Operating instructions

50051981

EJB 14/16

G

06.99 -

09.99

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.

A 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.

A 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

0699

GB

Table of contentsA Correct use and application of the truck ...............................A 1

B Truck description

1 Description of application .................................................................... B 12 Assembly groups ................................................................................. B 23 Technical data...................................................................................... B 33.1 Performance data................................................................................. B 33.2 Dimensions ......................................................................................... B 33.3 Standard hoist frame versions EJB 14................................................. B 53.4 Standard hoist frame versions EJB 16................................................. B 53.5 EN standards ...................................................................................... B 63.6 Operation conditions ........................................................................... B 64 Location of instruction labels and identification labels ........................ B 74.1 Truck identification label ...................................................................... B 84.2 Load capacity ....................................................................................... B 84.3 Label/Order/Inventory/Service No. ...................................................... B 9

C Transportation and commissioning

1 Transportation by crane ...................................................................... C 12 First Commissioning ............................................................................ C 13 Wheel arm adjustment ........................................................................ C 24 Moving the truck without own drive ...................................................... C 3

D Battery - servicing, recharging, replacing

1 Safety regulations governing the handling of lead-acid batteries ........ D 12 Battery types ....................................................................................... D 23 Open battery hood .............................................................................. D 24 Charging the battery ............................................................................ D 35 Removing and installing the battery .................................................... D 45.1 Remove battery by lifting it upwards

(truck without wheel-arm lifting device) ............................................... D 46 Combined instrument .......................................................................... D 5

I 1

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GB

Table of contentsA Correct use and application of the truck ...............................A 1

B Truck description

1 Description of application .................................................................... B 12 Assembly groups ................................................................................. B 23 Technical data...................................................................................... B 33.1 Performance data................................................................................. B 33.2 Dimensions ......................................................................................... B 33.3 Standard hoist frame versions EJB 14................................................. B 53.4 Standard hoist frame versions EJB 16................................................. B 53.5 EN standards ...................................................................................... B 63.6 Operation conditions ........................................................................... B 64 Location of instruction labels and identification labels ........................ B 74.1 Truck identification label ...................................................................... B 84.2 Load capacity ....................................................................................... B 84.3 Label/Order/Inventory/Service No. ...................................................... B 9

C Transportation and commissioning

1 Transportation by crane ...................................................................... C 12 First Commissioning ............................................................................ C 13 Wheel arm adjustment ........................................................................ C 24 Moving the truck without own drive ...................................................... C 3

D Battery - servicing, recharging, replacing

1 Safety regulations governing the handling of lead-acid batteries ........ D 12 Battery types ....................................................................................... D 23 Open battery hood .............................................................................. D 24 Charging the battery ............................................................................ D 35 Removing and installing the battery .................................................... D 45.1 Remove battery by lifting it upwards

(truck without wheel-arm lifting device) ............................................... D 46 Combined instrument .......................................................................... D 5

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I 2

E Operation

1 Safety regulations for the operation of the floor conveyor ................... E 12 Description of controls and indicating instruments .............................. E 23 Putting vehicle in operation ................................................................. E 44 Working with the truck ......................................................................... E 54.1 Safety regulations for operating mode Drive........................................ E 54.2 Driving, steering, braking .................................................................... E 64.3 Picking up or lowering load units ......................................................... E 94.4 Safe parking of the truck ..................................................................... E 104.5 Fault location ....................................................................................... E 11

F Maintenance of the truck

1 Operational safety and protection of the environment .........................F 12 Safety regulations for repair .................................................................F 13 Maintenance and service .....................................................................F 34 Maintenance check ist .........................................................................F 45 Lubrication schedule ............................................................................F 65.1 Operating material ................................................................................F 76 Notes on maintenance .........................................................................F 86.1 Preparation of the truck for servicing and maintenance operation .......F 86.2 Open the battery hood .........................................................................F 86.3 Open the front hood .............................................................................F 86.4 Check hydraulic oil level .......................................................................F 96.5 Check the transmission oil level ...........................................................F 96.6 Exchanging the coarse sieve ................................................................F 96.7 Checking the electric fuses ...................................................................F 106.8 Recommissioning the truck ...................................................................F 117 Taking the floor conveyor out of service ..............................................F 117.1 Operations to be performed prior to decommissioning ........................F 117.2 Measures to be taken during decommissioning ...................................F 117.3 Recommissioning the truck ...................................................................F 128 Safety checks to be performed at regular intervals and following

any untoward incidents (D: UVV according to VBG 36)....................F 12

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I 2

E Operation

1 Safety regulations for the operation of the floor conveyor ................... E 12 Description of controls and indicating instruments .............................. E 23 Putting vehicle in operation ................................................................. E 44 Working with the truck ......................................................................... E 54.1 Safety regulations for operating mode Drive........................................ E 54.2 Driving, steering, braking .................................................................... E 64.3 Picking up or lowering load units ......................................................... E 94.4 Safe parking of the truck ..................................................................... E 104.5 Fault location ....................................................................................... E 11

F Maintenance of the truck

1 Operational safety and protection of the environment .........................F 12 Safety regulations for repair .................................................................F 13 Maintenance and service .....................................................................F 34 Maintenance check ist .........................................................................F 45 Lubrication schedule ............................................................................F 65.1 Operating material ................................................................................F 76 Notes on maintenance .........................................................................F 86.1 Preparation of the truck for servicing and maintenance operation .......F 86.2 Open the battery hood .........................................................................F 86.3 Open the front hood .............................................................................F 86.4 Check hydraulic oil level .......................................................................F 96.5 Check the transmission oil level ...........................................................F 96.6 Exchanging the coarse sieve ................................................................F 96.7 Checking the electric fuses ...................................................................F 106.8 Recommissioning the truck ...................................................................F 117 Taking the floor conveyor out of service ..............................................F 117.1 Operations to be performed prior to decommissioning ........................F 117.2 Measures to be taken during decommissioning ...................................F 117.3 Recommissioning the truck ...................................................................F 128 Safety checks to be performed at regular intervals and following

any untoward incidents (D: UVV according to VBG 36)....................F 12

A 1

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A Correct use and application of the truck

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

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

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

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

Mounting of attachments: The mounting or installation of any attachments whichwill interfere with, or supplement, the functions of the truck is permitted only after writ-ten approval by the manufacturer has been obtained. If necessary, the approval oflocal authorities has to be obtained.Any approval obtained from local authorities does not, however, make the approvalby the manufacturer unnecessary.

A 1

0600

.GB

A Correct use and application of the truck

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

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

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

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

Mounting of attachments: The mounting or installation of any attachments whichwill interfere with, or supplement, the functions of the truck is permitted only after writ-ten approval by the manufacturer has been obtained. If necessary, the approval oflocal authorities has to be obtained.Any approval obtained from local authorities does not, however, make the approvalby the manufacturer unnecessary.

0699

.GB

A 2

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A 2

B 1

0999

.GB

B Truck description1 Description of application

The truck is a four-wheel electric lift truck with control shaft and controlled drive wheel.It is conceived for lifting and transporting palleted goods on level ground.The nominal load capacity can be found on the identification label.The load capacity in relation to lifting height and load centre distance is specified onthe load capacity label.

B 1

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B Truck description1 Description of application

The truck is a four-wheel electric lift truck with control shaft and controlled drive wheel.It is conceived for lifting and transporting palleted goods on level ground.The nominal load capacity can be found on the identification label.The load capacity in relation to lifting height and load centre distance is specified onthe load capacity label.

