Operating Instructions

52025067

EKS 310k/310

G

07.04 -

07.08

0108

.GB

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

M Used before notices which must be observed to avoid material damage.

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right toalter the design, equipment and technical features of the truck. No guarantee ofparticular features of the truck should therefore be inferred from the present operatinginstructions.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

M Used before notices which must be observed to avoid material damage.

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right toalter the design, equipment and technical features of the truck. No guarantee ofparticular features of the truck should therefore be inferred from the present operatinginstructions.

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

0108

.GB

I 1

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Table of contentsA Correct use and application of the truck

B Truck Description

1 Application ........................................................................................... B 12 Assemblies and Operational Description ............................................ B 22.1 Truck ................................................................................................... B 33 Standard Version Specifications ......................................................... B 43.1 Performance data ................................................................................ B 43.2 Dimensions (as per data plate) ........................................................... B 63.3 Mast version ........................................................................................ B 63.4 EN norms ............................................................................................ B 73.5 Conditions of use ................................................................................ B 74 Identification points and data plates .................................................... B 84.1 Truck data plate .................................................................................. B 104.2 Capacity .............................................................................................. B 10

C Transport and Commissioning

1 Transport ............................................................................................. C 12 Lifting by crane .................................................................................... C 12.1 Crane points ........................................................................................ C 32.2 Lifting the battery by crane .................................................................. C 32.3 Securing the Truck for Transport. ....................................................... C 32.4 Basic truck transport safety ................................................................. C 42.5 Mast transport safety ........................................................................... C 52.6 Mast assembled .................................................................................. C 53 Commissioning .................................................................................... C 73.1 Moving the truck without a battery ...................................................... C 73.2 Installing and Removing / Assembling and Folding the Mast .............. C 74 Commissioning .................................................................................... C 7

D Battery Maintenance, Charging & Replacement

1 Safety Regulations for handling acid batteries .................................... D 12 Battery types ....................................................................................... D 23 Charging the battery ............................................................................ D 24 Battery removal and installation .......................................................... D 35 Check the battery condition, the acid level and acid density ............... D 56 Battery discharge indicator .................................................................. D 5

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Table of contentsA Correct use and application of the truck

B Truck Description

1 Application ........................................................................................... B 12 Assemblies and Operational Description ............................................ B 22.1 Truck ................................................................................................... B 33 Standard Version Specifications ......................................................... B 43.1 Performance data ................................................................................ B 43.2 Dimensions (as per data plate) ........................................................... B 63.3 Mast version ........................................................................................ B 63.4 EN norms ............................................................................................ B 73.5 Conditions of use ................................................................................ B 74 Identification points and data plates .................................................... B 84.1 Truck data plate .................................................................................. B 104.2 Capacity .............................................................................................. B 10

C Transport and Commissioning

1 Transport ............................................................................................. C 12 Lifting by crane .................................................................................... C 12.1 Crane points ........................................................................................ C 32.2 Lifting the battery by crane .................................................................. C 32.3 Securing the Truck for Transport. ....................................................... C 32.4 Basic truck transport safety ................................................................. C 42.5 Mast transport safety ........................................................................... C 52.6 Mast assembled .................................................................................. C 53 Commissioning .................................................................................... C 73.1 Moving the truck without a battery ...................................................... C 73.2 Installing and Removing / Assembling and Folding the Mast .............. C 74 Commissioning .................................................................................... C 7

D Battery Maintenance, Charging & Replacement

1 Safety Regulations for handling acid batteries .................................... D 12 Battery types ....................................................................................... D 23 Charging the battery ............................................................................ D 24 Battery removal and installation .......................................................... D 35 Check the battery condition, the acid level and acid density ............... D 56 Battery discharge indicator .................................................................. D 5

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 12 Control Panel Layout Variants ............................................................ E 23 Operating and Display Equipment ...................................................... E 43.1 Operating and display equipment on control panel ............................. E 43.2 Display unit controls and displays ...................................................... E 53.3 Truck operational status symbols ........................................................ E 94 Starting up the truck ............................................................................ E 115 Lift truck operation ............................................................................... E 125.1 Safety regulations for truck operation ................................................. E 125.2 Travelling, Steering, Braking ............................................................... E 135.3 Lifting – Lowering – outside and inside the rack aisles ....................... E 185.4 Order picking and stacking .................................................................. E 195.5 Park the truck securely ........................................................................ E 216 Troubleshooting .................................................................................. E 226.1 Emergency stop device ....................................................................... E 246.2 Driver’s cab / Aux. Lift emergency lowering ........................................ E 246.3 Exiting the driver's cab with the emergency abseil device .................. E 256.4 Bypassing the chain slack safety device ............................................. E 266.5 Bypassing the travel cutout (o) .......................................................... E 266.6 Lift cutout (o) ...................................................................................... E 266.7 Aisle end safety device (o) ................................................................. E 276.8 WG emergency operation ................................................................... E 276.9 Recovering the truck from a narrow aisle / Moving the truck without

a battery .............................................................................................. E 29

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E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 12 Control Panel Layout Variants ............................................................ E 23 Operating and Display Equipment ...................................................... E 43.1 Operating and display equipment on control panel ............................. E 43.2 Display unit controls and displays ...................................................... E 53.3 Truck operational status symbols ........................................................ E 94 Starting up the truck ............................................................................ E 115 Lift truck operation ............................................................................... E 125.1 Safety regulations for truck operation ................................................. E 125.2 Travelling, Steering, Braking ............................................................... E 135.3 Lifting – Lowering – outside and inside the rack aisles ....................... E 185.4 Order picking and stacking .................................................................. E 195.5 Park the truck securely ........................................................................ E 216 Troubleshooting .................................................................................. E 226.1 Emergency stop device ....................................................................... E 246.2 Driver’s cab / Aux. Lift emergency lowering ........................................ E 246.3 Exiting the driver's cab with the emergency abseil device .................. E 256.4 Bypassing the chain slack safety device ............................................. E 266.5 Bypassing the travel cutout (o) .......................................................... E 266.6 Lift cutout (o) ...................................................................................... E 266.7 Aisle end safety device (o) ................................................................. E 276.8 WG emergency operation ................................................................... E 276.9 Recovering the truck from a narrow aisle / Moving the truck without

a battery .............................................................................................. E 29

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1 Operational safety and environmental protection ................................ F 12 Maintenance Safety Regulations ........................................................ F 13 Servicing and inspection ..................................................................... F 34 EKS 310 maintenance checklist .......................................................... F 44.1 Fuels, coolants and lubricants ............................................................. F 85 Maintenance and Repairs ................................................................... F 95.1 Preparing the truck for maintenance and repairs ................................ F 95.2 Securing the driver’s position carriage ................................................ F 105.3 Maintaining the lift chains .................................................................... F 105.4 Inspecting the lift chains ...................................................................... F 105.5 Cleaning the discharge filter ................................................................ F 115.6 Replacing the hydraulic oil filter .......................................................... F 115.7 Hydraulic oil ......................................................................................... F 125.8 Hydraulic hoses ................................................................................... F 135.9 Check brake fluid ................................................................................ F 135.10 Checking electrical fuses .................................................................... F 145.11 Recommissioning ................................................................................ F 156 Decommissioning the forklift truck ...................................................... F 156.1 Prior to decommissioning: ................................................................... F 156.2 During decommissioning: .................................................................... F 166.3 Recommissioning ................................................................................ F 167 Safety checks to be performed at regular intervals and following any

unusual incidents ................................................................................ F 178 Final de-commissioning, disposal ....................................................... F 17

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F Maintenance of the forklift truck

1 Operational safety and environmental protection ................................ F 12 Maintenance Safety Regulations ........................................................ F 13 Servicing and inspection ..................................................................... F 34 EKS 310 maintenance checklist .......................................................... F 44.1 Fuels, coolants and lubricants ............................................................. F 85 Maintenance and Repairs ................................................................... F 95.1 Preparing the truck for maintenance and repairs ................................ F 95.2 Securing the driver’s position carriage ................................................ F 105.3 Maintaining the lift chains .................................................................... F 105.4 Inspecting the lift chains ...................................................................... F 105.5 Cleaning the discharge filter ................................................................ F 115.6 Replacing the hydraulic oil filter .......................................................... F 115.7 Hydraulic oil ......................................................................................... F 125.8 Hydraulic hoses ................................................................................... F 135.9 Check brake fluid ................................................................................ F 135.10 Checking electrical fuses .................................................................... F 145.11 Recommissioning ................................................................................ F 156 Decommissioning the forklift truck ...................................................... F 156.1 Prior to decommissioning: ................................................................... F 156.2 During decommissioning: .................................................................... F 166.3 Recommissioning ................................................................................ F 167 Safety checks to be performed at regular intervals and following any

unusual incidents ................................................................................ F 178 Final de-commissioning, disposal ....................................................... F 17

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1

0506

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Appendix

JH Traction Battery Operating Instructions

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

1

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Appendix

JH Traction Battery Operating Instructions

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

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2

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2

A 1

0504

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A Correct use and application of the truck

Z The “Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) aresupplied with the truck. The guidelines form part of these operating instructions andmust be observed. National regulations apply in full.

The truck described in the present operator manual is an industrial truck designed forlifting and transporting load units.It must be used, operated and serviced in accordance with the present instructions.Any other type of use is beyond the scope of application and can result in damage topersonnel, the truck or property. In particular, avoid overloading the truck with loadswhich are too heavy or placed on one side. The data plate attached to the truck or theload diagram are binding for the maximum load capacity. The industrial truck mustnot be used in fire or explosion endangered areas or in places which can result incorrosion or produce dust.

Proprietor responsibilities: The “proprietor” within the meaning of this operatormanual is defined as any natural or legal person who either uses the industrial truckhimself, or on whose behalf it is used. In special cases (e.g. leasing or renting) theproprietor is considered the person who, in accordance with existing contractualagreements between the owner and user of the industrial truck, is charged withoperational duties.The proprietor must ensure that the truck is only used for the purpose it is designedfor and that all dangers to life and limb of the user and third parties are avoided.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The proprietor must ensure that alltruck users have read and understood this operator manual.

M Failure to comply with the operator manual shall invalidate the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer’s customer service department.

Mounting attachments: The mounting or installation of additional equipment whichaffects or supplements the performance of the industrial truck requires the writtenpermission of the manufacturer. In some cases, local authority approval shall berequired. Approval of the local authorities however does not constitute the manufacturer’sapproval.

A 1

0504

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A Correct use and application of the truck

Z The “Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) aresupplied with the truck. The guidelines form part of these operating instructions andmust be observed. National regulations apply in full.

The truck described in the present operator manual is an industrial truck designed forlifting and transporting load units.It must be used, operated and serviced in accordance with the present instructions.Any other type of use is beyond the scope of application and can result in damage topersonnel, the truck or property. In particular, avoid overloading the truck with loadswhich are too heavy or placed on one side. The data plate attached to the truck or theload diagram are binding for the maximum load capacity. The industrial truck mustnot be used in fire or explosion endangered areas or in places which can result incorrosion or produce dust.

Proprietor responsibilities: The “proprietor” within the meaning of this operatormanual is defined as any natural or legal person who either uses the industrial truckhimself, or on whose behalf it is used. In special cases (e.g. leasing or renting) theproprietor is considered the person who, in accordance with existing contractualagreements between the owner and user of the industrial truck, is charged withoperational duties.The proprietor must ensure that the truck is only used for the purpose it is designedfor and that all dangers to life and limb of the user and third parties are avoided.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The proprietor must ensure that alltruck users have read and understood this operator manual.

M Failure to comply with the operator manual shall invalidate the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer’s customer service department.

Mounting attachments: The mounting or installation of additional equipment whichaffects or supplements the performance of the industrial truck requires the writtenpermission of the manufacturer. In some cases, local authority approval shall berequired. Approval of the local authorities however does not constitute the manufacturer’sapproval.

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B Truck Description1 Application

The EKS 310 is an electric powered stockpicker. It is designed to be used on levelsurfaces in accordance with DIN 15185 to transport and pick goods. Open or crossboard pallets can be lifted outside the contour of the load wheels or trolley.

Loads can be stacked and unstacked and transported over long distances.

The driver's cab is raised together with the load lifting device to provide excellentvisibility and easy access to the rack levels.

The racks must be suitable for the EKS 310. The safety distances stipulated by themanufacturer (e. g. EN 1726-2 item 7.3.2) must be observed. The ground surfacemust comply with DIN 15185. Guide rails must be installed in the narrow aisles for therail guidance system.Vulkollan guide rollers attached to the truck chassis guide the truck between theguide rails. A guidance wire must be routed in the ground for the wire guidance system. Thesignals from the wire are received on the chassis and processed in the on-boardcomputer.

The capacity is shown on the data plate.

Travel direction definition

The following determinations have been made for travel direction specification.

Type Capacity Load centre of gravityEKS 310k 1000 kg 400 mmEKS 310 1000 kg 600 mm

Left

Right

Drive direction

Load direction

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B Truck Description1 Application

The EKS 310 is an electric powered stockpicker. It is designed to be used on levelsurfaces in accordance with DIN 15185 to transport and pick goods. Open or crossboard pallets can be lifted outside the contour of the load wheels or trolley.

Loads can be stacked and unstacked and transported over long distances.

The driver's cab is raised together with the load lifting device to provide excellentvisibility and easy access to the rack levels.

The racks must be suitable for the EKS 310. The safety distances stipulated by themanufacturer (e. g. EN 1726-2 item 7.3.2) must be observed. The ground surfacemust comply with DIN 15185. Guide rails must be installed in the narrow aisles for therail guidance system.Vulkollan guide rollers attached to the truck chassis guide the truck between theguide rails. A guidance wire must be routed in the ground for the wire guidance system. Thesignals from the wire are received on the chassis and processed in the on-boardcomputer.

The capacity is shown on the data plate.

Travel direction definition

The following determinations have been made for travel direction specification.

Type Capacity Load centre of gravityEKS 310k 1000 kg 400 mmEKS 310 1000 kg 600 mm

Left

Right

Drive direction

Load direction

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2 Assemblies and Operational Description

Pos. Bezeichnung1 t Mast2 t Aux. lift3 t Control panel4 t Battery5 t Chassis

t = Series Equipment o = Optional Equipment

3

2

1

45

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2 Assemblies and Operational Description

Pos. Bezeichnung1 t Mast2 t Aux. lift3 t Control panel4 t Battery5 t Chassis

t = Series Equipment o = Optional Equipment

3

2

1

45

B 3

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2.1 Truck

Safety devices: An enclosed truck contour with rounded edges ensures safe hand-ling of the truck. The overhead guard protects the driver from falling objects.The Emergency Disconnect switch immediately cuts out all truck movements in ha-zardous situations. Safety gates on either side of the cab interrupt all truck move-ments as soon as they are opened.Travelling and lifting/lowering can only be activated when the foot switch is pressed.

Drive: 4.4 kW (S2 60 min) vertically mounted, heavy duty threephase motor(asynchronous). The motor is directly attached to the single-wheel driving gear,ensuring rapid and trouble-free maintenance.

Brake system:

– The truck can be braked gently and without inducing wear by pushing back thetravel selection switch or steering in the opposite direction. This feeds energy intothe battery (operating brake).

– The electromagnetic spring pressure brake acting on the drive motor serves as aparking and handbrake.

Steering:

Especially smooth steering with threephase drive system. The practical steeringwheel is integrated within the control panel. With the mechanical rail guidance systemthe drive wheel is set to the straight-ahead position at the press of a button.Theposition of the steered drive wheel is shown in the display unit. The steering angle is+/- 90°, offering maximum manoeuvrability in narrow main aisles.

In wire guidance systems, steering is automatically managed by the truck controller,manual steering is not available.

Controls and display units: The functions are activated via ergonomic thumb mo-vements to ensure fatigue-free operation without straining the wrists; sensitive appli-cation of travel and hydraulic movements to spare and position the goods exactly. The display unit is used to display all the important driver information such as steeringwheel position, overall lift, truck status reports (e. g. faults), service hours, battery ca-pacity, time and wire guidance status etc..

Hydraulic system:

All hydraulic movements are controlled by a maintenance-free 9.5 kW threephasemotor with a flanged low emission gear pump. Oil is distributed via magnetic switchvalves. The varying oil requirements are controlled by the speed of the motor. Whenthe truck performs a lowering operation, the hydraulic pump drives the motor whichthen acts as a generator (regenerative lowering). The energy produced is then fedback to the battery.

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2.1 Truck

Safety devices: An enclosed truck contour with rounded edges ensures safe hand-ling of the truck. The overhead guard protects the driver from falling objects.The Emergency Disconnect switch immediately cuts out all truck movements in ha-zardous situations. Safety gates on either side of the cab interrupt all truck move-ments as soon as they are opened.Travelling and lifting/lowering can only be activated when the foot switch is pressed.

Drive: 4.4 kW (S2 60 min) vertically mounted, heavy duty threephase motor(asynchronous). The motor is directly attached to the single-wheel driving gear,ensuring rapid and trouble-free maintenance.

Brake system:

– The truck can be braked gently and without inducing wear by pushing back thetravel selection switch or steering in the opposite direction. This feeds energy intothe battery (operating brake).

– The electromagnetic spring pressure brake acting on the drive motor serves as aparking and handbrake.

Steering:

Especially smooth steering with threephase drive system. The practical steeringwheel is integrated within the control panel. With the mechanical rail guidance systemthe drive wheel is set to the straight-ahead position at the press of a button.Theposition of the steered drive wheel is shown in the display unit. The steering angle is+/- 90°, offering maximum manoeuvrability in narrow main aisles.

In wire guidance systems, steering is automatically managed by the truck controller,manual steering is not available.

Controls and display units: The functions are activated via ergonomic thumb mo-vements to ensure fatigue-free operation without straining the wrists; sensitive appli-cation of travel and hydraulic movements to spare and position the goods exactly. The display unit is used to display all the important driver information such as steeringwheel position, overall lift, truck status reports (e. g. faults), service hours, battery ca-pacity, time and wire guidance status etc..

Hydraulic system:

All hydraulic movements are controlled by a maintenance-free 9.5 kW threephasemotor with a flanged low emission gear pump. Oil is distributed via magnetic switchvalves. The varying oil requirements are controlled by the speed of the motor. Whenthe truck performs a lowering operation, the hydraulic pump drives the motor whichthen acts as a generator (regenerative lowering). The energy produced is then fedback to the battery.

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Electrical System:

Service laptop connection interface:

– Configures all key truck data (lift limit damping, lift cutout, retardation andacceleration patterns, cut-outs, etc.) rapidly and reliably.

– Reads off the error log to analyse fault causes.– Simulates and analyses program operations.– Simple function extention by releasing code numbers.

The controller is fitted with a CAN Bus and a constantly measuring sensor system.

The controller provide smooth starting and braking of the load in all limit positionsthrough lift limit and intermediate dampers.

Highly efficient threephase technology with energy retention for the traction and liftmotors provides high travel and lift speeds and better use of energy.

The 48 volt MOSFET threephase controller provides a smooth start to eachmovement.

For drive battery options see chapter D.

3 Standard Version Specifications

Z Technical data specified in accordance with VDI 2198.Technical modifications and additions reserved.

3.1 Performance data

Description EKS 310k EKS 310Q Capacity (where C = 600 mm) 1000 1000 kgc Load centre of gravity distance 400 600 mm

Travel speed without load (RG) 9 10,5 km/hTravel speed with load (RG) 8,8 10,0 km/hTravel speed without load (IG) 7,0 9,0 km/hTravel speed with load (IG) 6,8 8,8 km/hLift speed without load 0,22 0,37 m/sLift speed with load 0,18 0,32 m/sLowering speed with load 0,32 0,37 m/sLowering speed without load 0,3 0,34 m/s

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Electrical System:

Service laptop connection interface:

– Configures all key truck data (lift limit damping, lift cutout, retardation andacceleration patterns, cut-outs, etc.) rapidly and reliably.

– Reads off the error log to analyse fault causes.– Simulates and analyses program operations.– Simple function extention by releasing code numbers.

The controller is fitted with a CAN Bus and a constantly measuring sensor system.

The controller provide smooth starting and braking of the load in all limit positionsthrough lift limit and intermediate dampers.

Highly efficient threephase technology with energy retention for the traction and liftmotors provides high travel and lift speeds and better use of energy.

The 48 volt MOSFET threephase controller provides a smooth start to eachmovement.

For drive battery options see chapter D.

3 Standard Version Specifications

Z Technical data specified in accordance with VDI 2198.Technical modifications and additions reserved.

