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52020290

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EFG 110k/110/113/115
Operating instructions
52020290
03.10
01.04-
G
F
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
Safety instructions and important explanations are indicated by the following
graphics:
F
Used before safety instructions which must be observed to avoid danger to
personnel.
M
Z
Used before notices which must be observed to avoid material damage.
Used before notices and explanations.
Used before safety instructions which must be observed to avoid danger to
personnel.
Used before notices which must be observed to avoid material damage.
Used before notices and explanations.
t Used to indicate standard equipment.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
www.jungheinrich.com
0108.GB
0108.GB
M
Z
Foreword
0108.GB
0108.GB
A
Correct use and application of the truck
A
Correct use and application of the truck
B
Truck description
B
Truck description
1
2
2.1
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
Description of application .................................................................... B 1
Description of assemblies and functions ............................................. B 2
Description of truck ............................................................................. B 3
Technical data of standard version ..................................................... B 4
Types of hoist frame ............................................................................ B 6
Performance data ............................................................................... B 8
Weights ............................................................................................... B 9
Tyres ................................................................................................... B 9
EN standards ...................................................................................... B 10
Conditions for application .................................................................... B 10
Location of instruction labels and identification plates ........................ B 11
Truck identification plate ..................................................................... B 12
Capacity label Truck ............................................................................ B 12
Capacity label Fork tines (basic device) .............................................. B 13
Capacity label Attachment .................................................................. B 13
1
2
2.1
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
Description of application .................................................................... B 1
Description of assemblies and functions ............................................. B 2
Description of truck ............................................................................. B 3
Technical data of standard version ..................................................... B 4
Types of hoist frame ............................................................................ B 6
Performance data ............................................................................... B 8
Weights ............................................................................................... B 9
Tyres ................................................................................................... B 9
EN standards ...................................................................................... B 10
Conditions for application .................................................................... B 10
Location of instruction labels and identification plates ........................ B 11
Truck identification plate ..................................................................... B 12
Capacity label Truck ............................................................................ B 12
Capacity label Fork tines (basic device) .............................................. B 13
Capacity label Attachment .................................................................. B 13
C
Transportation and commissioning
C
Transportation and commissioning
1
2
3
4
Transportation by crane ...................................................................... C 1
Securing the truck during transport ..................................................... C 1
First commissioning ............................................................................ C 3
Moving of the truck without own drive ................................................. C 3
1
2
3
4
Transportation by crane ...................................................................... C 1
Securing the truck during transport ..................................................... C 1
First commissioning ............................................................................ C 3
Moving of the truck without own drive ................................................. C 3
D
Battery - Servicing, recharging, replacement
D
Battery - Servicing, recharging, replacement
1
2
3
4
5
6
7
Safety regulations governing the handling of lead-acid batteries ........ D 1
Battery types ....................................................................................... D 2
Exposing the battery ........................................................................... D 3
Charging the battery ............................................................................ D 4
Removing and installing the battery .................................................... D 5
Closing battery cover .......................................................................... D 6
Battery discharge indicator, battery discharge monitor,
operating hour meter ........................................................................... D 6
1
2
3
4
5
6
7
Safety regulations governing the handling of lead-acid batteries ........ D 1
Battery types ....................................................................................... D 2
Exposing the battery ........................................................................... D 3
Charging the battery ............................................................................ D 4
Removing and installing the battery .................................................... D 5
Closing battery cover .......................................................................... D 6
Battery discharge indicator, battery discharge monitor,
operating hour meter ........................................................................... D 6
0310.GB
Table of contents
0310.GB
Table of contents
I1
I1
E
Operation
E
1
2
2.1
2.1.1
2.1.2
3
3.1
3.2
4
4.1
4.2
4.3
4.4
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
Safety regulations governing the operation of the fork lift truck .......... E 1
Description of the operating controls and indicators ........................... E 2
Auxiliary electrical system o ............................................................... E 5
Dashboard switches o ....................................................................... E 5
Operating console switches o ............................................................ E 5
Multi function display t ...................................................................... E 6
LED warning indicators ....................................................................... E 7
Displays ............................................................................................... E 7
Enhanced multi function display o ..................................................... E 8
Warning indicators, push buttons, and switches ................................. E 9
Displays ............................................................................................... E 10
Warning messages on the operator display ........................................ E 10
Setting the time ................................................................................... E 11
Commissioning the truck ..................................................................... E 12
Checks and actions before routine start-up ........................................ E 12
Trucks with reduced headroom X (o) ................................................. E 12
Adjustment of driver's seat .................................................................. E 13
Adjusting the steering column ............................................................. E 14
Provide operatability ............................................................................ E 14
Safety belt ........................................................................................... E 15
Operation of the fork lift truck .............................................................. E 17
Safety regulations applicable when operating the truck ...................... E 17
Driving ................................................................................................. E 19
Steering ............................................................................................... E 22
Braking ................................................................................................ E 22
Operating the lifting device and attachments (control lever t) ........... E 24
Operating the lifting device and attachments (Multi Pilot o) ............... E 25
Operating the lifting device and the attachments
(operating pattern N o) ....................................................................... E 27
6.8 Picking up, transporting and setting down of loads ............................. E 29
6.9 Safe parking of the truck ..................................................................... E 32
6.10 Trailer towing ....................................................................................... E 32
6.11 Trailer loads ........................................................................................ E 33
7
Fault location ....................................................................................... E 33
7.1 Temperature monitoring ...................................................................... E 33
I2
0310.GB
Safety regulations governing the operation of the fork lift truck .......... E 1
Description of the operating controls and indicators ........................... E 2
Auxiliary electrical system o ............................................................... E 5
Dashboard switches o ....................................................................... E 5
Operating console switches o ............................................................ E 5
Multi function display t ...................................................................... E 6
LED warning indicators ....................................................................... E 7
Displays ............................................................................................... E 7
Enhanced multi function display o ..................................................... E 8
Warning indicators, push buttons, and switches ................................. E 9
Displays ............................................................................................... E 10
Warning messages on the operator display ........................................ E 10
Setting the time ................................................................................... E 11
Commissioning the truck ..................................................................... E 12
Checks and actions before routine start-up ........................................ E 12
Trucks with reduced headroom X (o) ................................................. E 12
Adjustment of driver's seat .................................................................. E 13
Adjusting the steering column ............................................................. E 14
Provide operatability ............................................................................ E 14
Safety belt ........................................................................................... E 15
Operation of the fork lift truck .............................................................. E 17
Safety regulations applicable when operating the truck ...................... E 17
Driving ................................................................................................. E 19
Steering ............................................................................................... E 22
Braking ................................................................................................ E 22
Operating the lifting device and attachments (control lever t) ........... E 24
Operating the lifting device and attachments (Multi Pilot o) ............... E 25
Operating the lifting device and the attachments
(operating pattern N o) ....................................................................... E 27
6.8 Picking up, transporting and setting down of loads ............................. E 29
6.9 Safe parking of the truck ..................................................................... E 32
6.10 Trailer towing ....................................................................................... E 32
6.11 Trailer loads ........................................................................................ E 33
7
Fault location ....................................................................................... E 33
7.1 Temperature monitoring ...................................................................... E 33
0310.GB
1
2
2.1
2.1.1
2.1.2
3
3.1
3.2
4
4.1
4.2
4.3
4.4
5
5.1
5.2
5.3
5.4
5.5
5.6
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
Operation
I2
F
Maintenance of the fork lift truck
F
Maintenance of the fork lift truck
1
2
3
4
5
5.1
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
7
7.1
7.2
7.3
8
Operational safety and environmental protection ................................ F 1
Safety regulations applicable to truck maintenance ............................ F 1
Servicing and inspection ..................................................................... F 3
Maintenance check list for EFG 110k/110/113/115 ............................ F 4
Lubrication plan for EFG 110k/110/113/115 ....................................... F 6
Fuels, coolants and lubricants ............................................................. F 7
Description of servicing operations ..................................................... F 8
Preparation of the truck for servicing and maintenance operation ...... F 8
Check fixing of the wheels .................................................................. F 8
Check hydraulic oil level ...................................................................... F 9
Check the transmission oil level .......................................................... F 10
Let off oil .............................................................................................. F 10
Refill oil ................................................................................................ F 10
Top up brake fluid ............................................................................... F 11
Changing of hydraulic oil filter ............................................................. F 11
Safety belt maintenance ...................................................................... F 12
Checking the electric fuses ................................................................. F 13
Recommissioning the truck ................................................................. F 15
Decommissioning the fork lift truck ..................................................... F 15
Operations to be performed prior to decommissioning ....................... F 15
Measures to be taken during decommissioning .................................. F 15
Recommissioning the truck ................................................................. F 16
Safety checks to be performed at regular intervals
and following any unusual incidents .................................................... F 17
Final de-commissioning, disposal ....................................................... F 17
1
2
3
4
5
5.1
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
7
7.1
7.2
7.3
8
Operational safety and environmental protection ................................ F 1
Safety regulations applicable to truck maintenance ............................ F 1
Servicing and inspection ..................................................................... F 3
Maintenance check list for EFG 110k/110/113/115 ............................ F 4
Lubrication plan for EFG 110k/110/113/115 ....................................... F 6
Fuels, coolants and lubricants ............................................................. F 7
Description of servicing operations ..................................................... F 8
Preparation of the truck for servicing and maintenance operation ...... F 8
Check fixing of the wheels .................................................................. F 8
Check hydraulic oil level ...................................................................... F 9
Check the transmission oil level .......................................................... F 10
Let off oil .............................................................................................. F 10
Refill oil ................................................................................................ F 10
Top up brake fluid ............................................................................... F 11
Changing of hydraulic oil filter ............................................................. F 11
Safety belt maintenance ...................................................................... F 12
Checking the electric fuses ................................................................. F 13
Recommissioning the truck ................................................................. F 15
Decommissioning the fork lift truck ..................................................... F 15
Operations to be performed prior to decommissioning ....................... F 15
Measures to be taken during decommissioning .................................. F 15
Recommissioning the truck ................................................................. F 16
Safety checks to be performed at regular intervals
and following any unusual incidents .................................................... F 17
Final de-commissioning, disposal ....................................................... F 17
0310.GB
9
0310.GB
9
I3
I3
I4
I4
0310.GB
0310.GB
Appendix
Appendix
JH Traction Battery Operating Instructions
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
M
If using a battery with closed EPzV and EPzV ironclad plates, this must first be
discussed with the manufacturer.
M
If using a battery with closed EPzV and EPzV ironclad plates, this must first be
discussed with the manufacturer.
0506.GB
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB
Z
1
1
2
2
0506.GB
0506.GB
A Correct use and application of the truck
A Correct use and application of the truck
Z
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.
The fork-lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork-lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.
The fork-lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork-lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.
Duties of the user: A “user” within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork-lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between
the owner and the user of the fork-lift truck, is charged with the observance of the operating duties.
The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
Duties of the user: A “user” within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork-lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between
the owner and the user of the fork-lift truck, is charged with the observance of the operating duties.
The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
M
If these Operating Instruction are not observed the warranty becomes void. The same
applies if improper work is carried out on the device by the customer and/or third parties without permission of our Customer Service.
If these Operating Instruction are not observed the warranty becomes void. The same
applies if improper work is carried out on the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
Trailing and slipping loads: The truck may only be used for trailing or slipping loads
for which the truck has been approved.
Trailing and slipping loads: The truck may only be used for trailing or slipping loads
for which the truck has been approved.
1203.GB
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
1203.GB
M
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.
A1
A1
A2
A2
1203.GB
1203.GB
B Truck description
B Truck description
1
1
Description of application
Description of application
The EFG is a three-wheel type electric fork-lift truck that is provided with a driver's
seat. The truck is a cantilever counterweight stacker which is able to unload trucks by
means of the load lifting device mounted to the stacker front and depose the load on
ramps or on stacks. Also closed-ground pallets can be picked up.
The EFG is a three-wheel type electric fork-lift truck that is provided with a driver's
seat. The truck is a cantilever counterweight stacker which is able to unload trucks by
means of the load lifting device mounted to the stacker front and depose the load on
ramps or on stacks. Also closed-ground pallets can be picked up.
Vehicle types and maximum load capacity:
Vehicle types and maximum load capacity:
Model
max. load capacity *)
Load centre
Model
max. load capacity *)
Load centre
EFG 110k
EFG 110
EFG 113
EFG 115
1,000 kg
1,000 kg
1,250 kg
1,500 kg
500 mm
500 mm
500 mm
500 mm
EFG 110k
EFG 110
EFG 113
EFG 115
1,000 kg
1,000 kg
1,250 kg
1,500 kg
500 mm
500 mm
500 mm
500 mm
0708.GB
*) The capacity labels fixed to the vehicle are binding for the load capacity
0708.GB
*) The capacity labels fixed to the vehicle are binding for the load capacity
B1
B1
2
Description of assemblies and functions
2
Description of assemblies and functions
1
1
8
8
2
7
2
7
3
3
4
4
5
5
6
Designation
Steering system
Hoist frame
Drive axle
Batteries
Fork carrier
Counterweight
Driver's seat
Overhead guard
Item
1
2
3
4
5
6
7
8
B2
t
t
t
t
t
t
t
t
Designation
Steering system
Hoist frame
Drive axle
Batteries
Fork carrier
Counterweight
Driver's seat
Overhead guard
0708.GB
t
t
t
t
t
t
t
t
0708.GB
Item
1
2
3
4
5
6
7
8
6
B2
Description of truck
2.1
Description of truck
Steering (1): Low steering forces of 15 N and an ideal ratio of 5 steering wheel revolutions for a steering angle of 180°. A hydraulic steering motor drives the steering
axle via a gear wheel pair. Efficient energy usage due to the implemented dynamic
load sensing system. The steering column is adjustable.
Driver seat (7): The driver seat is a comfort seat with lengthwise, backrest and weight
adjustability. As safety feature for the driver, the seat is equipped with an automatic
lap belt.
Driver seat (7): The driver seat is a comfort seat with lengthwise, backrest and weight
adjustability. As safety feature for the driver, the seat is equipped with an automatic
lap belt.
Electrics/electronics: Three-phase technology via CAN bus, reduces the number of
cable harnesses. This results in a lower susceptibility to wire breaks and speeds up
malfunction finding. Energy recuperation by means of regenerative brake. Controller
error analysis and programming occurs via a PC connected to the provided interface.
As an option, five drive programs for different loads and application purposes are
available.
Electrics/electronics: Three-phase technology via CAN bus, reduces the number of
cable harnesses. This results in a lower susceptibility to wire breaks and speeds up
malfunction finding. Energy recuperation by means of regenerative brake. Controller
error analysis and programming occurs via a PC connected to the provided interface.
As an option, five drive programs for different loads and application purposes are
available.
Drive system: The complete drive unit is screwed to the counterweight. The steerable rear wheel is also the drive wheel. It is driven by a stationary, low-noise threephase gear motor. The electronic drive controller allows the drive motor speed to be
continuously regulated and thus ensures smooth, jolt-free starting, powerful acceleration and electronically controlled braking with energy regeneration. In case of the
steering angle acquisition (o), the travelling speed is automatically reduced in accordance with the steering angle.
Drive system: The complete drive unit is screwed to the counterweight. The steerable rear wheel is also the drive wheel. It is driven by a stationary, low-noise threephase gear motor. The electronic drive controller allows the drive motor speed to be
continuously regulated and thus ensures smooth, jolt-free starting, powerful acceleration and electronically controlled braking with energy regeneration. In case of the
steering angle acquisition (o), the travelling speed is automatically reduced in accordance with the steering angle.
Brake system: The hydraulically actuated power drum brake on both front wheels
requires only little pedal force to effectively brake the truck. In addition, the truck is
regeneratively braked by the drive motor. Thus, operation of the service brake is
made almost obsolete, and energy consumption and brake wear are minimised.
Brake system: The hydraulically actuated power drum brake on both front wheels
requires only little pedal force to effectively brake the truck. In addition, the truck is
regeneratively braked by the drive motor. Thus, operation of the service brake is
made almost obsolete, and energy consumption and brake wear are minimised.
Overhead guard (8): Constructed as a sturdy four-pole roof. Narrow roof sections
and cross beams ensure good allround view. The overhead guard is prepared for a
roof configuration with front and rear safety glass pane.
Overhead guard (8): Constructed as a sturdy four-pole roof. Narrow roof sections
and cross beams ensure good allround view. The overhead guard is prepared for a
roof configuration with front and rear safety glass pane.
Hydraulic system: Two systems: Solo Pilot (t) and Multi Pilot (o).
Hydraulic system: Two systems: Solo Pilot (t) and Multi Pilot (o).
Solo Pilot: Individual levers for lifting/lowering, forward/backward tilting and, as an option, two additional levers for auxiliary functions (e.g. side shift, clamp, etc.). The drive
direction switch is integrated in the lifting function lever.
Solo Pilot: Individual levers for lifting/lowering, forward/backward tilting and, as an option, two additional levers for auxiliary functions (e.g. side shift, clamp, etc.). The drive
direction switch is integrated in the lifting function lever.
Multi Pilot (option): All hydraulic functions, drive direction switch and horn have been
combined in one lever.
Multi Pilot (option): All hydraulic functions, drive direction switch and horn have been
combined in one lever.
The hydraulic unit speed is always adapted to the demands of the respective function.
The hydraulic unit speed is always adapted to the demands of the respective function.
Lifting mast (2): The high-strength steel sections are extraordinarily narrow. An excellent view on the forks is thus ensured.
Lifting rails and fork carriage run on lifetime-lubricated, maintenance-free angular rollers.
Lifting mast (2): The high-strength steel sections are extraordinarily narrow. An excellent view on the forks is thus ensured.
Lifting rails and fork carriage run on lifetime-lubricated, maintenance-free angular rollers.
0708.GB
Steering (1): Low steering forces of 15 N and an ideal ratio of 5 steering wheel revolutions for a steering angle of 180°. A hydraulic steering motor drives the steering
axle via a gear wheel pair. Efficient energy usage due to the implemented dynamic
load sensing system. The steering column is adjustable.