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B 2

2 Assembly groups

Pos. EJB 14/16 Description1 t Key switch2 o Combined instrument

(battery discharge monitor and operating hour meter)3 t Control shaft with control shaft head4 t "Shunt driving" button5 t Driving regulator6 t Collision-guard button7 t Hoist frame8 t Protective pane9 t Battery hood

10 t Master switch (emergency stop)11 o Load protection screen12 t Lifting device13 t Wheel arm14 t Front hood 15 t Supporting wheel16 t Drive wheel17 o Document case

1

17

16

2

3

45 5

6

10

9

1415

12

7

8

11

13

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.GB

B 2

2 Assembly groups

Pos. EJB 14/16 Description1 t Key switch2 o Combined instrument

(battery discharge monitor and operating hour meter)3 t Control shaft with control shaft head4 t "Shunt driving" button5 t Driving regulator6 t Collision-guard button7 t Hoist frame8 t Protective pane9 t Battery hood

10 t Master switch (emergency stop)11 o Load protection screen12 t Lifting device13 t Wheel arm14 t Front hood 15 t Supporting wheel16 t Drive wheel17 o Document case

1

17

16

2

3

45 5

6

10

9

1415

12

7

8

11

13

B 3

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3 Technical data

A Specification of technical data according to VDI 2198. Technical modifications andsupplements reserved.

3.1 Performance data

3.2 Dimensions

1) with DZ hoist frame:+ 4 mm

Description EJB 14 EJB 16Q Nominal load capacity 1400 1600 kgC Load centre distance at standard fork length 600 600 mm

Driving speed with / without load 6.0 / 6.0 6.0 / 6.0 km/hLifting speed with / without load 15 / 23 14 / 23 cm/sLowering speed with / without load 44 / 42 40 / 40 cm/sMax. hill-climbing ability with / without load 8 / 16 7 / 16 %

Description EJB 14 EJB 16s lowered height of the load fork 40 40 mmy Wheel base 1409 1409 mm

l1Truck length at fork length1150 mm 2050 2050 mm

l2 Length of front section 900 900 mmB Truck width (Adjustable min/max) 1120 / 1570 1120 / 1570 mm

b4Dimension between wheel arms (adju-stable) 900 - 1350 900 - 1350 mm

b5Overall distance of fork(adjustable) 316 - 900 316 - 900 mm

m2 Ground clearance 30 30 mm

Ast Working corridor width 1)

1000 x 1200 diagonal 2162 2162 mm

Ast Working corridor width1)

800 x 1200 longitudinal 2362 2362 mm

Wa Turning circle for shunt driving (raised control shaft) 1629 1629 mm

B 3

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3 Technical data

A Specification of technical data according to VDI 2198. Technical modifications andsupplements reserved.

3.1 Performance data

3.2 Dimensions

1) with DZ hoist frame:+ 4 mm

Description EJB 14 EJB 16Q Nominal load capacity 1400 1600 kgC Load centre distance at standard fork length 600 600 mm

Driving speed with / without load 6.0 / 6.0 6.0 / 6.0 km/hLifting speed with / without load 15 / 23 14 / 23 cm/sLowering speed with / without load 44 / 42 40 / 40 cm/sMax. hill-climbing ability with / without load 8 / 16 7 / 16 %

Description EJB 14 EJB 16s lowered height of the load fork 40 40 mmy Wheel base 1409 1409 mm

l1Truck length at fork length1150 mm 2050 2050 mm

l2 Length of front section 900 900 mmB Truck width (Adjustable min/max) 1120 / 1570 1120 / 1570 mm

b4Dimension between wheel arms (adju-stable) 900 - 1350 900 - 1350 mm

b5Overall distance of fork(adjustable) 316 - 900 316 - 900 mm

m2 Ground clearance 30 30 mm

Ast Working corridor width 1)

1000 x 1200 diagonal 2162 2162 mm

Ast Working corridor width1)

800 x 1200 longitudinal 2362 2362 mm

Wa Turning circle for shunt driving (raised control shaft) 1629 1629 mm

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B 4

h4

h3h1

l2

l1

lc

y

Q

h

s

h8

b5

Ast

Wa

B

m2

20

5

h2

b4

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B 4

h4

h3h1

l2

l1

lc

y

Q

h

s

h8

b5

Ast

Wa

B

m2

20

5

h2

b4

B 5

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3.3 Standard hoist frame versions EJB 14

3.4 Standard hoist frame versions EJB 16

1) h1 = +50 mm for ZT hoist frame at 100 mm free lift (h2)2) only for ZT hoist frame 3) only for ZZ and DZ hoist frame4) with LSG +410 mm5) with LSG -410 mm

Description Telescopic mast(ZT)

Doubledual reach lift (ZZ)

Dual lifttriplex mast

(DZ)h1 Overall height 1) 1700 - 2600 1700 - 2600 1800 - 2250 mmh2 Free lifting capacity 2) 100 - - mmh3 Lifting height 2500 - 4300 2500 - 4300 4000 - 5350 mmh4 Max. height 4) 3060 - 4860 3060 - 4860 4560 - 5910 mmh5 Free lifting capacity 3) 5) 1219 - 2119 1219 - 2119 1169 - 2069 mm

Description Telescopic mast(ZT)

Doubledual reach lift (ZZ)

Dual lifttriplex mast

(DZ)h1 Overall height 1) 1700 - 2600 1700 - 2600 1800 - 2250 mmh2 Free lifting capacity 2) 100 - - mmh3 Lifting height 2400 - 4200 2400 - 4200 3900 - 5250 mmh4 Max. height 4) 2960 - 4760 2960 - 4760 4460 - 5810 mmh5 Free lifting capacity 3) 5) - 1140 - 2040 1240 - 1690 mm

B 5

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3.3 Standard hoist frame versions EJB 14

3.4 Standard hoist frame versions EJB 16

1) h1 = +50 mm for ZT hoist frame at 100 mm free lift (h2)2) only for ZT hoist frame 3) only for ZZ and DZ hoist frame4) with LSG +410 mm5) with LSG -410 mm

Description Telescopic mast(ZT)

Doubledual reach lift (ZZ)

Dual lifttriplex mast

(DZ)h1 Overall height 1) 1700 - 2600 1700 - 2600 1800 - 2250 mmh2 Free lifting capacity 2) 100 - - mmh3 Lifting height 2500 - 4300 2500 - 4300 4000 - 5350 mmh4 Max. height 4) 3060 - 4860 3060 - 4860 4560 - 5910 mmh5 Free lifting capacity 3) 5) 1219 - 2119 1219 - 2119 1169 - 2069 mm

Description Telescopic mast(ZT)

Doubledual reach lift (ZZ)

Dual lifttriplex mast

(DZ)h1 Overall height 1) 1700 - 2600 1700 - 2600 1800 - 2250 mmh2 Free lifting capacity 2) 100 - - mmh3 Lifting height 2400 - 4200 2400 - 4200 3900 - 5250 mmh4 Max. height 4) 2960 - 4760 2960 - 4760 4460 - 5810 mmh5 Free lifting capacity 3) 5) - 1140 - 2040 1240 - 1690 mm

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B 6

3.5 EN Standards

Permanent sound level: 65 dB(A)according to prEN 12053 as stipulated in ISO4871.

A The permanent sound level is an average value determined according to the stan-dard’s guidelines and takes into consideration the sound level when driving, liftingand in idle mode. The sound level is measured at the driver’s ear.