3.1 Performance data

Description EKS 310k EKS 310Q Capacity (where C = 600 mm) 1000 1000 kgc Load centre of gravity distance 400 600 mm

Travel speed without load (RG) 9 10,5 km/hTravel speed with load (RG) 8,8 10,0 km/hTravel speed without load (IG) 7,0 9,0 km/hTravel speed with load (IG) 6,8 8,8 km/hLift speed without load 0,22 0,37 m/sLift speed with load 0,18 0,32 m/sLowering speed with load 0,32 0,37 m/sLowering speed without load 0,3 0,34 m/s

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3.2 Dimensions (as per data plate)

3.3 Mast version

Description EKS 310k EKS 310h1 Mast height retracted 3005 3830 mmh3 Lift 4250 5500 mmh4 Mast height extended 6550 7820 mmh7 Seat height / standing height 290 290 mmh9 Aux. lift 840 840 mmh10 Overall lift 5090 6340 mmh15 Stockpicking height 6140 7390 mmAst Working aisle width for pallets

1000 x 1200 traverse1400 1400 mm

b2 Overall width 1015 1100 mmb5 Width across forks (PAL width

1200)830 830 mm

b6 Width across guide rollers 1200 1200 mml1 Overall length w.o. load (PAL

width 1200)2667 2870 mm

l2 Length incl. fork back (PAL width 1200)

1867 1970 mm

l Fork length 800 800 mmWa Turning radius 1530 1723 mmm2 Ground clearance centre

wheelbase67 67 mm

Net weight incl. battery, w.o. load 2800 3500 kg

Description EKS 310k EKS 310h1 Retracted height (ZT) 2380 - 3005 2380 - 5530 mmh3 Lift 3000 - 4250 3000 - 8500 mmh4 Extended height 5300 - 6550 5300 - 10800 mmh6 Height above overhead

guard2300 2300 mm

h9 Aux. lift 840 840 mmh10 Overall lift height 3840 - 5090 3840 - 9340 mmh15 Stockpicking height 4890 - 6140 4890 - 10390 mm

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3.2 Dimensions (as per data plate)

3.3 Mast version

Description EKS 310k EKS 310h1 Mast height retracted 3005 3830 mmh3 Lift 4250 5500 mmh4 Mast height extended 6550 7820 mmh7 Seat height / standing height 290 290 mmh9 Aux. lift 840 840 mmh10 Overall lift 5090 6340 mmh15 Stockpicking height 6140 7390 mmAst Working aisle width for pallets

1000 x 1200 traverse1400 1400 mm

b2 Overall width 1015 1100 mmb5 Width across forks (PAL width

1200)830 830 mm

b6 Width across guide rollers 1200 1200 mml1 Overall length w.o. load (PAL

width 1200)2667 2870 mm

l2 Length incl. fork back (PAL width 1200)

1867 1970 mm

l Fork length 800 800 mmWa Turning radius 1530 1723 mmm2 Ground clearance centre

wheelbase67 67 mm

Net weight incl. battery, w.o. load 2800 3500 kg

Description EKS 310k EKS 310h1 Retracted height (ZT) 2380 - 3005 2380 - 5530 mmh3 Lift 3000 - 4250 3000 - 8500 mmh4 Extended height 5300 - 6550 5300 - 10800 mmh6 Height above overhead

guard2300 2300 mm

h9 Aux. lift 840 840 mmh10 Overall lift height 3840 - 5090 3840 - 9340 mmh15 Stockpicking height 4890 - 6140 4890 - 10390 mm

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3.4 EN norms

Noise emission: 65 dB(A)

in accordance with EN 12053 as harmonised withISO 4871.

Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the driver’s ear.

Vibration: 1,11 m/s2 in accordance with EN 13059

Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weighted accelerationin the vertical direction. It is calculated during travel over bumps at constant speed.

Electromagnetic compatibility (EMC)

The manufacturer confirms that equipment complies withtolerance levels for electromagnetic emissions andresistance as well as static electricity discharge testing inaccordance with EN 12895 including the normativeprocedures contained therein.

Z No changes to electrical or electronic components or their assembly may be madewithout the written agreement of the manufacturer.

3.5 Conditions of use

Ambient temperature- operating at 5°C to 40 °C

Z Special equipment and a special approval are required if fork-lifttrucks are operatedunder continued extreme temperature or humidity fluctuations.

The truck is not authorised for use in cold stores.

The truck may only be used in closed areas. The following applies:

– Average ambient temperature over 24 hours: max. 25 °C– max. air humidity (inside) 70%, non-condensing.

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3.4 EN norms

Noise emission: 65 dB(A)

in accordance with EN 12053 as harmonised withISO 4871.

Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the driver’s ear.

Vibration: 1,11 m/s2 in accordance with EN 13059

Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weighted accelerationin the vertical direction. It is calculated during travel over bumps at constant speed.

Electromagnetic compatibility (EMC)

The manufacturer confirms that equipment complies withtolerance levels for electromagnetic emissions andresistance as well as static electricity discharge testing inaccordance with EN 12895 including the normativeprocedures contained therein.

Z No changes to electrical or electronic components or their assembly may be madewithout the written agreement of the manufacturer.

3.5 Conditions of use

Ambient temperature- operating at 5°C to 40 °C

Z Special equipment and a special approval are required if fork-lifttrucks are operatedunder continued extreme temperature or humidity fluctuations.

The truck is not authorised for use in cold stores.

The truck may only be used in closed areas. The following applies:

– Average ambient temperature over 24 hours: max. 25 °C– max. air humidity (inside) 70%, non-condensing.

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4 Identification points and data plates

F Warning and information labels, such as capacity diagrams, attachment points andidentification plates, must be readable at all times or be replaced, if necessary.

Item Description6 Strapping points for lifting by crane7 Truck data plate8 Decal: Capacity9 Decal: “Abseil device”

10a "Do not lean out" notice10b Decal: “No passengers”11 Test sticker (o)

6

17

mV1,5 V

15

16

13a

14

10a8

718

D (mm)

h3 (mm) Q (kg)

13a 13b

9

9

10b

12

11

0708

.GB

B 8

4 Identification points and data plates

F Warning and information labels, such as capacity diagrams, attachment points andidentification plates, must be readable at all times or be replaced, if necessary.

Item Description6 Strapping points for lifting by crane7 Truck data plate8 Decal: Capacity9 Decal: “Abseil device”

10a "Do not lean out" notice10b Decal: “No passengers”11 Test sticker (o)

6

17

mV1,5 V

15

16

13a

14

10a8

718

D (mm)

h3 (mm) Q (kg)

13a 13b

9

9

10b

12

11

B 9

0708

.GB

Item Description12 Decal: Do not step onto or beneath the load, risk of trapping13a Jack contact point13b Serial number (engraved in chassis underneath the battery cover)14 Decal: Add hydraulic oil15 Decal: Emergency drain16 Decal: Emergency drain key17 Decal: “Caution: Low voltage electronics system"18 “Read Operating Instructions” label

6

17

mV1,5 V

15

16

13a

14

10a8

718

D (mm)

h3 (mm) Q (kg)

13a 13b

9

9

10b

12

11

B 9

0708

.GB

Item Description12 Decal: Do not step onto or beneath the load, risk of trapping13a Jack contact point13b Serial number (engraved in chassis underneath the battery cover)14 Decal: Add hydraulic oil15 Decal: Emergency drain16 Decal: Emergency drain key17 Decal: “Caution: Low voltage electronics system"18 “Read Operating Instructions” label

6

17

mV1,5 V

15

16

13a

14

10a8

718

D (mm)

h3 (mm) Q (kg)

13a 13b

9

9

10b

12

11

0708

.GB

B 10

4.1 Truck data plate

For queries regarding the truck or spare part orders, please quote the serial number(20).

4.2 Capacity

The plate (8) gives the capacity (Q in kg) of the truck as a function of the load centreof gravity distance (D in mm) and lift height (H in mm) in tabular form.

Item Description Item Description19 Type 25 Manufacturer20 Serial no. 26 Min./Max. battery weight (kg)21 Rated capacity (kg) 27 Drive output (kw)22 Battery voltage (V) 28 Load centre of gravity (mm)23 Net weight w.o. battery (kg) 29 Year of manufacture24 Manufacturer’s logo 30 Option

25

24

2623

2722

2821

2920

3019

8

D (mm)

h3 (mm) Q (kg)

0708

.GB

B 10

4.1 Truck data plate

For queries regarding the truck or spare part orders, please quote the serial number(20).

4.2 Capacity

The plate (8) gives the capacity (Q in kg) of the truck as a function of the load centreof gravity distance (D in mm) and lift height (H in mm) in tabular form.

Item Description Item Description19 Type 25 Manufacturer20 Serial no. 26 Min./Max. battery weight (kg)21 Rated capacity (kg) 27 Drive output (kw)22 Battery voltage (V) 28 Load centre of gravity (mm)23 Net weight w.o. battery (kg) 29 Year of manufacture24 Manufacturer’s logo 30 Option

25

24

2623

2722

2821

2920

3019

8

D (mm)

h3 (mm) Q (kg)

C 1

0504

.GB

C Transport and Commissioning1 Transport

The truck can be transported in three different ways, depending on the height of themast and the local conditions.

– Vertically, with mast and load lifting device assembled (for low heights)– Vertically, with mast and load lifting device disassembled (for large heights)– Standing, with collapsed mast.

M Only personnel trained by the manufacturer may assemble the truck on site,commission it and instruct the driver.

2 Lifting by crane

M Only use lifting gear with sufficient capacity (for truck weight see truck data plate. SeeChapter B).

M The truck must only be lifted by crane with the battery removed.

Park the truck securely(See Chapter E).

Crane loading with mast assembled

Attach the crane slings to the strap points (1,2) so that it cannot slip under anycircumstances!

1

2

C 1

0504

.GB

C Transport and Commissioning1 Transport

The truck can be transported in three different ways, depending on the height of themast and the local conditions.

– Vertically, with mast and load lifting device assembled (for low heights)– Vertically, with mast and load lifting device disassembled (for large heights)– Standing, with collapsed mast.

M Only personnel trained by the manufacturer may assemble the truck on site,commission it and instruct the driver.

2 Lifting by crane

M Only use lifting gear with sufficient capacity (for truck weight see truck data plate. SeeChapter B).

M The truck must only be lifted by crane with the battery removed.

Park the truck securely(See Chapter E).

Crane loading with mast assembled

Attach the crane slings to the strap points (1,2) so that it cannot slip under anycircumstances!

1

2

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.GB

C 2

Crane loading with collapsed mast

– When the mast is collapsed the cranelifting gear must be attached to the topand bottom mast cross members.

– If the truck is attached to the crane withthe mast collapsed, the transport partsmust be attached to it.

M Attach the crane slings to the strap points(1) so that it cannot slip under anycircumstances.

Crane loading with mast disassembled

– When the mast is disassembled, attachthe crane slings to either side of theframe (2) and the top mast bearing (3).

M Attach the crane slings to the strap points (2, 3) so that it cannot slip under any cir-cumstances.

11

3

2

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.GB

C 2

Crane loading with collapsed mast

– When the mast is collapsed the cranelifting gear must be attached to the topand bottom mast cross members.

– If the truck is attached to the crane withthe mast collapsed, the transport partsmust be attached to it.

M Attach the crane slings to the strap points(1) so that it cannot slip under anycircumstances.

Crane loading with mast disassembled

– When the mast is disassembled, attachthe crane slings to either side of theframe (2) and the top mast bearing (3).

M Attach the crane slings to the strap points (2, 3) so that it cannot slip under any cir-cumstances.

11

3

2

C 3

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.GB

2.1 Crane points

The crane points (1) are the eyes in the mast.

Crane points (2) are located on either side of the frame and crane points (3) arelocated on the top mast bearing respectively. Suitable ring screws must be screwedin at this point.

When lifting by crane, use the following crane points:

– Crane points for complete truck with mast assembled:points (1) and (2) (for weight see data plate)

– Crane points for the basic truck:points (2) and (3) (weight 1200 kg)

– Crane points incl. cab and load lifting device:points (1) (weight 3000 kg)

2.2 Lifting the battery by crane

When lifting the battery with a crane attach suitable lifting gear to the four eyes of thebattery container (for weight see battery data plate).

For battery removal see Chapter D, Section 4.

2.3 Securing the Truck for Transport.

F When transported on a lorry or a trailer the truck must be securely fastened down.The lorry or trailer must have fastening rings.

M Loading shall be carried out by staff especially trained for that purpose in accordancewith recommendations contained in Guidelines VDI 2700 and VDI 2703. In each casecorrect measurements shall be determined and appropriate safety measuresadopted.

C 3

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2.1 Crane points

The crane points (1) are the eyes in the mast.

Crane points (2) are located on either side of the frame and crane points (3) arelocated on the top mast bearing respectively. Suitable ring screws must be screwedin at this point.

When lifting by crane, use the following crane points:

– Crane points for complete truck with mast assembled:points (1) and (2) (for weight see data plate)

– Crane points for the basic truck:points (2) and (3) (weight 1200 kg)

– Crane points incl. cab and load lifting device:points (1) (weight 3000 kg)

2.2 Lifting the battery by crane

When lifting the battery with a crane attach suitable lifting gear to the four eyes of thebattery container (for weight see battery data plate).

For battery removal see Chapter D, Section 4.

2.3 Securing the Truck for Transport.

F When transported on a lorry or a trailer the truck must be securely fastened down.The lorry or trailer must have fastening rings.

M Loading shall be carried out by staff especially trained for that purpose in accordancewith recommendations contained in Guidelines VDI 2700 and VDI 2703. In each casecorrect measurements shall be determined and appropriate safety measuresadopted.

0504

.GB

C 4

2.4 Basic truck transport safety

M The mast must only be disassembled by the manufacturer’s authorised servicedepartment.

To ensure secure transport of a disassembled EKS 310 use the prescribedattachment points for fastening/quick release belts.

Z Only use belts with a rated capacity of >5 tonnes.

M During transport always discharge the drive wheel and secure the load wheels (5).

M If the truck battery is supplied in the chassis, disconnect the battery.

Fastening belts should be attached to at least 4 different lorry eyes (6).

Belts placed over “sharp” edges must be protected by a suitable support material,e. g. foam.

The top holes of the counterweight attachment (10) can be used as attachment pointsfor the rear end of the truck chassis.

The tensioning belts are tightened over the battery compartment. To do this, removethe side parts and pack them separately.

M Note the cable routing and cover sharp edges with a suitable material.

The tensioning belt above the upper chassis section is routed behind the two mastattachment bars (4).

4

665 5

0504

.GB

C 4

2.4 Basic truck transport safety

M The mast must only be disassembled by the manufacturer’s authorised servicedepartment.

To ensure secure transport of a disassembled EKS 310 use the prescribedattachment points for fastening/quick release belts.

Z Only use belts with a rated capacity of >5 tonnes.

M During transport always discharge the drive wheel and secure the load wheels (5).

M If the truck battery is supplied in the chassis, disconnect the battery.

Fastening belts should be attached to at least 4 different lorry eyes (6).

Belts placed over “sharp” edges must be protected by a suitable support material,e. g. foam.

The top holes of the counterweight attachment (10) can be used as attachment pointsfor the rear end of the truck chassis.

The tensioning belts are tightened over the battery compartment. To do this, removethe side parts and pack them separately.

M Note the cable routing and cover sharp edges with a suitable material.

The tensioning belt above the upper chassis section is routed behind the two mastattachment bars (4).

4

665 5

C 5

0504

.GB

2.5 Mast transport safety

M Secure the driver’s position carriage (13) to prevent it from slipping.

If the mast is stored on a pallet(s), fasten them securely to the mast (11).

Use the lower attachment bracket (10) as the "mast bottom" strap point for securingto the lorry eyes (12).

Route the belt over the lift cylinder/chains to act as the "mast top” strap point.

M Protect the belt placed over the lift chains with a suitable material (8).

Any supplied parts (forks (9), guide rollers etc.) can be attached to a pallet, which canthen be fastened to the mast.

2.6 Mast assembled

Safely transporting the truck with the mast assembled

M If the truck battery is supplied in thechassis, disconnect the

Z Only use belts with a rated capacityof >5 to.

At least 4 belts, 2 on the left and 2 onthe right (14,15) must be attached tothe mast.

C 5

0504

.GB

2.5 Mast transport safety

M Secure the driver’s position carriage (13) to prevent it from slipping.

If the mast is stored on a pallet(s), fasten them securely to the mast (11).

Use the lower attachment bracket (10) as the "mast bottom" strap point for securingto the lorry eyes (12).

Route the belt over the lift cylinder/chains to act as the "mast top” strap point.

M Protect the belt placed over the lift chains with a suitable material (8).

Any supplied parts (forks (9), guide rollers etc.) can be attached to a pallet, which canthen be fastened to the mast.

2.6 Mast assembled

Safely transporting the truck with the mast assembled

M If the truck battery is supplied in thechassis, disconnect the

Z Only use belts with a rated capacityof >5 to.

At least 4 belts, 2 on the left and 2 onthe right (14,15) must be attached tothe mast.

0504

.GB

C 6

Safely transporting the truck withthe mast collapsed!

Z Only use belts with a rated capacityof >5 tonnes.

The fastening belts should beattached to at least 4 different lorry /truck eyes (16).

F Warning: Risking of tipping throughhigh centre of gravity

The tensioning belts are tightenedover the battery compartment. To dothis, remove the side parts and packthem separately.

Z Use wooden beams (17) to ensure a positive fit from the load wheels to the front endof the transporter.

Z Place the whole surface of a wooden beam (18) underneath the counterweight, atleast the chassis width to relieve the drive wheel.

1817

1616

0504

.GB

C 6

Safely transporting the truck withthe mast collapsed!

Z Only use belts with a rated capacityof >5 tonnes.

The fastening belts should beattached to at least 4 different lorry /truck eyes (16).

F Warning: Risking of tipping throughhigh centre of gravity

The tensioning belts are tightenedover the battery compartment. To dothis, remove the side parts and packthem separately.

Z Use wooden beams (17) to ensure a positive fit from the load wheels to the front endof the transporter.

Z Place the whole surface of a wooden beam (18) underneath the counterweight, atleast the chassis width to relieve the drive wheel.

1817

1616

C 7

0504

.GB

3 Commissioning

3.1 Moving the truck without a battery

M This operation must only be performed by suitably trained maintenance personnel.

M This operation is forbidden on slopes and inclines (no brakes).

See also Chapter E, Section 6.9

3.2 Installing and Removing / Assembling and Folding the Mast

M This operation must only be performed by the manufacturer or a customer serviceteam authorised by the manufacturer.

4 Commissioning

M Operate the truck only with battery current. Rectified AC current will damage theelectronic components. The battery leads (tow cable) must be less than 6m in length.

To prepare the truck after delivery or after transport, proceed as follows:

– If necessary, install and charge the battery (see Chapter D, Sections 4 and 3).– Commission the truck as per instructions (See Chapter E, Section 4).

M Before commissioning, check the truckto ensure the tilt safety device (19) ispresent.Check that all safety devices arepresent and operational.

19

C 7

0504

.GB

3 Commissioning

3.1 Moving the truck without a battery

M This operation must only be performed by suitably trained maintenance personnel.

M This operation is forbidden on slopes and inclines (no brakes).

See also Chapter E, Section 6.9

3.2 Installing and Removing / Assembling and Folding the Mast

M This operation must only be performed by the manufacturer or a customer serviceteam authorised by the manufacturer.

4 Commissioning

M Operate the truck only with battery current. Rectified AC current will damage theelectronic components. The battery leads (tow cable) must be less than 6m in length.

To prepare the truck after delivery or after transport, proceed as follows:

– If necessary, install and charge the battery (see Chapter D, Sections 4 and 3).– Commission the truck as per instructions (See Chapter E, Section 4).

M Before commissioning, check the truckto ensure the tilt safety device (19) ispresent.Check that all safety devices arepresent and operational.

19

0504

.GB

C 8

0504

.GB

C 8

D 1

0504

.GB

D Battery Maintenance, Charging &Replacement

1 Safety Regulations for handling acid batteries

Before any work is carried out on the batteries the truck must be safely parked (seeChapter E).

Maintenance personnel: Batteries may only be charged, serviced or replaced bytrained personnel. Observe the operator manual and the manufacturer’s regulationsconcerning batteries and charging stations when carrying out this work.

Fire protection: Do not smoke and avoid naked flames when working with batteriesWherever a truck is parked for charging there must be no inflammable material orconsumables capable of creatings sparks within 2 metres around the truck. The areamust be well ventilated. Fire protection equipment must be provided.

