible.
Lifting is only enabled again when the battery is 70%charged.
7.6.2 Service hour display
The service hour display range is between 0.0 and99,999.0 hours. The display (77) has backgroundlighting.
Z For maintenance-free batteries a "T" (76) symbol is shown in the display.
7.6.3 Event Messages
The service hours display is also used to display event messages. The eventmessages overwrite the service hour display. Event message start with an ”E” forEvent and a four-digit error number.The event message is displayed as long as the fault persists. If there are severalevent messages they are displayed consecutively. Most event messages result in theEmergency Stop being activated.
Z Remedies, (see "Troubleshooting" on page 60).
7.6.4 Power up test
Once the truck has become operational the following displays appear:
– Display unit software version is flashed briefly– Service hours– Battery charge status
7.7 ISM access module (o)
Z If the truck is equipped with an ISM access module or Can Code refer to the “ISMAccess Module” operator manual.
72
74
76
73
75
77
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F Industrial Truck Maintenance
1 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.
WARNING!
Risk of accidents and damage to componentsAll modifications to the forklift truck assemblies, in particular the safety mechanisms,are prohibited. The operating speeds of the truck must not be increased under anycircumstances.
NOTE
Only original spare parts have been certified by our quality assurance department. Toensure safe and reliable operation of the truck, use only the manufacturer's spareparts.For safety reasons, only components which have been specially agreed by themanufacturer for this truck may be installed near the computer, controllers and wireguidance sensors (antennae). These components (computers, controllers, wireguidance sensors (antennae)) must therefore not be replaced either by similarcomponents from other trucks of the same series.
2 Maintenance Safety Regulations
Maintenance personnel
The truck should only be serviced and repaired by the manufacturer's specialistcustomer service personnel who have been trained to do this. We thereforerecommend that you enter into a maintenance contract with the manufacturer’s localsales office.
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F Industrial Truck Maintenance
1 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.
WARNING!
Risk of accidents and damage to componentsAll modifications to the forklift truck assemblies, in particular the safety mechanisms,are prohibited. The operating speeds of the truck must not be increased under anycircumstances.
NOTE
Only original spare parts have been certified by our quality assurance department. Toensure safe and reliable operation of the truck, use only the manufacturer's spareparts.For safety reasons, only components which have been specially agreed by themanufacturer for this truck may be installed near the computer, controllers and wireguidance sensors (antennae). These components (computers, controllers, wireguidance sensors (antennae)) must therefore not be replaced either by similarcomponents from other trucks of the same series.
2 Maintenance Safety Regulations
Maintenance personnel
The truck should only be serviced and repaired by the manufacturer's specialistcustomer service personnel who have been trained to do this. We thereforerecommend that you enter into a maintenance contract with the manufacturer’s localsales office.
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Lifting and jacking up
WARNING!
Lifting and jacking up the truck safelyIn order to raise the truck, the lifting gear must only be secured to the points speciallyprovided for this purpose. You may only work under a raised load handler / raised cab if they have been securedwith a sufficiently strong chain or the fastening bolt.In order to raise and jack up the truck safely, proceed as follows:Jack up the truck only on a level surface and prevent it from moving accidentally.Always use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the pointsspecially provided for this purpose, (see "Transport and Commissioning" onpage 27).
When jacking up the truck, take appropriate measures to prevent it from slipping ortipping over (e.g. wedges, wooden blocks).
Cleaning
CAUTION!
Fire hazardDo not use flammable liquids to clean the industrial truck.Always disconnect the battery before starting cleaning work.Carry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
CAUTION!
Risk of electrical system damageThe electrical system can be damaged if it is cleaning with water. It is prohibited toclean the electrical system with water.Do not clean the electrical system with water.Clean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
CAUTION!
Risk of component damage when cleaning the truckIf the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck aftercleaning or maintenance work” ((see "Restoring the truck to service aftermaintenance and repairs" on page 109)).
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88
Lifting and jacking up
WARNING!
Lifting and jacking up the truck safelyIn order to raise the truck, the lifting gear must only be secured to the points speciallyprovided for this purpose. You may only work under a raised load handler / raised cab if they have been securedwith a sufficiently strong chain or the fastening bolt.In order to raise and jack up the truck safely, proceed as follows:Jack up the truck only on a level surface and prevent it from moving accidentally.Always use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the pointsspecially provided for this purpose, (see "Transport and Commissioning" onpage 27).
When jacking up the truck, take appropriate measures to prevent it from slipping ortipping over (e.g. wedges, wooden blocks).
Cleaning
CAUTION!
Fire hazardDo not use flammable liquids to clean the industrial truck.Always disconnect the battery before starting cleaning work.Carry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
CAUTION!
Risk of electrical system damageThe electrical system can be damaged if it is cleaning with water. It is prohibited toclean the electrical system with water.Do not clean the electrical system with water.Clean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
CAUTION!
Risk of component damage when cleaning the truckIf the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck aftercleaning or maintenance work” ((see "Restoring the truck to service aftermaintenance and repairs" on page 109)).
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NElectrical system
WARNING!
Accident riskOnly suitably trained electricians may operate on the truck's electrical system.Before working on the electrical system, take all precautionary measures to avoid
electric shocks.Always disconnect the battery before starting cleaning operations.
WARNING!
Electric currents can cause accidentsMake sure the electrical system is voltage-free before starting work on it. Beforestarting maintenance on the electrical system:Park the truck securely ((see "Parking the truck securely" on page 50)).Press the Emergency Disconnect. Disconnect the battery.Remove any rings or metal bracelets etc. before working on electrical components.
Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazardUsed parts, oils and fuels must be disposed of in accordance with the relevantenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.Note the safety regulations when handling these materials.
Welding
Remove electrical and electronic components from the truck before performingwelding operations, to avoid damage.
Settings
When repairing or replacing hydraulic, electric or electronic components orassemblies, always note the truck-specific settings.
Wheels
WARNING!
The use of wheels that do not match the manufacturer's specifications canresult in accidents.The quality of wheels affects the stability and performance of the truck. Uneven wear affects the truck's stability and increases the stopping distance. When replacing wheels make sure the truck is not skewed.Always replace wheels in pairs, i.e. left and right at the same time.
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Electrical system
WARNING!
Accident riskOnly suitably trained electricians may operate on the truck's electrical system.Before working on the electrical system, take all precautionary measures to avoid
electric shocks.Always disconnect the battery before starting cleaning operations.
WARNING!
Electric currents can cause accidentsMake sure the electrical system is voltage-free before starting work on it. Beforestarting maintenance on the electrical system:Park the truck securely ((see "Parking the truck securely" on page 50)).Press the Emergency Disconnect. Disconnect the battery.Remove any rings or metal bracelets etc. before working on electrical components.
Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazardUsed parts, oils and fuels must be disposed of in accordance with the relevantenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.Note the safety regulations when handling these materials.
Welding
Remove electrical and electronic components from the truck before performingwelding operations, to avoid damage.
Settings
When repairing or replacing hydraulic, electric or electronic components orassemblies, always note the truck-specific settings.
Wheels
WARNING!
The use of wheels that do not match the manufacturer's specifications canresult in accidents.The quality of wheels affects the stability and performance of the truck. Uneven wear affects the truck's stability and increases the stopping distance. When replacing wheels make sure the truck is not skewed.Always replace wheels in pairs, i.e. left and right at the same time.
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Z When replacing wheels fitted at the factory, only use the manufacturer’s originalspare parts. Otherwise the truck's rated performance cannot be ensured.
Hydraulic hoses
WARNING!
Leaky hydraulic systems can result in accidentsHydraulic oil can escape from leaky and faulty hydraulic systems.Report any defects immediately to your supervisor.Mark defective truck and take out of service.Do not return the industrial truck to service until you have identified and rectified the
fault.Remove any spilled hydraulic immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Faulty hydraulic hoses can result in injury and infectionPressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulichoses. Brittle hydraulic hoses can burst during operation. People standing near thetruck can be injured by the hydraulic oil.Call for a doctor immediately in the event of an injury.Do not touch pressurised hydraulic hoses. Report any defects immediately to your supervisor.Mark defective truck and take it out of service.Do not return the industrial truck to service until you have identified and rectified the
fault.