Electromagnetic compatibility (EC)

Observance of the following limit values accor-ding to prEN 12895 "Floor Conveyors, Electro-magnetic compatibility":

-Interference emission (EN 50081-1)

-Resistance to disturbance (EN 50 082-2)

-Electrostatic discharge (EN 61000-4-2)

A Alterations of the electric or electronic components and their arrangement must onlyby carried out with written approval of the manufacturer.

3.6 Operation conditions

Environmental temperature

Standard type during operation: +5°C to +40°C

A If the floor conveyor is to be permanently used in an environment with 5°C or less, incold storage depots or in areas with extreme temperature or humidity changes, a spe-cial equipment and approval is required.

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B 6

3.5 EN Standards

Permanent sound level: 65 dB(A)according to prEN 12053 as stipulated in ISO4871.

A The permanent sound level is an average value determined according to the stan-dard’s guidelines and takes into consideration the sound level when driving, liftingand in idle mode. The sound level is measured at the driver’s ear.

Electromagnetic compatibility (EC)

Observance of the following limit values accor-ding to prEN 12895 "Floor Conveyors, Electro-magnetic compatibility":

-Interference emission (EN 50081-1)

-Resistance to disturbance (EN 50 082-2)

-Electrostatic discharge (EN 61000-4-2)

A Alterations of the electric or electronic components and their arrangement must onlyby carried out with written approval of the manufacturer.

3.6 Operation conditions

Environmental temperature

Standard type during operation: +5°C to +40°C

A If the floor conveyor is to be permanently used in an environment with 5°C or less, incold storage depots or in areas with extreme temperature or humidity changes, a spe-cial equipment and approval is required.

B 7

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4 Location of instruction labels and identification labels

Item Description18 Load capacity 19 Prohibition sign “Do not transport other persons”20 Truck identification label21 Limit-stop for crane loading22 Prohibition sign “Keep away from under the load lifting device”23 Prohibition sign "Do not put your hands through the hoist frame"24 UVV control label25 Identification label, battery26 Warning sign “Caution: Low-voltage electronics”

18

22

26

JUNGHEINRICH

V

21

23

24

19

20

25

B 7

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4 Location of instruction labels and identification labels

Item Description18 Load capacity 19 Prohibition sign “Do not transport other persons”20 Truck identification label21 Limit-stop for crane loading22 Prohibition sign “Keep away from under the load lifting device”23 Prohibition sign "Do not put your hands through the hoist frame"24 UVV control label25 Identification label, battery26 Warning sign “Caution: Low-voltage electronics”

18

22

26

JUNGHEINRICH

V

21

23

24

19

20

25

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B 8

4.1 Truck identification label

A In the event of queries relating to the truck or spare part orders, please state the serialno. (28) of the truck.

4.2 Load capacity

f The label (18) includes a table indicatingthe loading capacity (Q in kg) in relation to the load centre di-stance (D in mm) and the lifting height (Hin mm).

The arrow-shaped markings on the inner mast (39) and outer mast(40) show the driver when he has reached the lifting height limits thatis defined on the load capacity label (18).

Item Description Item Description27 Model 33 Load centre distance in mm28 Serial no. 34 Min./max. battery weight in kg29 Order no. 35 Net weight without battery in kg30 Nominal load capacity in kg 36 Year of manufacture31 Battery: Voltage V

Ampere hours Ah37 Type no.

32 Maker 38 Maker’s logotype

X xx xx

xxxx xx

XxxXxxxXxxxXxxx

XxxxxxxXxxxxxXxxxxxxxXxxxxx

Xxxxxx

XxxxxxxxxXxxxxxxxxxXxxxxxxxxXxxxxxxxx

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XxxxxxxXxxxxxxxxxXxxxxxXxxxxxxxx

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Xx

27

28

29

30

31

33

37

38

36

35

3432

18

39 40

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B 8

4.1 Truck identification label

A In the event of queries relating to the truck or spare part orders, please state the serialno. (28) of the truck.

4.2 Load capacity

f The label (18) includes a table indicatingthe loading capacity (Q in kg) in relation to the load centre di-stance (D in mm) and the lifting height (Hin mm).

The arrow-shaped markings on the inner mast (39) and outer mast(40) show the driver when he has reached the lifting height limits thatis defined on the load capacity label (18).

Item Description Item Description27 Model 33 Load centre distance in mm28 Serial no. 34 Min./max. battery weight in kg29 Order no. 35 Net weight without battery in kg30 Nominal load capacity in kg 36 Year of manufacture31 Battery: Voltage V

Ampere hours Ah37 Type no.

32 Maker 38 Maker’s logotype

X xx xx

xxxx xx

XxxXxxxXxxxXxxx

XxxxxxxXxxxxxXxxxxxxxXxxxxx

Xxxxxx

XxxxxxxxxXxxxxxxxxxXxxxxxxxxXxxxxxxxx

XxxxxXxxxxXxxxxXxxxx

XxxxxxxXxxxxxxxxxXxxxxxXxxxxxxxx

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XxxxxxxxxxxxxxxxxxXxxxxxxxxxxxxxxxxx

XxxxxxxxxxxxxxxxxxxxxxXxxxxxxxxxxxxxxxxx

Xx

27

28

29

30

31

33

37

38

36

35

3432

18

39 40

B 9

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4.3 Label/Order/Inventory/Service No.

A This label contains the Full Service No. and is only handed out when a service con-tract is being concluded.

Item Description41 Order no.42 Inventory No.43 Full Service No.

41

42

43

B 9

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4.3 Label/Order/Inventory/Service No.

A This label contains the Full Service No. and is only handed out when a service con-tract is being concluded.

Item Description41 Order no.42 Inventory No.43 Full Service No.

41

42

43

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B 10

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B 10

C 1

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C Transportation and commissioning1 Transportation by crane

f Only use lifting equipment with sufficient bearing capacity (loading weight see identi-fication label on truck).

A A hoisting point (1) is provided at the hoist frame for loading the truck with the help ofhoisting gear.

– Park the truck and render it safe (refer to chapter E).

– Attach the hoisting gear to the stop (1)on the hoisting mast.

m Secure the hoisting gear to the hoistingpoints ensuring that the hoisting gear willnot slip! The hoisting gear must be atta-ched in such a way that it does touch anyadd-on parts while the truck is being lif-ted.

2 First commissioning

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

f It is prohibited to hoist loads when the truck is operated via a towing cable with anexternal battery.

In order to prepare the truck for work following delivery or transportation, the followingoperations must be performed:

– Check whether the equipment is complete and in perfect condition.– If required, mount the battery, make sure not to damage the battery cable

(see chapter D).– Load the battery (see chapter D).– If required, check whether the settings of the combined instrument correspond to

the battery (see chapter D).– Commission the truck as prescribed

(see chapter E).

A If the truck is parked for longer periods, the running surfaces of the wheels may beflattened. However, this flattening will disappear quickly when the truck is beingdriven.

1

C 1

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C Transportation and commissioning1 Transportation by crane

f Only use lifting equipment with sufficient bearing capacity (loading weight see identi-fication label on truck).

A A hoisting point (1) is provided at the hoist frame for loading the truck with the help ofhoisting gear.

– Park the truck and render it safe (refer to chapter E).

– Attach the hoisting gear to the stop (1)on the hoisting mast.

m Secure the hoisting gear to the hoistingpoints ensuring that the hoisting gear willnot slip! The hoisting gear must be atta-ched in such a way that it does touch anyadd-on parts while the truck is being lif-ted.