0708.GB
2.1
B3
B3
3
Technical data of standard version
3
(all dimensions in mm)
Designation
(all dimensions in mm)
EFG 110k
EFG 110
EFG 113
EFG 115
100
100
100
100
h1 Height with hoist frame
retracted
2,000
2,000
2,000
2,000
h2 Free lift
h3 Length of lift
150
3,000
150
3,000
150
3,000
h4 Height with hoist frame
extended
3,550
3,550
a/2 Safety distance
Designation
EFG 110k
EFG 110
EFG 113
EFG 115
100
100
100
100
h1 Height with hoist frame
retracted
2,000
2,000
2,000
2,000
150
3,000
h2 Free lift
h3 Length of lift
150
3,000
150
3,000
150
3,000
150
3,000
3,550
3,550
h4 Height with hoist frame
extended
3,550
3,550
3,550
3,550
a/2 Safety distance
h6 Height above protective roof
2,090
2,090
2,090
2,090
h6 Height above protective roof
2,090
2,090
2,090
2,090
h7 Height of seat
H1 Vertical clearance
900
1,140
900
1,140
900
1,140
900
1,140
h7 Height of seat
H1 Vertical clearance
900
1,140
900
1,140
900
1,140
900
1,140
h10 Height of clutch
L1 Length including fork
635
2,719
635
2,773
635
2,881
635
2,935
h10 Height of clutch
L1 Length including fork
635
2,719
635
2,773
635
2,881
635
2,935
L2 Length including fork
backing 1)
b1 Total width
e Fork width
m1 Road clearance with load
below hoist frame
m2 Road clearance centre wheel
base
Ast Width of corridors
for pallets 800 x 1200
longitudinal axis
Ast Width of corridors
for pallets 1000 x 1200
transversely
Wa Turning circle
x Load spacing 1)
y Wheel base
1,569
1,623
1,731
1,785
1,569
1,623
1,731
1,785
990
100
90
990
100
90
990
100
90
990
100
90
990
100
90
990
100
90
990
100
90
990
100
90
100
100
100
100
100
100
100
100
3,020
3,074
3,182
3,236
3,020
3,074
3,182
3,236
2,898
2,952
3,060
3,114
2,898
2,952
3,060
3,114
1,239
330
984
1,293
330
1,038
1,401
330
1,146
1,455
330
1,200
L2 Length including fork
backing 1)
b1 Total width
e Fork width
m1 Road clearance with load
below hoist frame
m2 Road clearance centre wheel
base
Ast Width of corridors
for pallets 800 x 1200
longitudinal axis
Ast Width of corridors
for pallets 1000 x 1200
transversely
Wa Turning circle
x Load spacing 1)
y Wheel base
1,239
330
984
1,293
330
1,038
1,401
330
1,146
1,455
330
1,200
1)
= +7 mm DZ mast
0708.GB
= +7 mm DZ mast
0708.GB
1)
B4
Technical data of standard version
B4
a
2
b1
b1
m1
s
x
Ast
W
a
Q
y
L2
e
a
2
B5
a
2
c
h7
h1
h1
h6
h3
h6
h4
h4
H1
5
x
L1
Ast
h10
m2
h7
c
m1
h10
m2
Q
s
h2
h2
h3
6
0708.GB
0708.GB
5
H1
6
y
L2
L1
e
W
a
a
2
B5
3.1
Types of hoist frame
3.1
(all dimensions in mm)
Types of hoist frame
(all dimensions in mm)
Lifting mast table EFG 110k/110/113/115
ZT
Lift
h3
Free lift
height
Lifting mast table EFG 110k/110/113/115
Overall height,
retracted h1
Overall height, extended
h4
VDI 3596
Designation
ZT
h3
Free lift
height
Overall height,
retracted h1
Overall height, extended
h4
2,300
h2
150
1,650
2,850
2,300
h2
150
1,650
2,850
3,000
150
2,000
3,550
3,000
150
2,000
3,550
3,100
3,300
150
150
2,050
2,150
3,650
3,850
3,100
3,300
150
150
2,050
2,150
3,650
3,850
3,600
150
2,300
4,150
3,600
150
2,300
4,150
4,000
4,500
150
150
2,500
2,800
4,550
5,050
4,000
4,500
150
150
2,500
2,800
4,550
5,050
5,000
5,500
150
150
3,050
3,400
5,550
6,050
5,000
5,500
150
150
3,050
3,400
5,550
6,050
ZZ
2,300
1,055
1,605
2,850
DZ
3,000
3,100
3,300
3,600
4,000
4,350
4,500
4,800
5,000
5,500
6,000
1,405
1,455
1,555
1,705
1,905
1,405
1,455
1,555
1,630
1,805
2,005
1,955
2,005
2,105
2,255
2,455
1,955
2,005
2,105
2,180
2,355
2,555
3,550
3,650
3,850
4,150
4,550
4,900
5,050
5,350
5,550
6,050
6,550
6,500
2,255
2,805
7,050
0708.GB
B6
Lift
ZZ
2,300
1,055
1,605
2,850
DZ
3,000
3,100
3,300
3,600
4,000
4,350
4,500
4,800
5,000
5,500
6,000
1,405
1,455
1,555
1,705
1,905
1,405
1,455
1,555
1,630
1,805
2,005
1,955
2,005
2,105
2,255
2,455
1,955
2,005
2,105
2,180
2,355
2,555
3,550
3,650
3,850
4,150
4,550
4,900
5,050
5,350
5,550
6,050
6,550
6,500
2,255
2,805
7,050
0708.GB
VDI 3596
Designation
B6
a
2
b1
b1
m1
s
x
Ast
W
a
Q
y
L2
e
a
2
a
2
B7
c
h7
h1
h1
h6
h3
h6
h4
h4
H1
5
x
L1
Ast
h10
m2
h7
c
m1
h10
m2
Q
s
h2
h2
h3
6
0708.GB
0708.GB
5
H1
6
y
L2
L1
e
W
a
a
2
B7
3.2
Performance data
Designation
3.2
EFG 110k
EFG 110
EFG 113
EFG 115
1,000
1,000
1,250
1,500
kg
500
500
500
500
mm
12/12.5
12/12.5
12/12.5
12/12.5
km/h
Lifting speed
with/without load
Lowering speed
with/without load
Hill climbing ability
(30 min) with /
without load
0.28/0.50
0.29/0.50
0.25/0.50
0.24/0.50
m/s
0.58/0.60
0.58/0.60
0.58/0.60
0.58/0.60
m/s
8.5/12
8/11.5
7/11
6.5/10.5
%
Max. hill climbing
ability (5 min) with /
without load
Acceleration
(10 m) with /
without load
13/18
12.5/17.5
11/16.5
10/16
%
5.1/4.6
5.1/4.6
5.4/4.7
5.6/4.8
s
Q Load capacity
(at c = 500 mm) *)
c Load centre
distance
Driving speed with /
without load
Designation
EFG 110k
EFG 110
EFG 113
EFG 115
1,000
1,000
1,250
1,500
kg
500
500
500
500
mm
12/12.5
12/12.5
12/12.5
12/12.5
km/h
Lifting speed
with/without load
Lowering speed
with/without load
Hill climbing ability
(30 min) with /
without load
0.28/0.50
0.29/0.50
0.25/0.50
0.24/0.50
m/s
0.58/0.60
0.58/0.60
0.58/0.60
0.58/0.60
m/s
8.5/12
8/11.5
7/11
6.5/10.5
%
Max. hill climbing
ability (5 min) with /
without load
Acceleration
(10 m) with /
without load
13/18
12.5/17.5
11/16.5
10/16
%
5.1/4.6
5.1/4.6
5.4/4.7
5.6/4.8
s
Q Load capacity
(at c = 500 mm) *)
c Load centre
distance
Driving speed with /
without load
0708.GB
*) with hoist frame in vertical position
0708.GB
*) with hoist frame in vertical position
B8
Performance data
B8
3.3
Weights
3.3
(all weights in kg)
(all weights in kg)
Designation
EFG 110k
EFG 110
EFG 113
EFG 115
EFG 110k
EFG 110
EFG 113
EFG 115
Dead weight
(including battery)
2,490
2,570
2,760
2,870
Dead weight
(including battery)
2,490
2,570
2,760
2,870
Axle load front (without load)
1,095
1,145
1,235
1,270
Axle load front (without load)
1,095
1,145
1,235
1,270
Axle load front (with load)
Axle load back (without load)
2,940
1,395
2,945
1,425
3,390
1,525
3,805
1,600
Axle load front (with load)
Axle load back (without load)
2,940
1,395
2,945
1,425
3,390
1,525
3,805
1,600
550
625
620
565
550
625
620
565
Axle load back (with load)
Axle load back (with load)
Tyres
3.4
Model
SE
Tyre size, front
Rubber
Pneumatic
SE
Tyre size, rear
Rubber
Pneumatic
EFG 110
EFG 113
Tyres
EFG 115
Model
18 x 7-8
SE
Tyre size, front
18 x 6 x 12 1/8“
180 / 70 - 8; Diagonal, 16PR; 10bar
Rubber
Pneumatic
18 x 7-8
SE
Tyre size, rear
18 x 6 x 12 1/8“
180 / 70 - 8; Diagonal, 16PR; 10bar
Rubber
Pneumatic
Z
Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries
please contact your Jungheinrich customer adviser.
0708.GB
Z
Designation
EFG 110
EFG 113
EFG 115
18 x 7-8
18 x 6 x 12 1/8“
180 / 70 - 8; Diagonal, 16PR; 10bar
18 x 7-8
18 x 6 x 12 1/8“
180 / 70 - 8; Diagonal, 16PR; 10bar
Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries
please contact your Jungheinrich customer adviser.
0708.GB
3.4
Weights
B9
B9
3.5
EN standards
Continuous sound level:
3.5
63 dB(A)
EN standards
Continuous sound level:
according to EN 12053 as stipulated in ISO 4871
Z
according to EN 12053 as stipulated in ISO 4871
Z
The continuous sound level is a value averaged according to standard regulations,
taking the sound pressure level into account when driving, lifting and idling. The
sound pressure level is measured at the ear.
Vibration:
0.62 m/s2
The continuous sound level is a value averaged according to standard regulations,
taking the sound pressure level into account when driving, lifting and idling. The
sound pressure level is measured at the ear.
Vibration:
according to EN 13059
Z
63 dB(A)
0.62 m/s2
according to EN 13059
Z
The swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical
plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical
plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other
standards contained therein.
The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other
standards contained therein.
Z
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
Z
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
3.6
Conditions for application
3.6
Conditions for application
Ambient temperature:
Ambient temperature:
- during operation: -20 °C to +40 °C
B 10
Industrial trucks must be specially equipped and approved for continuous use in environments with temperatures below 5 °C or in cold stores respectively with extreme
temperatures or humidity changes.
0708.GB
Z
Industrial trucks must be specially equipped and approved for continuous use in environments with temperatures below 5 °C or in cold stores respectively with extreme
temperatures or humidity changes.
0708.GB
Z
- during operation: -20 °C to +40 °C
B 10
4
Location of instruction labels and identification plates
4
Location of instruction labels and identification plates
F
Warning and information labels, such as capacity diagrams, attachment points and
identification plates, must be readable at all times or be replaced, if necessary.
F
Warning and information labels, such as capacity diagrams, attachment points and
identification plates, must be readable at all times or be replaced, if necessary.
9
(mm)
9
Q (kg)
D (mm)
(mm)
D (mm)
12
(mm)
Q (kg)
Q (kg)
13
14
16
15
12
(mm)
D (mm)
Q (kg)
13
14
16
15
D (mm)
11
11
17
17
10
10
18
18
19
9
20
15
16
17
18
19
20
20
Designation
Label Fit locations
Label Transport of passengers not permitted
Label Observe operating instructions
Capacity plate
Sign Put on safety belt
Label Driving with lifted load, forward inclination of mast with lifted load not
permitted
Label Warning in case of overturn
Label Do not step on or under load-carrying unit, danger of crushing
“Maximum body size” notice
Test sticker (o)
Identification plate
Jack contact points
B 11
Item
9
10
11
12
13
14
0708.GB
0708.GB
Item
9
10
11
12
13
14
19
9
15
16
17
18
19
20
Designation
Label Fit locations
Label Transport of passengers not permitted
Label Observe operating instructions
Capacity plate
Sign Put on safety belt
Label Driving with lifted load, forward inclination of mast with lifted load not
permitted
Label Warning in case of overturn
Label Do not step on or under load-carrying unit, danger of crushing
“Maximum body size” notice
Test sticker (o)
Identification plate
Jack contact points
B 11
Truck identification plate
4.1
Truck identification plate
21
32
21
32
22
31
22
31
23
30
23
30
24
29
24
29
25
28
25
28
Item Designation
27
27
26
26
Item Designation
Item Designation
Item Designation
21
Type
27
Manufacturer
21
Type
27
Manufacturer
22
Serial No.
28
Min./max. battery weight in kg
22
Serial No.
28
Min./max. battery weight in kg
23
Rated capacity in kg
29
Drive power in kW
23
Rated capacity in kg
29
Drive power in kW
24
Battery: Voltage V
30
Load centre distance in mm
24
Battery: Voltage V
30
Load centre distance in mm
25
Empty weight without battery in kg
31
Year of manufacture
25
Empty weight without battery in kg
31
Year of manufacture
26
Manufacturer logo
32
Option
26
Manufacturer logo
32
Option
Z
In the event of queries relating to the truck or spare part orders, please state the serial
No. (22) of the truck.
Z
In the event of queries relating to the truck or spare part orders, please state the serial
No. (22) of the truck.
4.2
Capacity label Truck
4.2
Capacity label Truck
The capacity Label Truck (12) indicates the load capacity Q of the truck in kg with
hoist frame in vertical position. The diagram reflects the design of the lifting mast
used. The maximum load capacity at a specific load centre D (in mm) and the desired
lifting height H (in mm) is given in a table.
The capacity Label Truck (12) indicates the load capacity Q of the truck in kg with
hoist frame in vertical position. The diagram reflects the design of the lifting mast
used. The maximum load capacity at a specific load centre D (in mm) and the desired
lifting height H (in mm) is given in a table.
Example:
Example:
12
12
4250
3600
2900
B 12
850
1105
1250
850
1105
1250
600
850
850
500
600
700
4250
3600
2900
850
1105
1250
850
1105
1250
600
850
850
500
600
700
Example for determination of maximum load capacity:
In case of a load centre D of 600 mm and a maximum lifting height H of 3.600 mm the
maximum load capacity Q is 1.105 kg.
In case of a load centre D of 600 mm and a maximum lifting height H of 3.600 mm the
maximum load capacity Q is 1.105 kg.
0708.GB
Example for determination of maximum load capacity:
B 12
0708.GB
4.1
4.3
Capacity label Fork tines (basic device)
4.3
The fork arm load diagram indicates the carrying capacity Q of the truck in kg. The
maximum load capacity at different load centers D is given in a diagram (in mm).
The fork arm load diagram indicates the carrying capacity Q of the truck in kg. The
maximum load capacity at different load centers D is given in a diagram (in mm).
Capacity label Attachment
4.4
Capacity label Attachment
The attachment load diagram indicates the carrying capacity Q of the truck in connection with the respective attachment in kg. The attachment serial number indicated in
the load diagram must correspond to the ID plate of the attachment, since the manufacturer must state the carrying capacity specially for each attachment. It is indicated
in the same way as the carrying capacity of the truck itself and must be determined
accordingly.
The attachment load diagram indicates the carrying capacity Q of the truck in connection with the respective attachment in kg. The attachment serial number indicated in
the load diagram must correspond to the ID plate of the attachment, since the manufacturer must state the carrying capacity specially for each attachment. It is indicated
in the same way as the carrying capacity of the truck itself and must be determined
accordingly.
The arrow-shaped markings (33 and 34)
at the inner and outer mast indicate the
lifting height limits that are prescribed in
the load diagram.
The arrow-shaped markings (33 and 34)
at the inner and outer mast indicate the
lifting height limits that are prescribed in
the load diagram.
34
33
34
0708.GB
33
0708.GB
4.4
Capacity label Fork tines (basic device)
B 13
B 13
B 14
B 14
0708.GB
0708.GB
C Transportation and commissioning
C Transportation and commissioning
1
Transportation by crane
1
Transportation by crane
M
Only use lifting equipment with sufficient
carrying capacity
(loading weight = own weight + battery
weight; see identification plate of the
truck).
M
Only use lifting equipment with sufficient
carrying capacity
(loading weight = own weight + battery
weight; see identification plate of the
truck).
– Park the truck and render it safe (refer
to chapter E).
– Attach the lifting gear to the cross
member of the hoist frame (1) and to
the tow bar (2).
1
– Park the truck and render it safe (refer
to chapter E).
– Attach the lifting gear to the cross
member of the hoist frame (1) and to
the tow bar (2).
2
1
2
M
The lifting gear must be attached to the attachment points in such a manner that it
absolutely cannot slip and cannot come into contact with any attachments or the overhead guard of the truck when the truck is lifted.
M
The lifting gear must be attached to the attachment points in such a manner that it
absolutely cannot slip and cannot come into contact with any attachments or the overhead guard of the truck when the truck is lifted.
2
Securing the truck during transport
2
Securing the truck during transport
M
The fork lift truck must be properly secured with wedges and restraints during transport on a lorry or trailer. The lorry or trailer must be equipped with lashing rings and a
wooden floor. Perform loading with suitably trained specialist staff according to the
recommendations of VDI 2700 and VDI 2703 guidelines. Correct dimensioning and
implementation of load securing measures is required for every separate case.
M
The fork lift truck must be properly secured with wedges and restraints during transport on a lorry or trailer. The lorry or trailer must be equipped with lashing rings and a
wooden floor. Perform loading with suitably trained specialist staff according to the
recommendations of VDI 2700 and VDI 2703 guidelines. Correct dimensioning and
implementation of load securing measures is required for every separate case.
Z
To lash down the fork lift truck with the lifting mast installed use the eyes on the top
cross beam of the mast and the trailer coupling pin.
Z
To lash down the fork lift truck with the lifting mast installed use the eyes on the top
cross beam of the mast and the trailer coupling pin.
1003.GB
Lashing and wedging with the lifting mast installed
1003.GB
Lashing and wedging with the lifting mast installed
C1
C1
Z
To transport the fork lift truck without lifting mast perform lashing across the overhead
guard front.
C2
To transport the fork lift truck without lifting mast perform lashing across the overhead
guard front.
Lashing and wedging without lifting mast
Approximate centre of gravity
Approximate centre of gravity
1003.GB
Lashing and wedging without lifting mast
1003.GB
Z
C2
3
F
M
4
First commissioning
3
F
Commisioning and instruction of the driver must only be carried out by personnel with
appropriate training. If several trucks are delivered it must be assured that only load
suspension devices, hoist frames and basic trucks with identical series number are
assembled.
M
Drive truck with battery power only.
Rectified alternate current will damage
the electronics. Cables connected to the
battery (towing cable) must be less than
6 meters in length.
First commissioning
Commisioning and instruction of the driver must only be carried out by personnel with
appropriate training. If several trucks are delivered it must be assured that only load
suspension devices, hoist frames and basic trucks with identical series number are
assembled.
Drive truck with battery power only.
Rectified alternate current will damage
the electronics. Cables connected to the
battery (towing cable) must be less than
6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following
operations must be performed:
In order to prepare the truck for work following delivery or transportation, the following
operations must be performed:
– Check equipment for completeness.
– Check battery connections and acid level (refer to chapter D, section 6).
– Commission truck as specified
(refer to chapter E).
– Check equipment for completeness.
– Check battery connections and acid level (refer to chapter D, section 6).
– Commission truck as specified
(refer to chapter E).
Moving of the truck without own drive
4
Moving of the truck without own drive
If the truck must be put on tow, proceed as follows:
If the truck must be put on tow, proceed as follows:
– Connect tow-bar or tow to the trailer coupling of the recovery vehicle and to the
truck to be recovered.
– Remove battery plug (refer to chapter D).
– Release parking brake.
