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 t t t t t t t t t t t 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! 0708.GB 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 0708.GB 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 0708.GB 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. 0708.GB Z F 17 F 17 F 18 F 18 0708.GB 0708.GB 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 0506.GB 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