NOTE
Testing and replacing hydraulic hosesHydraulic hoses can become brittle through age and must be checked at regularintervals. The application conditions of the industrial truck have a considerable impacton the ageing of the hydraulic hoses.Check the hydraulic hoses at least annually and replace if necessary.If the operating conditions become more arduous the inspection intervals must be
reduced accordingly.In normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6. The owner must carry out a risk assessment to ensuresafe, prolonged use. The resulting protection measures must be observed and theinspection interval reduced accordingly.
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Z When replacing wheels fitted at the factory, only use the manufacturer’s originalspare parts. Otherwise the truck's rated performance cannot be ensured.
Hydraulic hoses
WARNING!
Leaky hydraulic systems can result in accidentsHydraulic oil can escape from leaky and faulty hydraulic systems.Report any defects immediately to your supervisor.Mark defective truck and take out of service.Do not return the industrial truck to service until you have identified and rectified the
fault.Remove any spilled hydraulic immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Faulty hydraulic hoses can result in injury and infectionPressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulichoses. Brittle hydraulic hoses can burst during operation. People standing near thetruck can be injured by the hydraulic oil.Call for a doctor immediately in the event of an injury.Do not touch pressurised hydraulic hoses. Report any defects immediately to your supervisor.Mark defective truck and take it out of service.Do not return the industrial truck to service until you have identified and rectified the
fault.
NOTE
Testing and replacing hydraulic hosesHydraulic hoses can become brittle through age and must be checked at regularintervals. The application conditions of the industrial truck have a considerable impacton the ageing of the hydraulic hoses.Check the hydraulic hoses at least annually and replace if necessary.If the operating conditions become more arduous the inspection intervals must be
reduced accordingly.In normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6. The owner must carry out a risk assessment to ensuresafe, prolonged use. The resulting protection measures must be observed and theinspection interval reduced accordingly.
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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.
WARNING!
The application conditions of an industrial truck have a considerable impact on thewear of the service components.We recommend that a Jungheinrich customer service adviser carries out anapplication analysis on site to work out specific service intervals to prevent damagedue to wear.The service intervals stated are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and therespective intervals to be observed. Maintenance intervals are defined as:
Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check thewheel nuts / bolts and re-tighten if necessary.
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
k =Cold store maintenance interval (in addition to standard maintenance interval)
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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.
WARNING!
The application conditions of an industrial truck have a considerable impact on thewear of the service components.We recommend that a Jungheinrich customer service adviser carries out anapplication analysis on site to work out specific service intervals to prevent damagedue to wear.The service intervals stated are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and therespective intervals to be observed. Maintenance intervals are defined as:
Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check thewheel nuts / bolts and re-tighten if necessary.
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
k =Cold store maintenance interval (in addition to standard maintenance interval)
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4 Maintenance checklist
4.1 Owner
4.1.1 Standard equipment
Braking W A B C
1 Test brakes. t
Electrical system W A B C
1Test warning and safety devices in accordance with operating instructions.
t
2 Test Emergency Disconnect switch. t
Power Supply W A B C
1Check battery cable connections are secure, grease terminals if necessary.
t
2 Check battery and battery components. t
3Check battery connector for damage, test it and make sure it is secure.
t
Travel W A B C
1 Check wheels for wear and damage. t
Chassis and superstructure W A B C
1 Check doors and/or covers. t2 Check labels are legible and complete. t
Hydraulic operations W A B C
1 Test hydraulic system. t2 Check hydraulic oil level and top up if necessary. t3 Check forks or load handler for wear and damage. t
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4 Maintenance checklist
4.1 Owner
4.1.1 Standard equipment
Braking W A B C
1 Test brakes. t
Electrical system W A B C
1Test warning and safety devices in accordance with operating instructions.
t
2 Test Emergency Disconnect switch. t
Power Supply W A B C
1Check battery cable connections are secure, grease terminals if necessary.
t
2 Check battery and battery components. t
3Check battery connector for damage, test it and make sure it is secure.
t
Travel W A B C
1 Check wheels for wear and damage. t
Chassis and superstructure W A B C
1 Check doors and/or covers. t2 Check labels are legible and complete. t
Hydraulic operations W A B C
1 Test hydraulic system. t2 Check hydraulic oil level and top up if necessary. t3 Check forks or load handler for wear and damage. t
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Entry skids / rollers
Folding driver's seat
Optional equipment
Hydraulic operations W A B C
1Check entry skids or entry rollers for damage and wear, and test operation.
k
Chassis and superstructure W A B C
1Test driver's seat, backrest and padding in the operator position and check for damage.
t
Chassis and superstructure W A B C
1Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.
t
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4.1.2 Optional equipment
Entry skids / rollers
Folding driver's seat
Optional equipment
Hydraulic operations W A B C
1Check entry skids or entry rollers for damage and wear, and test operation.
k
Chassis and superstructure W A B C
1Test driver's seat, backrest and padding in the operator position and check for damage.
t
Chassis and superstructure W A B C
1Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.
t
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4.2 Customer Service
4.2.1 Standard equipment
Braking W A B C
1 Test brakes. t2 Check magnetic brake air gap. t
Electrical system W A B C
1 Test cable and motor attachments. t
2Test warning and safety devices in accordance with operating instructions.
t
3 Test displays and controls. t4 Test micro switch and adjust if necessary. t5 Test Emergency Disconnect switch. t6 Check contactors and/or relays. t7 Check fuse ratings. t
8Check carbon brushes and replace if necessary. Note: when replacing the carbon brushes apply compressed air to the motor.
t
9 Carry out a frame leakage test. t
10Check electric wiring for damage [insulation damage, connections]. Make sure wire connections are secure.
t
Power Supply W A B C
1Check battery cable connections are secure, grease terminals if necessary.
t
2 Check battery and battery components. t3 Check acid density and battery voltage. t
4Check battery connector for damage, test it and make sure it is secure.
t
Travel W A B C
1Check transmission oil level or grease filling of the transmission and top up if necessary.
t
2 Test Deadman switch . t3 Test pushbutton mode operation. t4 Check transmission for noise and leakage. t5 Note: Replace transmission oil after 10000 service hours.
6 Check wheels for wear and damage. t7 Check wheel suspension and attachment. t
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4.2 Customer Service
4.2.1 Standard equipment
Braking W A B C
1 Test brakes. t2 Check magnetic brake air gap. t
Electrical system W A B C
1 Test cable and motor attachments. t
2Test warning and safety devices in accordance with operating instructions.
t
3 Test displays and controls. t4 Test micro switch and adjust if necessary. t5 Test Emergency Disconnect switch. t6 Check contactors and/or relays. t7 Check fuse ratings. t
8Check carbon brushes and replace if necessary. Note: when replacing the carbon brushes apply compressed air to the motor.
t
9 Carry out a frame leakage test. t
10Check electric wiring for damage [insulation damage, connections]. Make sure wire connections are secure.
t
Power Supply W A B C
1Check battery cable connections are secure, grease terminals if necessary.
t
2 Check battery and battery components. t3 Check acid density and battery voltage. t
4Check battery connector for damage, test it and make sure it is secure.
t
Travel W A B C
1Check transmission oil level or grease filling of the transmission and top up if necessary.
t
2 Test Deadman switch . t3 Test pushbutton mode operation. t4 Check transmission for noise and leakage. t5 Note: Replace transmission oil after 10000 service hours.