– Connect tow-bar or tow to the trailer coupling of the recovery vehicle and to the
truck to be recovered.
– Remove battery plug (refer to chapter D).
– Release parking brake.
F
A person must sit on the driver`s seat of the truck on tow in order to do the steering.
Do not drive the truck on tow faster than walking pace.
Z
Since the truck's steering booster is switched off, a higher expenditure of force is necessary to steer the truck.
Z
Since the truck's steering booster is switched off, a higher expenditure of force is necessary to steer the truck.
1003.GB
A person must sit on the driver`s seat of the truck on tow in order to do the steering.
Do not drive the truck on tow faster than walking pace.
1003.GB
F
C3
C3
C4
C4
1003.GB
1003.GB
D Battery - Servicing, recharging, replacement
D Battery - Servicing, recharging, replacement
1
1
F
M
The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E).
The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations.
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be
present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept
ready.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be
present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept
ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a nonskid insulating mat.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a nonskid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for the disposal must be heeded.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for the disposal must be heeded.
M
Before closing the battery hood, make sure that the battery cable cannot be damaged.
F
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.
M
Only batteries with closed tray may be used.
F
Battery weight and dimensions have considerable influence on operational safety of
the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer.
1003.GB
F
Safety regulations governing the handling of lead-acid batteries
Before closing the battery hood, make sure that the battery cable cannot be damaged.
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.
Only batteries with closed tray may be used.
Battery weight and dimensions have considerable influence on operational safety of
the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer.
1003.GB
M
Safety regulations governing the handling of lead-acid batteries
D1
D1
2
Battery types
2
In dependence on the application, the truck is equipped with different battery types.
The following table shows which standard combinations are possible, similar to
DIN 43535/EN 60254 (IEC 254), with indication of the capacity:
EFG 110k
In dependence on the application, the truck is equipped with different battery types.
The following table shows which standard combinations are possible, similar to
DIN 43535/EN 60254 (IEC 254), with indication of the capacity:
24 V - 4PzS - Battery 440L Ah
24 V - 4PzV - Battery 400 Ah
24 V - 4PzW - Battery 400 Ah
24 V - 4PzS - Battery 480HX Ah (performance-enhanced)
24 V - 5PzS - Battery 550L Ah
24 V - 5PzV - Battery 500 Ah
24 V - 5PzW - Battery 500 Ah
24 V - 5PzS - Battery 600HX Ah (performance-enhanced)
24 V - 7PzS - Battery 770L Ah
24 V - 7PzV - Battery 700 Ah
24 V - 7PzW - Battery 700 Ah
24 V - 7PzS - Battery 840HX Ah (performance-enhanced)
24 V - 8PzS - Battery 880L Ah
24 V - 8PzV - Battery 800 Ah
24 V - 8PzW - Battery 800 Ah
24 V - 8PzS - Battery 960HX Ah (performance-enhanced)
EFG 110
EFG 113
EFG 115
EFG 110k
EFG 113
EFG 115
The battery weight is indicated on the rating plate of the battery.
similar to
DIN
43535
EN 60254
(IEC 254)
Drive battery 24 V
B max.
EFG 110k
830
273
612
627
372
EFG 110
830
327
612
627
445
EFG 113
830
435
612
627
600
EFG 115
830
489
612
627
676
Dimension (mm)
Truck
400 - 480
Ah
500 - 600
Ah
700 - 840
Ah
800 - 960
Ah
1003.GB
H1 +/- 2 mm H2 +/- 2 mm
Drive battery 24 V
Nom. weight
(-5/+8%)
in kg
L max.
similar to
DIN
43535
EN 60254
(IEC 254)
H1 +/- 2 mm H2 +/- 2 mm
Nom. weight
(-5/+8%)
in kg
L max.
B max.
EFG 110k
830
273
612
627
372
EFG 110
830
327
612
627
445
EFG 113
830
435
612
627
600
EFG 115
830
489
612
627
676
400 - 480
Ah
500 - 600
Ah
700 - 840
Ah
800 - 960
Ah
1003.GB
Dimension (mm)
D2
24 V - 4PzS - Battery 440L Ah
24 V - 4PzV - Battery 400 Ah
24 V - 4PzW - Battery 400 Ah
24 V - 4PzS - Battery 480HX Ah (performance-enhanced)
24 V - 5PzS - Battery 550L Ah
24 V - 5PzV - Battery 500 Ah
24 V - 5PzW - Battery 500 Ah
24 V - 5PzS - Battery 600HX Ah (performance-enhanced)
24 V - 7PzS - Battery 770L Ah
24 V - 7PzV - Battery 700 Ah
24 V - 7PzW - Battery 700 Ah
24 V - 7PzS - Battery 840HX Ah (performance-enhanced)
24 V - 8PzS - Battery 880L Ah
24 V - 8PzV - Battery 800 Ah
24 V - 8PzW - Battery 800 Ah
24 V - 8PzS - Battery 960HX Ah (performance-enhanced)
EFG 110
The battery weight is indicated on the rating plate of the battery.
Truck
Battery types
D2
3
Exposing the battery
3
Exposing the battery
F
Park the truck and render it safe (see chapter E).
F
Park the truck and render it safe (see chapter E).
F
– Release lock of the steering column (2)
push steering column (1) forward and
secure it in this position.
1
2
F
Danger of burns due to drive motor operating temperature > 80 °C. Special attention must be paid when the battery hood is
open.
– Release lock of the steering column (2)
push steering column (1) forward and
secure it in this position.
Danger of burns due to drive motor operating temperature > 80 °C. Special attention must be paid when the battery hood is
open.
With Multi-Pilot (option):
With Multi-Pilot (option):
– Pull control valve cover (4) forward until
it engages.
– Carefully fold back battery cover with
driver’s seat (3).
– Pull control valve cover (4) forward until
it engages.
– Carefully fold back battery cover with
driver’s seat (3).
4
1
2
3
4
3
With Solo-Pilot:
With Solo-Pilot:
– Unlatch control valve cover (5) by
pressing lever (6) and swivel forward.
– Carefully fold back battery cover with
driver’s seat (3).
– Unlatch control valve cover (5) by
pressing lever (6) and swivel forward.
– Carefully fold back battery cover with
driver’s seat (3).
5
5
6
– Unplug the battery connector (7) from
the socket (8).
– Remove insulation mat from battery, if
necessary.
– Unplug the battery connector (7) from
the socket (8).
– Remove insulation mat from battery, if
necessary.
8
F
7
8
The battery connector and the socket
must only be connected or disconnectedwith the master switch and the battery
charger switched off.
1003.GB
The battery connector and the socket
must only be connected or disconnectedwith the master switch and the battery
charger switched off.
1003.GB
F
7
6
D3
D3
4
Charging the battery
4
– Open the battery hood.
F
M
– Open the battery hood.
F
The battery and the charger must only be connected or disconnected with the battery
charger switched off.
The surface of the battery cells must be exposed to provide sufficient ventilation. Metal objects must not be placed on the battery.
M
Prior to starting the recharging operation, check all cable connections and plugged
connections for visible damage.
– Connect charging cable to battery
charger (8) by means of the battery
connector (7).
– Switch on the battery charger and
charge battery according to the specifications of the battery supplier and
the battery charger supplier.
Prior to starting the recharging operation, check all cable connections and plugged
connections for visible damage.
7
8
The safety instructions provided by the battery supplier and battery charger supplier
must be strictly observed. It is absolutely necessary to keep the battery hood open
during the charging process to ensure evaporation of gases formed during charging.
Smoking or naked flames are strictly forbidden when handling batteries. Explosion
hazard!
1003.GB
F
The safety instructions provided by the battery supplier and battery charger supplier
must be strictly observed. It is absolutely necessary to keep the battery hood open
during the charging process to ensure evaporation of gases formed during charging.
Smoking or naked flames are strictly forbidden when handling batteries. Explosion
hazard!
1003.GB
D4
The battery and the charger must only be connected or disconnected with the battery
charger switched off.
The surface of the battery cells must be exposed to provide sufficient ventilation. Metal objects must not be placed on the battery.
– Connect charging cable to battery
charger (8) by means of the battery
connector (7).
– Switch on the battery charger and
charge battery according to the specifications of the battery supplier and
the battery charger supplier.
7
8
F
Charging the battery
D4
5
Removing and installing the battery
5
– Open battery hood (see section 3).
F
– Open battery hood (see section 3).
F
Batteries with exposed terminals or connectors must be covered with a rubber mat to
prevent short-circuits. When changing the battery with the aid of a lifting gear ensure
that the lifting gear is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear is led through the opening of the overhead guard and must pull in a vertical direction to prevent damage to
the battery trough. Lifting hooks must be applied in such a way to the battery lifting
eyes that, with the lifting gear slack, they will not drop on to the battery cells.
– Attach lifting gear to the battery trough
(9).
– Lift battery over the frame on the right
side and pull it to the side.
9
– Installation is in the reverse order.
F
When replacing batteries, ensure that a battery of the same type is fitted. After reinstallation of the battery, visually check all leads and connectors for damage. The covers must be securely locked.
F
When replacing batteries, ensure that a battery of the same type is fitted. After reinstallation of the battery, visually check all leads and connectors for damage. The covers must be securely locked.
During replacement/installation of the battery, pay attention that the battery is tight in
the battery box of the truck.
1003.GB
During replacement/installation of the battery, pay attention that the battery is tight in
the battery box of the truck.
1003.GB
F
Batteries with exposed terminals or connectors must be covered with a rubber mat to
prevent short-circuits. When changing the battery with the aid of a lifting gear ensure
that the lifting gear is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear is led through the opening of the overhead guard and must pull in a vertical direction to prevent damage to
the battery trough. Lifting hooks must be applied in such a way to the battery lifting
eyes that, with the lifting gear slack, they will not drop on to the battery cells.
– Attach lifting gear to the battery trough
(9).
– Lift battery over the frame on the right
side and pull it to the side.
9
– Installation is in the reverse order.
F
Removing and installing the battery
D5
D5
6
7
Closing battery cover
6
With Multi-Pilot (o):
With Multi-Pilot (o):
– Push the control valve hood beyond
the locking point until the hood is automatically closed by spring force.
– Push the control valve hood beyond
the locking point until the hood is automatically closed by spring force.
With Solo-Pilot (t):
With Solo-Pilot (t):
– After closing the battery cover, swivel
control valve cover to the back until it
engages.
– After closing the battery cover, swivel
control valve cover to the back until it
engages.
Battery discharge indicator, battery discharge monitor, operating hour meter
7
Battery discharge indicator: The loading status of the battery (10) is indicated in
steps of 10% on the information and service indicator (100% = battery capacity 100%,
display 0% = battery capacity 20%).
M
Z
Battery discharge indicator, battery discharge monitor, operating hour meter
Battery discharge indicator: The loading status of the battery (10) is indicated in
steps of 10% on the information and service indicator (100% = battery capacity 100%,
display 0% = battery capacity 20%).
M
The manufacturer setting of the battery discharge indicator / discharge
monitor is standard batteries.
The manufacturer setting of the battery discharge indicator / discharge
monitor is standard batteries.
It is required to recharge the battery, if the residual capacity
amounts to 20% for standard batteries or 40% for maintenance-free
batteries.
It is required to recharge the battery, if the residual capacity
amounts to 20% for standard batteries or 40% for maintenance-free
batteries.
Battery discharge monitor: If the
residual capacity falls below the
specified minimum value, the lifting
function is switched off. A corresponding message is displayed in
the information and service indicator.
Battery discharge monitor: If the
residual capacity falls below the
specified minimum value, the lifting
function is switched off. A corresponding message is displayed in
the information and service indicator.
11
10
Z
The lifting function will only then be released, if the connected battery is reloaded by
min. 40%.
11
10
The lifting function will only then be released, if the connected battery is reloaded by
min. 40%.
1003.GB
Operating hours counter: The operating hours (11) are indicated next to the battery
discharge state. The operating hours counter indicates the overall times of driving
and lifting movements (below “Eff”).
1003.GB
Operating hours counter: The operating hours (11) are indicated next to the battery
discharge state. The operating hours counter indicates the overall times of driving
and lifting movements (below “Eff”).
D6
Closing battery cover
D6
E Operation
E Operation
1
1
F
Safety regulations governing the operation of the fork lift truck
Safety regulations governing the operation of the fork lift truck
Driving permission: The fork lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly
been charged by the user or his representative with the operation of the truck.
Driving permission: The fork lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly
been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights
and duties; trained in the operation of the fork lift truck; and familiar with the contents
of these operating instructions. All necessary rights must be granted to him.
If the fork lift truck can be used in the pedestrian-controlled mode, the driver must
wear safety boots when operating the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights
and duties; trained in the operation of the fork lift truck; and familiar with the contents
of these operating instructions. All necessary rights must be granted to him.
If the fork lift truck can be used in the pedestrian-controlled mode, the driver must
wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork lift truck during working time. He must forbid unauthorised persons to drive or operate the fork lift
truck. The transport or lifting of persons is forbidden.
Prohibition of unauthorised use: The driver is responsible for the fork lift truck during working time. He must forbid unauthorised persons to drive or operate the fork lift
truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork lift truck or on the attachments must immediately be brought to the notice of the person in charge. fork lift
trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes)
must not be used until they have been properly repaired.
Damage and defects: Damage or defects noted on the fork lift truck or on the attachments must immediately be brought to the notice of the person in charge. fork lift
trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes)
must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed
to perform any repairs or modifications on the fork lift truck. Under no circumstances
must the driver change the setting of switches or safety installations or render them
ineffective.
Repairs: Without specific training and express authorisation, the driver is not allowed
to perform any repairs or modifications on the fork lift truck. Under no circumstances
must the driver change the setting of switches or safety installations or render them
ineffective.
Danger area: A “danger area” is considered to be the area within which persons are
endangered by the travelling or lifting movements of the fork lift truck or its load lifting
devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling / lowering truck attachments.
Danger area: A “danger area” is considered to be the area within which persons are
endangered by the travelling or lifting movements of the fork lift truck or its load lifting
devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling / lowering truck attachments.
F
Unauthorised persons must be asked to leave the danger area. The driver must give
a warning signal whenever a situation presenting danger to persons might develop.
The fork lift truck must immediately be brought to a standstill if persons, although
asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning
notes described in the present operating instructions must always be heeded.
0207.GB
0207.GB
Safety devices and warning labels: The safety devices, warning labels and warning
notes described in the present operating instructions must always be heeded.
Unauthorised persons must be asked to leave the danger area. The driver must give
a warning signal whenever a situation presenting danger to persons might develop.
The fork lift truck must immediately be brought to a standstill if persons, although
asked, do not leave the danger area.
E1
E1
Description of the operating controls and indicators
Item Operating control or
indicator
1 Steering wheel
2
Multi function display
3
Enhanced multi
function display
Steering column lock
4
5
6
7
8
9
10
11
12
13
14
15
16
17
2
Function
Item Operating control or
indicator
1 Steering wheel
t Steering the truck with 5 steering wheel turns
from left to right.
t Indicates battery capacity, operating hours,
error, important warnings, wheel position and
drive direction (see section 3).
2
Multi function display
3
Enhanced multi
function display
Steering column lock
o
t The steering column is adjusted to the desired
distance and locked.
Driving direction switch o Selection of the desired drive direction.
Multi Pilot
Controls the lift mast functions.
Horn
Trigger warning signal.
Key switch
t Switches the truck's battery voltage on and off.
Master switch
t The power circuits are interrupted, all electrical
Emergency Stop
functions switch off.
Switch lever for special o e.g. indication whether the working lights are
equipment
switched on
Brake pedal
t The truck is decelerated.
Accelerator pedal
t The driving speed is continuously controlled.
Parking brake
t Secures the truck against rolling away when at a
standstill.
Backrest adjustment
t The driver seat backrest is adjustable.
Weight indicator
t Indicates the weight set.
“Driver seat”
Weight adjustment
t To adjust to the driver’s weight for optimum seat
“Driver seat”
cushioning.
Driver seat locking lever t For horizontal driver seat adjustment.
Dual-pedal control
o Truck drives backwards when actuated.
Driving pedal „BackDriving speed is controlled continuously.
ward“
Dual-pedal control
o Truck is decelerated.
Brake pedal
Dual-pedal control
o Truck drives forwards when actuated.
Driving pedal „Forward“
Driving speed is controlled continuously.
4
5
6
7
8
9
10
11
12
13
14
15
16
17
o = Optional equipment
Function
t Steering the truck with 5 steering wheel turns
from left to right.
t Indicates battery capacity, operating hours,
error, important warnings, wheel position and
drive direction (see section 3).
o
t The steering column is adjusted to the desired
distance and locked.
Driving direction switch o Selection of the desired drive direction.
Multi Pilot
Controls the lift mast functions.
Horn
Trigger warning signal.
Key switch
t Switches the truck's battery voltage on and off.
Master switch
t The power circuits are interrupted, all electrical
Emergency Stop
functions switch off.
Switch lever for special o e.g. indication whether the working lights are
equipment
switched on
Brake pedal
t The truck is decelerated.
Accelerator pedal
t The driving speed is continuously controlled.
Parking brake
t Secures the truck against rolling away when at a
standstill.
Backrest adjustment
t The driver seat backrest is adjustable.
Weight indicator
t Indicates the weight set.
“Driver seat”
Weight adjustment
t To adjust to the driver’s weight for optimum seat
“Driver seat”
cushioning.
Driver seat locking lever t For horizontal driver seat adjustment.
Dual-pedal control
o Truck drives backwards when actuated.
Driving pedal „BackDriving speed is controlled continuously.
ward“
Dual-pedal control
o Truck is decelerated.
Brake pedal
Dual-pedal control
o Truck drives forwards when actuated.
Driving pedal „Forward“
Driving speed is controlled continuously.
t = Standard equipment
0207.GB
t = Standard equipment
E2
Description of the operating controls and indicators
o = Optional equipment
0207.GB
2
E2
Truck with Multi Pilot (o)
Truck with Multi Pilot (o)
11
11
12
13
14
12
14
1
1
2
2
3
3
4
5
6
7
8
10
13
4
5
6
7
8
10
9
9
Dual-pedal control (o)
Dual-pedal control (o)
16
16
17
17
0207.GB
15
0207.GB
15
E3
E3
Item Operating control or
indicator
18 Driving direction switch
19 Horn
20 Solo Pilot
Lifting - lowering
21 Control lever
Hoist frame - lowering
22 Control lever
Auxiliary hydraulics
(ZH1)
e. g. side shifting device
23 Control lever
Supplementary hydraulic system (ZH2)
24 Changeover switch
Supplementary hydraulic system (ZH3)
Function
Item Operating control or
indicator
18 Driving direction switch
19 Horn
20 Solo Pilot
Lifting - lowering
21 Control lever
Hoist frame - lowering
22 Control lever
Auxiliary hydraulics
(ZH1)
e. g. side shifting device
23 Control lever
Supplementary hydraulic system (ZH2)
24 Changeover switch
Supplementary hydraulic system (ZH3)
t Selection of the desired drive direction.
t Trigger warning signal.
t The fork is lifted or lowered.
t The fork is inclined to the front or to the back.
o The fork is moved to the right or left.
o Intended for hydraulic attachments.
o Change over from ZH2 to ZH3
t = Standard equipment
o = Optional equipment
19
20
21
t The fork is inclined to the front or to the back.
o The fork is moved to the right or left.
o Intended for hydraulic attachments.
o Change over from ZH2 to ZH3
o = Optional equipment
Vehicle with Solo Pilot and control levers
22
23
18
19
20
21
22
23
0207.GB
24
0207.GB
24
E4
t Selection of the desired drive direction.
t Trigger warning signal.
t The fork is lifted or lowered.
t = Standard equipment
Vehicle with Solo Pilot and control levers
18
Function
E4
2.1
Auxiliary electrical system o
2.1
Auxiliary electrical system o
Z
All auxiliary electrical systems are activated regardless of the key switch position. The
battery master switch must have been switched on (see section “Provide opatability”).