Battery maintenance: The battery cell covers must be kept dry and clean. Theterminals and cable shoes must be clean, secure and have a light coating of dielectricgrease. Batteries with non insulated terminals must be covered with a non slipinsulation mat.

Battery Disposal: Batteries may only be disposed of in accordance with nationalEnvironmental Protection Regulations or Disposal Laws. The manufacturer’sdisposal instructions must be followed.

M Before closing the battery cover make sure that the battery lead cannot be damaged.

F Batteries contain an acid solution which is poisonous and corrosive Therefore, alwayswear protective clothing and eye protection when carrying out work on batteries.Above all avoid all contact with battery acid.Nevertheless, should clothing, skin or eyes come in contact with acid the affectedparts should be rinsed with plenty of clean water - if the skin or eyes are affected calla doctor immediately. Immediately neutralise any spilled battery acid.

M Only batteries with a sealed battery container may be used.

F The weight and dimensions of the battery have a considerable influence on theoperational safety of the truck. Battery equipment changes may only be made withthe agreement of the manufacturer.

D 1

0504

.GB

D Battery Maintenance, Charging &Replacement

1 Safety Regulations for handling acid batteries

Before any work is carried out on the batteries the truck must be safely parked (seeChapter E).

Maintenance personnel: Batteries may only be charged, serviced or replaced bytrained personnel. Observe the operator manual and the manufacturer’s regulationsconcerning batteries and charging stations when carrying out this work.

Fire protection: Do not smoke and avoid naked flames when working with batteriesWherever a truck is parked for charging there must be no inflammable material orconsumables capable of creatings sparks within 2 metres around the truck. The areamust be well ventilated. Fire protection equipment must be provided.

Battery maintenance: The battery cell covers must be kept dry and clean. Theterminals and cable shoes must be clean, secure and have a light coating of dielectricgrease. Batteries with non insulated terminals must be covered with a non slipinsulation mat.

Battery Disposal: Batteries may only be disposed of in accordance with nationalEnvironmental Protection Regulations or Disposal Laws. The manufacturer’sdisposal instructions must be followed.

M Before closing the battery cover make sure that the battery lead cannot be damaged.

F Batteries contain an acid solution which is poisonous and corrosive Therefore, alwayswear protective clothing and eye protection when carrying out work on batteries.Above all avoid all contact with battery acid.Nevertheless, should clothing, skin or eyes come in contact with acid the affectedparts should be rinsed with plenty of clean water - if the skin or eyes are affected calla doctor immediately. Immediately neutralise any spilled battery acid.

M Only batteries with a sealed battery container may be used.

F The weight and dimensions of the battery have a considerable influence on theoperational safety of the truck. Battery equipment changes may only be made withthe agreement of the manufacturer.

0504

.GB

D 2

2 Battery types

The EKS 310 can be fitted with a range of battery types. All the batteries correspondto DIN 43531-A. The following table indicates the capacities to show whichcombinations can be used as standard:

The battery weights can be taken from the battery data plate.

F The weight and dimensions of the battery have a considerable influence on theoperational safety of the truck. Battery equipment changes may only be made withthe agreement of the manufacturer.

3 Charging the battery

F Park the truck securely (See Chapter E).

– Turn the key switch to "0" (Zero) and press the EMERGENCY DISCONNECTswitch.

– Fully open the battery panels.

F Only connect and disconnect the battery connector and the socket when the mainsand charger are switched off.

– Disconnect the battery.– If necessary, remove the insulating mat from the battery.

F When charging, the top surfaces of the battery cells must be exposed to providesufficient ventilation. Do not place any metal objects on the battery. Before charging,check all cables and plug connections for visible signs of damage.

– Connect the charger lead of the battery charger station with the battery connector.– Switch on the charger.– Charge the battery in accordance with the battery and charger station

manufacturers’ instructions.

F It is essential to follow the safety regulations of the battery and charger stationmanufacturers.

Battery type Truck type48 V 3 E PzS 420 EKS 310k48 V 4 E PzS 560 EKS 310

0504

.GB

D 2

2 Battery types

The EKS 310 can be fitted with a range of battery types. All the batteries correspondto DIN 43531-A. The following table indicates the capacities to show whichcombinations can be used as standard:

The battery weights can be taken from the battery data plate.

F The weight and dimensions of the battery have a considerable influence on theoperational safety of the truck. Battery equipment changes may only be made withthe agreement of the manufacturer.

3 Charging the battery

F Park the truck securely (See Chapter E).

– Turn the key switch to "0" (Zero) and press the EMERGENCY DISCONNECTswitch.

– Fully open the battery panels.

F Only connect and disconnect the battery connector and the socket when the mainsand charger are switched off.

– Disconnect the battery.– If necessary, remove the insulating mat from the battery.

F When charging, the top surfaces of the battery cells must be exposed to providesufficient ventilation. Do not place any metal objects on the battery. Before charging,check all cables and plug connections for visible signs of damage.

– Connect the charger lead of the battery charger station with the battery connector.– Switch on the charger.– Charge the battery in accordance with the battery and charger station

manufacturers’ instructions.

F It is essential to follow the safety regulations of the battery and charger stationmanufacturers.

Battery type Truck type48 V 3 E PzS 420 EKS 310k48 V 4 E PzS 560 EKS 310

D 3

0504

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4 Battery removal and installation

F Only batteries with insulated cells and terminal connectors may be used. Whenreplacing the battery always use the same battery type. Extra weights must not beremoved and must remain in the same position.

F The truck must be horizontral to prevent the battery from falling out when the batteryretainer is removed.

F Only connect and disconnect the battery connector and the socket when the mainsand charger are switched off.

F When replacing/installing the battery make sure the battery is securely located in thebattery compartment of the truck.

– Turn the key switch (1) to "0" (Zero) and press the EMERGENCY DISCONNECTswitch (2).

– Open the battery covers (4).– Disconnect the battery (4).– Remove the battery covers (3).

D 3

0504

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4 Battery removal and installation

F Only batteries with insulated cells and terminal connectors may be used. Whenreplacing the battery always use the same battery type. Extra weights must not beremoved and must remain in the same position.

F The truck must be horizontral to prevent the battery from falling out when the batteryretainer is removed.

F Only connect and disconnect the battery connector and the socket when the mainsand charger are switched off.

F When replacing/installing the battery make sure the battery is securely located in thebattery compartment of the truck.

– Turn the key switch (1) to "0" (Zero) and press the EMERGENCY DISCONNECTswitch (2).

– Open the battery covers (4).– Disconnect the battery (4).– Remove the battery covers (3).

0504

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D 4

– Undo and remove the battery retainers (5;7).– Pull the battery (6) onto the side of the prepared battery transporter.

Assembly is the reverse order.

F After installing again, check all cables and connectors for signs of visible damage andbefore using the truck again check that:

– the battery retainers are inserted and secured,– the battery cover is properly closed.

6

5

7

0504

.GB

D 4

– Undo and remove the battery retainers (5;7).– Pull the battery (6) onto the side of the prepared battery transporter.

Assembly is the reverse order.

F After installing again, check all cables and connectors for signs of visible damage andbefore using the truck again check that:

– the battery retainers are inserted and secured,– the battery cover is properly closed.

6

5

7

D 5

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.GB

5 Check the battery condition, the acid level and acid density

– The battery manufacturer’s maintenance instructions apply.– Check the battery housing for cracks and any spilled acid.– Remove any oxydation residue from the battery terminals and apply an acid-free

grease to the battery terminals.– Unscrew the stops and check the acid level.

The acid level should be at least 10-15 mm above the top of the plates.– Check the acid density in accordance with the battery manufacturer’s instructions

and then refit the stops.– If necessary, charge up the battery.

6 Battery discharge indicator

When you turn the key in the keyswitchclockwise and pull the EMERGENCYDISCONNECT switch, the batterydischarge indicator will show theresidual capacity available. The displaystarts to flash when the battery hasreached a residual capacity of 30%. Liftcut-out occurs at a 20% capacitydisplay.

For maintenance-free and specialbatteries the display and cutout pointscan be adjusted by authorised personnelby assigning parameters.

+-

50%

D 5

0504

.GB

5 Check the battery condition, the acid level and acid density

– The battery manufacturer’s maintenance instructions apply.– Check the battery housing for cracks and any spilled acid.– Remove any oxydation residue from the battery terminals and apply an acid-free

grease to the battery terminals.– Unscrew the stops and check the acid level.

The acid level should be at least 10-15 mm above the top of the plates.– Check the acid density in accordance with the battery manufacturer’s instructions

and then refit the stops.– If necessary, charge up the battery.

6 Battery discharge indicator

When you turn the key in the keyswitchclockwise and pull the EMERGENCYDISCONNECT switch, the batterydischarge indicator will show theresidual capacity available. The displaystarts to flash when the battery hasreached a residual capacity of 30%. Liftcut-out occurs at a 20% capacitydisplay.

For maintenance-free and specialbatteries the display and cutout pointscan be adjusted by authorised personnelby assigning parameters.

+-

50%

0504

.GB

D 6

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D 6

E 1

0206

.GB

E Operation1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation The forklift truck may only be used by suitably trainedpersonnel, who have demonstrated to the proprietor or his representative that theycan drive and handle loads and have been authorised to operate the truck by theproprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.

Unauthorised Use of Truck: The driver is responsible for the truck during the timeit is in use. He shall prevent unauthorised persons from driving or operating the truck.It is forbidden to carry passengers or lift personnel.

Damage and Faults: Report any damage or faults concerning the forklift truck or itsattachments to a supervisor immediately. Trucks not safe for operation (e.g. wheel orbrake problems) shall not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the forklift truckwithout the necessary training and authoristion to do so. On no account may thedriver disable or adjust safety mechanisms or switches.

Danger area: A danger area is defined as the area in which a person is at risk due totruck movement, lifting operations, the load lifting device (e.g. forks or attachments)or the load itself. This also includes areas which can be reached by falling loads orlowering operating equipment.

F Unauthorised persons must be kept away from the danger area. Where there isdanger to personnel, a warning must be sounded in good time. If unauthorisedpersonnel are still within the danger area the truck shall be brought to restimmediately.

Safety Devices and Warning Signs: Safety devices, warning signs and warninginstructions shall be strictly observed.

E 1

0206

.GB

E Operation1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation The forklift truck may only be used by suitably trainedpersonnel, who have demonstrated to the proprietor or his representative that theycan drive and handle loads and have been authorised to operate the truck by theproprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.

Unauthorised Use of Truck: The driver is responsible for the truck during the timeit is in use. He shall prevent unauthorised persons from driving or operating the truck.It is forbidden to carry passengers or lift personnel.

Damage and Faults: Report any damage or faults concerning the forklift truck or itsattachments to a supervisor immediately. Trucks not safe for operation (e.g. wheel orbrake problems) shall not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the forklift truckwithout the necessary training and authoristion to do so. On no account may thedriver disable or adjust safety mechanisms or switches.

Danger area: A danger area is defined as the area in which a person is at risk due totruck movement, lifting operations, the load lifting device (e.g. forks or attachments)or the load itself. This also includes areas which can be reached by falling loads orlowering operating equipment.

F Unauthorised persons must be kept away from the danger area. Where there isdanger to personnel, a warning must be sounded in good time. If unauthorisedpersonnel are still within the danger area the truck shall be brought to restimmediately.

Safety Devices and Warning Signs: Safety devices, warning signs and warninginstructions shall be strictly observed.

0206

.GB

E 2

2 Control Panel Layout Variants

Variant I

The control panels are arranged as standardat the front, i.e. before the aux. lift.Accordingly, the display unit is below theoverhead guard also in the load direction

Variant II

The control panels and information displayare arranged on the mast side. The displayunit is arranged below the overhead guard.

Variant III

Diagonal arrangement of controls. The driverlooks out to the left in the load direction.The “Steering” control panel module isarranged on the load side. The display unit islocated on the load side below the overheadguard. The aux. lift is operated from the loadside.

0206

.GB

E 2

2 Control Panel Layout Variants

Variant I

The control panels are arranged as standardat the front, i.e. before the aux. lift.Accordingly, the display unit is below theoverhead guard also in the load direction

Variant II

The control panels and information displayare arranged on the mast side. The displayunit is arranged below the overhead guard.

Variant III

Diagonal arrangement of controls. The driverlooks out to the left in the load direction.The “Steering” control panel module isarranged on the load side. The display unit islocated on the load side below the overheadguard. The aux. lift is operated from the loadside.

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Load side and diagonal arrangement ofcontrols. The driver looks directly in the loaddirection or diagonally to the left in the loaddirection. The “Steering” control panel moduleis also present on the mast side. The displayunit is located on the load side below theoverhead guard.The aux. lift is operated from the load side.

Variant V

Mast side and diagonal arrangement ofcontrols. The driver looks directly in the mastdirection or diagonally to the left in the mastdirection. The “Steering” control panel moduleis also present on the load side. The displayunit is located on the mast side below theoverhead guard.The aux. lift is operated from the load side.

Variant VI

Twin arrangement of controls both in load andmast directions. The display unit is arrangedon either the load or mast side.The aux. lift is operated from the load and themast sides.

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Variant IV

Load side and diagonal arrangement ofcontrols. The driver looks directly in the loaddirection or diagonally to the left in the loaddirection. The “Steering” control panel moduleis also present on the mast side. The displayunit is located on the load side below theoverhead guard.The aux. lift is operated from the load side.

Variant V

Mast side and diagonal arrangement ofcontrols. The driver looks directly in the mastdirection or diagonally to the left in the mastdirection. The “Steering” control panel moduleis also present on the load side. The displayunit is located on the mast side below theoverhead guard.The aux. lift is operated from the load side.

Variant VI

Twin arrangement of controls both in load andmast directions. The display unit is arrangedon either the load or mast side.The aux. lift is operated from the load and themast sides.

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3 Operating and Display Equipment

3.1 Operating and display equipment on control panel

Item Operating / Display Equipment

Function

1 EMERGENCY DISCONNECT switch

t Interrupts the main supply, all truck movements are disabled

2 Steering wheel t Steers the truck in the required direction.3 Support handle t Two-hand operation4 “Lift cutout override”

switcho Automatic lift cutout is deactivated.

5 Guidance On „switch“ RG

WG

Sets the drive wheel to straight ahead position

Activates the aligning process (and frequency selection for multi-frequencies)

6 Travel selection switch t Controls the travel direction and speed of the truck

7 “Warning” switch t Activates a warning.8 Hydraulic control switch t Raising and lowering of Main and Aux. lift,

reach and swivel of load forks9 Keyswitch t Switches control voltage on and off. Removing

the key prevents the truck from being switched on by unauthorised personnel.

10 Optionalfunction keys

t Activates or confirms the function related to the symbol displayed above it

t = Standard equipment o = Optional Equipment

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3 Operating and Display Equipment

3.1 Operating and display equipment on control panel

Item Operating / Display Equipment

Function

1 EMERGENCY DISCONNECT switch

t Interrupts the main supply, all truck movements are disabled

2 Steering wheel t Steers the truck in the required direction.3 Support handle t Two-hand operation4 “Lift cutout override”

switcho Automatic lift cutout is deactivated.

5 Guidance On „switch“ RG

WG

Sets the drive wheel to straight ahead position

Activates the aligning process (and frequency selection for multi-frequencies)

6 Travel selection switch t Controls the travel direction and speed of the truck

7 “Warning” switch t Activates a warning.8 Hydraulic control switch t Raising and lowering of Main and Aux. lift,

reach and swivel of load forks9 Keyswitch t Switches control voltage on and off. Removing

the key prevents the truck from being switched on by unauthorised personnel.

10 Optionalfunction keys

t Activates or confirms the function related to the symbol displayed above it

t = Standard equipment o = Optional Equipment

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3.2 Display unit controls and displays

Upper range symbols

Item Symbol Operating / Display Equipment

Function

11 Displays possible travel speeds: Turtle Rabbit

t

Creep modeMax. travel speed

12 “Guidance wire recognition” display

WG Sensors which have detected the guidance wire have a dark background

13 Steering angle display

changes with display– “Tracking in

progress ”– “Guidance wire led”

– “Deviation from guidance wire”

t

RG

WG

WG

WG

WG

Indicates the current steering angle with reference to the centre positionCentre position is permanently displayed once the truck is in the track The steering angle display fades and is replaced by guidance wire symbols

– when the truck is governed by theguidance wire (inductive guidance)

– when the truck is automaticallyguided by the guidance wire

– when the truck deviates withoutguidance from the guidance wire andautomatic guidance

11

12

13 14 15 16 17

181920

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3.2 Display unit controls and displays

Upper range symbols

Item Symbol Operating / Display Equipment

Function

11 Displays possible travel speeds: Turtle Rabbit

t

Creep modeMax. travel speed

12 “Guidance wire recognition” display

WG Sensors which have detected the guidance wire have a dark background

13 Steering angle display

changes with display– “Tracking in

progress ”– “Guidance wire led”

– “Deviation from guidance wire”

t

RG

WG

WG

WG

WG

Indicates the current steering angle with reference to the centre positionCentre position is permanently displayed once the truck is in the track The steering angle display fades and is replaced by guidance wire symbols

– when the truck is governed by theguidance wire (inductive guidance)

– when the truck is automaticallyguided by the guidance wire

– when the truck deviates withoutguidance from the guidance wire andautomatic guidance

11

12

13 14 15 16 17

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Activates switch (10) under the respective symbols (18) displayed or confirms therelated function. The symbol will be given a dark background.

Lower range symbols and keys

14 Display “Overall lift”“Referencing required” display: Main lift - lift

Main lift - lower

Aux. lift - lift

Aux. lift - lower

t Displays the lift height of the forks

Requests Main Lift to lift

Requests Main Lift to lower

Requests Aux. Lift to lift

Requests Aux. Lift to lower

15 “Operating hours” display

t Displays the number of operating hours since the truck was commissioned

16 “Time” display t Shows the time17 Battery discharge

indicatort Displays the battery charge condition

(residual capacity as a percentage)19 Optional function o20 Optional function o

Symbol Operating / display unit FunctionWarnings

“Chain slack safety device” display

t Displayed when the chain slack safety device engages

“Chain slack safety device bypass” switch

Bypasses the chain slack safety device to lift the driver's position freely

“Fwd./Rev. travel only” display

t Displayed when the lift cutout device is actvated due to low battery capacity and only forward or reverse travel is possible.

“Acknowledge lift cutout due to battery discharge” switch

Confirms the lift cutout due to low battery capacity and releases travel (the Fwd./Rev. travel only display has a dark background)

Display“Lift limit”

o Displayed when the height dependent lift cutout is activated

“Lift limitoverride”switch Overrides the height dependent lift cutout (display has a dark background). Observe the maximum passage heights

“Lower limit” display o Indicates that the automatic lowering limit has been activated.

“Lowering limit bypass” switch

Bypasses the lowering limit, controlled by hydraulic control switch

Item Symbol Operating / Display Equipment

Function

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Activates switch (10) under the respective symbols (18) displayed or confirms therelated function. The symbol will be given a dark background.

Lower range symbols and keys

14 Display “Overall lift”“Referencing required” display: Main lift - lift

Main lift - lower

Aux. lift - lift

Aux. lift - lower

t Displays the lift height of the forks

Requests Main Lift to lift

Requests Main Lift to lower

Requests Aux. Lift to lift

Requests Aux. Lift to lower

15 “Operating hours” display

t Displays the number of operating hours since the truck was commissioned

16 “Time” display t Shows the time17 Battery discharge

indicatort Displays the battery charge condition

(residual capacity as a percentage)19 Optional function o20 Optional function o

Symbol Operating / display unit FunctionWarnings

“Chain slack safety device” display

t Displayed when the chain slack safety device engages

“Chain slack safety device bypass” switch

Bypasses the chain slack safety device to lift the driver's position freely

“Fwd./Rev. travel only” display

t Displayed when the lift cutout device is actvated due to low battery capacity and only forward or reverse travel is possible.

“Acknowledge lift cutout due to battery discharge” switch

Confirms the lift cutout due to low battery capacity and releases travel (the Fwd./Rev. travel only display has a dark background)

Display“Lift limit”

o Displayed when the height dependent lift cutout is activated

“Lift limitoverride”switch Overrides the height dependent lift cutout (display has a dark background). Observe the maximum passage heights

“Lower limit” display o Indicates that the automatic lowering limit has been activated.

“Lowering limit bypass” switch

Bypasses the lowering limit, controlled by hydraulic control switch

Item Symbol Operating / Display Equipment

Function

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“Travel cutout” display o Indicates that automatic, height dependent travel cutout has been activated

“Travel cutout bypass” switch

Bypasses the automatic, height dependent travel cutout

“Aisle end safety device” display (option)

o Indicates that the aisle end safety device has been activated. The truck brakes.