6 Check wheels for wear and damage. t7 Check wheel suspension and attachment. t
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Chassis and superstructure W A B C
1 Check chassis and screw connections for damage. t2 Check doors and/or covers. t3 Check labels are legible and complete. t
4Test backrest and/or padding in the operator position and check for damage.
t
5 Test the operator platform and check for damage. t6 Check operator mat and steps are non-slip and damage-free. t
Hydraulic operations W A B C
1Test "hydraulic" controls and make sure the labels are present, legible and complete.
t
2 Test lifting mechanism, check for wear, damage and test the settings. t
3Check cylinders and piston rods for damage and leaks, and make sure they are secure.
t
4Check settings and wear levels of slide pieces and stops and adjust the slide pieces if necessary.
t
5Check lateral clearance of the mast connections and the fork carriage.
t
6Visually inspect the mast rollers and check contact surface wear level.
t
7 Test hydraulic system. t8 Replace hydraulic oil filter, ventilation/discharge filter. k t
9Check that hydraulic ports, hose and pipe lines are secure, check for leaks and damage.
t
10 Check hydraulic oil level and top up if necessary. t11 Test relief valve and adjust if necessary. t12 Replace hydraulic oil. k t13 Check forks or load handler for wear and damage. t14 Check tie / plunger rods. t15 Test lift and lowering speeds. t
Agreed performance levels W A B C
1Carry out a test run with rated load, if necessary with a customer-specific load.
t
2 Lubricate truck according to the lubrication schedule. t3 Demonstration after servicing. t
Steering W A B C
1 Test electric steering and its components. t
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Chassis and superstructure W A B C
1 Check chassis and screw connections for damage. t2 Check doors and/or covers. t3 Check labels are legible and complete. t
4Test backrest and/or padding in the operator position and check for damage.
t
5 Test the operator platform and check for damage. t6 Check operator mat and steps are non-slip and damage-free. t
Hydraulic operations W A B C
1Test "hydraulic" controls and make sure the labels are present, legible and complete.
t
2 Test lifting mechanism, check for wear, damage and test the settings. t
3Check cylinders and piston rods for damage and leaks, and make sure they are secure.
t
4Check settings and wear levels of slide pieces and stops and adjust the slide pieces if necessary.
t
5Check lateral clearance of the mast connections and the fork carriage.
t
6Visually inspect the mast rollers and check contact surface wear level.
t
7 Test hydraulic system. t8 Replace hydraulic oil filter, ventilation/discharge filter. k t
9Check that hydraulic ports, hose and pipe lines are secure, check for leaks and damage.
t
10 Check hydraulic oil level and top up if necessary. t11 Test relief valve and adjust if necessary. t12 Replace hydraulic oil. k t13 Check forks or load handler for wear and damage. t14 Check tie / plunger rods. t15 Test lift and lowering speeds. t
Agreed performance levels W A B C
1Carry out a test run with rated load, if necessary with a customer-specific load.
t
2 Lubricate truck according to the lubrication schedule. t3 Demonstration after servicing. t
Steering W A B C
1 Test electric steering and its components. t
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4.2.2 Optional equipment
Aquamatik
Battery refill system
Data recorder
Data radio
Entry skids / rollers
Electrolyte recirculation
Folding driver's seat
Power Supply W A B C
1Test Aquamatik plug, hose connections and float and check for leaks.
t
2 Test flow indicator and check for leaks. t
Power Supply W A B C
1 Test battery refill system and check for leaks. t
Electrical system W A B C
1 Check data recorder is secure and check for damage. t
System components W A B C
1Test scanner and terminal, check for damage and make sure they are secure and clean.
t
2 Check fuse ratings. t3 Check wiring is secure and check for damage. t
Hydraulic operations W A B C
1Check entry skids or entry rollers for damage and wear, and test operation.
t
Power Supply W A B C
1 Replace air filter wadding. t2 Check hose connections and test the pump. t
Chassis and superstructure W A B C
1 Check attachment and setting function of the driver's seat. t
2Test driver's seat, backrest and padding in the operator position and check for damage.
t
3 Check condition of the driver’s seat. t
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4.2.2 Optional equipment
Aquamatik
Battery refill system
Data recorder
Data radio
Entry skids / rollers
Electrolyte recirculation
Folding driver's seat
Power Supply W A B C
1Test Aquamatik plug, hose connections and float and check for leaks.
t
2 Test flow indicator and check for leaks. t
Power Supply W A B C
1 Test battery refill system and check for leaks. t
Electrical system W A B C
1 Check data recorder is secure and check for damage. t
System components W A B C
1Test scanner and terminal, check for damage and make sure they are secure and clean.
t
2 Check fuse ratings. t3 Check wiring is secure and check for damage. t
Hydraulic operations W A B C
1Check entry skids or entry rollers for damage and wear, and test operation.
t
Power Supply W A B C
1 Replace air filter wadding. t2 Check hose connections and test the pump. t
Chassis and superstructure W A B C
1 Check attachment and setting function of the driver's seat. t
2Test driver's seat, backrest and padding in the operator position and check for damage.
t
3 Check condition of the driver’s seat. t
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NImpact sensor
Lateral battery removal
Lower cutout
Access module
Optional equipment
Issued on: 21.11.2011 09:36:28
Electrical system W A B C
1 Check impact sensor is secure and check for damage. t
Power Supply W A B C
1 Test battery lock / battery attachment. t
Hydraulic operations W A B C
1 Test lower cutout during travel. t
Electrical system W A B C
1 Test access module, check for damage and make sure it is secure. t
Chassis and superstructure W A B C
1Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.
t
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Impact sensor
Lateral battery removal
Lower cutout
Access module
Optional equipment
Issued on: 21.11.2011 09:36:28
Electrical system W A B C
1 Check impact sensor is secure and check for damage. t
Power Supply W A B C
1 Test battery lock / battery attachment. t
Hydraulic operations W A B C
1 Test lower cutout during travel. t
Electrical system W A B C
1 Test access module, check for damage and make sure it is secure. t
Chassis and superstructure W A B C
1Check that optional equipment such as mirrors, storage compartments, grips, windscreen wipers and washing systems etc. are working correctly and check for damage.
t
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5 Lubricants and Lubrication Schedule
5.1 Handling consumables safely
Handling consumables
Consumables must always be handled correctly. Follow the manufacturer’sinstructions.
WARNING!
Improper handling is hazardous to health, life and the environmentConsumables can be flammable.Keep consumables away from hot components and naked flames.Always keep consumables in prescribed containers.Always fill consumables in clean containers.Do not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
CAUTION!
Spilled liquids can cause slipping and endanger the environmentRisk of slipping from spilled liquids. The risk is greater when combined with water.Do not spill fluids.Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous.Dispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.Do not spill oil.Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance with
regulations.Observe national regulations when handling oils.Wear safety gloves when handling oils.Prevent oil from coming into contact with hot motor parts.Do not smoke when handling oil.Avoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.Seek fresh air after breathing in oil fumes or vapours.If oil has come into contact with your skin, rinse your skin with water.If oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately.Replace oil-soaked clothing and shoes immediately.
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5 Lubricants and Lubrication Schedule
5.1 Handling consumables safely
Handling consumables
Consumables must always be handled correctly. Follow the manufacturer’sinstructions.
WARNING!
Improper handling is hazardous to health, life and the environmentConsumables can be flammable.Keep consumables away from hot components and naked flames.Always keep consumables in prescribed containers.Always fill consumables in clean containers.Do not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
CAUTION!
Spilled liquids can cause slipping and endanger the environmentRisk of slipping from spilled liquids. The risk is greater when combined with water.Do not spill fluids.Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous.Dispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations.Do not spill oil.Spilled fluids must be removed immediately with an appropriate bonding agent.The bonding agent / consumable mixture must be disposed of in accordance with
regulations.Observe national regulations when handling oils.Wear safety gloves when handling oils.Prevent oil from coming into contact with hot motor parts.Do not smoke when handling oil.Avoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately.Seek fresh air after breathing in oil fumes or vapours.If oil has come into contact with your skin, rinse your skin with water.If oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately.Replace oil-soaked clothing and shoes immediately.
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NConsumables and used parts
CAUTION!
Consumables and used parts are an environmental hazardUsed parts, oils and fuels must be disposed of in accordance with the relevantenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.Note the safety regulations when handling these materials.