To prevent discharge of the battery after the truck has been parked, always heed section 6.9, “Safe parking of the truck”.
Z
All auxiliary electrical systems are activated regardless of the key switch position. The
battery master switch must have been switched on (see section “Provide opatability”).
To prevent discharge of the battery after the truck has been parked, always heed section 6.9, “Safe parking of the truck”.
2.1.1 Dashboard switches o
2.1.1 Dashboard switches o
Function
Function
Switch “Truck lighting”
Switch “Truck lighting”
Function
Function
Override switch “Lift switch-off”
Override switch “Lift switch-off”
Switch “Creep speed”
Switch “Creep speed”
Switch “Seat heater”
Switch “Seat heater”
Switch “360° warning light / Flash lamp”
Switch “360° warning light / Flash lamp”
Switch “windscreen washer”
Switch “windscreen washer”
Switch “working lights” and/or ”backing up
lights”
Switch “working lights” and/or ”backing up
lights”
Switch “rear window heater”
Switch “rear window heater”
0207.GB
2.1.2 Operating console switches o
0207.GB
2.1.2 Operating console switches o
E5
E5
3
Multi function display t
3
The multi function display indicates operating data, battery capacity, operating hours,
errors and information. To indicate warnings, the display features four LEDs (25) to
(28).
25
26
Multi function display t
The multi function display indicates operating data, battery capacity, operating hours,
errors and information. To indicate warnings, the display features four LEDs (25) to
(28).
27
25
26
27
28
31
31
29
Item
25
26
27
28
29
30
31
E6
30
29
Display
LED “over temperature”
LED “parking brake”
LED “brake fluid”
LED “attention”
Drive direction and wheel position indicator
Battery capacity indicator
“Eff”: effective operating hours
0207.GB
Display
LED “over temperature”
LED “parking brake”
LED “brake fluid”
LED “attention”
Drive direction and wheel position indicator
Battery capacity indicator
“Eff”: effective operating hours
0207.GB
Item
25
26
27
28
29
30
31
30
28
E6
3.1
LED warning indicators
3.1
Four indicator LEDs signal the following states:
Item
25
Four indicator LEDs signal the following states:
Function
Item
LED “over temperature”
– Lights up in case of drive or lift motor over temperature
– Lights up in case of drive or lift controller over temperature
25
Function
LED “over temperature”
– Lights up in case of drive or lift motor over temperature
– Lights up in case of drive or lift controller over temperature
26
LED “parking brake”
– Lights up in case of parking brake applied
26
LED “parking brake”
– Lights up in case of parking brake applied
27
LED “brake fluid”
– Lights up in case the brake fluid level is too low
27
LED “brake fluid”
– Lights up in case the brake fluid level is too low
28
3.2
LED warning indicators
LED ATTENTION
– Flashes in case of errors (Err) or warnings (Inf)
– Flashes when the battery capacity is 10% and 0%
28
Displays
3.2
Displays
Item Function
29 Drive direction and wheel position indicator
– In case of trucks without steering angle acquisition, the drive direction is indicated only (arrow pointing up or down)
– Trucks with steering angle acquisition indicate the drive direction and the
wheel position.
30 Battery capacity indicator
The residual capacity still available is indicated.
Display 0% = battery discharged by 80%.
The Attention LED flashes when 10% and 0% are indicated.
The lifting function is cut out when the capacity is 0%.
31 Operating hours / error display
– Indicates the operating hours:
– Eff: Indicates the overall operating hours
Error display:
– The operating hours display is cleared when an error (Err) or a warning (Inf)
is received. The error code is displayed.
0207.GB
0207.GB
Item Function
29 Drive direction and wheel position indicator
– In case of trucks without steering angle acquisition, the drive direction is indicated only (arrow pointing up or down)
– Trucks with steering angle acquisition indicate the drive direction and the
wheel position.
30 Battery capacity indicator
The residual capacity still available is indicated.
Display 0% = battery discharged by 80%.
The Attention LED flashes when 10% and 0% are indicated.
The lifting function is cut out when the capacity is 0%.
31 Operating hours / error display
– Indicates the operating hours:
– Eff: Indicates the overall operating hours
Error display:
– The operating hours display is cleared when an error (Err) or a warning (Inf)
is received. The error code is displayed.
LED ATTENTION
– Flashes in case of errors (Err) or warnings (Inf)
– Flashes when the battery capacity is 10% and 0%
E7
E7
Enhanced multi function display o
4
The multi function display indicates operating data, battery capacity, operating hours,
errors and information. Graphical symbols on the multi function display issue warnings.
33
49
34
35
36
37
39 41
38 40
48
32
42
43
44
45
46
47
48
49
E8
33
34
35
36
37
39 41
38 40
42
42
43
43
44
47
46
Item
32
33
34
35
36
37
38
39
40
41
The multi function display indicates operating data, battery capacity, operating hours,
errors and information. Graphical symbols on the multi function display issue warnings.
49
45
Display
Push button to toggle between operating hours and time
Controller over temperature
Pump motor over temperature
Drive motor over temperature
Seat switch
Parking brake applied
Travel direction indicator o
Truck in operation (key switch “ON”)
Service display / UVV display
Brake fluid level too low
Lights up in case of errors or flashes when battery capacity is lower than
10 %
Inching speed push button
Program selector button
SET button
Operating program indicator (programs 1 to 5)
Drive direction and wheel position indicator
Battery capacity indicator
Time and operating hours or diagnosis and error display
48
44
47
46
Item
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
0207.GB
32
Enhanced multi function display o
E8
45
Display
Push button to toggle between operating hours and time
Controller over temperature
Pump motor over temperature
Drive motor over temperature
Seat switch
Parking brake applied
Travel direction indicator o
Truck in operation (key switch “ON”)
Service display / UVV display
Brake fluid level too low
Lights up in case of errors or flashes when battery capacity is lower than
10 %
Inching speed push button
Program selector button
SET button
Operating program indicator (programs 1 to 5)
Drive direction and wheel position indicator
Battery capacity indicator
Time and operating hours or diagnosis and error display
0207.GB
4
4.1
Warning indicators, push buttons, and switches
4.1
Indicate or control the following:
Indicate or control the following:
Item Display / function
Push button to toggle between operating hours and time
– Truck operating hours counted while key switch was set to “ON”
32
– “Eff” operating hours can be switched “ON” or “OFF” with a code
– Time display
34
35
36
37
38
39
40
41
42
43
44
45
Controller over temperature
– Lights up in case of controller over temperature
– Power is continuously reduced in relation to temperature
33
Pump motor, power steering motor over temperature
– Pump motor, power steering motor temperature is continuously monitored
– Power is reduced in case of over temperature
Drive motor over temperature
– Drive motor temperature is monitored
– Power is reduced in case of over temperature
34
35
Seat switch
– Seat switch not closed
– Truck ready for operation, seat not occupied
Parking brake applied
– Truck ready for operation, parking brake applied
Travel direction indicator o
– In case of lighting system with flashing system
Truck is in operation
– Key switch to “ON”
Service display / UVV display
– Service interval set has elapsed (1000 operating hours)
or annual UVV inspection is due (display flashes)
Brake fluid level too low
– A sensor on the brake fluid reservoir monitors the brake fluid level
WARNING
– Lights up in case of errors
– Flashes when battery capacity is less than 10 %
Inching speed push button
– Maximum travel speed km/h (adjustable)
Program selector button
– Push button for “Up” and “Down”
SET button
– Selects special functions
Operating program indicator
– Indicates the drive program selected (1 to 5)
36
37
38
39
40
41
42
43
44
45
46
0207.GB
46
Item Display / function
Push button to toggle between operating hours and time
– Truck operating hours counted while key switch was set to “ON”
32
– “Eff” operating hours can be switched “ON” or “OFF” with a code
– Time display
Controller over temperature
– Lights up in case of controller over temperature
– Power is continuously reduced in relation to temperature
Pump motor, power steering motor over temperature
– Pump motor, power steering motor temperature is continuously monitored
– Power is reduced in case of over temperature
Drive motor over temperature
– Drive motor temperature is monitored
– Power is reduced in case of over temperature
Seat switch
– Seat switch not closed
– Truck ready for operation, seat not occupied
Parking brake applied
– Truck ready for operation, parking brake applied
Travel direction indicator o
– In case of lighting system with flashing system
Truck is in operation
– Key switch to “ON”
Service display / UVV display
– Service interval set has elapsed (1000 operating hours)
or annual UVV inspection is due (display flashes)
Brake fluid level too low
– A sensor on the brake fluid reservoir monitors the brake fluid level
WARNING
– Lights up in case of errors
– Flashes when battery capacity is less than 10 %
Inching speed push button
– Maximum travel speed km/h (adjustable)
Program selector button
– Push button for “Up” and “Down”
SET button
– Selects special functions
Operating program indicator
– Indicates the drive program selected (1 to 5)
0207.GB
33
Warning indicators, push buttons, and switches
E9
E9
4.2
Displays
4.2
48
Battery capacity display in %
The residual capacity available is indicated.
Display 0% = battery discharged by 80%.
With a 10% display, the Attention display (42) flashes.
The lifting function is disabled after 30 to 40 seconds at a capacity of 0%.
49
Operating hours / error display
– Indicates the operating hours:
– Eff: Indicates the overall operating hours
Error display:
– The operating hours display is cleared when an error (Err) or a warning (Inf)
is received. The error code is displayed.
– When several errors have occurred, these will be alternately displayed for
1.5 seconds, and a warning tone sounds.
Item Function
0207.GB
47
Drive direction and wheel position indicator
– Indicates the drive direction selected (forward or reverse) or the wheel
position of steered wheels
E 10
47
Drive direction and wheel position indicator
– Indicates the drive direction selected (forward or reverse) or the wheel
position of steered wheels
48
Battery capacity display in %
The residual capacity available is indicated.
Display 0% = battery discharged by 80%.
With a 10% display, the Attention display (42) flashes.
The lifting function is disabled after 30 to 40 seconds at a capacity of 0%.
49
Operating hours / error display
– Indicates the operating hours:
– Eff: Indicates the overall operating hours
Error display:
– The operating hours display is cleared when an error (Err) or a warning (Inf)
is received. The error code is displayed.
– When several errors have occurred, these will be alternately displayed for
1.5 seconds, and a warning tone sounds.
0207.GB
Item Function
Displays
E 10
5
Commissioning the truck
5
Commissioning the truck
F
Before starting or operating the truck, or before lifting any loads, the driver has to
make sure that nobody is within the danger area.
F
Before starting or operating the truck, or before lifting any loads, the driver has to
make sure that nobody is within the danger area.
5.1
Checks and actions before routine start-up
5.1
Checks and actions before routine start-up
Prior to setting the truck into operation the driver must confirm the operationally
reliable condition. Prior to starting work the following items must be verified:
Prior to setting the truck into operation the driver must confirm the operationally
reliable condition. Prior to starting work the following items must be verified:
– operation of the service and parking brakes respectively the automatic brake
(Emergency Stop)
– no damages at the fork securing device against lifting out and shifting
– no visible damages at the load-carrying unit (bends, cracks, severe abrasion)
– operation of the warning equipment
– operation of the service and parking brakes respectively the automatic brake
(Emergency Stop)
– no damages at the fork securing device against lifting out and shifting
– no visible damages at the load-carrying unit (bends, cracks, severe abrasion)
– operation of the warning equipment
5.2
Trucks with reduced headroom X (o)
M
Failure to comply with the recommended
body size may result in overload and
constitute a danger to the driver,
possibly resulting in permanent damage
caused by an unhealthy posture and
excessive physical exertions on the part
of the driver.
The owner must ensure that the truck
operator does not exceed the maximum
body size indicated.
The owner must also check that the
drivers can sit normally, in an upright
position without having to exert himself.
M
Failure to comply with the recommended
body size may result in overload and
constitute a danger to the driver,
possibly resulting in permanent damage
caused by an unhealthy posture and
excessive physical exertions on the part
of the driver.
The owner must ensure that the truck
operator does not exceed the maximum
body size indicated.
The owner must also check that the
drivers can sit normally, in an upright
position without having to exert himself.
0207.GB
Trucks with reduced headroom X (o)
0207.GB
5.2
E 11
E 11
5.3
Adjustment of driver's seat
5.3
Adjustment of driver's seat
Z
The driver`s seat must be adjusted to the driver`s weight in order to achieve an optimum damping of the seat.
The driver`s seat must be load-free when adjusting to the driver`s weight!
Z
The driver`s seat must be adjusted to the driver`s weight in order to achieve an optimum damping of the seat.
The driver`s seat must be load-free when adjusting to the driver`s weight!
Adjusting the driver`s weight:
– Pull weight adjustment “Driver's seat”
(13) in arrow direction until stop and
release again.
– Pull weight adjustment “Driver's seat”
(13) in arrow direction again until the
appropriate weight is indicated on the
weight display “Driver's seat” (12).
Push weight adjustment “Driver`s
seat” back again.
– Sit down on the driver`s seat.
F
11
12
13
E 12
The previous weight adjustment is set
back to the minimum value. Adjusting
range of seat damping from 50 kg to
130 kg.
– Pull weight adjustment “Driver's seat”
(13) in arrow direction again until the
appropriate weight is indicated on the
weight display “Driver's seat” (12).
Push weight adjustment “Driver`s
seat” back again.
– Sit down on the driver`s seat.
14
11
12
13
14
Backrest adjusment:
Backrest adjusment:
– Pull backrest adjustment (11) up and adjust backrest (50) inclination.
– Release backrest adjustment (11), backrest locks in.
– Pull backrest adjustment (11) up and adjust backrest (50) inclination.
– Release backrest adjustment (11), backrest locks in.
Adjusting the seat position:
Adjusting the seat position:
– Pull locking of driver's seat (14) out and adjust the desired seat position by moving
the seat forward or backward.
– Release locking of driver's seat (14) to arrest the seat.
– Pull locking of driver's seat (14) out and adjust the desired seat position by moving
the seat forward or backward.
– Release locking of driver's seat (14) to arrest the seat.
F
The driver`s seat locking must be securely arrested in the adjusted position. The driver`s seat adjustment must not be changed while driving the truck!
Z
The driver`s seat adjustment relates to the standard equipment. Use the adjustment
instructions of the supplier if the truck equipment deviates from the standard. When
adjusting the seat your have to make sure that all operating controls can be
easily reached.
0207.GB
Z
Z
The previous weight adjustment is set
back to the minimum value. Adjusting
range of seat damping from 50 kg to
130 kg.
50
The driver`s seat locking must be securely arrested in the adjusted position. The driver`s seat adjustment must not be changed while driving the truck!
The driver`s seat adjustment relates to the standard equipment. Use the adjustment
instructions of the supplier if the truck equipment deviates from the standard. When
adjusting the seat your have to make sure that all operating controls can be
easily reached.
0207.GB
Z
Adjusting the driver`s weight:
– Pull weight adjustment “Driver's seat”
(13) in arrow direction until stop and
release again.
50
E 12
5.4
Adjusting the steering column
5.4
– Release steering column lock (3) and
push or pull steering column to the desired position.
– Tighten steering column lock again.
– Release steering column lock (3) and
push or pull steering column to the desired position.
– Tighten steering column lock again.
7
5.5
F
1
3
7
Provide operatability
– Unlock master switch (7).
To do this:
Push rocker (s) in and pull it upward
(r) until you notice that the master
switch locks in.
– Put key into the key switch (5) and turn
right until stop to position “I”.
– Check function of horn key (51).
5.5
5
F
Check function of electric and hydraulic
brake and parking brake.
1
3
Provide operatability
– Unlock master switch (7).
To do this:
Push rocker (s) in and pull it upward
(r) until you notice that the master
switch locks in.
– Put key into the key switch (5) and turn
right until stop to position “I”.
– Check function of horn key (51).
51
The truck is now operative. The multi
function display (1) indicates the remaining battery capacity.
51
5
Check function of electric and hydraulic
brake and parking brake.
The truck is now operative. The multi
function display (1) indicates the remaining battery capacity.
Z
After pulling the EMERGENCY OFF and turning the key switch clockwise the truck
executes a selftest for approximately 3 to 4 seconds (controls and motors are
checked). During this period travelling movements are not possible.
0207.GB
After pulling the EMERGENCY OFF and turning the key switch clockwise the truck
executes a selftest for approximately 3 to 4 seconds (controls and motors are
checked). During this period travelling movements are not possible.
0207.GB
Z
Adjusting the steering column
E 13
E 13
5.6
Safety belt
5.6
Safety belt
F
Fasten safety belt before using the industrial truck.
The belt protects you from serious injuries!
F
Fasten safety belt before using the industrial truck.
The belt protects you from serious injuries!
Protect safety belt from dirt (e.g. cover during standstill) and clean it in regular intervals. Thaw out and dry frozen belt lock or belt winder to prevent them from freezing
up again.
Z
F
Protect safety belt from dirt (e.g. cover during standstill) and clean it in regular intervals. Thaw out and dry frozen belt lock or belt winder to prevent them from freezing
up again.
Z
The dry temperature of the warm air must not exceed +60°!
F
Do not change anything at the safety belt!
Increased danger because of malfunctions.
– Replace safety belts after each accident.
– Only original spare parts must be used for retrofitting and repairs.
F
F
Damaged or inoperative safety belts must be replaced by appointed retailers or
branches.
Damaged or inoperative safety belts must be replaced by appointed retailers or
branches.
Behaviour in exceptional situations
F
Never loose the belt and never alight if
the industrial truck threatens to overturn.
Jumping down increases the danger of
injuries!
Never loose the belt and never alight if
the industrial truck threatens to overturn.
Jumping down increases the danger of
injuries!
Proper behaviour:
– Bend trunk over the steering wheel.
– Bend trunk over the steering wheel.
– Hold steering wheel tight with both
hands and support with feet.
– Hold steering wheel tight with both
hands and support with feet.
– Bend body against the falling direction.
– Bend body against the falling direction.
0207.GB
Proper behaviour:
0207.GB
E 14
Do not change anything at the safety belt!
Increased danger because of malfunctions.
– Replace safety belts after each accident.
– Only original spare parts must be used for retrofitting and repairs.
Behaviour in exceptional situations
F
The dry temperature of the warm air must not exceed +60°!