“Personal safety system” display (PSA)

o Indicates that the personal safety system has identified persons or objects in the aisle. The truck brakes.

“Personalsafety system” switch (PSA)

Bypasses the protective function and enables creep mode if there is sufficient distance from the obstacle.If a personal safety system is fitted, read the accompanying operator manual.

Select “Warning sub-menu” display

o Indicates that several warnings (e.g. chain slack safety device height dependent lift cutout) have been issued.

Quit “warnings” sub-menu.

Displays individual warnings

Quit “warnings” sub-menu.

o Indicates that the sub-menu can be quit.

“Cancel warnings sub-menu” switch

Sets the “warnings” sub-menu to the standard menu

Guidance systems“Guidance on” display (dark background when activated)

t

RG

WG

Displays automatic guidance in the aisle:

Rail guidance display(drive wheel set straight ahead)

Indicates that wire guidance is activated“Guidance on” switch RG

WG

Sets the drive wheel to straight ahead positionActivates the aligning process (and frequency selection for multi-frequencies)

Displays “Select Frequency 1” (similar to other frequencies) (“Guidance on” sub-menu)

o

WG

Indicates that guidance is possible through Frequency 1

“Select Frequency 1” switch (similar to other frequencies)

Activates guidance through Frequency 1 (sub-menu is quit automatically after 1 sec. duration)

“Special attachment” display

o Indicates that the special attachment can be controlled

“Special attachment” switch

Activates control of the special attachment, controlled via the hydraulic control switch

Symbol Operating / display unit Function

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“Travel cutout” display o Indicates that automatic, height dependent travel cutout has been activated

“Travel cutout bypass” switch

Bypasses the automatic, height dependent travel cutout

“Aisle end safety device” display (option)

o Indicates that the aisle end safety device has been activated. The truck brakes.

“Personal safety system” display (PSA)

o Indicates that the personal safety system has identified persons or objects in the aisle. The truck brakes.

“Personalsafety system” switch (PSA)

Bypasses the protective function and enables creep mode if there is sufficient distance from the obstacle.If a personal safety system is fitted, read the accompanying operator manual.

Select “Warning sub-menu” display

o Indicates that several warnings (e.g. chain slack safety device height dependent lift cutout) have been issued.

Quit “warnings” sub-menu.

Displays individual warnings

Quit “warnings” sub-menu.

o Indicates that the sub-menu can be quit.

“Cancel warnings sub-menu” switch

Sets the “warnings” sub-menu to the standard menu

Guidance systems“Guidance on” display (dark background when activated)

t

RG

WG

Displays automatic guidance in the aisle:

Rail guidance display(drive wheel set straight ahead)

Indicates that wire guidance is activated“Guidance on” switch RG

WG

Sets the drive wheel to straight ahead positionActivates the aligning process (and frequency selection for multi-frequencies)

Displays “Select Frequency 1” (similar to other frequencies) (“Guidance on” sub-menu)

o

WG

Indicates that guidance is possible through Frequency 1

“Select Frequency 1” switch (similar to other frequencies)

Activates guidance through Frequency 1 (sub-menu is quit automatically after 1 sec. duration)

“Special attachment” display

o Indicates that the special attachment can be controlled

“Special attachment” switch

Activates control of the special attachment, controlled via the hydraulic control switch

Symbol Operating / display unit Function

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E 8

Attachment fork adjustment“Symmetrical fork adjustment” display

o Indicates that fork adjustment can be operated

“Symmetrical fork adjustment” switch

Activates fork adjustment with simultaneous operation of hydraulic control switch, Right turn = forks turn in; Left turn = forks turn out

“Asymmetrical fork adjustment menu change” display

o Indicates that it is possible to change to the “Asymmetrical fork adjustment” menu

“Asymmetrical fork adjustment menu change” switch

Changes the display unit menu to “asymmetrical fork adjustment” functions

t = Standard equipment o = Optional EquipmentRG = Rail guidance IG = Wire guidance

Symbol Operating / display unit Function

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E 8

Attachment fork adjustment“Symmetrical fork adjustment” display

o Indicates that fork adjustment can be operated

“Symmetrical fork adjustment” switch

Activates fork adjustment with simultaneous operation of hydraulic control switch, Right turn = forks turn in; Left turn = forks turn out

“Asymmetrical fork adjustment menu change” display

o Indicates that it is possible to change to the “Asymmetrical fork adjustment” menu

“Asymmetrical fork adjustment menu change” switch

Changes the display unit menu to “asymmetrical fork adjustment” functions

t = Standard equipment o = Optional EquipmentRG = Rail guidance IG = Wire guidance

Symbol Operating / display unit Function

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3.3 Truck operational status symbols

The operational status of the truck when it has been switched on is indicated bysymbols in the display unit.

Safety gates open

Foot switch not pressed

Attachment in home position

When the following symbols are displayed you must carry out a reference movementin accordance with the display, i.e. the Main Lift must be raised approx. 10 cm andlowered again. This is the only way for the controller to release all the truckmovements at full speed.

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3.3 Truck operational status symbols

The operational status of the truck when it has been switched on is indicated bysymbols in the display unit.

Safety gates open

Foot switch not pressed

Attachment in home position

When the following symbols are displayed you must carry out a reference movementin accordance with the display, i.e. the Main Lift must be raised approx. 10 cm andlowered again. This is the only way for the controller to release all the truckmovements at full speed.

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E 10

Referencing: Main lift - lift

Referencing: Main lift - lower

Referencing: Aux. lift - lift

Referencing: Aux. lift - lower

Lift cutout during referencing

F When disabling the lift cutout the driver must look out forobstacles when the mast is extended.

Pressing the “bypass lift cutout” switch disables the liftcutout mechanism.

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E 10

Referencing: Main lift - lift

Referencing: Main lift - lower

Referencing: Aux. lift - lift

Referencing: Aux. lift - lower

Lift cutout during referencing

F When disabling the lift cutout the driver must look out forobstacles when the mast is extended.

Pressing the “bypass lift cutout” switch disables the liftcutout mechanism.

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4 Starting up the truck

F Before the truck can be put into operation, operated or a load unit lifted, the drivermust ensure that there is nobody within the danger area.

Checks and operations to be performed before starting daily work

– Check the entire truck on the outside for signs of visible damage and leaks.– Check the battery attachment and wire connections for damage, make sure they

are secure.– Check the battery connector is fixed.– Check the overhead guard for damage.– Check the load lifting device for visible damage such as cracks, bent or severely

worn load forks.– Check the load wheels for damage.– Make sure the load chains are evenly tensioned.– Make sure all safety mechanisms are correct and functional.– Test the operating and parking brake.– Check the brake fluide.– For rail guidance systems check the guidance rollers are smooth and check for

damage.

F It is forbidden for more than one person to enter the driver’s cab at a time.

Preparing the truck for operation

– Close the safey gates securely on both sides.– Turn the EMERGENCY DISCONNECT switch (1) to undo it.– Insert the key in the keyswitch (9) and turn it clockwise.– Test the warning device (horn).– Test the operating and parking brake.– Carry out a test movement of the lift mast to adjust the height display.

F Press the EMERGENCY DISCONNECT switch immediately if the truck starts tomove or lift when it is switched on.

1

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4 Starting up the truck

F Before the truck can be put into operation, operated or a load unit lifted, the drivermust ensure that there is nobody within the danger area.

Checks and operations to be performed before starting daily work

– Check the entire truck on the outside for signs of visible damage and leaks.– Check the battery attachment and wire connections for damage, make sure they

are secure.– Check the battery connector is fixed.– Check the overhead guard for damage.– Check the load lifting device for visible damage such as cracks, bent or severely

worn load forks.– Check the load wheels for damage.– Make sure the load chains are evenly tensioned.– Make sure all safety mechanisms are correct and functional.– Test the operating and parking brake.– Check the brake fluide.– For rail guidance systems check the guidance rollers are smooth and check for

damage.

F It is forbidden for more than one person to enter the driver’s cab at a time.

Preparing the truck for operation

– Close the safey gates securely on both sides.– Turn the EMERGENCY DISCONNECT switch (1) to undo it.– Insert the key in the keyswitch (9) and turn it clockwise.– Test the warning device (horn).– Test the operating and parking brake.– Carry out a test movement of the lift mast to adjust the height display.

F Press the EMERGENCY DISCONNECT switch immediately if the truck starts tomove or lift when it is switched on.

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5 Lift truck operation

5.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorised persons must stay away from work areas. Loads must onlybe stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions. Thetruck must be driven at slow speed when negotiating bends or narrow passageways,when passing through swing doors and at blind spots. The driver must alwaysobserve an adequate braking distance between the forklift truck and the vehicle infront and must be in control of the truck at all times. Abrupt stopping (except inemergencies), rapid U turns and overtaking at dangerous or blind spots are notpermitted. It is forbidden to lean out of or reach beyond the working and operatingarea.

Visibility when travelling outside the narrow aisle: The driver must look in thedirection of travel and must always have a clear view of the route ahead. Whencarrying loads which affect visibility, these must be stored at the rear of the truck. Ifthis is not possible, a second person must walk in front of the truck as a lookout.

M Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines.

M Negotiating docks: It is forbidden to negotiate docks.

Negotiating lifts: Lifts may only be negotiated if they have sufficient capacity, aresuitable for driving on and authorised for truck traffic by the owner. The driver mustsatisfy himself of the above before entering these areas. The truck must enter liftswith the load in front and must take up a position which does not allow it to come intocontact with the walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck hascome to a rest and must leave the lift before the truck.

Type of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Do not carry loads unless they are positioned safely andcarefully. Use suitable precautions to prevent parts of the load from tipping or fallingdown.

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5 Lift truck operation

5.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorised persons must stay away from work areas. Loads must onlybe stored in places specially designated for this purpose.

Driving conduct: The driver must adapt the travel speed to local conditions. Thetruck must be driven at slow speed when negotiating bends or narrow passageways,when passing through swing doors and at blind spots. The driver must alwaysobserve an adequate braking distance between the forklift truck and the vehicle infront and must be in control of the truck at all times. Abrupt stopping (except inemergencies), rapid U turns and overtaking at dangerous or blind spots are notpermitted. It is forbidden to lean out of or reach beyond the working and operatingarea.

Visibility when travelling outside the narrow aisle: The driver must look in thedirection of travel and must always have a clear view of the route ahead. Whencarrying loads which affect visibility, these must be stored at the rear of the truck. Ifthis is not possible, a second person must walk in front of the truck as a lookout.

M Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines.

M Negotiating docks: It is forbidden to negotiate docks.

Negotiating lifts: Lifts may only be negotiated if they have sufficient capacity, aresuitable for driving on and authorised for truck traffic by the owner. The driver mustsatisfy himself of the above before entering these areas. The truck must enter liftswith the load in front and must take up a position which does not allow it to come intocontact with the walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck hascome to a rest and must leave the lift before the truck.

Type of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Do not carry loads unless they are positioned safely andcarefully. Use suitable precautions to prevent parts of the load from tipping or fallingdown.

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5.2 Travelling, Steering, Braking

EMERGENCY DISCONNECT

– Press the EMERGENCYDISCONNECT switch (1) down.All truck movements are inhibited.The switch operation must not beaffected by any objects placed in itsway.

Travelling

The truck can be driven in 3 modes:Free travel in apron, with wire or railguidance.The operating mode used depends onthe guidance system of the rackingsystem operated.

M Do not drive the truck unless the panels are closed and properly locked.

The foot switch must be kept depressed for travel.

Travelling in apron field

– Close the safety gates.– Turn the EMERGENCY

DISCONNECT switch (1) to undo it.– Insert the key in the keyswitch and

turn clockwise; the “operational”display lamp goes on.

– Apply the foot switch (21). – Carry out a test run, see Seite E9.

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5.2 Travelling, Steering, Braking

EMERGENCY DISCONNECT

– Press the EMERGENCYDISCONNECT switch (1) down.All truck movements are inhibited.The switch operation must not beaffected by any objects placed in itsway.

Travelling

The truck can be driven in 3 modes:Free travel in apron, with wire or railguidance.The operating mode used depends onthe guidance system of the rackingsystem operated.

M Do not drive the truck unless the panels are closed and properly locked.

The foot switch must be kept depressed for travel.

Travelling in apron field

– Close the safety gates.– Turn the EMERGENCY

DISCONNECT switch (1) to undo it.– Insert the key in the keyswitch and

turn clockwise; the “operational”display lamp goes on.

– Apply the foot switch (21). – Carry out a test run, see Seite E9.

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E 14

– Fully lower the Aux. lift and raise theMain lift with the hydraulic controlswitch (8) until the forks are clear ofthe ground.

– Slowly turn the travel selection switch(6) with the right thumb. Turn clockwise = forward travelTurn anti-clockwise = reverse travel

– You can control the travel speed bycontinuing to turn or retracting the tra-vel selection switch.

Use the steering wheel (2) to steer thetruck in the required direction.

Steering

Use the steering wheel to steer the truckoutside narrow aisles.The position of the drive wheel is shownin the display unit (13).

Braking

Z The braking pattern of the truck depends largely on the ground conditions. The drivermust take this into consideration when handling the truck.

– The truck can be braked in three different ways:- with the operating brake- with the parking brake- with the main switch.

Braking with the operating brake

While driving set the travel direction switch to the zero position or the opposite traveldirection; the traction current controller will cause the truck to brake.

Braking with the foot switch

Releasing the foot switch causes the truck to brake.

Z This type of braking can only be used as a parking brake and not as an operatingbrake.

Braking with the EMERGENCY DISCONNECT switch

Applying the EMERGENCY DISCONNECT switch will cause the truck to brakesuddenly until it comes to a halt.

M The EMERGENCY DISCONNECT switch must only be used in dangerous situations.

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– Fully lower the Aux. lift and raise theMain lift with the hydraulic controlswitch (8) until the forks are clear ofthe ground.

– Slowly turn the travel selection switch(6) with the right thumb. Turn clockwise = forward travelTurn anti-clockwise = reverse travel

– You can control the travel speed bycontinuing to turn or retracting the tra-vel selection switch.

Use the steering wheel (2) to steer thetruck in the required direction.

Steering

Use the steering wheel to steer the truckoutside narrow aisles.The position of the drive wheel is shownin the display unit (13).

Braking

Z The braking pattern of the truck depends largely on the ground conditions. The drivermust take this into consideration when handling the truck.

– The truck can be braked in three different ways:- with the operating brake- with the parking brake- with the main switch.

Braking with the operating brake

While driving set the travel direction switch to the zero position or the opposite traveldirection; the traction current controller will cause the truck to brake.

Braking with the foot switch

Releasing the foot switch causes the truck to brake.

Z This type of braking can only be used as a parking brake and not as an operatingbrake.

Braking with the EMERGENCY DISCONNECT switch

Applying the EMERGENCY DISCONNECT switch will cause the truck to brakesuddenly until it comes to a halt.

M The EMERGENCY DISCONNECT switch must only be used in dangerous situations.

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0206

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M It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes inracking systems with safety distances < 500 mm) or for personnel to cross throughthem. These work areas must be marked and identified accordingly. Carry out a dailyinspection of the safety devices on the truck or the racking sysem to avoid hazardsand protect personnel. These must not be made ineffective, misused, adjusted orremoved. Immediately report and rectify any missing safety devices.

M Observe the instructions of DIN 15185 Part 2.

Z Before entering a narrow aisle, the driver must look for people or other trucks in theaisle. Never enter an aisle where there are people or other trucks. If there are peoplein the aisle, stop the truck immediately.

Z Only enter narrow aisles in trucks which are designated for such use. If a narrow aisleis equipped with a non-mechanical wire guidance system, if the system is faulty orswitched off, the truck may only be removed from the narrow aisle at creep speed.

Rail guidance truck

Rail guidance trucks are equipped withsensors which activate aisle recognitionwhen they enter the racking lanes.

– Approach the aisle at reduced speedso that the truck is aligned with thenarrow aisle and is within thedemarcation.

Z Observe the notices attached along theroute.

– Slowly enter the narrow aisle.

Ensure that the truck guide rollers enter the narrow aisle guidance rails.

– Press the “guidance on” (22) switch.– The drive wheel is automatically set straight ahead and the “guidance on” lamp (23)

is lit. Manual steering is disabled.– To prepare for travel, grab the hand rest with the left hand (two-handed operation).– Slowly turn the travel selection switch in the travel direction required.

Right turn =Forward travel; Left turn = Reverse travel– Continue to travel along the narrow aisle at your required speed.

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Negotiating narrow aisles

M It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes inracking systems with safety distances < 500 mm) or for personnel to cross throughthem. These work areas must be marked and identified accordingly. Carry out a dailyinspection of the safety devices on the truck or the racking sysem to avoid hazardsand protect personnel. These must not be made ineffective, misused, adjusted orremoved. Immediately report and rectify any missing safety devices.

M Observe the instructions of DIN 15185 Part 2.

Z Before entering a narrow aisle, the driver must look for people or other trucks in theaisle. Never enter an aisle where there are people or other trucks. If there are peoplein the aisle, stop the truck immediately.

Z Only enter narrow aisles in trucks which are designated for such use. If a narrow aisleis equipped with a non-mechanical wire guidance system, if the system is faulty orswitched off, the truck may only be removed from the narrow aisle at creep speed.

Rail guidance truck

Rail guidance trucks are equipped withsensors which activate aisle recognitionwhen they enter the racking lanes.

– Approach the aisle at reduced speedso that the truck is aligned with thenarrow aisle and is within thedemarcation.

Z Observe the notices attached along theroute.

– Slowly enter the narrow aisle.

Ensure that the truck guide rollers enter the narrow aisle guidance rails.

– Press the “guidance on” (22) switch.– The drive wheel is automatically set straight ahead and the “guidance on” lamp (23)

is lit. Manual steering is disabled.– To prepare for travel, grab the hand rest with the left hand (two-handed operation).– Slowly turn the travel selection switch in the travel direction required.

Right turn =Forward travel; Left turn = Reverse travel– Continue to travel along the narrow aisle at your required speed.

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Wire guidance trucks

F When starting or continuing to travel after disconnecting the wire guidance, check theposition of the drive wheel as manual steering is now activated again.

F If an automatically guided wire guidance truck is switched off, the wire guidance is nolonger active when it is switched on again. Risk of accidents! When the truckcontinues a warning is sounded and the speed reduced. Apply pushbutton (22) to re-activate the wire guidance (“Wire Guidance Active” display light (23) is lit) and re-trackthe truck.

F When re-tracking the truck, the rear section may move out if the front sensor (25) hasalready crossed over the guidance wire before the "Wire Guidance On" switch ispressed.

– Approach the guidance wire (26) at anangle at reduced speed.

When the truck is correctly positioned itshould not be parallel to the guidancewire; the ideal angle is between 10° and50°.

Tracking should preferably be forward,as this involves less time and distance.

When the truck is close to the guidancewire, switch on the wire guidance withpressure switch „Guidance On“ (22).

The “wire guidance active” (23) lampgoes on.

When the guidance wire is reached thetruck is automatically guided.

When the guidance wire is reachedtracking automtically ensues at reducedspeed. The “tracking on” (27) displayappears. The audible tracking signal issounded.

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Wire guidance trucks

F When starting or continuing to travel after disconnecting the wire guidance, check theposition of the drive wheel as manual steering is now activated again.

F If an automatically guided wire guidance truck is switched off, the wire guidance is nolonger active when it is switched on again. Risk of accidents! When the truckcontinues a warning is sounded and the speed reduced. Apply pushbutton (22) to re-activate the wire guidance (“Wire Guidance Active” display light (23) is lit) and re-trackthe truck.

F When re-tracking the truck, the rear section may move out if the front sensor (25) hasalready crossed over the guidance wire before the "Wire Guidance On" switch ispressed.

– Approach the guidance wire (26) at anangle at reduced speed.

When the truck is correctly positioned itshould not be parallel to the guidancewire; the ideal angle is between 10° and50°.

Tracking should preferably be forward,as this involves less time and distance.

When the truck is close to the guidancewire, switch on the wire guidance withpressure switch „Guidance On“ (22).

The “wire guidance active” (23) lampgoes on.

When the guidance wire is reached thetruck is automatically guided.

When the guidance wire is reachedtracking automtically ensues at reducedspeed. The “tracking on” (27) displayappears. The audible tracking signal issounded.