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Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazardUsed parts, oils and fuels must be disposed of in accordance with the relevantenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.Note the safety regulations when handling these materials.
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100
5.2 Lubrication Schedule
1 Compound ratio for cold store usage 1:1
g Contact surfaces a Transmission oil drain plug
s Grease nipple Hydraulic oil filler neck
Cold Store Application
E
A
B 1,05 l
s E
A + C0,7 l
1)
a
2)
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100
5.2 Lubrication Schedule
1 Compound ratio for cold store usage 1:1
g Contact surfaces a Transmission oil drain plug
s Grease nipple Hydraulic oil filler neck
Cold Store Application
E
A
B 1,05 l
s E
A + C0,7 l
1)
a
2)
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the oil.
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2 Gear oil is guideline value only. The spur wheel should be dipped approx. 2mm inthe oil.
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102
5.3 Consumables
*) also for cold store applications
Grease guidelines
Code Order no. Package quantity
Component Used for
A 50 449 669 5.0 l H-LPD 46, DIN 51524
Hydraulic system
B 50 380 904 5.0 l Fuchs Titan Cytrac HSY 75W-90 *)
Transmission
C 29 200 810 5.0 l H-LP 10, DIN 51524
Hydraulic system
E 29 202 050 1.0 kg Grease, Polylube GA 352P
Lubrication
Code Saponification Dew point°C
Worked penetration at 25 °C
NLG1 class Application temperature °C
E Lithium >220 280 - 310 2 -35/+120
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102
5.3 Consumables
*) also for cold store applications
Grease guidelines
Code Order no. Package quantity
Component Used for
A 50 449 669 5.0 l H-LPD 46, DIN 51524
Hydraulic system
B 50 380 904 5.0 l Fuchs Titan Cytrac HSY 75W-90 *)
Transmission
C 29 200 810 5.0 l H-LP 10, DIN 51524
Hydraulic system
E 29 202 050 1.0 kg Grease, Polylube GA 352P
Lubrication
Code Saponification Dew point°C
Worked penetration at 25 °C
NLG1 class Application temperature °C
E Lithium >220 280 - 310 2 -35/+120
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6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying outmaintenance and repairs. The following preparations must be made:
Procedure• Park the truck on a level surface.• Fully lower the main and auxiliary lift.• Park the truck securely, (see "Parking the truck securely" on page 50).• Disconnect the battery to prevent the truck from being switched on accidentally.• When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
WARNING!
Risk of accidents when working under the load handler, driver's cab and lifttruckWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.When raising the truck, follow the instructions, (see "Transport and
Commissioning" on page 27). When working on the parking brake, prevent thetruck from accidentally rolling away (e.g. with wedges).
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6 Maintenance and repairs
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying outmaintenance and repairs. The following preparations must be made:
Procedure• Park the truck on a level surface.• Fully lower the main and auxiliary lift.• Park the truck securely, (see "Parking the truck securely" on page 50).• Disconnect the battery to prevent the truck from being switched on accidentally.• When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away.
WARNING!
Risk of accidents when working under the load handler, driver's cab and lifttruckWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.When raising the truck, follow the instructions, (see "Transport and
Commissioning" on page 27). When working on the parking brake, prevent thetruck from accidentally rolling away (e.g. with wedges).
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104
6.2 Tightening the wheel nuts
Z The wheel nuts on the drive wheel must be retightened in accordance with themaintenance intervals indicated in the maintenance checklist, (see "Servicing andInspection" on page 91)
Tightening the wheel nuts
Requirements– To prepare the truck for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 103)
Tools and Material Required– Steckschlüssel
Procedure• Position the drive wheel (84) at right angles to the longitudinal axis of the truck.• Tighten all the wheel nuts (83) in the skirt with the socket wrench through the hole
(85).To do this, torque the wheel nuts in the prescribed order• initially to 10 Nm• then to 150 Nm.
The wheel nuts are now tightened.
1
3
5
2
4
8384
85
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104
6.2 Tightening the wheel nuts
Z The wheel nuts on the drive wheel must be retightened in accordance with themaintenance intervals indicated in the maintenance checklist, (see "Servicing andInspection" on page 91)
Tightening the wheel nuts
Requirements– To prepare the truck for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 103)
Tools and Material Required– Steckschlüssel
Procedure• Position the drive wheel (84) at right angles to the longitudinal axis of the truck.• Tighten all the wheel nuts (83) in the skirt with the socket wrench through the hole
(85).To do this, torque the wheel nuts in the prescribed order• initially to 10 Nm• then to 150 Nm.
The wheel nuts are now tightened.
1
3
5
2
4
8384
85
105
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N6.3 Removing the front panel
Front panel disassembly
Requirements– Open the battery panel, (see "Exposing the battery" on page 33).
Tools and Material Required– Allen key
Procedure• Remove the hex socket screws (86) located under the battery cover using a hex
socket wrench.• Lift off the front panel (15) and put it to one side.
The front panel is now disassembled.
Z Assembly is the reverse order.
15
86
105
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6.3 Removing the front panel
Front panel disassembly
Requirements– Open the battery panel, (see "Exposing the battery" on page 33).
Tools and Material Required– Allen key
Procedure• Remove the hex socket screws (86) located under the battery cover using a hex
socket wrench.• Lift off the front panel (15) and put it to one side.
The front panel is now disassembled.
Z Assembly is the reverse order.
15
86
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6.4 Flipping the JetPilot back for maintenance purposes (o)
Flipping back the JetPilot
Requirements– Forks and standing platform are lowered.
Procedure• Depress the Emergency Disconnect switch
(12). • Remove the battery connector (46).• Push the JetPilot lock(87) down and flip back
the JetPilot (11).
JetPilot is flipped back and the battery covercan be opened.
Flipping the JetPilot forward
Procedure• Close and lock the battery cover.• Flip the JetPilot (11) forward and push the
JetPilot lock (87) up until it engages.Z The Jet Pilot must always be correctly
engaged during operation. Otherwise thetruck cannot be switched on.
The battery cover is closed and the JetPilot isflipped forward.
87
11
11
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6.4 Flipping the JetPilot back for maintenance purposes (o)
Flipping back the JetPilot
Requirements– Forks and standing platform are lowered.
Procedure• Depress the Emergency Disconnect switch
(12). • Remove the battery connector (46).• Push the JetPilot lock(87) down and flip back
the JetPilot (11).
JetPilot is flipped back and the battery covercan be opened.
Flipping the JetPilot forward
Procedure• Close and lock the battery cover.• Flip the JetPilot (11) forward and push the
JetPilot lock (87) up until it engages.Z The Jet Pilot must always be correctly
engaged during operation. Otherwise thetruck cannot be switched on.
The battery cover is closed and the JetPilot isflipped forward.
87
11
11
107
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Check fuses
Requirements– Truck prepared for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 103).– Front panel removed, (see "Removing the front panel" on page 105).
Procedure• Check the fuse ratings against the table and replace if necessary.
The fuses are now checked.
Fuses up to 10.11
Fuses up to 10.11
Item Component To protect Rating (A)88 F17 Radio data transmission (o) 1089 3F1 Electric steering control fuse 3090 F1 Overall fuse 1091 6F1 Battery discharge indicator / battery hour meter 292 1F1 Drive motor 30093 2F1 Pump motor 150
88 89 90 91 92 93
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6.5 Checking electrical fuses
Check fuses
Requirements– Truck prepared for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 103).– Front panel removed, (see "Removing the front panel" on page 105).
Procedure• Check the fuse ratings against the table and replace if necessary.
The fuses are now checked.