2 First commissioning

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

f It is prohibited to hoist loads when the truck is operated via a towing cable with anexternal battery.

In order to prepare the truck for work following delivery or transportation, the followingoperations must be performed:

– Check whether the equipment is complete and in perfect condition.– If required, mount the battery, make sure not to damage the battery cable

(see chapter D).– Load the battery (see chapter D).– If required, check whether the settings of the combined instrument correspond to

the battery (see chapter D).– Commission the truck as prescribed

(see chapter E).

A If the truck is parked for longer periods, the running surfaces of the wheels may beflattened. However, this flattening will disappear quickly when the truck is beingdriven.

1

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C 2

3 Wheel arm adjustment

The distance between the wheel arms is adjustable (refer to chapter B).

f Adjusting the wheel arms must only be carried out be trained service personnel.

4 Moving the truck without own drive

f This type of operation is prohibited on slopes and inclinations.

If the truck must still be moved after a fault has occurred, proceed as follows:

– Set master switch to "OFF" position.– Set key switch to "0" position and re-

move the key.– Secure the truck against rolling away.– Open and remove front hood

(see chapter F).– Turn the screws (2) anticlockwise until

you reach the limit stop.

The solenoid brake is triggered. Thetruck can now no longer be moved.

f If you reached the target location, resetthe brake system to its original condition! The truck must not be parked with releasedbrake!

– Return the screws (2) anticlockwise until they touch the limit stop.

The original brake condition is restored.

2

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3 Wheel arm adjustment

The distance between the wheel arms is adjustable (refer to chapter B).

f Adjusting the wheel arms must only be carried out be trained service personnel.

4 Moving the truck without own drive

f This type of operation is prohibited on slopes and inclinations.

If the truck must still be moved after a fault has occurred, proceed as follows:

– Set master switch to "OFF" position.– Set key switch to "0" position and re-

move the key.– Secure the truck against rolling away.– Open and remove front hood

(see chapter F).– Turn the screws (2) anticlockwise until

you reach the limit stop.

The solenoid brake is triggered. Thetruck can now no longer be moved.

f If you reached the target location, resetthe brake system to its original condition! The truck must not be parked with releasedbrake!

– Return the screws (2) anticlockwise until they touch the limit stop.

The original brake condition is restored.

2

D 1

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D Battery - servicing, recharging, replacing1 Safety regulations governing the handling of lead-acid batteries

Before works are performed on the batteries, the truck must be parked and sufficient-ly secured (see chapter E).

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

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

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-minals and cable shoes must be clean, lightly greased with pole grease and must besecurely tightened. Batteries with non-insulated poles must be covered with an anti-slip insulating jacket.

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

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

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

m Only batteries with closed battery trough may be used.

f Battery weight and dimensions have considerable influence on the safety of truckoperation. A change of battery equipment is only permitted with approval of the ma-nufacturer.

D 1

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D Battery - servicing, recharging, replacing1 Safety regulations governing the handling of lead-acid batteries

Before works are performed on the batteries, the truck must be parked and sufficient-ly secured (see chapter E).

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

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

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-minals and cable shoes must be clean, lightly greased with pole grease and must besecurely tightened. Batteries with non-insulated poles must be covered with an anti-slip insulating jacket.

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

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

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

m Only batteries with closed battery trough may be used.

f Battery weight and dimensions have considerable influence on the safety of truckoperation. A change of battery equipment is only permitted with approval of the ma-nufacturer.

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2 Battery types

Depending on the type, the truck can be equipped with different battery types.The battery weights are specified on identification label of the battery.

m When changing / assembling the battery, make sure that it is properly fixed in the bat-tery compartment the truck.

The following table shows the standard battery combinations and battery capacities:

Depending on the battery type, also high-performance or maintenance-free batteriescan be used.

3 Open battery hood

– Park the truck and render it safe (refer to chapter E).– Set master switch (2) to "OFF" position.– Open the battery hood (1).

f The battery hood (1) is held in place by its own weight.

Truck type 24V - Pz... - batteryEJB 14 / 16EJB 14 / 16

3 PzS L 270 Ah3 PzS L 330 Ah

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D 2

2 Battery types

Depending on the type, the truck can be equipped with different battery types.The battery weights are specified on identification label of the battery.

m When changing / assembling the battery, make sure that it is properly fixed in the bat-tery compartment the truck.

The following table shows the standard battery combinations and battery capacities:

Depending on the battery type, also high-performance or maintenance-free batteriescan be used.

3 Open battery hood

– Park the truck and render it safe (refer to chapter E).– Set master switch (2) to "OFF" position.– Open the battery hood (1).

f The battery hood (1) is held in place by its own weight.

Truck type 24V - Pz... - batteryEJB 14 / 16EJB 14 / 16

3 PzS L 270 Ah3 PzS L 330 Ah

D 3

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4 Charging the battery

As default, the truck is to be loaded with a stationary battery charger.

m For recharging the battery, the truck has to parked in-doors in a sufficiently ventilatedenvironment.

– Park the truck and render it safe (see chapter E).

m Connection / disconnecting battery connector and socket as well as pressing the ma-ster switch (2) may only be performed with truck and battery charger being switchedoff.

– Expose the battery (see section 3).

f During the recharging operation the tops of the battery cells must be exposed to en-sure adequate ventilation. Metal objects must not be placed on the battery. Prior tostarting the recharging operation, check all cable connections and plugged connec-tions for visible damage.The safety instructions provided by the battery supplier and battery charger suppliermust be strictly observed.

– Pull battery connector (3) from the plug and socket connection of the truck.– Remove insulation mat from battery, if necessary.– Connect the charging cable (4) of the battery recharging station with the battery

connector (3) and switch on the battery charger.

m Recharge the battery observing the instructions provided by the battery supplier andby the battery charger supplier.

D 3

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4 Charging the battery

As default, the truck is to be loaded with a stationary battery charger.

m For recharging the battery, the truck has to parked in-doors in a sufficiently ventilatedenvironment.

– Park the truck and render it safe (see chapter E).

m Connection / disconnecting battery connector and socket as well as pressing the ma-ster switch (2) may only be performed with truck and battery charger being switchedoff.

– Expose the battery (see section 3).

f During the recharging operation the tops of the battery cells must be exposed to en-sure adequate ventilation. Metal objects must not be placed on the battery. Prior tostarting the recharging operation, check all cable connections and plugged connec-tions for visible damage.The safety instructions provided by the battery supplier and battery charger suppliermust be strictly observed.

– Pull battery connector (3) from the plug and socket connection of the truck.– Remove insulation mat from battery, if necessary.– Connect the charging cable (4) of the battery recharging station with the battery

connector (3) and switch on the battery charger.

m Recharge the battery observing the instructions provided by the battery supplier andby the battery charger supplier.

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D 4

5 Removing and installing the battery

– Expose the battery (see section 3).

f The truck must stand horizontally. Batteries with exposed terminals or connectorsmust be covered with a rubber mat to prevent short-circuits. Place battery connectorand battery cable in such a way that they do not get caught within the truck interiorwhen the battery is pulled out.

f When replacing batteries, ensure that a battery of the same type is fitted. Supplemen-tary weights may not be removed or changed in their position.

f After reinstallation of the battery, visually check all leads and connectors for damage.Before commissioning the truck, the battery hood must be properly closed.