E 14
F
F
Z
Safety belt instructions
Safety belt instructions
Before starting the industrial truck, pull
belt out of the winder slowly, place it over
your thighs tight to your body and close
the lock.
Before starting the industrial truck, pull
belt out of the winder slowly, place it over
your thighs tight to your body and close
the lock.
F
The belt must not be twisted when fastening it!
When operating the industrial truck (e.g.
driving, lifting, lowering, etc.), the driver
must be seated with the back at the
backrest.
When operating the industrial truck (e.g.
driving, lifting, lowering, etc.), the driver
must be seated with the back at the
backrest.
The automatic blocking system of the
belt winder gives you sufficient freedom
of movement on the seat.
The automatic blocking system of the
belt winder gives you sufficient freedom
of movement on the seat.
F
Sitting on the front edge of the seat reduces the protection because of the long
belt.
Z
The belt must only be used to protect
one person.
– Press red key after use and place lock tongue back to the winder with your hand.
The belt must only be used to protect
one person.
– Press red key after use and place lock tongue back to the winder with your hand.
Z
The automatic blocking system may be released if the lock tongue hits the housing.
In this case the belt cannot be pulled out.
The automatic blocking system may be released if the lock tongue hits the housing.
In this case the belt cannot be pulled out.
Release blocking:
Release blocking:
– Pull belt 10 to 15 mm out of the housing with increased power.
– Let the belt move in again to release the automatic blocking system.
– Pull belt 10 to 15 mm out of the housing with increased power.
– Let the belt move in again to release the automatic blocking system.
Belt can be pulled out again.
Belt can be pulled out again.
Behaviour when starting the industrial truck on a slope
Behaviour when starting the industrial truck on a slope
The automatic blocking system blocks the belt extension if the industrial truck is tilted
too much. The belt cannot be pulled out of the winder anymore.
The automatic blocking system blocks the belt extension if the industrial truck is tilted
too much. The belt cannot be pulled out of the winder anymore.
Z
Carefully drive industrial truck out of the slope and fasten belt.
0207.GB
Z
Sitting on the front edge of the seat reduces the protection because of the long
belt.
Carefully drive industrial truck out of the slope and fasten belt.
0207.GB
Z
The belt must not be twisted when fastening it!
E 15
E 15
6
Operation of the fork lift truck
6
Operation of the fork lift truck
6.1
Safety regulations applicable when operating the truck
6.1
Safety regulations applicable when operating the truck
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow
passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork lift truck and the vehicle
in front and he must be in control of his truck at all times. Sudden stopping (except in
emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow
passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork lift truck and the vehicle
in front and he must be in control of his truck at all times. Sudden stopping (except in
emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear
view of the route ahead. When loads blocking the view are carried, the fork lift truck
must be driven with the load at the rear. If this is not possible, a second person must
walk in front of the fork lift truck to give suitable warnings.
Visibility: The driver must look in the direction of travel and must always have a clear
view of the route ahead. When loads blocking the view are carried, the fork lift truck
must be driven with the load at the rear. If this is not possible, a second person must
walk in front of the fork lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted
only when they are recognised lanes, when they are clean and non-slipping, and
when the technical specification of the truck permits safe driving on such slopes or
inclines. Loads must always be carried at that end of the truck facing uphill. U-turns,
cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or
inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted
only when they are recognised lanes, when they are clean and non-slipping, and
when the technical specification of the truck permits safe driving on such slopes or
inclines. Loads must always be carried at that end of the truck facing uphill. U-turns,
cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or
inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only
be used if they are of adequate load bearing capacity, if suitable for driving on, and if
authorised by the user of the truck for truck traffic. The fork lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. The truck
must enter lifts with the load in front and must take up a position which does not allow
it to come into contact with the walls of the lift shaft.
Persons riding in the lift together with the fork lift truck must only enter the lift after the
fork lift truck has come safely to a standstill, and must leave the lift before the fork lift
truck.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only
be used if they are of adequate load bearing capacity, if suitable for driving on, and if
authorised by the user of the truck for truck traffic. The fork lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. The truck
must enter lifts with the load in front and must take up a position which does not allow
it to come into contact with the walls of the lift shaft.
Persons riding in the lift together with the fork lift truck must only enter the lift after the
fork lift truck has come safely to a standstill, and must leave the lift before the fork lift
truck.
Nature of the loads carried: Only loads that have been safely and correctly secured
must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
Nature of the loads carried: Only loads that have been safely and correctly secured
must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
E 16
0207.GB
Driving lanes and work areas: Only such lanes and routes that are specially allocated for truck traffic must be used. Unauthorized persons must stay away from work
areas. Loads must only be stored at places specially provided for this purpose.
0207.GB
Driving lanes and work areas: Only such lanes and routes that are specially allocated for truck traffic must be used. Unauthorized persons must stay away from work
areas. Loads must only be stored at places specially provided for this purpose.
E 16
Towing of trailers or other vehicles is only allowed occasionally and on paved, level driveways with a maximum deviation of +/-1% and a maximum speed of 5 km/h.
Permanent trailer operation is not permitted.
While towing, loads are not allowed on the forks.
The maximum trailer load given for the fork lift truck for braked and/or unbraked trailers must not be exceeded. The indicated trailer load is only valid for the auxiliary coupling at the fork lift truck counterweight. Also heed the instructions of the coupling manufacturer if the genuine trailer coupling is replaced by another make.
After attaching the trailer but before starting driving, the driver must check that the
trailer coupling is secured against detaching. Towing fork lift trucks must be operated
in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
0207.GB
0207.GB
Towing of trailers or other vehicles is only allowed occasionally and on paved, level driveways with a maximum deviation of +/-1% and a maximum speed of 5 km/h.
Permanent trailer operation is not permitted.
While towing, loads are not allowed on the forks.
The maximum trailer load given for the fork lift truck for braked and/or unbraked trailers must not be exceeded. The indicated trailer load is only valid for the auxiliary coupling at the fork lift truck counterweight. Also heed the instructions of the coupling manufacturer if the genuine trailer coupling is replaced by another make.
After attaching the trailer but before starting driving, the driver must check that the
trailer coupling is secured against detaching. Towing fork lift trucks must be operated
in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
E 17
E 17
6.2
F
Driving
6.2
F
During operation in electromagnetic fields beyond the admissible limit values uncontrolled driving motion can occur.
Press EMERGENCY STOP (master switch) immediately, decelerate truck with the
service brake and pull the parking brake.
Determine the cause of the malfunction and inform the supplier`s service, if necessary.
Safety switch, driver`s seat
Z
F
Z
If the driver's seat is free or if the driver's weight is set too high, the driving function is
interrupted by the safety switch (see chapter E, section “Adjusting the driver's
weight”).
F
Do not drive the truck unless the hoods
are closed and locked in the stipulated
manner.
The lanes and routes must be free from
any obstacles.
The driving speed must be adapted to
the load and the prevailing local conditions of the routes, lanes and working areas!
Depending on the truck version,
the driving direction switch can be located
If the driver's seat is free or if the driver's weight is set too high, the driving function is
interrupted by the safety switch (see chapter E, section “Adjusting the driver's
weight”).
Do not drive the truck unless the hoods
are closed and locked in the stipulated
manner.
The lanes and routes must be free from
any obstacles.
The driving speed must be adapted to
the load and the prevailing local conditions of the routes, lanes and working areas!
– Lift fork carrier approx. 200 mm so that
the fork tines are lifted above the
ground.
– Incline hoist frame backward.
M
18
at the Solo Pilot (t, 18) or
Depending on the truck version,
the driving direction switch can be located
18
at the Solo Pilot (t, 18) or
R
0207.GB
R
at the Multi Pilot (o, 52).
V 52
V 52
0207.GB
at the Multi Pilot (o, 52).
E 18
During operation in electromagnetic fields beyond the admissible limit values uncontrolled driving motion can occur.
Press EMERGENCY STOP (master switch) immediately, decelerate truck with the
service brake and pull the parking brake.
Determine the cause of the malfunction and inform the supplier`s service, if necessary.
Safety switch, driver`s seat
– Lift fork carrier approx. 200 mm so that
the fork tines are lifted above the
ground.
– Incline hoist frame backward.
M
Driving
E 18
Forward motion (single-pedal t)
F
52
Make sure that the driving area is free
from obstacles.
– Release parking brake (10).
– Push direction switch (52) at the Multi
pilot (o) or at the Solo pilot (18) in forward direction.
– Slowly actuate driving pedal (9).
Forward motion (dual-pedal o)
F
Forward motion (single-pedal t)
F
V
R
10
– Release parking brake (10).
– Push direction switch (52) at the Multi
pilot (o) or at the Solo pilot (18) in forward direction.
– Slowly actuate driving pedal (9).
8 9
Forward motion (dual-pedal o)
7
F
Make sure that the driving area is free
from obstacles.
– Release parking brake (10).
– Slowly actuate right driving pedal (17).
F
Do not move Multi Pilot for driving.
52
Make sure that the driving area is free
from obstacles.
10
– Release parking brake (10).
– Slowly actuate right driving pedal (17).
F
15
16
Do not move Multi Pilot for driving.
15
16
17
Changing the drive direction (single-pedal t)
F
8 9
7
Make sure that the driving area is free
from obstacles.
17
F
V
R
Changing the drive direction (single-pedal t)
F
Before starting to drive in opposite direction you have to make sure, that the rear driving area is free from obstacles.
Before starting to drive in opposite direction you have to make sure, that the rear driving area is free from obstacles.
– Release foot from accelerator pedal (9).
– Decelerate truck with the brake pedal (8) until standstill.
– Set driving direction switch (52) or (18) via the neutral position to the desired direction.
– Carefully press accelerator pedal until the desired speed is reached.
– Release foot from accelerator pedal (9).
– Decelerate truck with the brake pedal (8) until standstill.
– Set driving direction switch (52) or (18) via the neutral position to the desired direction.
– Carefully press accelerator pedal until the desired speed is reached.
Changing the drive direction (dual-pedal o)
Changing the drive direction (dual-pedal o)
F
Before starting to drive in opposite direction you have to make sure, that the rear driving area is free from obstacles.
– Release foot from the actuated driving pedal (17).
– Decelerate truck with the brake pedal (16) until standstill.
– Slowly actuate driving pedal (15), until the desired driving speed has been reached.
0207.GB
0207.GB
– Release foot from the actuated driving pedal (17).
– Decelerate truck with the brake pedal (16) until standstill.
– Slowly actuate driving pedal (15), until the desired driving speed has been reached.
Before starting to drive in opposite direction you have to make sure, that the rear driving area is free from obstacles.
E 19
E 19
Backward motion (single-pedal t)
F
Backward motion (single-pedal t)
F
Make sure that the rear driving area is free from obstacles.
– Switch driving direction switch (52) on
the Multi Pilot (o) or at the Solo pilot
(t, 18) backward (R).
– Slowly press accelerator pedal (9) until the desired speed is reached.
52
V
R
Backward motion (dual-pedal o)
F
Make sure that the rear driving area is
free from obstacles.
– Slowly actuate left driving pedal (15)
until the desired driving speed has
been reached.
F
Make sure that the rear driving area is free from obstacles.
– Switch driving direction switch (52) on
the Multi Pilot (o) or at the Solo pilot
(t, 18) backward (R).
– Slowly press accelerator pedal (9) until the desired speed is reached.
10
F
8
9
Make sure that the rear driving area is
free from obstacles.
– Slowly actuate left driving pedal (15)
until the desired driving speed has
been reached.
7
F
10
8
9
7
Do not move Multi Pilot for driving.
15
15
Accelerating the truck
(single-pedal t)
16
16
– Slowly press accelerator pedal (9) un17
til the truck starts to move.
– Press accelerator pedal (9) further
down.
Engine speed and riding speed increase in relation to the actuation travel.
Accelerating the truck (dual-pedal o)
Accelerating the truck (dual-pedal o)
– Slowly actuate driving pedal (15 or 17) depending on selected driving direction, until the vehicle starts moving.
– Press down driving pedal (15/17) further. Motor speed and driving velocity increase
in relation to the actuation.
– Slowly actuate driving pedal (15 or 17) depending on selected driving direction, until the vehicle starts moving.
– Press down driving pedal (15/17) further. Motor speed and driving velocity increase
in relation to the actuation.
0207.GB
– Slowly press accelerator pedal (9) un17
til the truck starts to move.
– Press accelerator pedal (9) further
down.
Engine speed and riding speed increase in relation to the actuation travel.
0207.GB
E 20
V
R
Backward motion (dual-pedal o)
Do not move Multi Pilot for driving.
Accelerating the truck
(single-pedal t)
52
E 20
Decelerating the truck
F
Decelerating the truck
F
The braking effect of the truck is mainly dependent on the road surface. This must be
taken into account by the driver for his driving behaviour. Decelerate the truck carefully so that the load does not slip.
When driving with trailed loads the resulting longer braking path must be kept in mind.
– Take your foot from the accelerator pedal (9) (15/17) and press down lightly the
brake pedal (16/8), if required.
– Take your foot from the accelerator pedal (9) (15/17) and press down lightly the
brake pedal (16/8), if required.
6.3
Steering
6.3
Steering
M
The power to be applied for steering is very low due to the hydrostatic steering system. Therefore the steering wheel must be turned very carefully.
M
The power to be applied for steering is very low due to the hydrostatic steering system. Therefore the steering wheel must be turned very carefully.
6.4
Driving a right turn
Driving a right turn
– Turn the steering wheel clockwise according to the desired radius of the turn.
– Turn the steering wheel clockwise according to the desired radius of the turn.
Driving a left turn
Driving a left turn
– Turn the steering wheel counter-clockwise according to the desired radius of the
turn.
– Turn the steering wheel counter-clockwise according to the desired radius of the
turn.
Braking
6.4
There are four possibilities available to
decelerate the truck:
–
–
–
–
52
Service brake
Coasting brake
Reverse brake
Parking brake
– Press brake pedal (16/8) down until
you feel brake pressure.
Z
V
–
–
–
–
R
10
7
8 9
– Press brake pedal (16/8) down until
you feel brake pressure.
Z
Coasting brake:
This operating mode decreases the energy consumption.
V
R
10
7
8 9
The service brake is used to brake the
front wheels with the drum brakes.
Coasting brake:
– Release foot from accelerator pedal
(9) (15/17). The truck is slowed down
generatorically by means of the drive
current control system.
15
16
17
0207.GB
Z
52
Service brake
Coasting brake
Reverse brake
Parking brake
Service brake:
The service brake is used to brake the
front wheels with the drum brakes.
– Release foot from accelerator pedal
(9) (15/17). The truck is slowed down
generatorically by means of the drive
current control system.
Braking
There are four possibilities available to
decelerate the truck:
Service brake:
0207.GB
The braking effect of the truck is mainly dependent on the road surface. This must be
taken into account by the driver for his driving behaviour. Decelerate the truck carefully so that the load does not slip.
When driving with trailed loads the resulting longer braking path must be kept in mind.
E 21
Z
This operating mode decreases the energy consumption.
15
16
17
E 21
Z
Reverse brake (single-pedal):
Reverse brake (single-pedal):
– Switch driving direction switch (52) or (18) to opposite driving direction while driving. The truck is decelerated generatorically by means of the drive current control
system until the truck starts to travel in the opposite direction.
– Switch driving direction switch (52) or (18) to opposite driving direction while driving. The truck is decelerated generatorically by means of the drive current control
system until the truck starts to travel in the opposite direction.
Depending on the truck type, the driving
direction switch can be locatede
V 52
Z
18
R
– at the Multi Pilot, (o, figure 1) or
– at the adjustment lever, (t, figure 2).
(1)
(2)
Reversing brake (dual-pedal) o
– While travelling, push down accelerator pedal (15/17) for the opposite travel direction. By means of the drive
current controller the truck is generatively braked until travel continues in
opposite direction.
E 22
18
(2)
Reversing brake (dual-pedal) o
– While travelling, push down accelerator pedal (15/17) for the opposite travel direction. By means of the drive
current controller the truck is generatively braked until travel continues in
opposite direction.
15
16
17
Locking brake:
Locking brake:
– Pull back locking brake (10). The lokking brake is engaged and the locking
brake lever is locked into this position.
10
– Press the locking knob of the locking
brake (10) and press lever forward, in
order to release the locking brake.
– Pull back locking brake (10). The lokking brake is engaged and the locking
brake lever is locked into this position.
10
– Press the locking knob of the locking
brake (10) and press lever forward, in
order to release the locking brake.
Z
The parking brake is used to mechanically brake the load wheels with the
drum brakes.
An “Attention” LED flashes on the multi
function display when you attempt to
start the truck with the parking brake applied. The drive motor switches off after
3 secs.
15
16
17
The parking brake is used to mechanically brake the load wheels with the
drum brakes.
An “Attention” LED flashes on the multi
function display when you attempt to
start the truck with the parking brake applied. The drive motor switches off after
3 secs.
The parking brake holds the truck with
the highest admissible load and clean
lane on an incline of 15 %.
0207.GB
F
The parking brake holds the truck with
the highest admissible load and clean
lane on an incline of 15 %.
0207.GB
F
V 52
R
– at the Multi Pilot, (o, figure 1) or
– at the adjustment lever, (t, figure 2).
(1)
Z
Depending on the truck type, the driving
direction switch can be locatede
E 22
6.5
F
F
F
Operating the lifting device and attachments (control lever t)
20
21
22
The control lever must only be operated
while the driver is sitting on his seat. The
driver must be instructed in the operation of the lifting device and attachments!
6.5
23
F
24
Operating the lifting device and attachments (control lever t)
20
Lifting/lowering fork carrier
– Pull Solo Pilot (20) backward to lift the fork carrier.
– Press Solo Pilot (20) to the front to lower the fork carrier.
– Pull Solo Pilot (20) backward to lift the fork carrier.
– Press Solo Pilot (20) to the front to lower the fork carrier.
Inclining of hoist frame
Inclining of hoist frame
F
22
The control lever must only be operated
while the driver is sitting on his seat. The
driver must be instructed in the operation of the lifting device and attachments!
Lifting/lowering fork carrier
Keep your body parts out of the gap between mast and front wall when inclining the
mast backward.
21
– Pull control lever (21) backward to incline hoist frame backward.
– Push control lever (21) forward to incline hoist frame forward.
Controlling attachments
Controlling attachments
F
– Auxiliary hydraulic system control lever ZH 1 (22) (e. g. side shifting device).
– Control lever ZH2 (23) for controlling the attachment, pull to the back or press to
the front.
– The control lever ZH2 (23) can be switched over to the auxiliary hydraulic system
(ZH3) with key (24).
24
Keep your body parts out of the gap between mast and front wall when inclining the
mast backward.
– Pull control lever (21) backward to incline hoist frame backward.
– Push control lever (21) forward to incline hoist frame forward.
Observe load capacity of the attachment.
23
Observe load capacity of the attachment.
– Auxiliary hydraulic system control lever ZH 1 (22) (e. g. side shifting device).
– Control lever ZH2 (23) for controlling the attachment, pull to the back or press to
the front.