Fuses up to 10.11
Fuses up to 10.11
Item Component To protect Rating (A)88 F17 Radio data transmission (o) 1089 3F1 Electric steering control fuse 3090 F1 Overall fuse 1091 6F1 Battery discharge indicator / battery hour meter 292 1F1 Drive motor 30093 2F1 Pump motor 150
88 89 90 91 92 93
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Fuses from 11.11
Fuses from 11.11
Item Component To protect Rating (A)88 F17 Radio data transmission (o) 1089 1F9 Travel / display instrument 1090 F13 Brake / Options 1091 6F1 Battery Discharge Indicator 292 1F1 Drive motor / pump motor / controller 300
88
908991 92
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Fuses from 11.11
Fuses from 11.11
Item Component To protect Rating (A)88 F17 Radio data transmission (o) 1089 1F9 Travel / display instrument 1090 F13 Brake / Options 1091 6F1 Battery Discharge Indicator 292 1F1 Drive motor / pump motor / controller 300
88
908991 92
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Procedure• Thoroughly clean the truck.• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 100).• Clean the battery, grease the terminals and connect the battery.• Charge the battery, (see "Charging the battery" on page 35).• Check the transmission oil for condensation water and replace if necessary.• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry outthese operations.
WARNING!Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 47).Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls byapplying them repeatedly.
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6.6 Restoring the truck to service after maintenance and repairs
Procedure• Thoroughly clean the truck.• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 100).• Clean the battery, grease the terminals and connect the battery.• Charge the battery, (see "Charging the battery" on page 35).• Check the transmission oil for condensation water and replace if necessary.• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry outthese operations.
WARNING!Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 47).Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls byapplying them repeatedly.
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7 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercialreasons, it must be stored in a frost-free and dry room. All necessary measuresmust be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safelyIn order to raise the truck, the lifting gear must only be secured to the points speciallyprovided for this purpose. You may only work under a raised load handler / raised cab if they have been securedwith a sufficiently strong chain or the fastening bolt.In order to raise and jack up the truck safely, proceed as follows:Jack up the truck only on a level surface and prevent it from moving accidentally.Only use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).In order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose. (see "Identification points and data plates" onpage 25).
When jacking up the truck, take appropriate measures to prevent it from slipping ortipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clearof the ground. This is the only way of ensuring that the wheels and wheel bearingsare not damaged.
If the truck is to be out of service for more than 6 months, agree further measures withthe manufacturer's customer service department.
7.1 Before taking the truck out of service
Procedure• Thoroughly clean the truck.
WARNING!Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
• Test the brakes.• Check the hydraulic oil level and replenish if necessary, (see "Consumables" on
page 102).• Apply a thin layer of oil or grease to any non-painted mechanical components.• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 100).• Charge the battery, (see "Charging the battery" on page 35).• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer's instructions.
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7 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercialreasons, it must be stored in a frost-free and dry room. All necessary measuresmust be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safelyIn order to raise the truck, the lifting gear must only be secured to the points speciallyprovided for this purpose. You may only work under a raised load handler / raised cab if they have been securedwith a sufficiently strong chain or the fastening bolt.In order to raise and jack up the truck safely, proceed as follows:Jack up the truck only on a level surface and prevent it from moving accidentally.Only use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).In order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose. (see "Identification points and data plates" onpage 25).
When jacking up the truck, take appropriate measures to prevent it from slipping ortipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clearof the ground. This is the only way of ensuring that the wheels and wheel bearingsare not damaged.
If the truck is to be out of service for more than 6 months, agree further measures withthe manufacturer's customer service department.
7.1 Before taking the truck out of service
Procedure• Thoroughly clean the truck.
WARNING!Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
• Test the brakes.• Check the hydraulic oil level and replenish if necessary, (see "Consumables" on
page 102).• Apply a thin layer of oil or grease to any non-painted mechanical components.• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 100).• Charge the battery, (see "Charging the battery" on page 35).• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer's instructions.
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7.2 Action to be taken during decommissioning
NOTE
Full discharge can damage the batterySelf-discharge can cause the battery to fully discharge. Full discharge shortens theuseful life of the battery. Charge the battery at least every 2 months.
Z Charge the battery (see "Charging the battery" on page 35).
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• Spay all exposed electrical contacts with a suitable contact spray.
7.2 Action to be taken during decommissioning
NOTE
Full discharge can damage the batterySelf-discharge can cause the battery to fully discharge. Full discharge shortens theuseful life of the battery. Charge the battery at least every 2 months.
Z Charge the battery (see "Charging the battery" on page 35).
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7.3 Restoring the truck to service after decommissioning
Procedure• Thoroughly clean the truck.• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 100).• Clean the battery, grease the terminals and connect the battery.• Charge the battery, (see "Charging the battery" on page 35).• Check the transmission oil for condensation water and replace if necessary.• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry outthese operations.
WARNING!Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 47).Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls byapplying them repeatedly.
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7.3 Restoring the truck to service after decommissioning
Procedure• Thoroughly clean the truck.• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 100).• Clean the battery, grease the terminals and connect the battery.• Charge the battery, (see "Charging the battery" on page 35).• Check the transmission oil for condensation water and replace if necessary.• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry outthese operations.
WARNING!Faulty brakes can cause accidentsAs soon as the truck has been started, test the brakes several times.Report any defects immediately to your supervisor.Tag out and decommission a faulty lift truck.Only return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 47).Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls byapplying them repeatedly.
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incidents
Z Perform a safety check in accordance with national regulations. Jungheinrichrecommends the truck be checked to FEM guideline 4.004. The Jungheinrichsafety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualifiedinspector (be sure to comply with national regulations). The inspector shall assess thecondition of the truck from purely a safety viewpoint, without regard to operational oreconomic circumstances. The inspector shall be sufficiently instructed andexperienced to be able to assess the condition of the truck and the effectiveness ofthe safety mechanisms based on the technical regulations and principles governingthe inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical conditionfrom a safety aspect. The truck must also be examined for damage caused bypossible improper use. A test report shall be provided. The test results must be keptfor at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z Final de-commissioning or disposal of the truck in must be performed inaccordance with the regulations of the country of use. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systemsmust be observed.
The truck must only be disassembled by trained personnel in accordance with theprocedures as specified by the manufacturer. Note the manufacturer’s safetyinstructions as specified in the service documentation.
10 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day areknown as human vibrations. Excessive human vibrations will cause the driver longterm health problems. The European "2002/44/EC/Vibration" operator directive hastherefore been established to protect drivers. To help operators to assess the application situation, the manufacturer offers aservice of measuring these human vibrations.
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8 Safety tests to be performed at intervals and after unusualincidents
Z Perform a safety check in accordance with national regulations. Jungheinrichrecommends the truck be checked to FEM guideline 4.004. The Jungheinrichsafety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualifiedinspector (be sure to comply with national regulations). The inspector shall assess thecondition of the truck from purely a safety viewpoint, without regard to operational oreconomic circumstances. The inspector shall be sufficiently instructed andexperienced to be able to assess the condition of the truck and the effectiveness ofthe safety mechanisms based on the technical regulations and principles governingthe inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical conditionfrom a safety aspect. The truck must also be examined for damage caused bypossible improper use. A test report shall be provided. The test results must be keptfor at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z Final de-commissioning or disposal of the truck in must be performed inaccordance with the regulations of the country of use. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systemsmust be observed.
The truck must only be disassembled by trained personnel in accordance with theprocedures as specified by the manufacturer. Note the manufacturer’s safetyinstructions as specified in the service documentation.
10 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day areknown as human vibrations. Excessive human vibrations will cause the driver longterm health problems. The European "2002/44/EC/Vibration" operator directive hastherefore been established to protect drivers. To help operators to assess the application situation, the manufacturer offers aservice of measuring these human vibrations.