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Tracking is completed once the truckhas been set to the guidance wire. Thedisplay (28) changes to “guidance wireapplied”. The tracking signal is no longersounded. The track is now automaticallyguided.

Z Travel and hydraulic operations can onlybe activated in the narrow aisle with two-handed operation.

Hold onto the support handle (3) of the“Steering” control panel module and thehydraulic control switch (8). Turn thetravel selection switch (6) to changetravel speed and direction.

Diagonal travel

Diagonal travel is possible(simultaneous travelling and lifting /lowering) when both control switches (6and 8) are pressed simultaneously).

Press the pressure switch (22) to quit theguidance wire. The display (23) goesout.

F You can only change from automatic tomanual steering once the truck has fullyleft the rack lane.

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Inductive automatic steering takes overthe steering and applies it to theguidance wire.

Tracking is completed once the truckhas been set to the guidance wire. Thedisplay (28) changes to “guidance wireapplied”. The tracking signal is no longersounded. The track is now automaticallyguided.

Z Travel and hydraulic operations can onlybe activated in the narrow aisle with two-handed operation.

Hold onto the support handle (3) of the“Steering” control panel module and thehydraulic control switch (8). Turn thetravel selection switch (6) to changetravel speed and direction.

Diagonal travel

Diagonal travel is possible(simultaneous travelling and lifting /lowering) when both control switches (6and 8) are pressed simultaneously).

Press the pressure switch (22) to quit theguidance wire. The display (23) goesout.

F You can only change from automatic tomanual steering once the truck has fullyleft the rack lane.

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5.3 Lifting – Lowering – outside and inside the rack aisles

F Risk of injury when the driver’s cab and the load lifting device are lowered.There must be nobody in the danger zone.

Lift – Lower (Main Lift)

– Apply the foot switch.– Turn the hydraulic control button (8)

simultaneouslyClockwise = LiftAnti-clockwise = Lower

Z The lift and lower speeds areproportional to the amount of turn of thehydraulic control switch.

Z If the wire break safety device is applied,lift again and slowly lower.

Lift – Lower (Aux. Lift)

– Apply the foot switch.– Press the aux. lift pressure switch (4).– Turn the hydraulic control button (8)

simultaneouslyClockwise = LiftAnti-clockwise = Lower

The lift and lower speeds areproportional to the amount of turn.

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5.3 Lifting – Lowering – outside and inside the rack aisles

F Risk of injury when the driver’s cab and the load lifting device are lowered.There must be nobody in the danger zone.

Lift – Lower (Main Lift)

– Apply the foot switch.– Turn the hydraulic control button (8)

simultaneouslyClockwise = LiftAnti-clockwise = Lower

Z The lift and lower speeds areproportional to the amount of turn of thehydraulic control switch.

Z If the wire break safety device is applied,lift again and slowly lower.

Lift – Lower (Aux. Lift)

– Apply the foot switch.– Press the aux. lift pressure switch (4).– Turn the hydraulic control button (8)

simultaneouslyClockwise = LiftAnti-clockwise = Lower

The lift and lower speeds areproportional to the amount of turn.

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5.4 Order picking and stacking

Picking up, transporting and placing load units

M Before picking up a load unit the driver must make sure that it has been correctlypalletised and does not exceed the truck’s capacity. Observe the load diagram.

– Check the fork distance for the pallet and adjust if necessary.

o Adjusting the forks

To pick up the load securely, the forksmust be as far apart as possible andcentrally positioned with respect to thefork carriage. The load centre of gravitymust be centrally aligned between theforks.

– Swivel the locking lever (29) up.– Push the forks (30) into the correct

position on the fork carriage (31). – Swivel the locking lever (29) down and

move the forks until the locking pinengages in a notch.

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5.4 Order picking and stacking

Picking up, transporting and placing load units

M Before picking up a load unit the driver must make sure that it has been correctlypalletised and does not exceed the truck’s capacity. Observe the load diagram.

– Check the fork distance for the pallet and adjust if necessary.

o Adjusting the forks

To pick up the load securely, the forksmust be as far apart as possible andcentrally positioned with respect to thefork carriage. The load centre of gravitymust be centrally aligned between theforks.

– Swivel the locking lever (29) up.– Push the forks (30) into the correct

position on the fork carriage (31). – Swivel the locking lever (29) down and

move the forks until the locking pinengages in a notch.

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Picking up a load from the front

– Drive the truck at creep speed.– Slowly insert the forks into the pallet

until the fork back touches the load orthe pallet.

– Raise the load slightly and reverse thetruck slowly (creep speed).

M The ground surface must be in goodcondition to ensure this works correctly.

Transporting loads

– Always transport a load outside therack aisle as low as possible, allowingfor ground clearance.

– Always transport loads with both forks. When transporting heavy loads alwaysensure that both forks carry the same weight.

– Gradually accelerate the truck.– Travel at a constant speed. – Always be prepared to brake. Only stop suddenly in dangerous situations.– Reduce speed accordingly on narrow bends.

Placing loads

– Drive the truck carefully up to the storage location

M Before a load can be placed, the driver must ensure that the storage location issuitable for storing the load (size and capacity).

– Raise the load lifting device so that theload can be taken to the storagelocation without striking any objects.

– Carefully set the load into its storagelocation.

– Carefully lower the load lifting deviceso that the forks are clear of the load.

M Avoid placing the load down suddenly toavoid damaging the load and the loadlifting device.Carefully remove the loadlifting device from the load.

– Fully lower the load lifting device.

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Picking up a load from the front

– Drive the truck at creep speed.– Slowly insert the forks into the pallet

until the fork back touches the load orthe pallet.

– Raise the load slightly and reverse thetruck slowly (creep speed).

M The ground surface must be in goodcondition to ensure this works correctly.

Transporting loads

– Always transport a load outside therack aisle as low as possible, allowingfor ground clearance.

– Always transport loads with both forks. When transporting heavy loads alwaysensure that both forks carry the same weight.

– Gradually accelerate the truck.– Travel at a constant speed. – Always be prepared to brake. Only stop suddenly in dangerous situations.– Reduce speed accordingly on narrow bends.

Placing loads

– Drive the truck carefully up to the storage location

M Before a load can be placed, the driver must ensure that the storage location issuitable for storing the load (size and capacity).

– Raise the load lifting device so that theload can be taken to the storagelocation without striking any objects.

– Carefully set the load into its storagelocation.

– Carefully lower the load lifting deviceso that the forks are clear of the load.

M Avoid placing the load down suddenly toavoid damaging the load and the loadlifting device.Carefully remove the loadlifting device from the load.

– Fully lower the load lifting device.

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5.5 Park the truck securely

When you leave the truck it must be securely parked even if you only intend to leaveit for a short time.

F Do not park the truck on an incline. In special cases the truck may need to be securedwith wedges.

Z Select a parking place where nobody will collide with the forks.

– Always park the truck with the mast completely lowered.– Lower the forks to the ground. – Set the keyswitch to “0” and remove the safety key.

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5.5 Park the truck securely

When you leave the truck it must be securely parked even if you only intend to leaveit for a short time.

F Do not park the truck on an incline. In special cases the truck may need to be securedwith wedges.

Z Select a parking place where nobody will collide with the forks.

– Always park the truck with the mast completely lowered.– Lower the forks to the ground. – Set the keyswitch to “0” and remove the safety key.

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6 Troubleshooting

This chapter enables the user to identify and rectify basic faults and the effects ofincorrect operation. When trying to locate a fault, proceed in the order shown in thetable.

Fault Possible cause ActionTruck does not start.

– Battery not connected – Check battery plug and plug in ifnecessary.

– Safety gates open – Close the safety gates– EMERGENCY

DISCONNECT switchpressed

– Unlatch EMERGENCYDISCONNECT switch

– Keyswitch in “0”position

– Set key switch to “I”

– Battery charge too low – Check battery charge, charge batteryif necessary

– Foot switch notpressed

– Press foot switch

– Fuse blown – Check fuses– Travel cutout activated – Press travel cutout bypass switch

(charge battery)– Travel cutout activated

via aisle end safetydevice

– Switch off automatic tractioncontroller and re-align truck withguidance wire.

– Chains slack – Bypass chain slack safety deviceLoad cannot be lifted

– Truck not operational – Carry out all measures listed under“Truck does not start”

– Battery charge too low,lift cutout

– Check battery charge, charge batteryif necessary

– Insufficient hydraulicoil

– Check hydraulic oil level and ifnecessary replenish

– Fuse blown – Check fusesRapid travel disabled

– Main Lift / Aux. Liftraised above 0.5m

– Lower Main Lift / Aux. Lift below 0.5m

– WG search modeactivated

– Align truck or turn off WG mode

– No test run performed – Perform lifting and loweringTruck cannot be steered

– Truck not operational – Carry out all measures listed under“Truck does not start”

– Narrow aisle modeswitch pressed

– Switch off narrow aisle travel function

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6 Troubleshooting

This chapter enables the user to identify and rectify basic faults and the effects ofincorrect operation. When trying to locate a fault, proceed in the order shown in thetable.

Fault Possible cause ActionTruck does not start.

– Battery not connected – Check battery plug and plug in ifnecessary.

– Safety gates open – Close the safety gates– EMERGENCY

DISCONNECT switchpressed

– Unlatch EMERGENCYDISCONNECT switch

– Keyswitch in “0”position

– Set key switch to “I”

– Battery charge too low – Check battery charge, charge batteryif necessary

– Foot switch notpressed

– Press foot switch

– Fuse blown – Check fuses– Travel cutout activated – Press travel cutout bypass switch

(charge battery)– Travel cutout activated

via aisle end safetydevice

– Switch off automatic tractioncontroller and re-align truck withguidance wire.

– Chains slack – Bypass chain slack safety deviceLoad cannot be lifted

– Truck not operational – Carry out all measures listed under“Truck does not start”

– Battery charge too low,lift cutout

– Check battery charge, charge batteryif necessary

– Insufficient hydraulicoil

– Check hydraulic oil level and ifnecessary replenish

– Fuse blown – Check fusesRapid travel disabled

– Main Lift / Aux. Liftraised above 0.5m

– Lower Main Lift / Aux. Lift below 0.5m

– WG search modeactivated

– Align truck or turn off WG mode

– No test run performed – Perform lifting and loweringTruck cannot be steered

– Truck not operational – Carry out all measures listed under“Truck does not start”

– Narrow aisle modeswitch pressed

– Switch off narrow aisle travel function

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Z If, after carrying out the remedial action, the truck cannot be restored to operation orif a fault in the electronics system is displayed with a corresponding error code,contact the manufacturer’s service department. Additional troubleshooting must only be performed by the manufacturer’s specialistservice engineers. The manufacturer has a customer service department speciallytrained for these tasks. To provide targeted and rapid response to faults, the following details are useful andimportant to provide for the customer service department:

- Truck serial number- Display unit error number (if present)- Error description- Current location of truck.

Error 144 – Truck has quitguidance wire

– Restore wire guidance

Error 330Error 334

– Travel control buttonpressed during power-up test

– Do not press travel control button,switch truck off and on again

Error 331Error 335

– Hydraulic controlbutton pressed duringpower-up test

– Do not press hydraulic control button,switch truck off and on again

Error 332Error 336

– During the power uptest a functionpreselect key waspressed on the controlpanel

– Do not press function preselect key,switch truck off and on again

Error 338 – Foot switch pressedduring power-up test

– Do not press foot switch, switch truckoff and on again

Error 339 – During the power-uptest a key was pressedbelow the display unit

– Do not press key, switch truck off andon again

Error 344 – Personal safetysystem

– PSA scanner contaminated, clean

Fault Possible cause Action

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Z If, after carrying out the remedial action, the truck cannot be restored to operation orif a fault in the electronics system is displayed with a corresponding error code,contact the manufacturer’s service department. Additional troubleshooting must only be performed by the manufacturer’s specialistservice engineers. The manufacturer has a customer service department speciallytrained for these tasks. To provide targeted and rapid response to faults, the following details are useful andimportant to provide for the customer service department:

- Truck serial number- Display unit error number (if present)- Error description- Current location of truck.

Error 144 – Truck has quitguidance wire

– Restore wire guidance

Error 330Error 334

– Travel control buttonpressed during power-up test

– Do not press travel control button,switch truck off and on again

Error 331Error 335

– Hydraulic controlbutton pressed duringpower-up test

– Do not press hydraulic control button,switch truck off and on again

Error 332Error 336

– During the power uptest a functionpreselect key waspressed on the controlpanel

– Do not press function preselect key,switch truck off and on again

Error 338 – Foot switch pressedduring power-up test

– Do not press foot switch, switch truckoff and on again

Error 339 – During the power-uptest a key was pressedbelow the display unit

– Do not press key, switch truck off andon again

Error 344 – Personal safetysystem

– PSA scanner contaminated, clean

Fault Possible cause Action

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6.1 Emergency stop device

When the automatic emergency stop device is applied (e.g. if the wire guidance islost, or the electrical steering fails) the truck automatically comes to a halt. Beforestarting again, the cause of the error must be identified and corrected. When startingthe truck again, follow the manufacturer’s instructions as laid down in the presentoperator manual.

6.2 Driver’s cab / Aux. Lift emergency lowering

F When using emergency lowering, make sure that nobody is present in the dangerzone. If a second person is used to lower the load lifting device via the emergencylowering device, this person must consult with the driver. Both people must be in asafe area to avoid danger.The truck may only be started again once the error has been localised and rectified.

If necessary, a second person can be deployed to lower the cabin from the ground.

– Remove the Allen key from the bracket above the beacon.– Insert the Allen key into the hole (33).– Slowly open the drain valve (32) using the Allen key.– The cabin lowers.

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6.1 Emergency stop device

When the automatic emergency stop device is applied (e.g. if the wire guidance islost, or the electrical steering fails) the truck automatically comes to a halt. Beforestarting again, the cause of the error must be identified and corrected. When startingthe truck again, follow the manufacturer’s instructions as laid down in the presentoperator manual.

6.2 Driver’s cab / Aux. Lift emergency lowering

F When using emergency lowering, make sure that nobody is present in the dangerzone. If a second person is used to lower the load lifting device via the emergencylowering device, this person must consult with the driver. Both people must be in asafe area to avoid danger.The truck may only be started again once the error has been localised and rectified.

If necessary, a second person can be deployed to lower the cabin from the ground.

– Remove the Allen key from the bracket above the beacon.– Insert the Allen key into the hole (33).– Slowly open the drain valve (32) using the Allen key.– The cabin lowers.

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6.3 Exiting the driver's cab with the emergency abseil device

Industrial trucks with a height-adjustable operator position which can exceed 3m fromthe ground, have an emergency lowering mechanism and an emergency abseildevice for the driver which he can use if the operator position ever becomes stuck.

Z If the driver’s cab cannot be lowered due to a fault, not even manually, the operatormust exit the driver's cab via the emergency abseil device. The driver must be instructed in how to use the emergency abseil device. To exit thecabin with the emergency abseil device, proceed as follows:

– Turn the keyswitch to “0”.– Press the EMERGENCY DISCONNECT switch.– Take the emergency abseil device (35) out of its compartment.– Attach the karabiner hook (38) of the abseil device (left or right) to the eye (34) of

the overhead guard.– Throw out the rope without knots, the rope must pass over fixed objects. Do not

pass the rope over sharp edges.– Fit the safety belt or slings in accordance with the accompanying operating

instructions or as instructed.– Attach the safety belt to the abseil device (39).

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6.3 Exiting the driver's cab with the emergency abseil device

Industrial trucks with a height-adjustable operator position which can exceed 3m fromthe ground, have an emergency lowering mechanism and an emergency abseildevice for the driver which he can use if the operator position ever becomes stuck.

Z If the driver’s cab cannot be lowered due to a fault, not even manually, the operatormust exit the driver's cab via the emergency abseil device. The driver must be instructed in how to use the emergency abseil device. To exit thecabin with the emergency abseil device, proceed as follows:

– Turn the keyswitch to “0”.– Press the EMERGENCY DISCONNECT switch.– Take the emergency abseil device (35) out of its compartment.– Attach the karabiner hook (38) of the abseil device (left or right) to the eye (34) of

the overhead guard.– Throw out the rope without knots, the rope must pass over fixed objects. Do not

pass the rope over sharp edges.– Fit the safety belt or slings in accordance with the accompanying operating

instructions or as instructed.– Attach the safety belt to the abseil device (39).

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Abseiling

F Do not drop into loose rope. Watch out for obstacles when abseiling.

– Make the rope (37) taut.– Exit with your face towards the truck.– To abseil, press the lever (36) on the abseil device down.– To stop abseiling, release the brake lever (36).

6.4 Bypassing the chain slack safety device

If the chain slack safety device applies, e. g. when assembling the fork carriage,loosening or rupturing the lift chain. It is possible to “Raise” the Main Lift if the overrideswitch is held down. “Travel” and “Lower” are no longer possible.

Before starting again, rectify the damage.

M The truck can only be started again when the damage has been rectified.

6.5 Bypassing the travel cutout (o)

If travel is inhibited from a certain lift height, but the position of the truck relative to therack must be adjusted to load or unload goods, press the “unlock travel” switch andapply the travel lever as described in “Travelling”. This allows you to travel in creepmode.

6.6 Lift cutout (o)

If local conditions require, an automatic lift cutout to apply from a given lift height canbe fitted for safety reasons.

M Lift cutout only becomes effective after a test run has been carried out. You can tellwhen this is the case, because the actual height is shown in the display unit.

F When disabling the lift cutout the driver must look out for obstacles when the mast isextended.

Pressing the “bypass lift cutout” switch disables the lift cutout mechanism.

Z Lift cutout is re-activated each time the mast falls below the lift limit height.

The respective travel and lift limit keys are located in the control panel.

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Abseiling

F Do not drop into loose rope. Watch out for obstacles when abseiling.

– Make the rope (37) taut.– Exit with your face towards the truck.– To abseil, press the lever (36) on the abseil device down.– To stop abseiling, release the brake lever (36).

6.4 Bypassing the chain slack safety device

If the chain slack safety device applies, e. g. when assembling the fork carriage,loosening or rupturing the lift chain. It is possible to “Raise” the Main Lift if the overrideswitch is held down. “Travel” and “Lower” are no longer possible.

Before starting again, rectify the damage.

M The truck can only be started again when the damage has been rectified.

6.5 Bypassing the travel cutout (o)

If travel is inhibited from a certain lift height, but the position of the truck relative to therack must be adjusted to load or unload goods, press the “unlock travel” switch andapply the travel lever as described in “Travelling”. This allows you to travel in creepmode.

6.6 Lift cutout (o)

If local conditions require, an automatic lift cutout to apply from a given lift height canbe fitted for safety reasons.

M Lift cutout only becomes effective after a test run has been carried out. You can tellwhen this is the case, because the actual height is shown in the display unit.

F When disabling the lift cutout the driver must look out for obstacles when the mast isextended.

Pressing the “bypass lift cutout” switch disables the lift cutout mechanism.

Z Lift cutout is re-activated each time the mast falls below the lift limit height.

The respective travel and lift limit keys are located in the control panel.

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6.7 Aisle end safety device (o)

Trucks with the aisle end safety device brake before the aisle exit or in the transferaisle. There are two basic versions for this:

1. Braking to a halt

2. Braking to 2.5 km/h

Other variants (affecting the subsequent travel speed, lift height etc.) are available.

1. Braking to a halt:

When the truck passes over the aisle end safety magnets heading for the aisle end,it comes to a halt.

To continue traveling:

– Briefly release the foot switch and then apply it again

The truck can be driven out of the narrow aisle at max. 2.5 km/h.

2. Braking to 2.5 km/h

When the truck passes over the aisle end safety magnets heading for the aisle end,it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.

M In both cases the braking distance depends on the travel speed.

F Aisle end safety braking is an additional function designed to support the operator,but which does not release him from any responsiblity, e.g. to monitor braking at theaisle end and if necessary to apply the brakes.

6.8 WG emergency operation

If in a wire guidance system the guiding antenna goes beyond the pre-determinedrange of the guidance wire, an emergency stop is immediately carried out.

If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The“tracking on” display and the audible tracking signal however remain permanently onand hence warn the driver.

Automatic EMERGENCY STOP

If during operation one of the monitors for steering control, steering system, wireguidance or the safety cutout for the traction electronics or power electronics applies,the truck safety devices will cause the truck to stop.

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6.7 Aisle end safety device (o)

Trucks with the aisle end safety device brake before the aisle exit or in the transferaisle. There are two basic versions for this:

1. Braking to a halt

2. Braking to 2.5 km/h

Other variants (affecting the subsequent travel speed, lift height etc.) are available.