A When changing the battery with the aid of a lifting gear, ensure that the lifting gear isof adequate capacity (the battery weight is indicated on the battery identification plateat the battery trough). The battery must be lifted vertically to prevent crushing of thebattery trough. The hooks are to be attached to the battery hoisting ears (5) that theycannot fall onto the battery cells when the hoisting gear is released.

5.1 Remove battery by lifting it upwards (truck without wheel-arm lifting device)

– Withdraw the battery connector.– Attach hoisting gear to the hoisting ears (5).– Lift out the battery.

The re-assembly can be performed by reversing the above actions; pay attention tothe correct mounting position and battery connection.

5

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D 4

5 Removing and installing the battery

– Expose the battery (see section 3).

f The truck must stand horizontally. Batteries with exposed terminals or connectorsmust be covered with a rubber mat to prevent short-circuits. Place battery connectorand battery cable in such a way that they do not get caught within the truck interiorwhen the battery is pulled out.

f When replacing batteries, ensure that a battery of the same type is fitted. Supplemen-tary weights may not be removed or changed in their position.

f After reinstallation of the battery, visually check all leads and connectors for damage.Before commissioning the truck, the battery hood must be properly closed.

A When changing the battery with the aid of a lifting gear, ensure that the lifting gear isof adequate capacity (the battery weight is indicated on the battery identification plateat the battery trough). The battery must be lifted vertically to prevent crushing of thebattery trough. The hooks are to be attached to the battery hoisting ears (5) that theycannot fall onto the battery cells when the hoisting gear is released.

5.1 Remove battery by lifting it upwards (truck without wheel-arm lifting device)

– Withdraw the battery connector.– Attach hoisting gear to the hoisting ears (5).– Lift out the battery.

The re-assembly can be performed by reversing the above actions; pay attention tothe correct mounting position and battery connection.

5

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6 Combined instrument

Battery discharge indicator: The di-scharging status of the battery is indica-ted by 10 beams on battery icon (6) re-presenting 10 %-steps.

As the discharge proceeds, the beamsgo out from top to bottom.

m If maintenance-free batteries are used,the instrument must be adjusted in sucha way that the T icon (9) appears next tothe operating hours indicator. If this set-ting is not selected, the battery may bedamaged due to a complete discharge.For adjusting the instrument, it is recom-mended to consult the manufacturer ser-vice.

When a remaining battery capacity of- 30 % for standard batteries- 50 % for maintenance-free batteriesis reached, a "CAUTION" icon (7) is indi-cated.Recharging the battery is recommen-ded.

When a remaining battery capacity of- 20 % for standard batteries- 40 % for maintenance-free batteriesis reached, the "CAUTION" icon goesout and a flashing "STOP" icon (8) ap-pears.After 5 min., the "STOP" icon box lightsup permanently. Recharging the batteryis recommended.

Battery discharge monitor: When the "STOP" icon is permanently lit, the liftingfunction is switched off.

A The lifting function can only be re-activated, when the connected battery is at leastrecharged by 70%.

Operating hour meter: The operating hour meter (10) is integrated in the battery di-scharge indicator and displays the overall operating time of all driving and lifting mo-vements.

A The digit to the right-hand side of the decimal point is flashing when the device is ac-tive.

h

h

h

STOP

T

T

T

6

7

8

9

10

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6 Combined instrument

Battery discharge indicator: The di-scharging status of the battery is indica-ted by 10 beams on battery icon (6) re-presenting 10 %-steps.

As the discharge proceeds, the beamsgo out from top to bottom.

m If maintenance-free batteries are used,the instrument must be adjusted in sucha way that the T icon (9) appears next tothe operating hours indicator. If this set-ting is not selected, the battery may bedamaged due to a complete discharge.For adjusting the instrument, it is recom-mended to consult the manufacturer ser-vice.

When a remaining battery capacity of- 30 % for standard batteries- 50 % for maintenance-free batteriesis reached, a "CAUTION" icon (7) is indi-cated.Recharging the battery is recommen-ded.

When a remaining battery capacity of- 20 % for standard batteries- 40 % for maintenance-free batteriesis reached, the "CAUTION" icon goesout and a flashing "STOP" icon (8) ap-pears.After 5 min., the "STOP" icon box lightsup permanently. Recharging the batteryis recommended.

Battery discharge monitor: When the "STOP" icon is permanently lit, the liftingfunction is switched off.

A The lifting function can only be re-activated, when the connected battery is at leastrecharged by 70%.

Operating hour meter: The operating hour meter (10) is integrated in the battery di-scharge indicator and displays the overall operating time of all driving and lifting mo-vements.

A The digit to the right-hand side of the decimal point is flashing when the device is ac-tive.

h

h

h

STOP

T

T

T

6

7

8

9

10

E 1

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E Operation1 Safety regulations for the operation of the floor conveyor

Driving licence: The floor conveyor must only be operated by persons who havebeen adequately trained and have proved to the persons in charge or their represen-tatives their ability to handle the truck correctly and who have been explicitly entru-sted with the operation of the truck.

Rights, obligations and behavioural rules for the driver: The driver must havebeen informed about his rights and duties, must have been trained in the operation ofthe truck and must be familiar with these operating instructions. All necessary rightsmust be granted to him. If the floor conveyor is to be accompanied by a second person, it is required to wearprotective shoes.

Operation through unauthorised persons is prohibited: The driver is responsiblefor his truck during working time. He must forbid unauthorised persons to drive or ope-rate the truck. Persons may neither be transported nor lifted.

Damages and defects: Damages or defects noted on the truck or on the attach-ments must immediately be brought to the notice of the person in charge. Trucks thatcannot be safely operated (e.g. due to worn tires or defective brakes) must not beused until they have been properly repaired.

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

Danger zone: The danger zone is that area in which persons are endangered by dri-ving or lifting movements of the floor conveyor, its load lifting devices (e.g. fork tinesor attachments) or the load. Also the area in which the load may fall down or in whicha operating device may be lowered or fall down belongs to this area.

f Unauthorised persons must be told to leave the danger area. The driver must give awarning signal, whenever a situation presenting danger to persons might develop.The truck must immediately be brought to a standstill, if persons, although asked, donot leave the danger area.

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

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E Operation1 Safety regulations for the operation of the floor conveyor

Driving licence: The floor conveyor must only be operated by persons who havebeen adequately trained and have proved to the persons in charge or their represen-tatives their ability to handle the truck correctly and who have been explicitly entru-sted with the operation of the truck.

Rights, obligations and behavioural rules for the driver: The driver must havebeen informed about his rights and duties, must have been trained in the operation ofthe truck and must be familiar with these operating instructions. All necessary rightsmust be granted to him. If the floor conveyor is to be accompanied by a second person, it is required to wearprotective shoes.

Operation through unauthorised persons is prohibited: The driver is responsiblefor his truck during working time. He must forbid unauthorised persons to drive or ope-rate the truck. Persons may neither be transported nor lifted.

Damages and defects: Damages or defects noted on the truck or on the attach-ments must immediately be brought to the notice of the person in charge. Trucks thatcannot be safely operated (e.g. due to worn tires or defective brakes) must not beused until they have been properly repaired.

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

Danger zone: The danger zone is that area in which persons are endangered by dri-ving or lifting movements of the floor conveyor, its load lifting devices (e.g. fork tinesor attachments) or the load. Also the area in which the load may fall down or in whicha operating device may be lowered or fall down belongs to this area.

f Unauthorised persons must be told to leave the danger area. The driver must give awarning signal, whenever a situation presenting danger to persons might develop.The truck must immediately be brought to a standstill, if persons, although asked, donot leave the danger area.