1
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A Traction Battery Appendix
Contents
A Traction Battery Appendix....................................................... 1
1 Correct Use and Application.................................................................... 22 Data plate ................................................................................................ 23 Safety Instructions, Warning Indications and other Notes....................... 34 Lead acid batteries with armour plated cells and liquid electrolyte.......... 44.1 Description............................................................................................... 44.2 Operation................................................................................................. 54.3 Servicing lead-acid batteries with armour plated cells............................. 85 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 95.1 Description............................................................................................... 95.2 Operation................................................................................................. 105.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 136 Aquamatik water replenishment system.................................................. 146.1 Water replenishment system design ....................................................... 146.2 Functional Description ............................................................................. 156.3 Adding water............................................................................................ 156.4 Water pressure ........................................................................................ 156.5 Filling time ............................................................................................... 166.6 Water quality............................................................................................ 166.7 Battery tubing .......................................................................................... 166.8 Operating temperature ............................................................................ 166.9 Cleaning measures.................................................................................. 176.10 Service mobile vehicle............................................................................. 177 Electrolyte circulation............................................................................... 187.1 Functional Description ............................................................................. 188 Cleaning batteries.................................................................................... 209 Storing the battery ................................................................................... 2210 Troubleshooting....................................................................................... 2211 Disposal................................................................................................... 22
1
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A Traction Battery Appendix
Contents
A Traction Battery Appendix....................................................... 1
1 Correct Use and Application.................................................................... 22 Data plate ................................................................................................ 23 Safety Instructions, Warning Indications and other Notes....................... 34 Lead acid batteries with armour plated cells and liquid electrolyte.......... 44.1 Description............................................................................................... 44.2 Operation................................................................................................. 54.3 Servicing lead-acid batteries with armour plated cells............................. 85 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 95.1 Description............................................................................................... 95.2 Operation................................................................................................. 105.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 136 Aquamatik water replenishment system.................................................. 146.1 Water replenishment system design ....................................................... 146.2 Functional Description ............................................................................. 156.3 Adding water............................................................................................ 156.4 Water pressure ........................................................................................ 156.5 Filling time ............................................................................................... 166.6 Water quality............................................................................................ 166.7 Battery tubing .......................................................................................... 166.8 Operating temperature ............................................................................ 166.9 Cleaning measures.................................................................................. 176.10 Service mobile vehicle............................................................................. 177 Electrolyte circulation............................................................................... 187.1 Functional Description ............................................................................. 188 Cleaning batteries.................................................................................... 209 Storing the battery ................................................................................... 2210 Troubleshooting....................................................................................... 2211 Disposal................................................................................................... 22
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2
1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-originalspare parts, tampering with the battery or using electrolyte additives will invalidate thewarranty.
Observe the instructions for maintaining the safety rating during operation forbatteries in accordance with Ex I and Ex II (see relevant certification).
2 Data plate
1,2
4
8
10
11
6
3
5
9
7
12 13
14
15
1 Battery name2 Battery type3 Production week/year manf.4 Serial number5 Supplier number6 Rated voltage7 Rated capacity9 Battery weight in kg8 Number of cells15 Electrolyte volume in litres10 Battery number11 Manufacturer13 Manufacturer's logo12 CE mark only for batteries beyond 75 volts14 Safety instructions and warning information
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2
1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-originalspare parts, tampering with the battery or using electrolyte additives will invalidate thewarranty.
Observe the instructions for maintaining the safety rating during operation forbatteries in accordance with Ex I and Ex II (see relevant certification).
2 Data plate
1,2
4
8
10
11
6
3
5
9
7
12 13
14
15
1 Battery name2 Battery type3 Production week/year manf.4 Serial number5 Supplier number6 Rated voltage7 Rated capacity9 Battery weight in kg8 Number of cells15 Electrolyte volume in litres10 Battery number11 Manufacturer13 Manufacturer's logo12 CE mark only for batteries beyond 75 volts14 Safety instructions and warning information
3
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N3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste.
These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. waste.
Buy-back terms and type of recycling are to be agreed with the manufacturer as described in § 8 of the battery legislation.
Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire and explosion hazard!
Avoid fire and explosion hazards and short circuits due to overheating!
Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries. batteries. Always wash your hands after completing the work. Use insulated tools only. Do not physically alter the battery, strike, crush, compress, notch, dent or modify it in any way. Hazardous electric voltage! The metal parts of the battery cells are permanently live. Therefore do not place any foreign objects or tools on the battery.Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the charging area.
Work on the batteries should be performed only as instructed by specialist personnel.
3
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3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste.
These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. waste.
Buy-back terms and type of recycling are to be agreed with the manufacturer as described in § 8 of the battery legislation.
Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire and explosion hazard!
Avoid fire and explosion hazards and short circuits due to overheating!
Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries. batteries. Always wash your hands after completing the work. Use insulated tools only. Do not physically alter the battery, strike, crush, compress, notch, dent or modify it in any way. Hazardous electric voltage! The metal parts of the battery cells are permanently live. Therefore do not place any foreign objects or tools on the battery.Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the charging area.
Work on the batteries should be performed only as instructed by specialist personnel.
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4
4 Lead acid batteries with armour plated cells and liquid electrolyte
4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells andliquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte
The rated density of the electrolyte assumes a temperature of 30°C and the ratedelectrolyte level is fully charged. Higher temperatures will reduce, lower temperatureswill increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations.
4.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Nominal electrolyte density1
1. Reached within the first 10 cycles.
1.29 kg/l
6. Nominal temperature2
2. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.
30 °C
7. System rated electrolyte level up to "Max" electrolyte level marking
Limit temperature3
3. Not permissible as operating temperature.
55°C
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4
4 Lead acid batteries with armour plated cells and liquid electrolyte
4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells andliquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte
The rated density of the electrolyte assumes a temperature of 30°C and the ratedelectrolyte level is fully charged. Higher temperatures will reduce, lower temperatureswill increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations.
4.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Nominal electrolyte density1
1. Reached within the first 10 cycles.
1.29 kg/l
6. Nominal temperature2
2. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.
30 °C
7. System rated electrolyte level up to "Max" electrolyte level marking
Limit temperature3
3. Not permissible as operating temperature.
55°C
5
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4.2.1 Commissioning unfilled batteries
Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.
4.2.2 Commissioning filled and charged batteries
Checks and operations to be performed before starting daily work
Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. • Charge up the battery.• Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator.• Add electrolyte with distilled water up to the nominal level.
Checks completed.
4.2.3 Discharging the battery
Z To achieve an optimum useful life avoid operational discharge of more than 80% ofnominal capacity (full discharge). This corresponds to a minimum electrolytedensity of 1.13 kg/l at the end of the discharge. Recharge a discharged batteryimmediately.
5
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4.2 Operation
4.2.1 Commissioning unfilled batteries
Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.
4.2.2 Commissioning filled and charged batteries
Checks and operations to be performed before starting daily work
Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. • Charge up the battery.• Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator.• Add electrolyte with distilled water up to the nominal level.
Checks completed.
4.2.3 Discharging the battery
Z To achieve an optimum useful life avoid operational discharge of more than 80% ofnominal capacity (full discharge). This corresponds to a minimum electrolytedensity of 1.13 kg/l at the end of the discharge. Recharge a discharged batteryimmediately.
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6
4.2.4 Charging the battery
WARNING!
The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.
Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of2 m from the truck.
Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The battery must only be charged with DC current. All charging processes inaccordance with DIN 41773 and DIN 41774 are permissible.
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6
4.2.4 Charging the battery
WARNING!
The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.
Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of2 m from the truck.
Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station
manufacturers.
NOTE
The battery must only be charged with DC current. All charging processes inaccordance with DIN 41773 and DIN 41774 are permissible.
7
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Z The electrolyte temperature rises by approx. 10 K during charging. Charging shouldtherefore only begin when the electrolyte temperature is below 45°C. Theelectrolyte temperature of batteries must be at least +10°C before charging.Otherwise the battery will not charge correctly. Below 10°C the battery isinsufficiently charged with standard charging systems.
Charging the battery
Requirements– Electrolyte temperature min. 10°C to max. 45°C
Procedure• Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain onthe cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are connect(positive to positive and negative to negative).
• Switch on the charger.
Battery charged
Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging. The maximum compensationcharge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which reduce the usefullife of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Usereplacement batteries instead of regular trickle charging.
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Z The electrolyte temperature rises by approx. 10 K during charging. Charging shouldtherefore only begin when the electrolyte temperature is below 45°C. Theelectrolyte temperature of batteries must be at least +10°C before charging.Otherwise the battery will not charge correctly. Below 10°C the battery isinsufficiently charged with standard charging systems.