– The control lever ZH2 (23) can be switched over to the auxiliary hydraulic system
(ZH3) with key (24).
The lifting speed of the hydraulic cylinder is controlled by the excursion of the control
lever.
The lifting speed of the hydraulic cylinder is controlled by the excursion of the control
lever.
When the control lever is released, it jumps back to neutral position automatically and
the attachment remains in the current position.
When the control lever is released, it jumps back to neutral position automatically and
the attachment remains in the current position.
M
Use control lever very sensitively and do not jerk it. When the stop of the attachment
is reached, let control lever loose immediately.
F
Lifting persons with the lifting device is
not allowed.
F
Lifting persons with the lifting device is
not allowed.
0207.GB
Use control lever very sensitively and do not jerk it. When the stop of the attachment
is reached, let control lever loose immediately.
0207.GB
M
E 23
E 23
6.6
F
Operating the lifting device and attachments (Multi Pilot o)
The Multi Pilot must only be operated
while the driver is sitting on his seat. The
driver must be instructed in the operation of the lifting device and attachments!
6.6
55
57
53
F
59
4
57
56
58
59
55
Push the Multi Pilot to the respective direction according to the hydraulic function.
54
53
Lifting/lowering fork carrier
Lifting/lowering fork carrier
– Press Multi Pilot (4) to the back (53) to
lift the fork carrier.
– Press Multi Pilot (4) to the front (57) to
lower the fork carrier.
– Press Multi Pilot (4) to the back (53) to
lift the fork carrier.
– Press Multi Pilot (4) to the front (57) to
lower the fork carrier.
59
55
53
F
57
57
56
58
59
55
54
53
59
55
53
55
Keep your body parts out of the gap between mast and front wall when inclining
the mast backward.
– Press Multi Pilot (4) to the left (55) to
incline the hoist frame to the back.
– Press Multi Pilot (4) to the right (59) to
incline the hoist frame to the front.
57
Combined function
– In order to lower the fork carrier and to
incline the hoist frame forward at the
same time, push Multi Pilot forward
and to the right (58).
– In order to lift the fork carrier and to incline the hoist frame to the back at the
same time, push Multi Pilot back and
to the left (54).
– In order to lower the fork carrier and to
incline the hoist frame backward simultaneously, push Multi Pilot forward
and to the left (56).
59
0207.GB
– In order to lower the fork carrier and to
incline the hoist frame forward at the
same time, push Multi Pilot forward
and to the right (58).
– In order to lift the fork carrier and to incline the hoist frame to the back at the
same time, push Multi Pilot back and
to the left (54).
– In order to lower the fork carrier and to
incline the hoist frame backward simultaneously, push Multi Pilot forward
and to the left (56).
59
4
53
57
57
53
55
59
0207.GB
Combined function
57
Inclining of hoist frame
Keep your body parts out of the gap between mast and front wall when inclining
the mast backward.
– Press Multi Pilot (4) to the left (55) to
incline the hoist frame to the back.
– Press Multi Pilot (4) to the right (59) to
incline the hoist frame to the front.
E 24
The Multi Pilot must only be operated
while the driver is sitting on his seat. The
driver must be instructed in the operation of the lifting device and attachments!
55
53
Push the Multi Pilot to the respective direction according to the hydraulic function.
Inclining of hoist frame
F
Operating the lifting device and attachments (Multi Pilot o)
E 24
Additional Control I
(Integrated side shifting device)
– Press key (60) on the Multi Pilot to
push fork carrier to the left.
– Press key (61) on the Multi Pilot to
push fork carrier to the right.
– Press key (60) on the Multi Pilot to
push fork carrier to the left.
– Press key (61) on the Multi Pilot to
push fork carrier to the right.
Additional control II
Additional control II
The Multi Pilot can be turned for the operation of a hydraulic attachment. When
operating attachments the operating instructions of the respective suppliers
have to be observed.
Z
62
F
Observe load capacity of the attachment.
The Multi Pilot can be turned for the operation of a hydraulic attachment. When
operating attachments the operating instructions of the respective suppliers
have to be observed.
60
61
62
Observe load capacity of the attachment.
Additional control III
Additional control III
To control auxiliary controller II instead
of auxiliary controller III, turn the Multi Pilot and at the same time press push button (62).
To control auxiliary controller II instead
of auxiliary controller III, turn the Multi Pilot and at the same time press push button (62).
0207.GB
F
Additional Control I
(Integrated side shifting device)
61
0207.GB
Z
60
E 25
E 25
6.7
F
Operating the lifting device and the
attachments (operating pattern N o)
The Multi Pilot must be operated from
the driver seat only. The driver must
have been instructed on how to operate
the lifting device and the attachments!
6.7
67
66
65
64
69
63
Depending on the hydraulic function desired, push the Multi Pilot into the appropriate direction.
– Push the Multi Pilot to the right (68) to
lift the fork carriage.
– Push the Multi Pilot to the left (65) to
lower the fork carriage.
63
68
Combined function
65
F
68
Combined function
69
63
67
63
68
65
65
68
– Push the Multi Pilot forward and to the
left (66) to simultaneously lower the
fork carriage and tilt the mast forward.
– Push the Multi Pilot backward and to
the right (69) to simultaneously lift the
fork carriage and tilt the mast
backward.
– Push the Multi Pilot backward and to
the left (64) to simultaneously lower
the fork carriage and tilt the mast
backward.
67
63
67
0207.GB
63
0207.GB
E 26
64
Do not to put any body parts between
mast and rear wall while the mast is tilted
backward.
– Push the Multi Pilot backward (63) to
tilt the mast backward.
– Push the Multi Pilot forward (67) to tilt
the mast forward.
65
– Push the Multi Pilot forward and to the
left (66) to simultaneously lower the
fork carriage and tilt the mast forward.
– Push the Multi Pilot backward and to
the right (69) to simultaneously lift the
fork carriage and tilt the mast
backward.
– Push the Multi Pilot backward and to
the left (64) to simultaneously lower
the fork carriage and tilt the mast
backward.
68
65
Tilting the lifting device forward/
backward
Do not to put any body parts between
mast and rear wall while the mast is tilted
backward.
– Push the Multi Pilot backward (63) to
tilt the mast backward.
– Push the Multi Pilot forward (67) to tilt
the mast forward.
66
Lifting/lowering the fork carriage
67
Tilting the lifting device forward/
backward
F
The Multi Pilot must be operated from
the driver seat only. The driver must
have been instructed on how to operate
the lifting device and the attachments!
67
Depending on the hydraulic function desired, push the Multi Pilot into the appropriate direction.
Lifting/lowering the fork carriage
– Push the Multi Pilot to the right (68) to
lift the fork carriage.
– Push the Multi Pilot to the left (65) to
lower the fork carriage.
F
68
Operating the lifting device and the
attachments (operating pattern N o)
E 26
Speed control of the attachments
Speed control of the attachments
The speed of the hydraulic cylinders is controlled by the excursion of the Multi Pilot.
The speed of the hydraulic cylinders is controlled by the excursion of the Multi Pilot.
When the control lever is released, it jumps back to neutral position automatically and
the attachment remains in the current position.
When the control lever is released, it jumps back to neutral position automatically and
the attachment remains in the current position.
M
Use control lever very sensitively and do not jerk it. When the stop of the attachment
is reached, let Multi Pilot loose immediately.
F
Lifting persons with the lifting device is
not allowed.
F
Lifting persons with the lifting device is
not allowed.
0207.GB
Use control lever very sensitively and do not jerk it. When the stop of the attachment
is reached, let Multi Pilot loose immediately.
0207.GB
M
E 27
E 27
6.8
Picking up, transporting and setting down of loads
6.8
Picking up, transporting and setting down of loads
M
Before a load unit is taken up the driver has to make sure, that it is correctly palettised
and that the load capacity of the truck is not exceeded.
Observe capacity label!
M
Before a load unit is taken up the driver has to make sure, that it is correctly palettised
and that the load capacity of the truck is not exceeded.
Observe capacity label!
Adjusting fork tines
F
Adjusting fork tines
The fork tines must be adjusted so that
both tines have the same distance to the
outer edges of the fork carrier. The load
centre must be centred between the fork
tines.
– Swivel locking lever (72) upward.
– Push fork tines (70) on the fork carrier
(71) to the correct position.
– Swivel locking lever downward and
push fork tine until it is arrested in the
groove.
71
F
72
– Swivel locking lever (72) upward.
– Push fork tines (70) on the fork carrier
(71) to the correct position.
– Swivel locking lever downward and
push fork tine until it is arrested in the
groove.
70
Taking up load
– Drive carefully close to the load to be
lifted.
– Brake with the service brake and keep
the foot on the pedal or apply the parking brake (10).
71
72
70
Taking up load
– Drive carefully close to the load to be
lifted.
– Brake with the service brake and keep
the foot on the pedal or apply the parking brake (10).
3
10
3
10
0207.GB
– Put hoist frame into vertical position.
– Lift fork tines to the correct height of
the load.
0207.GB
– Put hoist frame into vertical position.
– Lift fork tines to the correct height of
the load.
E 28
The fork tines must be adjusted so that
both tines have the same distance to the
outer edges of the fork carrier. The load
centre must be centred between the fork
tines.
E 28
– Drive the truck with the fork tines as far
as possible below the load unit.
F
– Drive the truck with the fork tines as far
as possible below the load unit.
F
The fork tines must be under the load
with at least two third of their lengths.
– Pull parking brake (10). Lift fork carrier
until the load is lying freely on the fork
tines.
– Switch driving direction switch (52/18)
to reverse driving and release the
parking brake.
Z
Depending on the truck type, the driving
direction switch can be locatede
at the Multi Pilot, (o, figure 1) or
at the adjustment lever, (t, figure 2).
F
Make sure that the way to the rear is free (1)
from obstacles.
– Pull parking brake (10). Lift fork carrier
until the load is lying freely on the fork
tines.
– Switch driving direction switch (52/18)
to reverse driving and release the
parking brake.
V 52
18
R
(2)
Z
Depending on the truck type, the driving
direction switch can be locatede
at the Multi Pilot, (o, figure 1) or
at the adjustment lever, (t, figure 2).
F
Make sure that the way to the rear is free (1)
from obstacles.
– Drive carefully backward until the load is outside of the storage area.
F
V 52
18
R
(2)
– Drive carefully backward until the load is outside of the storage area.
F
Persons are not permitted to stay underneath the lifted load!
Do not put your hands through the hoist
frame.
– Incline hoist frame carefully backward.
– Lower the load as far as possible for
the transport (road clearance approx.
150...200 mm).
Persons are not permitted to stay underneath the lifted load!
Do not put your hands through the hoist
frame.
– Incline hoist frame carefully backward.
– Lower the load as far as possible for
the transport (road clearance approx.
150...200 mm).
F
When moving loads the hoist frame
must be inclined backward and the fork
tines must be lowered as far as possible.
0207.GB
When moving loads the hoist frame
must be inclined backward and the fork
tines must be lowered as far as possible.
0207.GB
F
The fork tines must be under the load
with at least two third of their lengths.
E 29
E 29
Transporting a load
F
Transporting a load
F
If the load is stacked so high that the view in forward direction is impeded, you have
to drive backward..
– Accelerate truck carefully with the accelerator pedal (9). Decelerate the
truck carefully by means of the brake
pedal (8). Make sure that you can stop
the truck at any time.
– Choose the speed with respect to the
conditions of lanes and the load to be
moved.
– Observe other traffic at crossroads
and passages.
– Use the help of a second person if areas are unclear.
F
When negotiating slopes and inclines
the load must always be carried at that
end of the truck facing uphill. U-turns
and cutting obliquely over inclines or
slopes is not permitted.
– Accelerate truck carefully with the accelerator pedal (9). Decelerate the
truck carefully by means of the brake
pedal (8). Make sure that you can stop
the truck at any time.
– Choose the speed with respect to the
conditions of lanes and the load to be
moved.
– Observe other traffic at crossroads
and passages.
– Use the help of a second person if areas are unclear.
8
F
9
10
Setting down a load
–
–
–
–
–
–
–
–
E 30
8
9
10
Drive the truck carefully to the load.
Pull parking brake (10).
Put hoist frame in vertical position.
Lift fork tine to the correct height of the
load suspension device.
– Release parking brake.
– Drive the fork tines carefully
below the load carrying device.
– Lower the tines slowly until they come
free.
M
Avoid pancaking the load, in order to
prevent damaging the load and the load
lifting device.
Avoid pancaking the load, in order to
prevent damaging the load and the load
lifting device.
Bending forward with lifted load-carrying
unit only in front of or above the stack.
0207.GB
F
Bending forward with lifted load-carrying
unit only in front of or above the stack.
0207.GB
F
When negotiating slopes and inclines
the load must always be carried at that
end of the truck facing uphill. U-turns
and cutting obliquely over inclines or
slopes is not permitted.
Setting down a load
Drive the truck carefully to the load.
Pull parking brake (10).
Put hoist frame in vertical position.
Lift fork tine to the correct height of the
load suspension device.
– Release parking brake.
– Drive the fork tines carefully
below the load carrying device.
– Lower the tines slowly until they come
free.
M
If the load is stacked so high that the view in forward direction is impeded, you have
to drive backward..
E 30
6.9
Safe parking of the truck
6.9
Safe parking of the truck
F
If the truck is left unattended, even for only short periods of time, it must be rendered
safe.
F
If the truck is left unattended, even for only short periods of time, it must be rendered
safe.
– Driving the truck on even ground.
– Pull parking brake (10).
– Lower forks completely and incline
hoist frame forward.
F
10
7
– Driving the truck on even ground.
– Pull parking brake (10).
– Lower forks completely and incline
hoist frame forward.
5
F
Never park the truck or leave it unattended while a load is lifted.
– Press down the master switch (7).
– Switch the key in the key switch (5) to
position “0”.
– Remove the key from the key switch
(5).
6.10
10
7
5
Never park the truck or leave it unattended while a load is lifted.
– Press down the master switch (7).
– Switch the key in the key switch (5) to
position “0”.
– Remove the key from the key switch
(5).
Trailer towing
6.10
Trailer towing
The truck may be used for occasional towing of trailers on dry, level and smooth surfaces.
The truck may be used for occasional towing of trailers on dry, level and smooth surfaces.
Coupling the trailer
Coupling the trailer
73
73
0207.GB
– Push the socket pin (73) down and
turn it by 90 degrees.
– Pull the socket pin upward and insert
the trailer drawbar into the opening.
– Insert the socket pin, push it down,
turn it by 90 degrees until it engages.
0207.GB
– Push the socket pin (73) down and
turn it by 90 degrees.
– Pull the socket pin upward and insert
the trailer drawbar into the opening.
– Insert the socket pin, push it down,
turn it by 90 degrees until it engages.
E 31
E 31
6.11
Trailer loads
6.11
Trailer loads
M
The driver must make sure not to exceed the maximum permissible trailer load prior
to coupling the trailer.
M
The driver must make sure not to exceed the maximum permissible trailer load prior
to coupling the trailer.
Maximum trailer load
7
Dead weight
Pulling force
Trailer loads
(kg)
(N)
(kg)
Truck
Dead weight
Pulling force
Trailer loads
(kg)
(N)
(kg)
EFG 110k
2490
4500
7000
EFG 110k
2490
4500
7000
EFG 110
2570
4500
7000
EFG 110
2570
4500
7000
EFG 113
2760
4500
7000
EFG 113
2760
4500
7000
EFG 115
2870
4500
7000
EFG 115
2870
4500
7000
Fault location
7
Fault location
This chapter enables the operator to locate and rectify minor faults and malfunctions,
or the effect of operating errors. The order of the work stated in the table must be observed for fault location.
This chapter enables the operator to locate and rectify minor faults and malfunctions,
or the effect of operating errors. The order of the work stated in the table must be observed for fault location.
Fault
Possible cause
Truck
– Battery connector
does not move
not connected
– Master switch
depressed
– Key switch
in position “0”
– Battery
exhausted
– Faulty fuse
Load cannot
– Truck not
be lifted
operative
Fault
Possible cause
Truck
– Battery connector
does not move
not connected
– Master switch
depressed
– Key switch
in position “0”
– Battery
exhausted
– Faulty fuse
Load cannot
– Truck not
be lifted
operative
Remedy
– Check the battery connector and connect if
necessary
– Unlock main switch
– Set the key switch to position “I”
– Check the charging condition of the battery
and recharge if necessary
– Check fuses
– Perform all remedial actions listed under
the fault “Truck does not move”
– Hydraulic oil level – Check hydraulic oil level
too low
– Faulty fuse
– Check fuses
Remedy
– Check the battery connector and connect if
necessary
– Unlock main switch
– Set the key switch to position “I”
– Check the charging condition of the battery
and recharge if necessary
– Check fuses
– Perform all remedial actions listed under
the fault “Truck does not move”
– Hydraulic oil level – Check hydraulic oil level
too low
– Faulty fuse
– Check fuses
M
If it is not possible to rectify the fault by performing the indicated “remedial actions”,
please contact the Customer Service, as more intricate faults can only be rectified by
specially trained and qualified service personnel.
M
If it is not possible to rectify the fault by performing the indicated “remedial actions”,
please contact the Customer Service, as more intricate faults can only be rectified by
specially trained and qualified service personnel.
7.1
Temperature monitoring
7.1
Temperature monitoring
E 32
If one of the temperature switches emits the appropriate signal, the performance of
the truck will be reduced in relation to the temperature development:
while driving in the low-speed mode,
with the hydraulic function “Half lifting speed” being activated,
with the control function “Permanent performance adjustment” being activated.
0207.GB
If one of the temperature switches emits the appropriate signal, the performance of
the truck will be reduced in relation to the temperature development:
while driving in the low-speed mode,
with the hydraulic function “Half lifting speed” being activated,
with the control function “Permanent performance adjustment” being activated.
E 32
0207.GB
Truck
Maximum trailer load
F Maintenance of the fork lift truck
F Maintenance of the fork lift truck
1
1
Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
F
M
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
F
Modifications of fork lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
M
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F).
2
Safety regulations applicable to truck maintenance
2
Jacking point see chapter B.
M
If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted.
F
Cleaning operations: No inflammable liquids must be used when cleaning the fork
lift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery-operated fork lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of
electric or electronic assemblies.
Safety regulations applicable to truck maintenance
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength.
Z
Jacking point see chapter B.
M
If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted.
Cleaning operations: No inflammable liquids must be used when cleaning the fork
lift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery-operated fork lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of
electric or electronic assemblies.
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed.
0708.GB
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed.
0708.GB
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you.
Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the
manufacturer has external technicians trained especially for these assignments. We
thus recommend signing a maintenance contract with the relevant service location of
the manufacturer.
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength.
Z
Modifications of fork lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F).
Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the
manufacturer has external technicians trained especially for these assignments. We
thus recommend signing a maintenance contract with the relevant service location of
the manufacturer.
F
Operational safety and environmental protection
F1
F1
Welding operations: To prevent any damage to electric or electronic components,
these have to be removed from the fork lift truck before any welding operations are
undertaken.