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

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2 Description of controls and indicating instruments

Pos. Controls or indicating instrument respectively

EJB14/16

Function

1 Master switch (Emergency Stop)

t The circuit is interrupted, all electric functions are switched off. The truck is compulsory braked.

2 Key switch t Switches the control current on and off. When the key is removed from the key switch, the truck cannot be opera-ted by unauthorised persons.

3 Combined instrument o Indicates the remaining capacity of the battery and the hours of operation that truck has already performed(see chapter D).

4 Control shaft t Steering and braking the truck.5 Button - Shunt driving t If the control shaft is in the upper bra-

king range, the braking function can be by-passed by pressing this button. The truck can only be mo-ved with reduced speed (shunt dri-ving).

6 Driving regulator t Controls the driving direction driving speed.

7 Collision-guard button

t Truck drives away from the operator and stops.

8 Button - Lifting the lifting device

t Lifting the lifting device.The lifting speed can be continuously adjusted with this key (adjustment ran-ge 8 mm).

9 Button - Lowering the lifting de-vice

t Lowering the lifting device.The lowering speed can be conti-nuously adjusted with this key (adjust-ment range 8 mm).

10 Button - warning signal (horn)

t Trigger warning signal.

11 Terminal strip t Depositing of freight documents.12 Document case o Used for depositing documents

t = Standard equipment o = Optional equipment

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2 Description of controls and indicating instruments

Pos. Controls or indicating instrument respectively

EJB14/16

Function

1 Master switch (Emergency Stop)

t The circuit is interrupted, all electric functions are switched off. The truck is compulsory braked.

2 Key switch t Switches the control current on and off. When the key is removed from the key switch, the truck cannot be opera-ted by unauthorised persons.

3 Combined instrument o Indicates the remaining capacity of the battery and the hours of operation that truck has already performed(see chapter D).

4 Control shaft t Steering and braking the truck.5 Button - Shunt driving t If the control shaft is in the upper bra-

king range, the braking function can be by-passed by pressing this button. The truck can only be mo-ved with reduced speed (shunt dri-ving).

6 Driving regulator t Controls the driving direction driving speed.

7 Collision-guard button

t Truck drives away from the operator and stops.

8 Button - Lifting the lifting device

t Lifting the lifting device.The lifting speed can be continuously adjusted with this key (adjustment ran-ge 8 mm).

9 Button - Lowering the lifting de-vice

t Lowering the lifting device.The lowering speed can be conti-nuously adjusted with this key (adjust-ment range 8 mm).

10 Button - warning signal (horn)

t Trigger warning signal.

11 Terminal strip t Depositing of freight documents.12 Document case o Used for depositing documents

t = Standard equipment o = Optional equipment

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2

1

3

4

5

6 68

9

10

7

11

12

E 3

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2

1

3

4

5

6 68

9

10

7

11

12

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3 Putting vehicle in operation

f Before starting or operating the truck, or before lifting any loads, the driver has tomake sure that nobody is within the danger area.

Checks and actions before routine start-up

– Visual inspection for damages of the whole truck (especially tyres and load carryingdevices).

– Visual inspection of battery fixing and cable connections.

Starting up the truck

– Pull out master switch (1).– Put key into the key switch (2) and turn right until stop to position "I".

The combined instrument (3) indicates the available battery capacity.– Check function of horn (10).– Check control shaft (4) for braking and driving function (see section 4.2).

The truck is now ready for operation.

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3 Putting vehicle in operation

f Before starting or operating the truck, or before lifting any loads, the driver has tomake sure that nobody is within the danger area.

Checks and actions before routine start-up

– Visual inspection for damages of the whole truck (especially tyres and load carryingdevices).

– Visual inspection of battery fixing and cable connections.

Starting up the truck

– Pull out master switch (1).– Put key into the key switch (2) and turn right until stop to position "I".

The combined instrument (3) indicates the available battery capacity.– Check function of horn (10).– Check control shaft (4) for braking and driving function (see section 4.2).

The truck is now ready for operation.

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4 Working with the truck

4.1 Safety regulations for operating mode Drive

Routes and working areas: Only such lanes and routes that are specially allocatedfor truck traffic may be used. Unauthorised third parties must stay away from the wor-king area. Loads may only be stored at places specially provided for this purpose.

Driving the vehicle: The driver must choose a driving speed suitable for the localconditions. The truck must be driven at slow speed when negotiating bends or narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways keep an adequate braking distance between his truck and the vehicle in frontand he must be in control of the floor conveyor at all times. Sudden stopping (exceptin emergencies), rapid U-turns and overtaking at dangerous or blind spots is not per-mitted. Leaning or gripping out of the working and operating range is prohibited.

Visibility during driving: The driver must look into the driving direction and have asufficient overview of the driving route. If load units are transported which are obstruc-ting the driver's view, the floor conveyor is to be driven with the load pointing to theback. If this is not possible, a second person must give suitable warnings.

Driving on slopes: Driving on slopes or descents is only permitted, if they are defi-ned as traffic routes and if the surface is clean and suitable for driving. In addition,these routes must conform to the regulations for safe driving as defined in the tech-nical truck specifications. Loads must always be carried at that end of the truck facinguphill. U-turns, cutting obliquely over slopes or inclines and parking of the truck on slo-pes or inclines is not permitted. Inclines must only be negotiated at slow speed withthe driver ready to brake at any moment.

Driving in lifts or on loading platforms: Lifts and loading platforms must only beused, if they are of adequate load bearing capacity, if suitable for driving on, and ifauthorised by the user of the truck for truck traffic. The truck must enter lifts with theload in front and must take up a position which does not allow it to come into contactwith the walls of the lift shaft.Persons riding in the lift together with the truck must only enter the lift after the truckhas come safely to a standstill, and must leave the lift before the truck.

Requirements for the load to be transported: Only loads that have been securelyfastened according to the regulations may be transported. Never transport loads thathave been stacked higher than the top of the fork carrier or the load backrest.

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4 Working with the truck

4.1 Safety regulations for operating mode Drive

Routes and working areas: Only such lanes and routes that are specially allocatedfor truck traffic may be used. Unauthorised third parties must stay away from the wor-king area. Loads may only be stored at places specially provided for this purpose.

Driving the vehicle: The driver must choose a driving speed suitable for the localconditions. The truck must be driven at slow speed when negotiating bends or narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways keep an adequate braking distance between his truck and the vehicle in frontand he must be in control of the floor conveyor at all times. Sudden stopping (exceptin emergencies), rapid U-turns and overtaking at dangerous or blind spots is not per-mitted. Leaning or gripping out of the working and operating range is prohibited.

Visibility during driving: The driver must look into the driving direction and have asufficient overview of the driving route. If load units are transported which are obstruc-ting the driver's view, the floor conveyor is to be driven with the load pointing to theback. If this is not possible, a second person must give suitable warnings.

Driving on slopes: Driving on slopes or descents is only permitted, if they are defi-ned as traffic routes and if the surface is clean and suitable for driving. In addition,these routes must conform to the regulations for safe driving as defined in the tech-nical truck specifications. Loads must always be carried at that end of the truck facinguphill. U-turns, cutting obliquely over slopes or inclines and parking of the truck on slo-pes or inclines is not permitted. Inclines must only be negotiated at slow speed withthe driver ready to brake at any moment.