1. Braking to a halt:

When the truck passes over the aisle end safety magnets heading for the aisle end,it comes to a halt.

To continue traveling:

– Briefly release the foot switch and then apply it again

The truck can be driven out of the narrow aisle at max. 2.5 km/h.

2. Braking to 2.5 km/h

When the truck passes over the aisle end safety magnets heading for the aisle end,it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.

M In both cases the braking distance depends on the travel speed.

F Aisle end safety braking is an additional function designed to support the operator,but which does not release him from any responsiblity, e.g. to monitor braking at theaisle end and if necessary to apply the brakes.

6.8 WG emergency operation

If in a wire guidance system the guiding antenna goes beyond the pre-determinedrange of the guidance wire, an emergency stop is immediately carried out.

If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The“tracking on” display and the audible tracking signal however remain permanently onand hence warn the driver.

Automatic EMERGENCY STOP

If during operation one of the monitors for steering control, steering system, wireguidance or the safety cutout for the traction electronics or power electronics applies,the truck safety devices will cause the truck to stop.

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To enable the truck to travel again after an EMERGENCY STOP, carry out thefollowing:

– Determine the possible cause of the EMERGENCY STOP.– Press the EMERGENCY STOP switch and turn it again.– Apply inductive automatic steering.– Press the travel lever.

F If the truck now starts, test that it works with manual steering and inductive automaticsteering.

Automatic and manual EMERGENCY STOP

If, after an automatic or manual EMERGENCY STOP and having rectified theproblem, you cannot start the truck again, remove the keyswitch and put it back in.Now carry out a test run as follows:Raise and lower the Main Lift and Aux. Lift in accordance with the symbols until therespective display goes out.

Carry out a test run:

- REF-Test run: Raise Main Lift

- REF-Test run: Lower Main Lift

- REF-Test run: Raise Main Lift

- REF-Test run: Lower Aux. Lift

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To enable the truck to travel again after an EMERGENCY STOP, carry out thefollowing:

– Determine the possible cause of the EMERGENCY STOP.– Press the EMERGENCY STOP switch and turn it again.– Apply inductive automatic steering.– Press the travel lever.

F If the truck now starts, test that it works with manual steering and inductive automaticsteering.

Automatic and manual EMERGENCY STOP

If, after an automatic or manual EMERGENCY STOP and having rectified theproblem, you cannot start the truck again, remove the keyswitch and put it back in.Now carry out a test run as follows:Raise and lower the Main Lift and Aux. Lift in accordance with the symbols until therespective display goes out.

Carry out a test run:

- REF-Test run: Raise Main Lift

- REF-Test run: Lower Main Lift

- REF-Test run: Raise Main Lift

- REF-Test run: Lower Aux. Lift

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6.9 Recovering the truck from a narrow aisle / Moving the truck without a battery

F Before recovering the truck from a narrow aisle, disconnect the battery.

M This operation can only be performed by a specialist service engineer speciallytrained in operating the truck.

When the brakes are de-activated the truck must be parked on an even ground as thebrakes are no longer effective.

– Fully lower the mast

Z Obtain the help of another person. The other person must be trained and familiar withrecovery operations.

To recover the truck from the aisle, release the brakes.

Release the magnetic brake

– Remove the electronic compartment cover at the back.– Screw in the setscrews (41) on the magnetic brake above the traction motor to

release it.– Attach the tow rope to the service openings (40) and carefully pull the truck out of

the narrow aisle.– When bring the truck back into operation:

Check the brake retardation value.

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6.9 Recovering the truck from a narrow aisle / Moving the truck without a battery

F Before recovering the truck from a narrow aisle, disconnect the battery.

M This operation can only be performed by a specialist service engineer speciallytrained in operating the truck.

When the brakes are de-activated the truck must be parked on an even ground as thebrakes are no longer effective.

– Fully lower the mast

Z Obtain the help of another person. The other person must be trained and familiar withrecovery operations.

To recover the truck from the aisle, release the brakes.

Release the magnetic brake

– Remove the electronic compartment cover at the back.– Screw in the setscrews (41) on the magnetic brake above the traction motor to

release it.– Attach the tow rope to the service openings (40) and carefully pull the truck out of

the narrow aisle.– When bring the truck back into operation:

Check the brake retardation value.

41

40

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E 30

Dismantling the hydraulic brake

– Remove the electronic compartment cover at the back.– Remove the protective cap (43) from the discharge valve.– Push the hose (44) onto the vent connectino and insert the other end of the hose

in the brake fluid container (45) above it.

F Brake fluid container is pressurised. Risk of scalding.

– Open the discharge valve (42) and drain the brake fluid into the brake fluidcontainer.

– Close the discharge valve and brake fluid container.

Z Switch on the truck and press the foot switch several times to restore the functionalityof the brake system.

M Check the brake retardation.

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E 30

Dismantling the hydraulic brake

– Remove the electronic compartment cover at the back.– Remove the protective cap (43) from the discharge valve.– Push the hose (44) onto the vent connectino and insert the other end of the hose

in the brake fluid container (45) above it.

F Brake fluid container is pressurised. Risk of scalding.

– Open the discharge valve (42) and drain the brake fluid into the brake fluidcontainer.

– Close the discharge valve and brake fluid container.

Z Switch on the truck and press the foot switch several times to restore the functionalityof the brake system.

M Check the brake retardation.

E 31

0206

.GBAdjust the steering angle

F The battery must be disconnected whenadjusting the steering angle.

Using an Allen key set the steered wheelto the required direction via the screw inthe steering motor (46).

Z It is advisable to discharge the wheel ifsetting an angle greater than 4 degrees.

46

E 31

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Adjust the steering angle

F The battery must be disconnected whenadjusting the steering angle.

Using an Allen key set the steered wheelto the required direction via the screw inthe steering motor (46).

Z It is advisable to discharge the wheel ifsetting an angle greater than 4 degrees.

46

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E 32

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E 32

F 1

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F Maintenance of the forklift truck1 Operational safety and environmental protection

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

F Modifications to the forklift truck, especially to the safety devices, are not permitted.The operational speeds of the truck must not be changed under any circumstances.

M Only original spare parts come under the remit of our quality assurance service. Toensure safe and reliable operation of the forklift truck, only use the manufacturer’sspare parts. Used parts, oils and fuels must be disposed of in accordance with theapplicable environmental protection regulations. For oil changes, contact themanufacturer’s oil service department.

Upon completion of inspection and servicing, carry out the tasks contained in the„Recommissioning“ section (see Chapter F).

2 Maintenance Safety Regulations

Maintenance personnel: The forklift truck must only be serviced and maintained bytrained personnel provided by the manufacturer. The manufacturer’s servicedepartment has specially trained field engineers for this work. We thereforerecommend a maintenance contract with the manufacturer’s local service centre.

Lifting and jacking up: When a forklift truck is to be lifted, the lifting gear must onlybe secured to the points specially provided for this purpose. When the truck is to bejacked up, take appropriate measures to prevent the truck from slipping or tippingover (e.g. wedges, wooden blocks). Only work under a raised load handler and cabif they are secured by a chain of sufficient capacity or by the retaining bolt (see “Se-curing the Driver's Position Carriage” in Chapter F).

Z Jacking point see chapter B.

Cleaning: No inflammable liquids may be used to clean the forklift truck. Prior tocleaning, all safety measures required to prevent sparking (e.g. through short circuits)must be taken. For battery-operated trucks, the battery connector must be removed.Only weak suction or compressed air and non-conductive antistatic brushes may beused for cleaning electrical or electronic assemblies.

M If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfuntions.Do not clean with steam jets.

After cleaning, carry out the tasks detailed in the „Recommissioning“ section.

F 1

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F Maintenance of the forklift truck1 Operational safety and environmental protection

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

F Modifications to the forklift truck, especially to the safety devices, are not permitted.The operational speeds of the truck must not be changed under any circumstances.

M Only original spare parts come under the remit of our quality assurance service. Toensure safe and reliable operation of the forklift truck, only use the manufacturer’sspare parts. Used parts, oils and fuels must be disposed of in accordance with theapplicable environmental protection regulations. For oil changes, contact themanufacturer’s oil service department.

Upon completion of inspection and servicing, carry out the tasks contained in the„Recommissioning“ section (see Chapter F).

2 Maintenance Safety Regulations

Maintenance personnel: The forklift truck must only be serviced and maintained bytrained personnel provided by the manufacturer. The manufacturer’s servicedepartment has specially trained field engineers for this work. We thereforerecommend a maintenance contract with the manufacturer’s local service centre.

Lifting and jacking up: When a forklift truck is to be lifted, the lifting gear must onlybe secured to the points specially provided for this purpose. When the truck is to bejacked up, take appropriate measures to prevent the truck from slipping or tippingover (e.g. wedges, wooden blocks). Only work under a raised load handler and cabif they are secured by a chain of sufficient capacity or by the retaining bolt (see “Se-curing the Driver's Position Carriage” in Chapter F).

Z Jacking point see chapter B.

Cleaning: No inflammable liquids may be used to clean the forklift truck. Prior tocleaning, all safety measures required to prevent sparking (e.g. through short circuits)must be taken. For battery-operated trucks, the battery connector must be removed.Only weak suction or compressed air and non-conductive antistatic brushes may beused for cleaning electrical or electronic assemblies.

M If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfuntions.Do not clean with steam jets.

After cleaning, carry out the tasks detailed in the „Recommissioning“ section.

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F 2

Electrical System: Work on the electrical system may only be performed by trainedpersonnel. Before commencing work on the electrical system, take all precautionarymeasures to avoid electric shocks. For battery-operated trucks, also de-energise thetruck by removing the battery connector.

Welding: To avoid damaging electrical or electronic components, remove them fromthe truck before performing welding operations.

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, always keep the truck-specific settings.

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 spareparts. Otherwise the truck's rated performance cannot be ensured.When replacing wheels, ensure that the truck does not slew (e.g. always replace leftand right wheels at the same time)

Lift chains: Lift chains wear rapidly if not properly lubricated. The intervals given inthe service checklist apply to normal duty. More demanding conditions (dust,temperature) require more regular lubrication. The prescribed chain spray must beused in accordance with the instructions. Applying grease externally will not providesufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years.

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F 2

Electrical System: Work on the electrical system may only be performed by trainedpersonnel. Before commencing work on the electrical system, take all precautionarymeasures to avoid electric shocks. For battery-operated trucks, also de-energise thetruck by removing the battery connector.

Welding: To avoid damaging electrical or electronic components, remove them fromthe truck before performing welding operations.

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, always keep the truck-specific settings.

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 spareparts. Otherwise the truck's rated performance cannot be ensured.When replacing wheels, ensure that the truck does not slew (e.g. always replace leftand right wheels at the same time)

Lift chains: Lift chains wear rapidly if not properly lubricated. The intervals given inthe service checklist apply to normal duty. More demanding conditions (dust,temperature) require more regular lubrication. The prescribed chain spray must beused in accordance with the instructions. Applying grease externally will not providesufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years.

F 3

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3 Servicing and inspection

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

M The application conditions of an industrial truck considerably affect the wear levels ofthe service components. We recommend an application analysis carried out on site by a Jungheinrichcustomer adviser to establish specific maintenance intervals in order to restrictdamage caused by wear.The service intervals listed are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of heavy dust, temperature fluctuations or multiple shifts.

The following service checklist indicates the tasks to be performed and the respectiveintervals to be observed. The service intervals are defined as follows:

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

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

F 3

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3 Servicing and inspection

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

M The application conditions of an industrial truck considerably affect the wear levels ofthe service components. We recommend an application analysis carried out on site by a Jungheinrichcustomer adviser to establish specific maintenance intervals in order to restrictdamage caused by wear.The service intervals listed are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of heavy dust, temperature fluctuations or multiple shifts.

The following service checklist indicates the tasks to be performed and the respectiveintervals to be observed. The service intervals are defined as follows:

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

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

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F 4

4 EKS 310 maintenance checklist

Maintenance intervalsStandard = t W A B C

Chassis/Super-structure:

1.1 Check all load bearing items for damage t1.2 Check screw connections t1.3 Test the operator’s platform and check for damage t1.4 Check that identification points, data plates and

warnings are legible and replace if necessaryt

Drive: 2.1 Lubricate the bearing between traction motor and transmission

t

2.2 Check transmission for noise and leakage t2.3 Change transmission oil t

Wheels: 3.1 Check wheels for wear and damage t3.2 Check bearings and attachment t

Steering: 4.1 Test operation and setting of wheel setting display t4.2 Check the distance between the guide rollers and the

rail guidance over the entire length of the rails. The play between the two guide rollers and the rails (measured over the axle) should be 0-5 mm. The rollers should not jam.

t

Brake system:

5.1 Test operation and settings t5.2 Check the brake lining wear t5.3 Check brake mechanism, adjust and lubricate if

necessaryt

5.4 Check brake lines, connections and brake fluid level t5.5 Check brake fluid t5.6 Replace brake fluide t

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F 4

4 EKS 310 maintenance checklist

Maintenance intervalsStandard = t W A B C

Chassis/Super-structure:

1.1 Check all load bearing items for damage t1.2 Check screw connections t1.3 Test the operator’s platform and check for damage t1.4 Check that identification points, data plates and

warnings are legible and replace if necessaryt

Drive: 2.1 Lubricate the bearing between traction motor and transmission

t

2.2 Check transmission for noise and leakage t2.3 Change transmission oil t

Wheels: 3.1 Check wheels for wear and damage t3.2 Check bearings and attachment t

Steering: 4.1 Test operation and setting of wheel setting display t4.2 Check the distance between the guide rollers and the

rail guidance over the entire length of the rails. The play between the two guide rollers and the rails (measured over the axle) should be 0-5 mm. The rollers should not jam.

t

Brake system:

5.1 Test operation and settings t5.2 Check the brake lining wear t5.3 Check brake mechanism, adjust and lubricate if

necessaryt

5.4 Check brake lines, connections and brake fluid level t5.5 Check brake fluid t5.6 Replace brake fluide t

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p) Replace hydraulic hoses after 6 years' operation

Maintenance intervalsStandard = t W A B C

Hydraulic System:

6.1 Test operation t6.2 Check connections and ports for leaks and damage t6.3 Check hydraulic cylinder for leaks and damage and

make sure it is securet

6.4 Check oil level t6.5 Test the hoses and check for damage t6.6 Check ventilation and discharge filter on hydraulic

reservoirt

6.7 Replace ventilation and discharge filter on hydraulic reservoir

t

6.8 Replace hydraulic oil and filter cartridge t6.9 Test pressure relief valves t6.10 Make sure hydraulic hoses are sealed and check for

damage. p)t

6.11 Test line brake safety device tElectrical System:

7.1 Test static charge eliminator t7.2 Test operation t7.3 Make sure wire connections are secure and check for

wire damaget

7.4 Test cable guide operation and check for damage t7.5 Test operation of warning devices and safety switches. t7.6 Make sure sensors are fixed, not damaged, clean and

operationalt

7.7 Test operation of controls and displays. t7.8 Check contactors and relays; if necessary replace worn

partst

7.9 Check fuse rating tElectric motors:

8.2 Check motor attachment t

Battery: 9.1 Check acid density, acid level and cell voltage t9.2 Check terminals are securely attached, and apply

greaset

9.3 Clean battery plug connections, make sure they are firmly secured

t

9.4 Check battery cables for damage, replace if necessary. t

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p) Replace hydraulic hoses after 6 years' operation

Maintenance intervalsStandard = t W A B C

Hydraulic System:

6.1 Test operation t6.2 Check connections and ports for leaks and damage t6.3 Check hydraulic cylinder for leaks and damage and

make sure it is securet

6.4 Check oil level t6.5 Test the hoses and check for damage t6.6 Check ventilation and discharge filter on hydraulic

reservoirt

6.7 Replace ventilation and discharge filter on hydraulic reservoir

t

6.8 Replace hydraulic oil and filter cartridge t6.9 Test pressure relief valves t6.10 Make sure hydraulic hoses are sealed and check for

damage. p)t

6.11 Test line brake safety device tElectrical System:

7.1 Test static charge eliminator t7.2 Test operation t7.3 Make sure wire connections are secure and check for

wire damaget

7.4 Test cable guide operation and check for damage t7.5 Test operation of warning devices and safety switches. t7.6 Make sure sensors are fixed, not damaged, clean and

operationalt

7.7 Test operation of controls and displays. t7.8 Check contactors and relays; if necessary replace worn

partst

7.9 Check fuse rating tElectric motors:

8.2 Check motor attachment t

Battery: 9.1 Check acid density, acid level and cell voltage t9.2 Check terminals are securely attached, and apply

greaset

9.3 Clean battery plug connections, make sure they are firmly secured

t

9.4 Check battery cables for damage, replace if necessary. t

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F 6

e) IG: inductive guidance trucks

Maintenance intervalsStandard = t W A B C

Lift mechanism:

10.1 Clean rollers, guide rollers and contact surfaces in the mast sections and apply grease.

M Warning: Danger of crashing!

t

10.2 Check mast attachments (bearings and retaining screws)

t

10.3 Check lift chains and chain guide for wear, adjust and lubricate

t

10.4 Lubricate lift chains t10.5 Visually inspect rollers, slide pieces and stops t

Attachments: 11.1 Test operation and settings t11.2 Check attachment on truck and load bearing items t11.3 Check forks and fork carriage for wear and damage t11.4 Lubricate fork carriage rollers t

Lubrication: 12.1 Lubricate the truck according to the lubrication schedule tGeneral mea-surements:

13.1 Check electrical system for accidental earth t13.2 Check travel speed and braking distance t13.3 Check lift and lowering speeds t13.4 Check safety devices and cutouts t13.5 IG: Measure the current in the guidance wire, adjust if

necessary e)t

13.6 Check travel on the IG wire, check maximum deviation and adjust if necessary e)

t

13.7 Check tracking mode on the IG wire for aisle tracking. e)

t

13.8 Check IG EMERGENCY STOP operation e) tDemons-tration:

14.1 Test run with rated load t14.2 When maintenance is completed, present the truck to

the responsible person.t

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F 6

e) IG: inductive guidance trucks

Maintenance intervalsStandard = t W A B C

Lift mechanism:

10.1 Clean rollers, guide rollers and contact surfaces in the mast sections and apply grease.

M Warning: Danger of crashing!

t

10.2 Check mast attachments (bearings and retaining screws)

t

10.3 Check lift chains and chain guide for wear, adjust and lubricate

t

10.4 Lubricate lift chains t10.5 Visually inspect rollers, slide pieces and stops t

Attachments: 11.1 Test operation and settings t11.2 Check attachment on truck and load bearing items t11.3 Check forks and fork carriage for wear and damage t11.4 Lubricate fork carriage rollers t

Lubrication: 12.1 Lubricate the truck according to the lubrication schedule tGeneral mea-surements:

13.1 Check electrical system for accidental earth t13.2 Check travel speed and braking distance t13.3 Check lift and lowering speeds t13.4 Check safety devices and cutouts t13.5 IG: Measure the current in the guidance wire, adjust if

necessary e)t

13.6 Check travel on the IG wire, check maximum deviation and adjust if necessary e)

t

13.7 Check tracking mode on the IG wire for aisle tracking. e)

t

13.8 Check IG EMERGENCY STOP operation e) tDemons-tration:

14.1 Test run with rated load t14.2 When maintenance is completed, present the truck to

the responsible person.t

F 7

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g Slide surfaces a Transmission oil drain plugs Grease nipple

Hydraulic oil filler neck

c Hydraulic oil drain plug

G

G

H

E

B

E G

AE

F 7

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Lubrication Schedule

g Slide surfaces a Transmission oil drain plugs Grease nipple

Hydraulic oil filler neck

c Hydraulic oil drain plug

G

G

H

E

B

E G

AE

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F 8

4.1 Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Followthe manufacturer’s instructions.

F Improper handling is hazardous to health, life and the environment. Consumablesmust only be stored in appropriate containers. They may be flammable and musttherefore not come into contact with hot components or naked flames.

Consumables must always be stored in clean containers only. The mixing of differentgrade consumables is forbidden. The only exception to this is when mixing isexpressly stipulated in the operator manual.

Avoid spillage. Spilled liquids must be removed immediately with suitable bondingagents and the bonding agent / consumable mixture must be dispoed of according toregulations.

* Plus 2% additive 68 ID (order no. 50307735)

F The trucks are supplied from the factory with “HLP D22” hydraulic oil or the“Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive. You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The sameapplies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.