Charging the battery
Requirements– Electrolyte temperature min. 10°C to max. 45°C
Procedure• Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain onthe cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are connect(positive to positive and negative to negative).
• Switch on the charger.
Battery charged
Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging. The maximum compensationcharge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which reduce the usefullife of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Usereplacement batteries instead of regular trickle charging.
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4.3 Servicing lead-acid batteries with armour plated cells
Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.
4.3.1 Daily
– Charge the battery after each discharge.– After charging, check the electrolyte level.– If necessary, add purified water up to the rated level after charging.
Z The height of the electrolyte level should not be below the cell baffle or above thetop of the separator, or the "Min" and "Max" electrolyte markings respectively.
4.3.2 Weekly
– After re-charging, carry out a visual inspection for dirt and physical damage.– If the battery is charged regularly according to the IU characteristic, carry out a
compensation charge.
4.3.3 Monthly
– Towards the end of the charging process measure and record the voltages of allthe cells with the charger switched on.
– After charging measure and record the electrolyte density and the electrolytetemperature in all the cells.
– Compare the results with the previous ones.
Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.
4.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.
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4.3 Servicing lead-acid batteries with armour plated cells
Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.
4.3.1 Daily
– Charge the battery after each discharge.– After charging, check the electrolyte level.– If necessary, add purified water up to the rated level after charging.
Z The height of the electrolyte level should not be below the cell baffle or above thetop of the separator, or the "Min" and "Max" electrolyte markings respectively.
4.3.2 Weekly
– After re-charging, carry out a visual inspection for dirt and physical damage.– If the battery is charged regularly according to the IU characteristic, carry out a
compensation charge.
4.3.3 Monthly
– Towards the end of the charging process measure and record the voltages of allthe cells with the charger switched on.
– After charging measure and record the electrolyte density and the electrolytetemperature in all the cells.
– Compare the results with the previous ones.
Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.
4.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.
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plated cells
5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can beadded over the entire lifespan of the battery. Relief valves are used as plugs whichare destroyed when opened. During operation the same safety requirements apply tothe sealed batteries as for batteries with liquid electrolyte. This is to avoid electricshock, explosion of the electrolyte charging gases or hazardous electrolyte burns ifthe cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free.
Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolytecannot be measured.
5.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Rated temperature 30 °C
Limit temperature1
1. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.
45°C, not permissible as operating temperature.
6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured
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5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells
5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can beadded over the entire lifespan of the battery. Relief valves are used as plugs whichare destroyed when opened. During operation the same safety requirements apply tothe sealed batteries as for batteries with liquid electrolyte. This is to avoid electricshock, explosion of the electrolyte charging gases or hazardous electrolyte burns ifthe cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free.
Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolytecannot be measured.
5.1.1 Battery nominal data
1. Product Traction battery
2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate
4. Discharge current C5/5h
5. Rated temperature 30 °C
Limit temperature1
1. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.
45°C, not permissible as operating temperature.
6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured
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5.2 Operation
5.2.1 Commissioning
Checks and operations to be performed before starting daily work
Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. • Re-charge the battery.• Charge the battery.
Check completed.
5.2.2 Discharging the battery
Z To achieve an optimum useful life avoid operational discharges of more than 60%of nominal capacity.
Z If the battery is discharged during operation by more than 80% of rated capacity theuseful life of the battery will reduce significantly. Fully or partially dischargedbatteries must be re-charged immediately and not left unattended.
5.2.3 Charging the battery
WARNING!
The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.
Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of2 m from the truck.
Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station
manufacturers.
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5.2 Operation
5.2.1 Commissioning
Checks and operations to be performed before starting daily work
Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. • Re-charge the battery.• Charge the battery.
Check completed.
5.2.2 Discharging the battery
Z To achieve an optimum useful life avoid operational discharges of more than 60%of nominal capacity.
Z If the battery is discharged during operation by more than 80% of rated capacity theuseful life of the battery will reduce significantly. Fully or partially dischargedbatteries must be re-charged immediately and not left unattended.
5.2.3 Charging the battery
WARNING!
The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the
charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.
Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of2 m from the truck.
Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station
manufacturers.
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NOTE
Charging the battery incorrectly can result in material damage.Incorrect battery charging can result in overloading of the electric wires and contacts,hazardous gas formation and electrolyte leakage from the cells.Always charge the battery with DC current.All DIN 41773 charging procedures are permitted in the format approved by the
manufacturer.Always connect the battery to a charger that is appropriate to the size and type of
the battery.If necessary have the charger checked by the manufacturer's customer service
department for suitability.Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3.
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NOTE
Charging the battery incorrectly can result in material damage.Incorrect battery charging can result in overloading of the electric wires and contacts,hazardous gas formation and electrolyte leakage from the cells.Always charge the battery with DC current.All DIN 41773 charging procedures are permitted in the format approved by the
manufacturer.Always connect the battery to a charger that is appropriate to the size and type of
the battery.If necessary have the charger checked by the manufacturer's customer service
department for suitability.Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3.
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Charging the battery
Requirements– Electrolyte temperature between +15°C and 35°C
Procedure• Open or take off the tray lid or covers from the battery compartment.• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative). • Switch on the charger.
Z The electrolyte temperature rises by approx. 10 K during charging. If thetemperatures are permanently higher than 40°C or lower than 15°C, a temperature-dependent constant voltage control of the charger is required. The adjustmentfactor must be applied with -0.004 V/C per K.
Battery charged
Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which can reduce theuseful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Usereplacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries.
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Charging the battery
Requirements– Electrolyte temperature between +15°C and 35°C
Procedure• Open or take off the tray lid or covers from the battery compartment.• Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative). • Switch on the charger.
Z The electrolyte temperature rises by approx. 10 K during charging. If thetemperatures are permanently higher than 40°C or lower than 15°C, a temperature-dependent constant voltage control of the charger is required. The adjustmentfactor must be applied with -0.004 V/C per K.
Battery charged
Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.
Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly.
Trickle charging
Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which can reduce theuseful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Usereplacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries.
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N5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells
Z Do not add water!
5.3.1 Daily
– Charge the battery after each discharge.
5.3.2 Weekly
– Visually inspect for dirt and physical damage.
5.3.3 Every three months
– Measure and record the overall voltage.– Measure and record the individual voltages.– Compare the results with the previous ones.
Z Carry out the measurements after full charging and subsequent resting for at least5 hours.
Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.
5.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.
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5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells
Z Do not add water!
5.3.1 Daily
– Charge the battery after each discharge.
5.3.2 Weekly
– Visually inspect for dirt and physical damage.
5.3.3 Every three months
– Measure and record the overall voltage.– Measure and record the individual voltages.– Compare the results with the previous ones.
Z Carry out the measurements after full charging and subsequent resting for at least5 hours.
Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.
5.3.4 Annually
– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.
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6 Aquamatik water replenishment system
6.1 Water replenishment system design
15 Water container16 Tap connection with ball cock17 Flow indicator18 Shut-off cock19 Locking coupling 20 Battery lock connector
15
16
17
18
19
20
> 3 m
+ -
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6 Aquamatik water replenishment system
6.1 Water replenishment system design
15 Water container16 Tap connection with ball cock17 Flow indicator18 Shut-off cock19 Locking coupling 20 Battery lock connector
15
16
17
18
19
20
> 3 m
+ -
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The Aquamatik water replenishment system is used to adjust the rated electrolytelevel automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the watersupply (e.g. water container) through a plug connection. When the shut-off cock isopened all the cells are filled with water. The Aquamatik plug controls the amount ofwater required and, at the relevant water pressures, ensures the water supply is shutoff and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure thetemperature and electrolyte density and a degassing port.
6.3 Adding water
Water should be added to the batteries just before the battery is fully charged. Thisensures that the amount of water added is mixed with the electrolyte.
6.4 Water pressure
The water replenishment system must be operated with a water pressure in the waterline of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges willaffect the operation of the systems.