Welding operations: To prevent any damage to electric or electronic components,
these have to be removed from the fork lift truck before any welding operations are
undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, all truck-specific settings have to be retained.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, all truck-specific settings have to be retained.
Wheels: The quality of wheels affects the stability and performance of the truck.
When replacing wheels fitted at the factory, only use manufacturer’s original spare
parts. Otherwise the truck's rated performance cannot be ensured.
When replacing wheels, ensure that the truck does not slew (e.g. always replace
wheels in pairs, i.e. left and right wheels at the same time).
Wheels: The quality of wheels affects the stability and performance of the truck.
When replacing wheels fitted at the factory, only use manufacturer’s original spare
parts. Otherwise the truck's rated performance cannot be ensured.
When replacing wheels, ensure that the truck does not slew (e.g. always replace
wheels in pairs, i.e. left and right wheels at the same time).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication.
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
F2
0708.GB
Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork lift trucks, the truck must also be depowered by removing the battery plug.
0708.GB
Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork lift trucks, the truck must also be depowered by removing the battery plug.
F2
3
Servicing and inspection
3
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork lift truck. The neglect of regular servicing intervals can lead to fork
lift truck failure and constitutes a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck considerably affect the wear levels of
the service components.
We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage
caused by wear.
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be
shortened accordingly.
The application conditions of an industrial truck considerably affect the wear levels of
the service components.
We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage
caused by wear.
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be
shortened accordingly.
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
W
A
B
C
W
A
B
C
=
=
=
=
Every
50 service hours, at least weekly
Every 500 operating hours
Every 1000 operating hours, or at least annually
Every 2000 operating hours, or at least annually
Z
W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary.
0708.GB
Z
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork lift truck. The neglect of regular servicing intervals can lead to fork
lift truck failure and constitutes a potential hazard to personnel and equipment.
=
=
=
=
Every
50 service hours, at least weekly
Every 500 operating hours
Every 1000 operating hours, or at least annually
Every 2000 operating hours, or at least annually
W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary.
0708.GB
M
Servicing and inspection
F3
F3
4
Maintenance check list for EFG 110k/110/113/115
4
Maintenance intervals
Standard =
t
W A B C
Maintenance intervals
Standard =
t
W A B C
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
F4
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
0708.GB
Chassis/
1.1 Check all load bearing elements for damage
superstruct.: 1.2 Check all bolted connections
1.3 Check tow bar
1.4 Check overhead guard for damages and proper fixing
1.5 Check safety belt for damages and function
t
1.6 Check retaining system (option) for damages and func- t
tion
1.7 Check if labels are present, readable, and valid
Drive unit:
2.1 Check the transmission for noises and leakage
2.2 Check the transmission oil level
2.3 Check pedal mechanism and adjust and grease,
if necessary
2.4 Change the gear oil (at least once every 12 months)
Wheels:
3.1 Check for wear and damage
t
3.2 Check seating and fixing
3.3 Renew grease filling of wheel bearings of the front and
rear wheels and re-adjust wheel bearings.
Steering:
4.1 Check the hydraulic components for leakage and functioning
Grease the gear wheel pair of the steering drive.
Brake
5.1 Check for correct function and adjustment
system:
5.2 Check the brake linkage; adjust and grease,
if necessary
5.3 Check the brake lines, connections and brake fluid level
5.4 Change the brake fluid
Hydr. system: 6.1 Check all connections for leakage and damage
6.2 Check aeration and deaeration filters at the hydraulic
tank
6.3 Check the oil level
6.4 Check hydraulic cylinders for leakage, damage
and secure attachment
6.5 Check the hose line for correct functioning and damage
6.6 Change filter cartridge
(hydraulic oil and deaeration filter)
6.7 Change hydraulic oil
6.8 Check the pressure relief valves for correct functioning
0708.GB
Chassis/
1.1 Check all load bearing elements for damage
superstruct.: 1.2 Check all bolted connections
1.3 Check tow bar
1.4 Check overhead guard for damages and proper fixing
1.5 Check safety belt for damages and function
t
1.6 Check retaining system (option) for damages and func- t
tion
1.7 Check if labels are present, readable, and valid
Drive unit:
2.1 Check the transmission for noises and leakage
2.2 Check the transmission oil level
2.3 Check pedal mechanism and adjust and grease,
if necessary
2.4 Change the gear oil (at least once every 12 months)
Wheels:
3.1 Check for wear and damage
t
3.2 Check seating and fixing
3.3 Renew grease filling of wheel bearings of the front and
rear wheels and re-adjust wheel bearings.
Steering:
4.1 Check the hydraulic components for leakage and functioning
Grease the gear wheel pair of the steering drive.
Brake
5.1 Check for correct function and adjustment
system:
5.2 Check the brake linkage; adjust and grease,
if necessary
5.3 Check the brake lines, connections and brake fluid level
5.4 Change the brake fluid
Hydr. system: 6.1 Check all connections for leakage and damage
6.2 Check aeration and deaeration filters at the hydraulic
tank
6.3 Check the oil level
6.4 Check hydraulic cylinders for leakage, damage
and secure attachment
6.5 Check the hose line for correct functioning and damage
6.6 Change filter cartridge
(hydraulic oil and deaeration filter)
6.7 Change hydraulic oil
6.8 Check the pressure relief valves for correct functioning
Maintenance check list for EFG 110k/110/113/115
F4
Maintenance intervals
Standard =
t
W A B C
7.1
7.2
7.3
Electric
motors:
Battery:
7.4
7.5
7.6
8.1
8.2
9.1
9.2
9.3
9.4
Hoist frame: 10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
General
measurements:
11.1
t
t
t
t
t
Electr.
system:
7.1
t
t
7.2
7.3
t
t
t
t
t
7.4
7.5
7.6
8.1
8.2
9.1
Electric
motors:
Battery:
9.2
9.3
t
t
9.4
Hoist frame: 10.1
t
10.2
t
t
t
t
t
10.3
10.4
10.5
10.6
10.7
10.8
t
10.9
t
General
measurements:
t
t
t
t
11.1
11.2
11.3
Demonstra- 12.1
tion:
12.2
0708.GB
11.2
11.3
Demonstra- 12.1
tion:
12.2
Check the instrument and indicators for correct functioning
Check all cables for secure connection and damage
Check the cable runs for correct functioning and
damage
Check functioning of warning devices and safety circuits
Check the fuses for correct amperage
Clean impulse control
Check the motor for secure attachment
Clean motor cooling fins
Check the battery cables for damage and replace, if
necessary
Check acid density, acid level and cell voltage
Check the terminals for secure attachment and apply
pole grease
Clean battery connections, check for tight fit
Apply grease to running paths and side run areas of idler
pulleys in the hoist frame profiles.
Check lift chains and chain guide for wear, adjust and
grease them.
Lubricate lifting chains and chain guides.
Check secure attachment of hoist frame
Check bearing of inclination cylinder and fixing
Check fork tines and fork carrier for wear and damage
Visual check of rollers, slide pieces and stops
Check angle of inclination of hoist frame. Check uniform
extension of both tilting cylinders.
Check mast play and adjust lateral play by means of
shims, if necessary.
Check the electrical system for a grounding fault
VDI 2511
Check driving speed and braking distance
Check lifting and lowering speed
Perform a trial run under a nominal load
Demonstrate the truck to a person charged with inspection upon completion of the maintenance of the truck
Check the instrument and indicators for correct functioning
Check all cables for secure connection and damage
Check the cable runs for correct functioning and
damage
Check functioning of warning devices and safety circuits
Check the fuses for correct amperage
Clean impulse control
Check the motor for secure attachment
Clean motor cooling fins
Check the battery cables for damage and replace, if
necessary
Check acid density, acid level and cell voltage
Check the terminals for secure attachment and apply
pole grease
Clean battery connections, check for tight fit
Apply grease to running paths and side run areas of idler
pulleys in the hoist frame profiles.
Check lift chains and chain guide for wear, adjust and
grease them.
Lubricate lifting chains and chain guides.
Check secure attachment of hoist frame
Check bearing of inclination cylinder and fixing
Check fork tines and fork carrier for wear and damage
Visual check of rollers, slide pieces and stops
Check angle of inclination of hoist frame. Check uniform
extension of both tilting cylinders.
Check mast play and adjust lateral play by means of
shims, if necessary.
Check the electrical system for a grounding fault
VDI 2511
Check driving speed and braking distance
Check lifting and lowering speed
Perform a trial run under a nominal load
Demonstrate the truck to a person charged with inspection upon completion of the maintenance of the truck
t
t
t
t
t
t
t
t
t
t
t
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t
t
t
t
t
t
t
t
t
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t
t
t
t
0708.GB
Electr.
system:
Maintenance intervals
Standard =
t
W A B C
F5
F5
Lubrication plan for EFG 110k/110/113/115
5
Lubrication plan for EFG 110k/110/113/115
A
A
E
E
D
D
G
0,4l
0,4l
N
4,15 l
N
4,15 l
g
Slide faces
b
Filler neck gear oil
g
Slide faces
b
Filler neck gear oil
c
Grease nipple
a
Drain plug gear oil
c
Grease nipple
a
Drain plug gear oil
o
Transmission oil inspection
screw
o
Transmission oil inspection
screw
t
Filler neck brake fluid
t
Filler neck brake fluid
Filler neck hydraulic oil
0708.GB
Filler neck hydraulic oil
F6
G
F6
0708.GB
5
5.1
Fuels, coolants and lubricants
5.1
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed.
F
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited
to mix consumption type materials of different grades or qualitiies resp., except if mixing is expressively prescribed in these operating instructions.
When filling in consumption type materials use clean containers only. It is prohibited
to mix consumption type materials of different grades or qualitiies resp., except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Code
Code
Order-no.
Qty
A
50429647
Designation
Used for
H-LPD 32 1)
50426072
14.5 l
H-LPD 22 2)
H-LPD 22 2)
Hydraulic system
D
29201570
Brake fluid
SAE J 1703 4)
FMVSS 116
DOT 3 und DOT 4
Hydraulic brake system
Front and rear wheel - wheel
bearings
E
50157382
Grease K-L 3N 3)
Front and rear wheel - wheel
bearings
Chain spray
Chains
G
29201280
Gear oil EP 80
Transmission
N
50468784
D
29201570
Hydraulic brake system
E
50157382
Grease K-L 3N 3)
4.15 l
14.5 l
Plantosyn 46 HVI
(BIO hydraulic oil)
Brake fluid
SAE J 1703 4)
FMVSS 116
DOT 3 und DOT 4
29201280
Used for
51082888
Plantosyn 46 HVI
(BIO hydraulic oil)
50468784
50429647
Designation
H-LPD 32 1)
HV 68 3)
51082888
N
Qty
50124051
HV 68
G
A
Hydraulic system
3)
50124051
0.25 l
Order-no.
50426072
0.25 l
4.15 l
Grease standard values
Grease standard values
Code Type of Saponification
E
Lithium
Code Type of Saponification
E
Lithium
1)
2)
3)
4)
Drop point Walkpenetration NLG1-Class
Service°C
bei 25 °C
temperature °C
185
265-295
2
-35/+120
1)
2)
3)
4)
valid at temperature -5/+30 °C
valid at temperature -20/-5 °C
valid at temperature +30/+50 °C
Brake fluid DOT 4 should be favourably used.
F
The trucks are filled at the factory with H-LPD 22 hydraulic oil or Plantosyn 46 HVI
BIO hydraulic oil.
You cannot change from “Plantosyn 46 HVI” BIO hydraulic oil to H-LPD 22. The same
applies to changing from H-LPD 22 hydraulic oil to Plantosyn 46 HVI BIO hydraulic oil.
Furthermore you cannot mix H-LPD 22 hydraulic oil with Plantosyn 46 HVI BIO
hydraulic oil.
0708.GB
F
Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed.
Chain spray
Chains
Gear oil EP 80
Transmission
Drop point Walkpenetration NLG1-Class
Service°C
bei 25 °C
temperature °C
185
265-295
2
-35/+120
valid at temperature -5/+30 °C
valid at temperature -20/-5 °C
valid at temperature +30/+50 °C
Brake fluid DOT 4 should be favourably used.
The trucks are filled at the factory with H-LPD 22 hydraulic oil or Plantosyn 46 HVI
BIO hydraulic oil.
You cannot change from “Plantosyn 46 HVI” BIO hydraulic oil to H-LPD 22. The same
applies to changing from H-LPD 22 hydraulic oil to Plantosyn 46 HVI BIO hydraulic oil.
Furthermore you cannot mix H-LPD 22 hydraulic oil with Plantosyn 46 HVI BIO
hydraulic oil.
0708.GB
F
Fuels, coolants and lubricants
F7
F7
6
Description of servicing operations
6
Description of servicing operations
6.1
Preparation of the truck for servicing and maintenance operation
6.1
Preparation of the truck for servicing and maintenance operation
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance
operations. The following preparatory
operations must be performed:
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance
operations. The following preparatory
operations must be performed:
– Open the battery hood (refer to chapter D).
– Remove the floor plate (1) wit the floor
mat.
– Open the battery hood (refer to chapter D).
– Remove the floor plate (1) wit the floor
mat.
1
Fuses, hydraulic pump, filter, brake system and electric units are now accessible.
6.2
Fuses, hydraulic pump, filter, brake system and electric units are now accessible.
Check fixing of the wheels
6.2
Check fixing of the wheels
– Park the truck and render it safe
(see chapter E).
– Tighten wheel nuts (2) cross-wise with
a torque wrench.
– Park the truck and render it safe
(see chapter E).
– Tighten wheel nuts (2) cross-wise with
a torque wrench.
Torque
Front and rear wheels MA = 170 Nm
Torque
Front and rear wheels MA = 170 Nm
0708.GB
2
0708.GB
2
F8
1
F8
6.3
Check hydraulic oil level
6.3
Check hydraulic oil level
F
The load lifting device must be completely lowered.
F
The load lifting device must be completely lowered.
Z
– Prepare truck for maintenance and
service operations (see section 6.1).
– Unscrew air cleaner with level plunger
(3).
– Visual check of hydraulic oil level on
the level plunge
3
max.
min.
Z
The reading of the hydraulic oil level
must be at the upper mark (max.) when
the tank is sufficiently filled.
– If required, top up with hydraulic oil until the prescribed filling level is reached
(20 mm at the dipstick (3) correspond
to approx. 1 l hydraulic oil) (see section 5.1).
M
3
max.
min.
The reading of the hydraulic oil level
must be at the upper mark (max.) when
the tank is sufficiently filled.
– If required, top up with hydraulic oil until the prescribed filling level is reached
(20 mm at the dipstick (3) correspond
to approx. 1 l hydraulic oil) (see section 5.1).
M
Do not fill hydraulic tank higher than the upper mark. This can cause disturbances and
damage of the system.
Changed consumption type materials must be disposed of in accordance with the applicable environmental protection regulations.
Do not fill hydraulic tank higher than the upper mark. This can cause disturbances and
damage of the system.
Changed consumption type materials must be disposed of in accordance with the applicable environmental protection regulations.
F
Trucks with bio hydraulic oil have a warning notice on the
hydraulic reservoir: “Fill only with hydraulic oil”. Use only bio
hydraulic oil, see “Lubricants” section.
0708.GB
Trucks with bio hydraulic oil have a warning notice on the
hydraulic reservoir: “Fill only with hydraulic oil”. Use only bio
hydraulic oil, see “Lubricants” section.
0708.GB
F
– Prepare truck for maintenance and
service operations (see section 6.1).
– Unscrew air cleaner with level plunger
(3).
– Visual check of hydraulic oil level on
the level plunge
F9
F9
6.4
F
Check the transmission oil level
6.4
F
Gear oil must not run into the ground. To
prevent this, put an oilpan underneath
the gear box.
– Park the truck and render it safe (see
chapter E).
– Unscrew oil filler screw (4).
– Check the gear oil level and top up, if
required (see section 5.1).
– Take off the cap (5).
– Turn the drive wheel until the oil filler
plug (6) is visible.
– Use a wrench filled with grease to unscrew the oil filler plug (6).
– Use a small funnel to top up oil.
5,6
Check the transmission oil level
Gear oil must not run into the ground. To
prevent this, put an oilpan underneath
the gear box.
– Park the truck and render it safe (see
chapter E).
– Unscrew oil filler screw (4).
– Check the gear oil level and top up, if
required (see section 5.1).
– Take off the cap (5).
– Turn the drive wheel until the oil filler
plug (6) is visible.
– Use a wrench filled with grease to unscrew the oil filler plug (6).
– Use a small funnel to top up oil.
4
7
5,6
4
7
Z
The oil must reach the lower edge of the
inspection bore.
Z
The oil must reach the lower edge of the
inspection bore.
M
Changed consumption type materials must be disposed of in accordance with the applicable environmental protection regulations.
M
Changed consumption type materials must be disposed of in accordance with the applicable environmental protection regulations.
6.5
Let off oil
6.5
Let off oil
– Let off oil at service temperature.
– Use an oil pan.
– Unscrew waste oil screw (7) and let off gear oil.
6.6
– Let off oil at service temperature.
– Use an oil pan.
– Unscrew waste oil screw (7) and let off gear oil.
Refill oil
6.6
F 10
0708.GB
– Screw in waste oil screw.
– Fill in fresh gear oil with the oil filler screw (6) unscrewed.
0708.GB
– Screw in waste oil screw.
– Fill in fresh gear oil with the oil filler screw (6) unscrewed.
Refill oil
F 10
6.7
Top up brake fluid
6.7
Top up brake fluid
Z
An insufficient brake fluid level is indicated on the display.
Z
An insufficient brake fluid level is indicated on the display.
F
Brake fluid is poisonous and must only
be stored in closed original containers.
F
Brake fluid is poisonous and must only
be stored in closed original containers.
1
– Park the truck and render it safe (see
chapter E).
– Unscrew the fastening screws and remove the floor plate with the floor mat
(1).
– Take off the cap (8).
– Top up brake fluid (see section 5.1).
Z
The brake fluid level must be visible between the marks “Min.” and “Max.”.
Z
The brake fluid level must be visible between the marks “Min.” and “Max.”.
M
Changed consumption type materials
must be disposed of in accordance with
the applicable environmental protection
regulations.
M
Changed consumption type materials
must be disposed of in accordance with
the applicable environmental protection
regulations.
8
Changing of hydraulic oil filter
6.8
The hydraulic oil filter is located at the
front left next to the tilt cylinder and is accessible once the floor plate has been
removed.
– Unscrew the closing cap of the hydraulic filter (7).
– Change filter cartridge; if the O-ring is
damaged, it must also be changed.
Lubricate O-ring slightly when installing the filter.
– Screw in closing cap again.
– Unscrew the closing cap of the hydraulic filter (7).
– Change filter cartridge; if the O-ring is
damaged, it must also be changed.
Lubricate O-ring slightly when installing the filter.
– Screw in closing cap again.
7
0708.GB
7
8
Changing of hydraulic oil filter
The hydraulic oil filter is located at the
front left next to the tilt cylinder and is accessible once the floor plate has been
removed.