Code Order No. Quantity delivered

Filling quantity

Designation Used for

A

5103749751037494

5 l1 l

ca. 33 l

HLP D22 + 2%of 68 ID additive

Hydraulic system51085361* 5 l Plantohyd 22 S

(BIO hydraulic oil)B 50022968 5 l 2.5 l SAE 80 EP API GL4 Transmission

D 29201580 5 l 0.18 l Brake fluidSAE DOT 4 Hydraulic brake system

E14038650 400 g

cartridge ---Lithium-saponified grease KP2K-30 (DIN 51825)

General29201430 1 kg

G 29201280 400 ml --- Chain sprayTunfluid LT 220

Lifting mast sliding track, lifting chains

H 50157382 1 kg 400 gLithium-saponified grease K3K-20(DIN 51825)

Front wheel bearings

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F 8

4.1 Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Followthe manufacturer’s instructions.

F Improper handling is hazardous to health, life and the environment. Consumablesmust only be stored in appropriate containers. They may be flammable and musttherefore not come into contact with hot components or naked flames.

Consumables must always be stored in clean containers only. The mixing of differentgrade consumables is forbidden. The only exception to this is when mixing isexpressly stipulated in the operator manual.

Avoid spillage. Spilled liquids must be removed immediately with suitable bondingagents and the bonding agent / consumable mixture must be dispoed of according toregulations.

* Plus 2% additive 68 ID (order no. 50307735)

F The trucks are supplied from the factory with “HLP D22” hydraulic oil or the“Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive. You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The sameapplies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.

Code Order No. Quantity delivered

Filling quantity

Designation Used for

A

5103749751037494

5 l1 l

ca. 33 l

HLP D22 + 2%of 68 ID additive

Hydraulic system51085361* 5 l Plantohyd 22 S

(BIO hydraulic oil)B 50022968 5 l 2.5 l SAE 80 EP API GL4 Transmission

D 29201580 5 l 0.18 l Brake fluidSAE DOT 4 Hydraulic brake system

E14038650 400 g

cartridge ---Lithium-saponified grease KP2K-30 (DIN 51825)

General29201430 1 kg

G 29201280 400 ml --- Chain sprayTunfluid LT 220

Lifting mast sliding track, lifting chains

H 50157382 1 kg 400 gLithium-saponified grease K3K-20(DIN 51825)

Front wheel bearings

F 9

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5 Maintenance and Repairs

M Load bearing parts of the truck, e. g. chassis and mast, may only be welded afterconsultation with the manufacturer.

5.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents during maintenanceand repair work. The following preparations must be made:

– Park the truck securely (See Chapter E).– Disconnect the battery to prevent the truck from being switched on accidentally– When working under a raised lift truck, secure it to prevent it from lowering, tipping

or sliding away.

F When working under a raised load fork or a raised truck, secure them to prevent themfrom lowering, tipping or sliding away. When raising the truck also refer to theinstructions in the „Transport and Commissioning“ section.When working on the parking brake, prevent the truck from rolling away.

F 9

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5 Maintenance and Repairs

M Load bearing parts of the truck, e. g. chassis and mast, may only be welded afterconsultation with the manufacturer.

5.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents during maintenanceand repair work. The following preparations must be made:

– Park the truck securely (See Chapter E).– Disconnect the battery to prevent the truck from being switched on accidentally– When working under a raised lift truck, secure it to prevent it from lowering, tipping

or sliding away.

F When working under a raised load fork or a raised truck, secure them to prevent themfrom lowering, tipping or sliding away. When raising the truck also refer to theinstructions in the „Transport and Commissioning“ section.When working on the parking brake, prevent the truck from rolling away.

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F 10

5.2 Securing the driver’s position carriage

The driver’s position carriage can besecured in the raised position.– Raise the driver’s position carriage

until the inner mast (1) is above thecarriage (2) of the load lifting safetydevice.

– Unscrew the attachment screw (4)and remove the retaining bolt (3) fromthe carriage (2) on the mast.

– Place the retaining bolt (3) on thevertical hole of the carriage (2) andsecure them.

– Very slowly lower the driver’s positioncarriage until the inner mast (1) ispositioned on the retaining bolt.

5.3 Maintaining the lift chains

M It is important that all lift chains and pivots are at all times kept clean and welllubricated. Only lubricate discharged chains. A chain must be lubricated withparticular care where it passes over a deflection pulley. Lift chains are safety-criticalparts.Chains should not have any major contamination. They should only be cleaned withparafin derivatives e. g. petroleum or diesel fuels. Never clean chains with steam jethigh pressure cleaners, cold or chemical cleaning agents.

5.4 Inspecting the lift chains

Unauthorised wear and external damage:

In accordance with official regualtions, a chain is considered to be worn if it hasextended in length by 3% in the section which passes over the deflection pulley. Forsafety reasons, we advise replacing chains when they elongate by 2%.Chains should also be replaced immediately when visible damage is noted, as suchdamage leads to permanent breakage after a certain time.

M If the truck is fitted with two lift chains, both chains must always be replaced. This isthe only way to ensure even load distribution over the two chains. When replacingchains the connecting bolts between the chain anchor and the chain must bereplaced. Only new original parts may be used.

1

3

4

2

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F 10

5.2 Securing the driver’s position carriage

The driver’s position carriage can besecured in the raised position.– Raise the driver’s position carriage

until the inner mast (1) is above thecarriage (2) of the load lifting safetydevice.

– Unscrew the attachment screw (4)and remove the retaining bolt (3) fromthe carriage (2) on the mast.

– Place the retaining bolt (3) on thevertical hole of the carriage (2) andsecure them.

– Very slowly lower the driver’s positioncarriage until the inner mast (1) ispositioned on the retaining bolt.

5.3 Maintaining the lift chains

M It is important that all lift chains and pivots are at all times kept clean and welllubricated. Only lubricate discharged chains. A chain must be lubricated withparticular care where it passes over a deflection pulley. Lift chains are safety-criticalparts.Chains should not have any major contamination. They should only be cleaned withparafin derivatives e. g. petroleum or diesel fuels. Never clean chains with steam jethigh pressure cleaners, cold or chemical cleaning agents.

5.4 Inspecting the lift chains

Unauthorised wear and external damage:

In accordance with official regualtions, a chain is considered to be worn if it hasextended in length by 3% in the section which passes over the deflection pulley. Forsafety reasons, we advise replacing chains when they elongate by 2%.Chains should also be replaced immediately when visible damage is noted, as suchdamage leads to permanent breakage after a certain time.

M If the truck is fitted with two lift chains, both chains must always be replaced. This isthe only way to ensure even load distribution over the two chains. When replacingchains the connecting bolts between the chain anchor and the chain must bereplaced. Only new original parts may be used.

1

3

4

2

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5.5 Cleaning the discharge filter

Unscrew the discharge filter and the oildipstick (5) and clean with compressedair or a cleaning agent.

M Dispose of used filters in the correctmanner.

5.6 Replacing the hydraulic oil filter

– Unscrew the hydraulic oil filter sealingcap (6).

– Replace filter insert and O ring. Apply a thin layer of oil to the O-ring oninstallation.

– Screw the sealing cap back on.

5

6

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5.5 Cleaning the discharge filter

Unscrew the discharge filter and the oildipstick (5) and clean with compressedair or a cleaning agent.

M Dispose of used filters in the correctmanner.

5.6 Replacing the hydraulic oil filter

– Unscrew the hydraulic oil filter sealingcap (6).

– Replace filter insert and O ring. Apply a thin layer of oil to the O-ring oninstallation.

– Screw the sealing cap back on.

5

6

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F 12

5.7 Hydraulic oil

– Preparing the truck for maintenance and repairs

M Oil must never be allowed to enter the drainage system or the soil. Used oil must bepreserved until it can be disposed of in the correct manner.

Draining oil:

Suction off the hydraulic oil with thedischarge filter removed (5). If this is notpossible, the hydraulic oil can be drainedfrom the bottom of the hydraulicreservoir after the oil drain screw (8a)has been unscrewed.

Adding oil:

Screw in the oil drain screw (8a).Replenish with new hydraulic oil up tothe Max. mark on the dipstick (7). Screwthe discharge filter backon.

F Check which hydraulic oil is being added. If Plantohyd 22 SBIO hydraulic oil is being used, the warning: “Only add BIOhydraulic oil” (8b) will be on the hydraulic reservoir. In this caseyou may only use Hydrauliköl „Plantohyd 22 S BIO hydraulicoil to fill the hydraulic reservoir.

F You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The sameapplies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.

Checking the hydraulic oil level

When the mast is fully lowered, check that the hydraulic oil level is between the min.and max. markings on the dipstick (7).If this is not the case, add new hydraulic oil.

5

7

8a

8b

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F 12

5.7 Hydraulic oil

– Preparing the truck for maintenance and repairs

M Oil must never be allowed to enter the drainage system or the soil. Used oil must bepreserved until it can be disposed of in the correct manner.

Draining oil:

Suction off the hydraulic oil with thedischarge filter removed (5). If this is notpossible, the hydraulic oil can be drainedfrom the bottom of the hydraulicreservoir after the oil drain screw (8a)has been unscrewed.

Adding oil:

Screw in the oil drain screw (8a).Replenish with new hydraulic oil up tothe Max. mark on the dipstick (7). Screwthe discharge filter backon.

F Check which hydraulic oil is being added. If Plantohyd 22 SBIO hydraulic oil is being used, the warning: “Only add BIOhydraulic oil” (8b) will be on the hydraulic reservoir. In this caseyou may only use Hydrauliköl „Plantohyd 22 S BIO hydraulicoil to fill the hydraulic reservoir.

F You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The sameapplies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.

Checking the hydraulic oil level

When the mast is fully lowered, check that the hydraulic oil level is between the min.and max. markings on the dipstick (7).If this is not the case, add new hydraulic oil.

5

7

8a

8b

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5.8 Hydraulic hoses

Hose lines must be replaced every six years, see Safety Regulations for HydraulicHose Lines ZH 1/74.

5.9 Check brake fluid

F The brake fluid is poisonous and shouldtherefore only be kept in sealed originalcontainers. Also note that brake fluid willattack the truck’s paint.

M Brake fluid is added in the factory andmust be replaced after 12 months at thelatest, as it changes over time and losesits original qualities.

The brake fluid storage container (9) islocated at the rear of the truck and canbe accessed by removing the panel. Thestorage container should also be filledup to 2 cm below the lid.Only use the prescribed brake fluid.Make sure the entire brake system is fully sealed.

9

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5.8 Hydraulic hoses

Hose lines must be replaced every six years, see Safety Regulations for HydraulicHose Lines ZH 1/74.

5.9 Check brake fluid

F The brake fluid is poisonous and shouldtherefore only be kept in sealed originalcontainers. Also note that brake fluid willattack the truck’s paint.

M Brake fluid is added in the factory andmust be replaced after 12 months at thelatest, as it changes over time and losesits original qualities.

The brake fluid storage container (9) islocated at the rear of the truck and canbe accessed by removing the panel. Thestorage container should also be filledup to 2 cm below the lid.Only use the prescribed brake fluid.Make sure the entire brake system is fully sealed.

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5.10 Checking electrical fuses

F Electric fuses must only be checked and replaced by authorized personnel.

– Prepare the truck for maintenance and repairs (see Chapter F).

– Check all fuse ratings in accordance with the table; replace if necessary.

F Only use the rating indicated on the controller. DIN and EN standardised fuses mustnot be used for UL standardised fuses. The opposite also applies.

Item Description To protect: Rating10 1F11 Travel 160A (DIN, EN) 250A (UL)11 3F10 Steering 35A (DIN, EN) 35A (UL)12 2F15 Hydraulics 250A (DIN, EN) 400A (UL)13 F2.1 DC/DC converter U1 input 48 V 48V / 10A (UL)14 5F1 Lighting and special equipment 48 V 48V / 10A (UL)15 F3.1 DC/DC converter U1 output 24 V 24V / 10A (UL)16 F1.2 DC/DC converter U16 input 48 V 48V / 4A (UL)17 5F2 DC/DC converter U16 output 24 V 24V / 6,3A (UL)18 1F3 Drive controller 1A (UL)

1011

12

13 14

18 17 16 15

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5.10 Checking electrical fuses

F Electric fuses must only be checked and replaced by authorized personnel.

– Prepare the truck for maintenance and repairs (see Chapter F).

– Check all fuse ratings in accordance with the table; replace if necessary.

F Only use the rating indicated on the controller. DIN and EN standardised fuses mustnot be used for UL standardised fuses. The opposite also applies.

Item Description To protect: Rating10 1F11 Travel 160A (DIN, EN) 250A (UL)11 3F10 Steering 35A (DIN, EN) 35A (UL)12 2F15 Hydraulics 250A (DIN, EN) 400A (UL)13 F2.1 DC/DC converter U1 input 48 V 48V / 10A (UL)14 5F1 Lighting and special equipment 48 V 48V / 10A (UL)15 F3.1 DC/DC converter U1 output 24 V 24V / 10A (UL)16 F1.2 DC/DC converter U16 input 48 V 48V / 4A (UL)17 5F2 DC/DC converter U16 output 24 V 24V / 6,3A (UL)18 1F3 Drive controller 1A (UL)

1011

12

13 14

18 17 16 15

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5.11 Recommissioning

Recommissioning after cleaning or repair work is permitted only after the followingoperations have been performed.

– Test horn operation.– Test EMERGENCY DISCONNECT switch.– Test brake operation.– Lubricate the truck in accordance with the lubrication chart.

6 Decommissioning the forklift truck

If the forklift truck is to be decommissioned for more than one month, e.g. foroperational reasons, it must be parked in a frost-free and dry location and allnecessary measures must be taken before, during and after decommissioning asdescribed.

M During decommissioning the truck must be jacked up so that all the wheels are clearof the ground. This is the only way of ensuring that the wheels and wheel bearingsare not damaged.

If the truck is to be out of service for more than 6 months, further measures must betaken in consultation with the manufacturer.

6.1 Prior to decommissioning:

– Thoroughly clean the truck.– Check the brakes.– Check the hydraulic oil level and replenish as necessary (see Chapter F).– Apply a think film of oil or grease to all parts not protected by a coating of paint.– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).– Charge the battery (see Chapter D).– Disconnect the battery, clean it and apply grease to the terminals.

Z In addition, observe the battery manufacturer’s instructions.

– Apply a suitable contact spray to all exposed electrical contacts.

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5.11 Recommissioning

Recommissioning after cleaning or repair work is permitted only after the followingoperations have been performed.

– Test horn operation.– Test EMERGENCY DISCONNECT switch.– Test brake operation.– Lubricate the truck in accordance with the lubrication chart.

6 Decommissioning the forklift truck

If the forklift truck is to be decommissioned for more than one month, e.g. foroperational reasons, it must be parked in a frost-free and dry location and allnecessary measures must be taken before, during and after decommissioning asdescribed.

M During decommissioning the truck must be jacked up so that all the wheels are clearof the ground. This is the only way of ensuring that the wheels and wheel bearingsare not damaged.

If the truck is to be out of service for more than 6 months, further measures must betaken in consultation with the manufacturer.

6.1 Prior to decommissioning:

– Thoroughly clean the truck.– Check the brakes.– Check the hydraulic oil level and replenish as necessary (see Chapter F).– Apply a think film of oil or grease to all parts not protected by a coating of paint.– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).– Charge the battery (see Chapter D).– Disconnect the battery, clean it and apply grease to the terminals.

Z In addition, observe the battery manufacturer’s instructions.

– Apply a suitable contact spray to all exposed electrical contacts.

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6.2 During decommissioning:

Every 2 months:

– Charge the battery (see Chapter D).

M Battery powered trucks:The battery must be charged at regular intervals to avoid depletion of the batterythrough self-discharge. The sulfatisation would destroy the battery.

6.3 Recommissioning

– Thoroughly clean the truck.– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).– Clean the battery, grease the terminals and connect the battery.– Charge the battery (see Chapter D).– Check transmission oil for condensed water and replace if necessary.– Check hydraulic oil for condensed water and replace if necessary.– Start up the truck (see Chapter E).

Z Battery powered trucks:If there are switching problems in the electrical system, apply contact spray to theexposed contacts and remove any oxide layers on the contacts of the operatingcontrols by applying them repeatedly.

F Perform several brake tests immediately after starting the truck again.

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6.2 During decommissioning:

Every 2 months:

– Charge the battery (see Chapter D).

M Battery powered trucks:The battery must be charged at regular intervals to avoid depletion of the batterythrough self-discharge. The sulfatisation would destroy the battery.

6.3 Recommissioning

– Thoroughly clean the truck.– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).– Clean the battery, grease the terminals and connect the battery.– Charge the battery (see Chapter D).– Check transmission oil for condensed water and replace if necessary.– Check hydraulic oil for condensed water and replace if necessary.– Start up the truck (see Chapter E).

Z Battery powered trucks:If there are switching problems in the electrical system, apply contact spray to theexposed contacts and remove any oxide layers on the contacts of the operatingcontrols by applying them repeatedly.

F Perform several brake tests immediately after starting the truck again.

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7 Safety checks to be performed at regular intervals and following any unusualincidents

Z Carry out a safety check in accordance with national regulations. Junheinrichrecommends checks in accordance with FEM Guideline 4.004. Jungheinrich has aspecial safety department with trained personnel to carry out such checks.

The truck must be inspected at least annually (refer to national regulations) or afterany unusual event by a qualified inspector. The inspector shall assess the conditionof the truck from purely a safety viewpoint, without regard to operational or economiccircumstances. The inspector shall be sufficiently instructed and experienced to beable to assess the condition of the truck and the effectiveness of the safetymechanisms based on the technical regulations and principles governing theinspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical conditionfrom a safety aspect. The truck must also be examined for damage caused bypossible improper use. A test report shall be provided. The test results must be keptfor at least the next 2 inspections.

The owner is responsible for ensuring that faults are 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.

8 Final de-commissioning, disposal

Z Final, proper decommissioning or disposal of the truck must be performed inaccordance with the regulations of the country of application. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

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7 Safety checks to be performed at regular intervals and following any unusualincidents

Z Carry out a safety check in accordance with national regulations. Junheinrichrecommends checks in accordance with FEM Guideline 4.004. Jungheinrich has aspecial safety department with trained personnel to carry out such checks.

The truck must be inspected at least annually (refer to national regulations) or afterany unusual event by a qualified inspector. The inspector shall assess the conditionof the truck from purely a safety viewpoint, without regard to operational or economiccircumstances. The inspector shall be sufficiently instructed and experienced to beable to assess the condition of the truck and the effectiveness of the safetymechanisms based on the technical regulations and principles governing theinspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical conditionfrom a safety aspect. The truck must also be examined for damage caused bypossible improper use. A test report shall be provided. The test results must be keptfor at least the next 2 inspections.

The owner is responsible for ensuring that faults are 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.

8 Final de-commissioning, disposal

Z Final, proper decommissioning or disposal of the truck must be performed inaccordance with the regulations of the country of application. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

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Instructions for use

Jungheinrich traction battery

Table of contents1 Jungheinrich traction battery

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

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

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

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

Type plate Jungheinrich traction battery............................................17

1

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Instructions for use

Jungheinrich traction battery

Table of contents1 Jungheinrich traction battery

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

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

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

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

Type plate Jungheinrich traction battery............................................17

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1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB

Rating Data

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

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

5. Rated temperature: 30° C6. Nominal electrolyte level: up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles.

•Pay attention to the operation instruction and fix them close to the battery!•Work on batteries to be carried out by skilled personnel only!

•Use protective glasses and clothes when working on batteries!•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN 50110-1!

•No smoking!•Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the battery to explode!

•Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately!•Clothing contaminated by acid should be washed in water.

•Risk of explosion and fire, avoid short circuits!

•Electrolyte is highly corrosive!

•Batteries and cells are heavy!•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.

•Dangerous electrical voltage!•Caution! Metal parts of the battery are always live. Do not place tools or other me-tal objects on the battery!

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1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB

Rating Data

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

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

5. Rated temperature: 30° C6. Nominal electrolyte level: up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles.

•Pay attention to the operation instruction and fix them close to the battery!•Work on batteries to be carried out by skilled personnel only!

•Use protective glasses and clothes when working on batteries!•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN 50110-1!

•No smoking!•Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the battery to explode!

•Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately!•Clothing contaminated by acid should be washed in water.

•Risk of explosion and fire, avoid short circuits!

•Electrolyte is highly corrosive!

•Batteries and cells are heavy!•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.

•Dangerous electrical voltage!•Caution! Metal parts of the battery are always live. Do not place tools or other me-tal objects on the battery!