Water drop
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1bar
Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3- 1.8 bar.
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6.2 Functional Description
The Aquamatik water replenishment system is used to adjust the rated electrolytelevel automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the watersupply (e.g. water container) through a plug connection. When the shut-off cock isopened all the cells are filled with water. The Aquamatik plug controls the amount ofwater required and, at the relevant water pressures, ensures the water supply is shutoff and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure thetemperature and electrolyte density and a degassing port.
6.3 Adding water
Water should be added to the batteries just before the battery is fully charged. Thisensures that the amount of water added is mixed with the electrolyte.
6.4 Water pressure
The water replenishment system must be operated with a water pressure in the waterline of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges willaffect the operation of the systems.
Water drop
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1bar
Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3- 1.8 bar.
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6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperatureand the filling pressure. Filling ends automatically. The water supply line must bedisconnected from the battery when the water has been filled.
6.6 Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.
6.7 Battery tubing
The tubing of the individual plugs is in accordance with the existing electric circuit. Nochanges should be made.
6.8 Operating temperature
Batteries with automatic water replenishment systems should only be stored in roomswith temperatures > 0°C, as otherwise the systems could freeze.
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6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperatureand the filling pressure. Filling ends automatically. The water supply line must bedisconnected from the battery when the water has been filled.
6.6 Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.
6.7 Battery tubing
The tubing of the individual plugs is in accordance with the existing electric circuit. Nochanges should be made.
6.8 Operating temperature
Batteries with automatic water replenishment systems should only be stored in roomswith temperatures > 0°C, as otherwise the systems could freeze.
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The plug systems must only be cleaned with purified water in accordance with DIN43530-4. No parts of the plugs must come into contact with solvent-based materialsor soap.
6.10 Service mobile vehicle
Mobile water filling vehicle with pump and filling gun to fill individual cells. Theimmersion pump in the container generates the necessary filling pressure. Theservice mobile must be at exactly the same height as the battery base.
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6.9 Cleaning measures
The plug systems must only be cleaned with purified water in accordance with DIN43530-4. No parts of the plugs must come into contact with solvent-based materialsor soap.
6.10 Service mobile vehicle
Mobile water filling vehicle with pump and filling gun to fill individual cells. Theimmersion pump in the container generates the necessary filling pressure. Theservice mobile must be at exactly the same height as the battery base.
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7 Electrolyte circulation
7.1 Functional Description
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,thereby preventing any acid layer, shortening the charge time (charge factor approx.1.07) and reducing the formation of gas during charging. The charger must besuitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introducedto the battery cells via a hose system. The electrolyte is circulated via the inlet air andthe electrolyte density level is constant over the entire length of the electrode.
Pump
In the event of a fault, e.g. if the pressure control system responds for an unknownreason, the filters must be checked and replaced if necessary.
Battery connection
A hose is attached to the pump module which together with the charge leads is routedfrom the charger to the charging connector. The air is passed on to the battery via theelectrolyte circulation coupling ducts in the connector. When routing make sure thehose is not bent.
Pressure monitoring module
The electrolyte circulation pump is activated when charging begins. The pressuremonitoring module monitors the build up of pressure during charging. This ensuresthat the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as:– Battery air coupling not connected to circulation module (if coupling is separate) or
faulty.– Leaky or faulty hose connections on battery or– Intake filter contaminated
a visual error message appears on the charger.
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7 Electrolyte circulation
7.1 Functional Description
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,thereby preventing any acid layer, shortening the charge time (charge factor approx.1.07) and reducing the formation of gas during charging. The charger must besuitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introducedto the battery cells via a hose system. The electrolyte is circulated via the inlet air andthe electrolyte density level is constant over the entire length of the electrode.
Pump
In the event of a fault, e.g. if the pressure control system responds for an unknownreason, the filters must be checked and replaced if necessary.
Battery connection
A hose is attached to the pump module which together with the charge leads is routedfrom the charger to the charging connector. The air is passed on to the battery via theelectrolyte circulation coupling ducts in the connector. When routing make sure thehose is not bent.
Pressure monitoring module
The electrolyte circulation pump is activated when charging begins. The pressuremonitoring module monitors the build up of pressure during charging. This ensuresthat the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as:– Battery air coupling not connected to circulation module (if coupling is separate) or
faulty.– Leaky or faulty hose connections on battery or– Intake filter contaminated
a visual error message appears on the charger.
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NOTE
If an installed electrolyte circulation system is seldom used or not used at all,or if the battery is subjected to severe temperature fluctuations, the electrolytemay flow back into the hose system.Attach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side.
Schematic illustration
Electrolyte circulation on the battery and air supply via the charger.
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NOTE
If an installed electrolyte circulation system is seldom used or not used at all,or if the battery is subjected to severe temperature fluctuations, the electrolytemay flow back into the hose system.Attach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side.
Schematic illustration
Electrolyte circulation on the battery and air supply via the charger.
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8 Cleaning batteries
Batteries and trays must be cleaned in order to – maintain cell insulation and protect cells from ground or external conductive parts.– Avoid damage from corrosion and stray currents.– Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents.– Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that:– The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water.– All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water.– Protective goggles and clothing are worn.– Cell plugs are not removed or opened.– Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives.– After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths.– Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations.
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8 Cleaning batteries
Batteries and trays must be cleaned in order to – maintain cell insulation and protect cells from ground or external conductive parts.– Avoid damage from corrosion and stray currents.– Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents.– Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that:– The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water.– All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water.– Protective goggles and clothing are worn.– Cell plugs are not removed or opened.– Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives.– After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths.– Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations.
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Cleaning the battery with a high pressure cleaner
Requirements– Cell connectors tight, plugged in securely– Cell plugs closed
Procedure• Follow the high pressure cleaner's user instructions.• Do not use any cleaning additives.• Observe the permissible cleaning device temperature setting of 140°C.
Z This generally ensures that the temperature does not exceed 60°C at a distance of30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar.• Observe a minimum distance of 30 cm from the top of the battery.• The battery should be sprayed over its entire surface to avoid localised
overheating.Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C.• After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths.
Battery cleaned.
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Cleaning the battery with a high pressure cleaner
Requirements– Cell connectors tight, plugged in securely– Cell plugs closed
Procedure• Follow the high pressure cleaner's user instructions.• Do not use any cleaning additives.• Observe the permissible cleaning device temperature setting of 140°C.
Z This generally ensures that the temperature does not exceed 60°C at a distance of30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar.• Observe a minimum distance of 30 cm from the top of the battery.• The battery should be sprayed over its entire surface to avoid localised
overheating.Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C.• After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths.
Battery cleaned.
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9 Storing the battery
NOTE
The battery should not be stored for longer than 3 months without charging asotherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fullycharged in a dry room protected from frost. To ensure the availability of the batterythe following charges can be selected:
– Monthly compensation charge for PzS and PzB batteries or 3-monthly full chargefor PzV batteries.
– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzBbatteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, asfar as possible, be charged to 50% of its charge level and stored in a dry roomprotected from frost.
10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customerservice department immediately.
Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.
11 Disposal
Batteries marked with the recycling symbol and the sign showing acrossed-out rubbish bin should not be disposed of with ordinaryhousehold waste.
Buy-back terms and type of recycling are to be agreed with themanufacturer as described in § 8 of the battery legislation.
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9 Storing the battery
NOTE
The battery should not be stored for longer than 3 months without charging asotherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fullycharged in a dry room protected from frost. To ensure the availability of the batterythe following charges can be selected:
– Monthly compensation charge for PzS and PzB batteries or 3-monthly full chargefor PzV batteries.
– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzBbatteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, asfar as possible, be charged to 50% of its charge level and stored in a dry roomprotected from frost.
10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customerservice department immediately.
Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.
11 Disposal
Batteries marked with the recycling symbol and the sign showing acrossed-out rubbish bin should not be disposed of with ordinaryhousehold waste.
Buy-back terms and type of recycling are to be agreed with themanufacturer as described in § 8 of the battery legislation.