Driving in lifts or on loading platforms: Lifts and loading platforms must only beused, if they are of adequate load bearing capacity, if suitable for driving on, and ifauthorised by the user of the truck for truck traffic. The truck must enter lifts with theload in front and must take up a position which does not allow it to come into contactwith the walls of the lift shaft.Persons riding in the lift together with the truck must only enter the lift after the truckhas come safely to a standstill, and must leave the lift before the truck.

Requirements for the load to be transported: Only loads that have been securelyfastened according to the regulations may be transported. Never transport loads thathave been stacked higher than the top of the fork carrier or the load backrest.

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4.2 Driving, steering, braking

f Increased attention has to be paid during driving and steering the truck, especially ifmovements outside of the truck contour are to be performed.It is not admissible to stay on the vehicle during driving.

Driving with load lifting devices or loads lifted higher than the ground clearance di-stance is only permitted when the load is to be picked up or to be lowered to theground. Beginning with a construction-dependent lifting height the driving speed isautomatically reduced during lifting and increased again when lowering.

EMERGENCY STOP

– Push master switch (1) down.

All electric functions are switched off. The truck is compulsory braked.

Emergency stop

When the control shaft (4) is released, the truck is compulsory braked (emergencystop) - the control shaft (4) automatically swivels into the upper braking range (B).

f If the control shaft (4) swivels only slowly into the braking position, it is required to per-form troubleshooting measures. For example, the return spring must be exchanged!

Driving

f Do not drive the truck unless the hoods are closed and locked in the stipulated man-ner. When driving through swinging doors, etc., make sure that the doors do not trig-ger the collision-guard button (7).

– Commissioning the truck (see section 3).– Push the control shaft (4) into the driving range (F) and set the driving switch (6) to

the desired driving direction (V or R).

The truck starts to drive into the selected direction.

A The driving speed can be continuously regulated with the driving switch (6).

0

R

R

V

B

F

B

V

4

6

7

1

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4.2 Driving, steering, braking

f Increased attention has to be paid during driving and steering the truck, especially ifmovements outside of the truck contour are to be performed.It is not admissible to stay on the vehicle during driving.

Driving with load lifting devices or loads lifted higher than the ground clearance di-stance is only permitted when the load is to be picked up or to be lowered to theground. Beginning with a construction-dependent lifting height the driving speed isautomatically reduced during lifting and increased again when lowering.

EMERGENCY STOP

– Push master switch (1) down.

All electric functions are switched off. The truck is compulsory braked.

Emergency stop

When the control shaft (4) is released, the truck is compulsory braked (emergencystop) - the control shaft (4) automatically swivels into the upper braking range (B).

f If the control shaft (4) swivels only slowly into the braking position, it is required to per-form troubleshooting measures. For example, the return spring must be exchanged!

Driving

f Do not drive the truck unless the hoods are closed and locked in the stipulated man-ner. When driving through swinging doors, etc., make sure that the doors do not trig-ger the collision-guard button (7).

– Commissioning the truck (see section 3).– Push the control shaft (4) into the driving range (F) and set the driving switch (6) to

the desired driving direction (V or R).

The truck starts to drive into the selected direction.

A The driving speed can be continuously regulated with the driving switch (6).

0

R

R

V

B

F

B

V

4

6

7

1

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f If the truck can only be moved with reduced driving speed, a defect has occurredwhich is influencing the safety of operation of the truck. It may be that the service bra-ke can only be used after pressing the EMERGENCY-STOP switch (1).The truck needs to be taken out of service and must be repaired by expert personnel(see chapter F).

Driving on slopes

m The load must be transported pointing towards the mountain!

Securing the truck against "rolling downhill":

If the driving switch is set to zero, the service brake is automatically triggered whenthe truck starts to roll downhill (the control system detects the unintended movementof the truck). The driving switch can be used to release the service brake and to selectthe desired driving speed and direction.

f If the roll-off brake was deactivated by the service, only service brake and counterflowbrake are available.

Steering

– Swivelling the control shaft to the left-hand or right-hand side.

Shunt driving

f The driver must pay special attention if he uses the "Shunt driving" button (5).

The truck can be moved with its control shaft (4) in ver-tical position (e.g. in confined spaces / lifts):

– Press "Shunt driving" button (5).

Set the driving switch (6) to the desired driving direc-tion (V or R).The service brake is triggered. The truck changes tothe slow-driving mode.

m The service brake is only activated after releasing the "Shunt driving" button; in theShunt driving mode, braking is only possible using the counterflow brake (drivingswitch (6)).

f In case of danger, the truck can be immediately braked by releasing the "Shunt dri-ving" button (5).

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f If the truck can only be moved with reduced driving speed, a defect has occurredwhich is influencing the safety of operation of the truck. It may be that the service bra-ke can only be used after pressing the EMERGENCY-STOP switch (1).The truck needs to be taken out of service and must be repaired by expert personnel(see chapter F).

Driving on slopes

m The load must be transported pointing towards the mountain!

Securing the truck against "rolling downhill":

If the driving switch is set to zero, the service brake is automatically triggered whenthe truck starts to roll downhill (the control system detects the unintended movementof the truck). The driving switch can be used to release the service brake and to selectthe desired driving speed and direction.

f If the roll-off brake was deactivated by the service, only service brake and counterflowbrake are available.

Steering

– Swivelling the control shaft to the left-hand or right-hand side.

Shunt driving

f The driver must pay special attention if he uses the "Shunt driving" button (5).

The truck can be moved with its control shaft (4) in ver-tical position (e.g. in confined spaces / lifts):

– Press "Shunt driving" button (5).

Set the driving switch (6) to the desired driving direc-tion (V or R).The service brake is triggered. The truck changes tothe slow-driving mode.

m The service brake is only activated after releasing the "Shunt driving" button; in theShunt driving mode, braking is only possible using the counterflow brake (drivingswitch (6)).

f In case of danger, the truck can be immediately braked by releasing the "Shunt dri-ving" button (5).

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Braking

f The braking effect of the truck is mainly depending on the road surface. This must betaken into account by the driver for his driving behavior.

The truck may be braked in three ways:- Using the service brake (control shaft (4)),- Using dynamic braking (roll-off brake can be adjusted by the service),- Using the counterflow brake (adjustable via driving switch (6)).

A For standard driving operations, only the dynamic brake and that counterflow brakeare to be used, since these brake types are reduce wear and tear and help to saveenergy (energy return supply).

Braking with the service brake:

f In case of danger, the truck must be braked with the service brake (control shaft (4)).

– Swivel control shaft (4) upwards or downwards into one of the braking ranges (B).

The drive motor is mechanically braked.

A When the control shaft (4) is released, it swivels into the upper braking range (B).Ifthe truck is parked, the service brake is used as parking brake

Dynamic braking (roll-off brake):

– After releasing the driving switch - driving switch set to zero - the truck is brakedwith the help of the dynamic brake (roll-off brake), depending on the selected set-ting.

f If the roll-off brake was deactivated by the service, only service brake and counterflowbrake are available.

Braking with the counterflow brake:

m If the control system or driving mechanism breaks down, the counterflow brake beco-mes ineffective.

– Turn driving switch (6) into the opposite driving direction until the truck comes to astandstill.

A The braking effect depends on the position of the driving switch.

0

R

R

V

B

F

B

V

4

6

7

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Braking

f The braking effect of the truck is mainly depending on the road surface. This must betaken into account by the driver for his driving behavior.

The truck may be braked in three ways:- Using the service brake (control shaft (4)),- Using dynamic braking (roll-off brake can be adjusted by the service),- Using the counterflow brake (adjustable via driving switch (6)).