0708.GB
6.8
1
– Park the truck and render it safe (see
chapter E).
– Unscrew the fastening screws and remove the floor plate with the floor mat
(1).
– Take off the cap (8).
– Top up brake fluid (see section 5.1).
F 11
F 11
Safety belt maintenance
Daily inspections of the condition and operatability of the safety belt should be carried
out by the driver before using the industrial truck. A malfunction can only be detected
at an early stage by regular inspection.
– Pull belt out completely and check on unravelling
– Check operatability of belt lock and faultless drawing in of the belt into the winder
– Check cover on damages
– Pull belt out completely and check on unravelling
– Check operatability of belt lock and faultless drawing in of the belt into the winder
– Check cover on damages
Automatic blocking system test:
Automatic blocking system test:
– Park industrial truck horizontally
– Pull out belt jerky
– Park industrial truck horizontally
– Pull out belt jerky
The automatic system must block the belt.
M
The automatic system must block the belt
– Open hood by approx. 30 degree
M
The automatic system must block the belt.
M
The automatic system must block the belt
F
Do not operate industrial truck with defective safety belt but have it replaced immediately!
0708.GB
F 12
Safety belt maintenance
Daily inspections of the condition and operatability of the safety belt should be carried
out by the driver before using the industrial truck. A malfunction can only be detected
at an early stage by regular inspection.
M
F
6.9
– Open hood by approx. 30 degree
Do not operate industrial truck with defective safety belt but have it replaced immediately!
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6.9
F 12
6.10
Checking the electric fuses
6.10
– Preparation of the truck for servicing and maintenance operation.
(see section 6.1).
– Unscrew cover.
– Check fuses according to table for correct rating and damage.
F
– Preparation of the truck for servicing and maintenance operation.
(see section 6.1).
– Unscrew cover.
– Check fuses according to table for correct rating and damage.
F
In order to prevent damage to the electric system, only fuses with the respectively
specified ratings must be used.
Electric fuses of the base machine t
10
Description
4F1
F4
F3.1
1F9
1F
2F1
Circuit
Horn
Main contactor
Controller 24 V
Electronics
Drive motor
Pump motor
Electric fuses of the base machine t
13
9
14
10
Rating / Type
10 A
5A
40 A
10 A
250 A
250 A
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Item
9
10
11
12
13
14
11
12
In order to prevent damage to the electric system, only fuses with the respectively
specified ratings must be used.
Item
9
10
11
12
13
14
Description
4F1
F4
F3.1
1F9
1F
2F1
11
12
Circuit
Horn
Main contactor
Controller 24 V
Electronics
Drive motor
Pump motor
13
14
Rating / Type
10 A
5A
40 A
10 A
250 A
250 A
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9
Checking the electric fuses
F 13
F 13
Electric fuses o
Electric fuses o
15 16 17 18 19 20
16
5F3
17
18
4F4
5F1
19
5F6
20
21
22
23
24
25
26
9F2
F1.1
5F5.2
5F4
5F4.1
5F5
5F5.1
Circuit
Brake light
Reversing light or
rear working light
Beacon lamp
Front working light
Windscreen wipers, front, rear and
rear window defroster
Seat heater
Flasher relay
Reversing lamp
Tail light, right
Tail light, left
Illumination, right
Illumination, left
21
22
22
23
24
25
26
23
24
25
26
Rating / type
10 A
Item
15
Designation
4F6
10 A
16
5F3
5A
10 A
17
18
4F4
5F1
10 A
19
5F6
10 A
5A
5A
5A
5A
5A
5A
20
21
22
23
24
25
26
9F2
F1.1
5F5.2
5F4
5F4.1
5F5
5F5.1
F 14
Circuit
Brake light
Reversing light or
rear working light
Beacon lamp
Front working light
Windscreen wipers, front, rear and
rear window defroster
Seat heater
Flasher relay
Reversing lamp
Tail light, right
Tail light, left
Illumination, right
Illumination, left
Rating / type
10 A
10 A
5A
10 A
10 A
10 A
5A
5A
5A
5A
5A
5A
0708.GB
Designation
4F6
21
0708.GB
Item
15
15 16 17 18 19 20
F 14
6.11
7
Recommissioning the truck
6.11
Recommissioning of the truck following the performance of cleaning or maintenance
work is permitted only after the following operations have been performed:
Recommissioning of the truck following the performance of cleaning or maintenance
work is permitted only after the following operations have been performed:
–
–
–
–
–
–
–
–
Check the horn for proper functioning.
Check the master switch for correct functioning.
Check the brake for correct functioning.
Lubricate truck according to lubrication schedule.
Decommissioning the fork lift truck
7
If the fork lift truck is to be decommissioned for more than two months, it must be
parked in a frost-free and dry location and all measures to be taken before, during and
following decommissioning must be performed as detailed below.
M
M
During decommissioning, the fork lift truck must be jacked up, ensuring that the
wheels are clear of the ground. Only this measure will ensure that wheels and wheel
bearings do not suffer damage.
7.1
Thoroughly clean the fork lift truck.
Check the brakes for correct function.
Check the hydraulic oil level and top up if required (refer to chapter F).
Apply a thin film of oil or grease to all parts not protected by a paint coating.
Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
Recharge the battery (refer to chapter D).
Disconnect and clean the battery. Apply pole grease to the battery poles.
Z
In addition to this, all instructions given by the battery supplier must be observed.
7.2
Measures to be taken during decommissioning
During decommissioning, the fork lift truck must be jacked up, ensuring that the
wheels are clear of the ground. Only this measure will ensure that wheels and wheel
bearings do not suffer damage.
Operations to be performed prior to decommissioning
–
–
–
–
–
–
–
– Spray all exposed electrical contacts with a suitable contact spray.
Thoroughly clean the fork lift truck.
Check the brakes for correct function.
Check the hydraulic oil level and top up if required (refer to chapter F).
Apply a thin film of oil or grease to all parts not protected by a paint coating.
Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
Recharge the battery (refer to chapter D).
Disconnect and clean the battery. Apply pole grease to the battery poles.
Z
In addition to this, all instructions given by the battery supplier must be observed.
7.2
Measures to be taken during decommissioning
– Spray all exposed electrical contacts with a suitable contact spray.
Every 2 months:
Every 2 months:
– Recharge the battery (refer to chapter D).
– Recharge the battery (refer to chapter D).
M
Battery-operated fork lift trucks:
Regular recharging of the battery is very important; otherwise, exhaustive depletion
of the battery caused by self-discharging would occur. Owing to sulfatisation, this will
result in the destruction of the battery.
0708.GB
Battery-operated fork lift trucks:
Regular recharging of the battery is very important; otherwise, exhaustive depletion
of the battery caused by self-discharging would occur. Owing to sulfatisation, this will
result in the destruction of the battery.
0708.GB
M
Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.
Operations to be performed prior to decommissioning
–
–
–
–
–
–
–
Check the horn for proper functioning.
Check the master switch for correct functioning.
Check the brake for correct functioning.
Lubricate truck according to lubrication schedule.
If the fork lift truck is to be decommissioned for more than two months, it must be
parked in a frost-free and dry location and all measures to be taken before, during and
following decommissioning must be performed as detailed below.
If the fork lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.
7.1
Recommissioning the truck
F 15
F 15
7.3
Recommissioning the truck
7.3
– Thoroughly clean the fork lift truck.
– Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the
battery.
– Recharge the battery (refer to chapter D).
– Check if the gear oil contains condensed water and change if required.
– Check if the hydraulic oil contains condensed water and change if required.
– Start up the fork lift truck (refer to chapter E).
Z
Battery-operated fork lift trucks:
If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating
controls by repeated operation.
F
Perform several brake tests immediately after recommissioning the truck.
0708.GB
F
– Thoroughly clean the fork lift truck.
– Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the
battery.
– Recharge the battery (refer to chapter D).
– Check if the gear oil contains condensed water and change if required.
– Check if the hydraulic oil contains condensed water and change if required.
– Start up the fork lift truck (refer to chapter E).
F 16
Battery-operated fork lift trucks:
If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating
controls by repeated operation.
Perform several brake tests immediately after recommissioning the truck.
0708.GB
Z
Recommissioning the truck
F 16
8
Safety checks to be performed at regular intervals and following any unusual
incidents
8
Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich
recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks.
Z
Carry out a safety check in accordance with national regulations. Junheinrich
recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
The owner is responsible for ensuring that faults are immediately rectified.
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
9
Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
Z
Final, proper decommissioning or disposal of the truck must be performed in
accordance with the regulations of the country of application. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
0708.GB
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.
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Z
F 17
F 17
F 18
F 18
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Instructions for use
Instructions for use
Jungheinrich traction battery
Jungheinrich traction battery
Table of contents
Table of contents
1
1
Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB ..........................................2-6
with positive tubular plates type EPzS and EPzB ..........................................2-6
Type plate Jungheinrich traction battery............................................7
Type plate Jungheinrich traction battery............................................7
Instruction for use
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
Aquamatic/BFS III water refilling system ......................................................8-12
Jungheinrich traction battery
2
Jungheinrich traction battery
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS ............................................................................................13-17
Type plate Jungheinrich traction battery............................................17
Type plate Jungheinrich traction battery............................................17
0506.GB
Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS ............................................................................................13-17
0506.GB
2
Jungheinrich traction battery
1
1
Jungheinrich traction battery
1
with positive tubular plates type EPzS and EPzB
with positive tubular plates type EPzS and EPzB
Rating Data
Rating Data
1.
2.
3.
4.
Nominal capacity C5:
Nominal voltage:
Discharge current::
Nominal S.G. of electrolyte*
Type EPzS:
Type EPzB:
5. Rated temperature:
6. Nominal electrolyte level:
See type plate
2,0 V x No of cells
C5/5h
1.
2.
3.
4.
Nominal capacity C5:
Nominal voltage:
Discharge current::
Nominal S.G. of electrolyte*
Type EPzS:
Type EPzB:
5. Rated temperature:
6. Nominal electrolyte level:
1,29 kg/l
1,29 kg/l
30° C
up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
See type plate
2,0 V x No of cells
C5/5h
1,29 kg/l
1,29 kg/l
30° C
up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
0506.GB
2
Jungheinrich traction battery
0506.GB
1
2
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes
I and
II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
For batteries in classes
I and
II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
The specified torque loading for the polscrews of the charger cables and connectors
are:
steel
23 ± 1 Nm
M 10
steel
23 ± 1 Nm
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
3
0506.GB
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M 10
3
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Watch the temperature!
Watch the temperature!
2.4 Temperature
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
4
0506.GB
Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
0506.GB
Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
4
3.1 Daily
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and recorded.
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and recorded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
0506.GB
3. Maintenance
0506.GB
3. Maintenance
5
5
5. Storage
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery.
6. Malfunctions
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
6
0506.GB
We reserve the right make technical modification.
0506.GB
We reserve the right make technical modification.
6
7. Type plate, Jungheinrich traction battery
2/3
4
10
12
7
8
1
2
Typ
Type
6
5
11
13
Baujahr
Year of manufacture
Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
2/3
4
10
12
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
7
1
Pb
9
Item
1
2
3
4
5
6
7
7. Type plate, Jungheinrich traction battery
8
2
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
Item
1
2
3
4
5
6
7
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
1
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
14
Item
8
9
10
11
12
13
14
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
6
5
11
13
Baujahr
Year of manufacture
3
9
14
Item
8
9
10
11
12
13
14
1
Typ
Type
Serien-Nr.
Serial-Nr.
7
7
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
Aquamatic plug arrangement for the Operating Instructions
Cell series*
EPzS
EPzB
2/120 – 10/ 600
2/ 42 – 12/ 252
2/160 – 10/ 800
2/ 64 – 12/ 384
–
2/ 84 – 12/ 504
–
2/110 – 12/ 660
–
2/130 – 12/ 780
–
2/150 – 12/ 900
–
2/172 – 12/1032
–
2/200 – 12/1200
–
2/216 – 12/1296
2/180 – 10/900
–
2/210 – 10/1050
–
2/230 – 10/1150
–
2/250 – 10/1250
–
2/280 – 10/1400
–
2/310 – 10/1550
–
Aquamatic plug type (length)
Frötek (yellow)
BFS (black)
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
56,0 mm
56,0 mm
56,0 mm
56,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
72,0 mm
66,0 mm
72,0 mm
66,0 mm
Cell series*
EPzS
EPzB
2/120 – 10/ 600
2/ 42 – 12/ 252
2/160 – 10/ 800
2/ 64 – 12/ 384
–
2/ 84 – 12/ 504
–
2/110 – 12/ 660
–
2/130 – 12/ 780
–
2/150 – 12/ 900
–
2/172 – 12/1032
–
2/200 – 12/1200
–
2/216 – 12/1296
2/180 – 10/900
–
2/210 – 10/1050
–
2/230 – 10/1150
–
2/250 – 10/1250
–
2/280 – 10/1400
–
2/310 – 10/1550
–
Aquamatic plug BFS III with
diagnostics hole
Aquamatic plug with
diagnostics hole
length
stroke
length
stroke
length
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
stroke
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
length
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
stroke
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
0506.GB
Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty.
0506.GB
8
Aquamatic plug type (length)
Frötek (yellow)
BFS (black)
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
56,0 mm
56,0 mm
56,0 mm
56,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
72,0 mm
66,0 mm
72,0 mm
66,0 mm
8
Equipment for the
water refilling system
Equipment for the
water refilling system
1. Water tank
1. Water tank
2. Level switch
2. Level switch
3. Discharge point with ball
valve
3. Discharge point with ball
valve
4. Discharge point with solenoid valve
4. Discharge point with solenoid valve
5. Charger
6. Sealing coupler
6. Sealing coupler
7. Closing nipple
7. Closing nipple
8. Ion exchange cartridge with
conductance meter and
solenoid valve
8. Ion exchange cartridge with
conductance meter and
solenoid valve
9. Connection for untreated
water
9. Connection for untreated
water
10. Charging lead
10. Charging lead
1. Design
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
3. Function
3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
9
0506.GB
0506.GB
5. Charger
at least 3 m
Diagrammatic view
at least 3 m
Diagrammatic view
9
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of filling.
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of filling.
5.1 Falling water
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
7. Water quality
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
10
0506.GB
4. Filling (manual/automatic)
0506.GB
4. Filling (manual/automatic)
10
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made.
9. Operating temperature
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze).
9.1 Diagnostics hole
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
9.2 Float
Different floats are used depending on the cell design and type.
Different floats are used depending on the cell design and type.
9.3 Cleaning
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents.
10. Accessories
10. Accessories
10.1 Flow indicator
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542).
10.2 Plug lifter
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
0506.GB
8. Battery hose connections
0506.GB
8. Battery hose connections
11
11
10.2.1 Clamping ring tool
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D
BFS system none
- rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T
T
- permissible temperature range: 0° C to a maximum of 65° C
- permissible temperature range: 0° C to a maximum of 65° C
0506.GB
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
0506.GB
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
12
- rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
12
Jungheinrich traction batterie
2
Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Maintenance free Jungheinrich traction batterie with positive tubular plates
type EPzV and EPzV-BS
Rating Data
Rating Data
1. Nominal capacity C5:
See type plate
1. Nominal capacity C5:
See type plate
2. Nominal voltage:
2,0 Volt x No of cells
2. Nominal voltage:
2,0 Volt x No of cells
3. Discharge current:
C5/5h
3. Discharge current:
C5/5h
4. Rated temperature:
30° C
4. Rated temperature:
30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
When operating valve-regulated lead-acid batteries the same safety requirements as
for vented cells apply to protect against hazards from electric current, from explosion
of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte.
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire, avoid short circuits!
• Risk of explosion and fire, avoid short circuits!
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid)
is corrosive like the liquid electrolyte.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
0506.GB
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug
there are valves used, who will be destroyed when they are opened.
0506.GB
2
13
13
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning
1. Commissioning
The battery should be inspected to ensure it is in perfect physical condition.
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
The battery end cables must have a good contact to terminals, check that the polarity
is correct.
Otherwise battery, vehicle or charger could be destroyed.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors
are:
The specified torque loading for the pole screws of the end cables and connectors
are:
14
steel
23 ± 1 Nm
M 10
steel
23 ± 1 Nm
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
2.1 Discharging
Ventilation openings must not be sealed or covered.
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left discharged.
Discharged batteries must be recharged immediately and must not be left discharged.
This also applies to partially discharged batteries.
This also applies to partially discharged batteries.
2.2 Charging
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only
connect the battery assigned to a charger, suitable for the size of battery, in order to
avoid overloading of the electric cables and contacts and unacceptable gassing of the
cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or removed.
When charging, proper provision must be made for venting of the charging gases.
Battery container lids and the covers of battery compartments must be opened or removed.
0506.GB
2. Operation
14
0506.GB
M 10
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170
/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).
The attention pictograms has to be respected.
2.3 Equalising charge
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed chargers.
They are necessary after deep discharges and repeated incomplete recharges. For
the equalising charges has to be used only the battery manufacturer prescribed chargers.
Watch the temperature!
Watch the temperature!
2.4 Temperature
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating temperature.
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
3. Maintenance
Don’t refill water!
Don’t refill water!
3.1 Daily
3.1 Daily
Charge the battery immediately after every discharge.
Charge the battery immediately after every discharge.
0506.GB
With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
0506.GB
With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the battery rises by about 15° C, so charging should only
begin if the battery temperature is below 35° C. The battery temperature should be at
least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers
need a temperatures regulated voltage.
15
15
16
Visual inspection after recharging for signs of dirt and mechanical damage.
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
After the end of the charge and a rest time of 5 h following should be measured and
recorded:
• the voltages of the battery
• the voltages of the battery
• the voltages of every cells
• the voltages of every cells
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found, further testing and maintenance by the service department
should be requested.
3.4 Annually
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that
the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call our service department for this.
5. Storage
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room.
To ensure the battery is always ready for use a choice of charging methods can be
made:
To ensure the battery is always ready for use a choice of charging methods can be
made:
1. a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
1. a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary
every 14 days.
2. float charging at a charging voltage of 2.25 V x the number of cells.
2. float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the battery.
The storage time should be taken into account when considering the life of the battery.
16
0506.GB
3.2 Weekly
0506.GB
3.2 Weekly
6. Malfunctions
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
If malfunctions are found on the battery or the charger our service department should
be called without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
Batteries which are not returned for the recycling process must be
disposed of as hazardous waste!
We reserve the right make technical modification.
We reserve the right make technical modification.
7. Type plate, Jungheinrich traction battery
2/3
4
10
12
7
8
1
2
6
5
11
13
Baujahr
Year of manufacture
Typ
Type
Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
2/3
4
10
12
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
7
1
Pb
9
Item
1
2
3
4
5
6
7
7. Type plate, Jungheinrich traction battery
8
2
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
Item
1
2
3
4
5
6
7
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
1
Pb
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
14
Item
8
9
10
11
12
13
14
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
6
5
11
13
Baujahr
Year of manufacture
3
9
14
Item
8
9
10
11
12
13
14
1
Typ
Type
Serien-Nr.
Serial-Nr.
17
17
18
18
0506.GB
0506.GB
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