3

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

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

The battery should be inspected to ensure it is in perfect physical condition.

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

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

The level of the electrolyte must be checked. If it is below the antisurge baffle or thetop of the separator it must first be topped up to this height with purified water.

The battery is then charged as in item 2.2.

The electrolyte should be topped up to the specified level with purified water.

2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-plies to the operation traction batteries in industrial trucks.

2.1 Discharging

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

Electrical connections (e.g. plugs) must only be made or broken in the open circuitcondition.

To achieve the optimum life for the battery, operating discharges of more than 80%of the rated capacity should be avoided (deep discharge).

This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-scharge. Discharged batteries must be recharged immediately and must not be leftdischarged. This also applies to partially discharged batteries.

2.2 Charging

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

In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-ded. If the charger was not purchased together with the battery it is best to have itssuitability checked by the manufacturers service department. When charging, properprovision must be made for venting of the charging gases.

steel M 10 23 ± 1 Nm

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

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

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

The battery should be inspected to ensure it is in perfect physical condition.

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

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

The level of the electrolyte must be checked. If it is below the antisurge baffle or thetop of the separator it must first be topped up to this height with purified water.

The battery is then charged as in item 2.2.

The electrolyte should be topped up to the specified level with purified water.

2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-plies to the operation traction batteries in industrial trucks.

2.1 Discharging

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

Electrical connections (e.g. plugs) must only be made or broken in the open circuitcondition.

To achieve the optimum life for the battery, operating discharges of more than 80%of the rated capacity should be avoided (deep discharge).

This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-scharge. Discharged batteries must be recharged immediately and must not be leftdischarged. This also applies to partially discharged batteries.

2.2 Charging

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

In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-ded. If the charger was not purchased together with the battery it is best to have itssuitability checked by the manufacturers service department. When charging, properprovision must be made for venting of the charging gases.

steel M 10 23 ± 1 Nm

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4

Battery container lids and the covers of battery compartments must be opened or re-moved. The vent plugs should stay on the cells and remain closed.

With the charger switched off connect up the battery, ensuring that the polarity is cor-rect. (positive to positive, negative to negative). Now switch on the charger. Whencharging the temperature of the electrolyte rises by about 10°C, so charging shouldonly begin if the electrolyte temperature is below 45°C. The electrolyte temperatureof batteries should be at least +10°C before charging otherwise a full charge will notbe achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltagehave remained constant for two hours. Special instructions for the operation of batte-ries in hazardous areas. This concerns batteries which are used in accordance withEN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-tentially explosive areas). During charging and subsequent gassing the container lidsmust be removed or opened so that the explosive mixture of gases loses its flamma-bility due to adequate ventilation. The containers for batteries with plate protectionpacks must not be closed until at least half an hour after charging has past.

2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. They are necessary after deep discharges, repeated incomplete rechargesand charges to an IU characteristic curve. Equalising charges are carried out follo-wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-pacity (end of charge - see point 2.2).

Watch the temperature!

2.4 Temperature

An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-peratures shorten the life of the battery, lower temperatures reduce the capacity avai-lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-perature.

2.5 Electrolyte

The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°Cand the nominal electrolyte level in the cell in fully charged condition. Higher tempe-ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specificgravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.

The electrolyte must conform to the purity regulations in DIN 43530 part 2.

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4

Battery container lids and the covers of battery compartments must be opened or re-moved. The vent plugs should stay on the cells and remain closed.

With the charger switched off connect up the battery, ensuring that the polarity is cor-rect. (positive to positive, negative to negative). Now switch on the charger. Whencharging the temperature of the electrolyte rises by about 10°C, so charging shouldonly begin if the electrolyte temperature is below 45°C. The electrolyte temperatureof batteries should be at least +10°C before charging otherwise a full charge will notbe achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltagehave remained constant for two hours. Special instructions for the operation of batte-ries in hazardous areas. This concerns batteries which are used in accordance withEN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-tentially explosive areas). During charging and subsequent gassing the container lidsmust be removed or opened so that the explosive mixture of gases loses its flamma-bility due to adequate ventilation. The containers for batteries with plate protectionpacks must not be closed until at least half an hour after charging has past.

2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. They are necessary after deep discharges, repeated incomplete rechargesand charges to an IU characteristic curve. Equalising charges are carried out follo-wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-pacity (end of charge - see point 2.2).

Watch the temperature!

2.4 Temperature

An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-peratures shorten the life of the battery, lower temperatures reduce the capacity avai-lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-perature.

2.5 Electrolyte

The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°Cand the nominal electrolyte level in the cell in fully charged condition. Higher tempe-ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specificgravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.

The electrolyte must conform to the purity regulations in DIN 43530 part 2.

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3.1 Daily

Charge the battery after every discharge. Towards the end of charge the electrolytelevel should be checked and if necessary topped up to the specified level with purifiedwater. The electrolyte level must not fall below the anti-surge baffle or the top of theseparator or the electrolyte „min“ level mark.

3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-tery is charged regularly with a IU characteristic curve an equalising charge must becarried out (see point 2.3).

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measuredwith the charger switched on, and recorded. After charging has ended the specificgravity and the temperature of the electrolyte in all cells should be measured and re-corded.

If significant changes from earlier measurements or differences between the cells orbloc batteries are found further testing and maintenance by the service departmentshould be requested.

3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance ofthe truck and the battery must be checked by an electrical specialist.

The tests on the insulation resistance of the battery must be conducted in accordancewith DIN EN 60254-1.

The insulation resistance of the battery thus determined must not be below a value of50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea-ning must be done in accordance with the ZVEI code of practice «The Cleaning ofVehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man-ner. Damage to the insulation of the tray should be repaired after cleaning, to ensurethat the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call in our service department for this.

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3. Maintenance

3.1 Daily

Charge the battery after every discharge. Towards the end of charge the electrolytelevel should be checked and if necessary topped up to the specified level with purifiedwater. The electrolyte level must not fall below the anti-surge baffle or the top of theseparator or the electrolyte „min“ level mark.

3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-tery is charged regularly with a IU characteristic curve an equalising charge must becarried out (see point 2.3).

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measuredwith the charger switched on, and recorded. After charging has ended the specificgravity and the temperature of the electrolyte in all cells should be measured and re-corded.

If significant changes from earlier measurements or differences between the cells orbloc batteries are found further testing and maintenance by the service departmentshould be requested.

3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance ofthe truck and the battery must be checked by an electrical specialist.

The tests on the insulation resistance of the battery must be conducted in accordancewith DIN EN 60254-1.

The insulation resistance of the battery thus determined must not be below a value of50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea-ning must be done in accordance with the ZVEI code of practice «The Cleaning ofVehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man-ner. Damage to the insulation of the tray should be repaired after cleaning, to ensurethat the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call in our service department for this.

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5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room. To ensure the battery is always readyfor use a choice of charging methods can be made:

1. a monthly equalising charge as in point 2.3

2. float charging at a charging voltage of 2.23 V x the number of cells. The storagetime should be taken into account when considering the life of the battery.

6. Malfunctions

If malfunctions are found on the battery or the charger our service department shouldbe called in without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.

A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer!

Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must bedisposed of as hazardous waste!

We reserve the right make technical modification.

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6

5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room. To ensure the battery is always readyfor use a choice of charging methods can be made:

1. a monthly equalising charge as in point 2.3

2. float charging at a charging voltage of 2.23 V x the number of cells. The storagetime should be taken into account when considering the life of the battery.

6. Malfunctions

If malfunctions are found on the battery or the charger our service department shouldbe called in without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.

A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer!

Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must bedisposed of as hazardous waste!

We reserve the right make technical modification.

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* CE mark is only for batteries with a nominal voltage greater than 75 volt.

Item Designation Item Designation1 Logo 8 Recycling symbol2 Battery designation 9 Dustbin/material3 Battery type 10 Nominal battery voltage4 Battery number 11 Nominal battery capacity5 Battery tray number 12 Number of battery cells6 Delivery date 13 Battery weight7 Battery manufacturer's logo 14 Safety instructions and warnings

Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7

Number of CellsBatteriegewicht min/max 8

Battery mass min/max

Serien-Nr.3

Serial-Nr.Lieferanten Nr. 4

Supplier No.

Baujahr 2

Year of manufacture

Jungheinrich AG, D-22047 Hamburg, Germany

5

Pb Pb

2/3 651113

1

14

41012

7

8

9

7

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7.Type plate, Jungheinrich traction battery

* CE mark is only for batteries with a nominal voltage greater than 75 volt.

Item Designation Item Designation1 Logo 8 Recycling symbol2 Battery designation 9 Dustbin/material3 Battery type 10 Nominal battery voltage4 Battery number 11 Nominal battery capacity5 Battery tray number 12 Number of battery cells6 Delivery date 13 Battery weight7 Battery manufacturer's logo 14 Safety instructions and warnings

Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7

Number of CellsBatteriegewicht min/max 8

Battery mass min/max

Serien-Nr.3

Serial-Nr.Lieferanten Nr. 4

Supplier No.

Baujahr 2

Year of manufacture

Jungheinrich AG, D-22047 Hamburg, Germany

5

Pb Pb

2/3 651113

1

14

41012

7

8

9

0506

.GB

8

Aquamatic/BFS III water refilling system for Jungheinrich traction battery withEPzS and EPzB cells with tubular positive plates

Aquamatic plug arrangement for the Operating Instructions

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. columnEPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.2 EPzS 120.

Non-adherence to the operating instructions, repairs carried out with non-originalspare parts, unauthorised interference, and the use of additives for the electrolytes(alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the in-structions on maintaining the respective protection class during operation (see asso-ciated certification).

Cell series* Aquamatic plug type (length)

EPzS EPzB Frötek (yellow) BFS (black)

2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm

– 2/ 84 – 12/ 504 50,5 mm 51,0 mm– 2/110 – 12/ 660 50,5 mm 51,0 mm– 2/130 – 12/ 780 50,5 mm 51,0 mm– 2/150 – 12/ 900 50,5 mm 51,0 mm– 2/172 – 12/1032 50,5 mm 51,0 mm– 2/200 – 12/1200 56,0 mm 56,0 mm– 2/216 – 12/1296 56,0 mm 56,0 mm

2/180 – 10/900 – 61,0 mm 61,0 mm2/210 – 10/1050 – 61,0 mm 61,0 mm2/230 – 10/1150 – 61,0 mm 61,0 mm2/250 – 10/1250 – 61,0 mm 61,0 mm2/280 – 10/1400 – 72,0 mm 66,0 mm2/310 – 10/1550 – 72,0 mm 66,0 mm

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Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

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8

Aquamatic/BFS III water refilling system for Jungheinrich traction battery withEPzS and EPzB cells with tubular positive plates

Aquamatic plug arrangement for the Operating Instructions

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. columnEPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.2 EPzS 120.

Non-adherence to the operating instructions, repairs carried out with non-originalspare parts, unauthorised interference, and the use of additives for the electrolytes(alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the in-structions on maintaining the respective protection class during operation (see asso-ciated certification).

Cell series* Aquamatic plug type (length)

EPzS EPzB Frötek (yellow) BFS (black)

2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm

– 2/ 84 – 12/ 504 50,5 mm 51,0 mm– 2/110 – 12/ 660 50,5 mm 51,0 mm– 2/130 – 12/ 780 50,5 mm 51,0 mm– 2/150 – 12/ 900 50,5 mm 51,0 mm– 2/172 – 12/1032 50,5 mm 51,0 mm– 2/200 – 12/1200 56,0 mm 56,0 mm– 2/216 – 12/1296 56,0 mm 56,0 mm

2/180 – 10/900 – 61,0 mm 61,0 mm2/210 – 10/1050 – 61,0 mm 61,0 mm2/230 – 10/1150 – 61,0 mm 61,0 mm2/250 – 10/1250 – 61,0 mm 61,0 mm2/280 – 10/1400 – 72,0 mm 66,0 mm2/310 – 10/1550 – 72,0 mm 66,0 mm

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Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

9

0506

.GBDiagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with sole-noid valve

5. Charger

6. Sealing coupler

7. Closing nipple

8. Ion exchange cartridge with conductance meter and solenoid valve

9. Connection for untreated water

10. Charging lead

1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically adjus-ting the nominal electrolyte level. Venting holes are provided for letting off the gaseswhich arise during charging. In addition to the optical level indicator, the plug systemsalso have a diagnostics hole for measuring the temperature and the electrolyte den-sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-matic/BFS filling systems. The water can be refilled by means of a central sealingcoupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries forforklift trucks. The water refilling system is provided with a central water connectionfor the water supply. Soft PVC hose is used for this connection and for the hose con-nections for the individual plugs. The hose ends are put onto the hose connectionsleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve locatedin the plug in combination with the float and the float rods. In the Aquamatic Systemthe existing water pressure at the valve turns off the water supply and ensures thatthe valve closes securely. When the maximum filling level is reached in the BFS sys-tem, the float and the float rods through a lever system close the valve with five timesthe buoyant force and consequently interrupt the water supply reliably.

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Diagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with sole-noid valve

5. Charger

6. Sealing coupler

7. Closing nipple

8. Ion exchange cartridge with conductance meter and solenoid valve

9. Connection for untreated water

10. Charging lead

1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically adjus-ting the nominal electrolyte level. Venting holes are provided for letting off the gaseswhich arise during charging. In addition to the optical level indicator, the plug systemsalso have a diagnostics hole for measuring the temperature and the electrolyte den-sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-matic/BFS filling systems. The water can be refilled by means of a central sealingcoupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries forforklift trucks. The water refilling system is provided with a central water connectionfor the water supply. Soft PVC hose is used for this connection and for the hose con-nections for the individual plugs. The hose ends are put onto the hose connectionsleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve locatedin the plug in combination with the float and the float rods. In the Aquamatic Systemthe existing water pressure at the valve turns off the water supply and ensures thatthe valve closes securely. When the maximum filling level is reached in the BFS sys-tem, the float and the float rods through a lever system close the valve with five timesthe buoyant force and consequently interrupt the water supply reliably.

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4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the batterycharging comes to an end; this ensures that the refilled water quantity is mixed withthe electrolyte. In normal operation it is usually sufficient to fill once a week.

5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in thewater pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operatingpressure range of between 0.2 bars and 0.6 bars. The BFS system has an operatingpressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impairthe system's functional reliability. This wide pressure range permits three types of fil-ling.

5.1 Falling water

The height of the tank is chosen to suit whichever water refilling system is used. Forthe Aquamatic System the installation height is 2 m to 6 m and for the BFS systemthe installation height is 3 m to 18 m over the battery surface.

5.2 Pressurised water

The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 barsand from 0.3 bars to 1.8 bars in the BFS system.

5.3 Water Refill Trolley (serviceMobil)

The submergible pump located in the ServiceMobil's tank generates the necessaryfilling pressure. No difference in height is permitted between the standing level of theServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under whichthe battery is used, the ambient temperatures and the type of filling and/or the fillingpressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-ter feed pipe must be separated from the battery after filling.

7. Water quality

Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fillthe batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kindof dirt which could impair the functional reliability of the Aquamatic/BFS plug. Forsafety reasons it is recommendable to insert a filter element (optional) with a max.passage opening of 100 to 300 µm into the battery's main supply pipe.

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4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the batterycharging comes to an end; this ensures that the refilled water quantity is mixed withthe electrolyte. In normal operation it is usually sufficient to fill once a week.

5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in thewater pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operatingpressure range of between 0.2 bars and 0.6 bars. The BFS system has an operatingpressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impairthe system's functional reliability. This wide pressure range permits three types of fil-ling.

5.1 Falling water

The height of the tank is chosen to suit whichever water refilling system is used. Forthe Aquamatic System the installation height is 2 m to 6 m and for the BFS systemthe installation height is 3 m to 18 m over the battery surface.

5.2 Pressurised water

The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 barsand from 0.3 bars to 1.8 bars in the BFS system.

5.3 Water Refill Trolley (serviceMobil)

The submergible pump located in the ServiceMobil's tank generates the necessaryfilling pressure. No difference in height is permitted between the standing level of theServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under whichthe battery is used, the ambient temperatures and the type of filling and/or the fillingpressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-ter feed pipe must be separated from the battery after filling.

7. Water quality

Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fillthe batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kindof dirt which could impair the functional reliability of the Aquamatic/BFS plug. Forsafety reasons it is recommendable to insert a filter element (optional) with a max.passage opening of 100 to 300 µm into the battery's main supply pipe.

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Hose connections for the individual plugs are laid along the existing electric circuit.No changes may be made.

9. Operating temperature

The temperature limit for battery operation is set at 55° C. Exceeding this temperaturedamages the batteries. The battery filling systems may be operated within a tempe-rature range of > 0° C to a maximum of 55° C.

CAUTION:Batteries with automatic water refilling systems may only be operated in roomswith temperatures > 0° C (as there is otherwise a danger that the systems mayfreeze).

9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling sys-tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a7.5 mm-diameter (BFS plugs).

9.2 Float

Different floats are used depending on the cell design and type.

9.3 Cleaning

The plug systems may only be cleaned with water. No parts of the plugs may comein contact with soap or fabrics which contain solvents.

10. Accessories

10.1 Flow indicator

To monitor the filling process, a flow indicator can be inserted into the water feed pipeon the battery side. During the filling process, the paddlewheel is turned by the flowingwater. When the filling process ends, the wheel stops and this indicates the end ofthe filling process. (ident no.: 50219542).

10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug sys-tems (plug lifter). The greatest of care must be employed when prising out the plug toprevent any damage to the plug systems.

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8. Battery hose connections

Hose connections for the individual plugs are laid along the existing electric circuit.No changes may be made.

9. Operating temperature

The temperature limit for battery operation is set at 55° C. Exceeding this temperaturedamages the batteries. The battery filling systems may be operated within a tempe-rature range of > 0° C to a maximum of 55° C.

CAUTION:Batteries with automatic water refilling systems may only be operated in roomswith temperatures > 0° C (as there is otherwise a danger that the systems mayfreeze).

9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling sys-tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a7.5 mm-diameter (BFS plugs).

9.2 Float

Different floats are used depending on the cell design and type.

9.3 Cleaning

The plug systems may only be cleaned with water. No parts of the plugs may comein contact with soap or fabrics which contain solvents.

10. Accessories

10.1 Flow indicator

To monitor the filling process, a flow indicator can be inserted into the water feed pipeon the battery side. During the filling process, the paddlewheel is turned by the flowingwater. When the filling process ends, the wheel stops and this indicates the end ofthe filling process. (ident no.: 50219542).

10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug sys-tems (plug lifter). The greatest of care must be employed when prising out the plug toprevent any damage to the plug systems.

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10.2.1 Clamping ring tool

The clamping ring tool is used to push on a clamping ring to increase the contact pres-sure of the hose connection on the plugs' hose couplings and to loosen it again.

10.3 Filter element

For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-ry's main supply pipe for supplying battery water. This filter element has a maximumpassage cross-section of 100 to 300 µm and is designed as a bag filter.

10.4 Sealing coupler

The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-tral supply pipe. This is connected to the water supply system at the battery chargingstation by means of a sealing coupler system. On the battery side a closing nipple(ident no.: 50219538) is mounted and the customer must place a sealing couplerconstruction on the water supply side (obtainable under ident. no.: 50219537).

11. Functional data

PS - self-sealing pressure: Aquamatic > 1.2 bars

BFS system none

D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min

D1 - maximum permissible leakage rate in the closed valve when the pressure is at0.1 bars: 2 ml/min

T - permissible temperature range: 0° C to a maximum of 65° C

Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system andoperating pressure range: 0.3 to 1.8 bars in the BFS system.

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10.2.1 Clamping ring tool

The clamping ring tool is used to push on a clamping ring to increase the contact pres-sure of the hose connection on the plugs' hose couplings and to loosen it again.

10.3 Filter element

For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-ry's main supply pipe for supplying battery water. This filter element has a maximumpassage cross-section of 100 to 300 µm and is designed as a bag filter.

10.4 Sealing coupler

The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-tral supply pipe. This is connected to the water supply system at the battery chargingstation by means of a sealing coupler system. On the battery side a closing nipple(ident no.: 50219538) is mounted and the customer must place a sealing couplerconstruction on the water supply side (obtainable under ident. no.: 50219537).

11. Functional data

PS - self-sealing pressure: Aquamatic > 1.2 bars

BFS system none

D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min

D1 - maximum permissible leakage rate in the closed valve when the pressure is at0.1 bars: 2 ml/min

T - permissible temperature range: 0° C to a maximum of 65° C

Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system andoperating pressure range: 0.3 to 1.8 bars in the BFS system.