A For standard driving operations, only the dynamic brake and that counterflow brakeare to be used, since these brake types are reduce wear and tear and help to saveenergy (energy return supply).

Braking with the service brake:

f In case of danger, the truck must be braked with the service brake (control shaft (4)).

– Swivel control shaft (4) upwards or downwards into one of the braking ranges (B).

The drive motor is mechanically braked.

A When the control shaft (4) is released, it swivels into the upper braking range (B).Ifthe truck is parked, the service brake is used as parking brake

Dynamic braking (roll-off brake):

– After releasing the driving switch - driving switch set to zero - the truck is brakedwith the help of the dynamic brake (roll-off brake), depending on the selected set-ting.

f If the roll-off brake was deactivated by the service, only service brake and counterflowbrake are available.

Braking with the counterflow brake:

m If the control system or driving mechanism breaks down, the counterflow brake beco-mes ineffective.

– Turn driving switch (6) into the opposite driving direction until the truck comes to astandstill.

A The braking effect depends on the position of the driving switch.

0

R

R

V

B

F

B

V

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4.3 Picking up or lowering load units

f Before a load unit is picked up, the driver has to make sure that it is properly palletisedand does not exceed the permitted bearing capacity of the truck.Do not grab into the hoist frame during lifting and lowering.

– Drive the truck with the fork tines as far as possible below the load unit.It is not permitted to pick up long goods with the truck driving transversally belowthe good.

A The double-two lifting hoist frame (ZZ) and the triple-two hoist frame (DZ) the first lif-ting movement of the load carriage (free lifting capacity) is realised without changingthe overall height with the help of a short free-lifting cylinder which is centrally arran-ged.

Lifting

– Press the "Lift the lifting device" button(8) until the desired height has beenreached.

Lowering

– Press the "Lower the lifting device"button (9) until the desired height hasbeen reached.

A The lifting/lowering speed can be conti-nuously adjusted with this button (adju-stment range 8 mm).

Small button adjustment range= slow lifting/loweringLarge button adjustment range= fast lifting/lowering

m Avoid any abrupt lowering of the load unit.

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4.3 Picking up or lowering load units

f Before a load unit is picked up, the driver has to make sure that it is properly palletisedand does not exceed the permitted bearing capacity of the truck.Do not grab into the hoist frame during lifting and lowering.

– Drive the truck with the fork tines as far as possible below the load unit.It is not permitted to pick up long goods with the truck driving transversally belowthe good.

A The double-two lifting hoist frame (ZZ) and the triple-two hoist frame (DZ) the first lif-ting movement of the load carriage (free lifting capacity) is realised without changingthe overall height with the help of a short free-lifting cylinder which is centrally arran-ged.

Lifting

– Press the "Lift the lifting device" button(8) until the desired height has beenreached.

Lowering

– Press the "Lower the lifting device"button (9) until the desired height hasbeen reached.

A The lifting/lowering speed can be conti-nuously adjusted with this button (adju-stment range 8 mm).

Small button adjustment range= slow lifting/loweringLarge button adjustment range= fast lifting/lowering

m Avoid any abrupt lowering of the load unit.

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Emergency lowering system

f The emergency lowering system may only be used if there are no persons within thedanger zone.

If the lifting device can no longer be lowered due to a defect in the lifting control sy-stem, the emergency lowering system has to be activated.

– Set key switch (2) to its "0" positionand set the master switch (1) to its"OFF" position.

– Pull the battery connector (see chap-ter D).

– Open the front hood (see chapter F).– Loosen the screw on the valve group

(13).

A The required Allen key (2.5 mm) can befound at the valve group.

The lifting device is lowered.

– Retighten the screw (13) after theemergency lowering procedure has been performed.

f The truck may only be retaken into service after the required troubleshooting measu-res were successfully performed.

4.4 Safe parking of the truck

If the truck is left unattended, even for only short periods of time, it must be renderedsafe.

f Do not park the truck on slopes! The lifting device must always be completely lowe-red.

– Bring control shaft (4) into brake position (B).– Lowering the lifting device.– Set key switch (2) to "0" position and remove the key.– Set master switch (1) to "OFF" position.

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Emergency lowering system

f The emergency lowering system may only be used if there are no persons within thedanger zone.

If the lifting device can no longer be lowered due to a defect in the lifting control sy-stem, the emergency lowering system has to be activated.

– Set key switch (2) to its "0" positionand set the master switch (1) to its"OFF" position.

– Pull the battery connector (see chap-ter D).

– Open the front hood (see chapter F).– Loosen the screw on the valve group

(13).

A The required Allen key (2.5 mm) can befound at the valve group.

The lifting device is lowered.

– Retighten the screw (13) after theemergency lowering procedure has been performed.

f The truck may only be retaken into service after the required troubleshooting measu-res were successfully performed.

4.4 Safe parking of the truck

If the truck is left unattended, even for only short periods of time, it must be renderedsafe.

f Do not park the truck on slopes! The lifting device must always be completely lowe-red.

– Bring control shaft (4) into brake position (B).– Lowering the lifting device.– Set key switch (2) to "0" position and remove the key.– Set master switch (1) to "OFF" position.

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4.5 Fault location

This chapter helps the operator to locate and fix simple malfunctions or the results ofoperating errors him- or herself. The order of the work stated in the table must be ob-served for fault location.

f If it is not possible to rectify the fault by performing the indicated "remedial actions",please contact the Customer Service, as more intricate faults can only be rectified byspecially trained and qualified service personnel.

Fault Possible cause RemedyTruck does not move

– Battery connector not connected

– Check the battery connector and reconnect it, if necessary

– Master switch (EMERGENCYSTOP) pressed

– Release master switch (EMERGENCYSTOP)

– Key switch set to “0“ position – Set the key switch to position "I"– Battery voltage too low – Check the charging status of

the battery and recharge, if necessary

– Control shaft not swivelled intodriving range (F)

– Faulty fuse

– Swivel control shaft into drivingrange (F)

– Check fuses F1 and 1F1

Load cannot be lifted

– Truck not ready for operation – Perform all troubleshootingmeasures that are mentionedunder "truck does not drive"

– Hydraulic oil level too low – Check hydraulic oil level– Faulty fuse – Check fuse 2F1

– Pay attention to the maximumbearing capacity (see identifi-cation label)

– load too high

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4.5 Fault location

This chapter helps the operator to locate and fix simple malfunctions or the results ofoperating errors him- or herself. The order of the work stated in the table must be ob-served for fault location.

f If it is not possible to rectify the fault by performing the indicated "remedial actions",please contact the Customer Service, as more intricate faults can only be rectified byspecially trained and qualified service personnel.

Fault Possible cause RemedyTruck does not move

– Battery connector not connected

– Check the battery connector and reconnect it, if necessary

– Master switch (EMERGENCYSTOP) pressed

– Release master switch (EMERGENCYSTOP)

– Key switch set to “0“ position – Set the key switch to position "I"– Battery voltage too low – Check the charging status of

the battery and recharge, if necessary

– Control shaft not swivelled intodriving range (F)

– Faulty fuse

– Swivel control shaft into drivingrange (F)

– Check fuses F1 and 1F1

Load cannot be lifted

– Truck not ready for operation – Perform all troubleshootingmeasures that are mentionedunder "truck does not drive"

– Hydraulic oil level too low – Check hydraulic oil level– Faulty fuse – Check fuse 2F1

– Pay attention to the maximumbearing capacity (see identifi-cation label)

– load too high

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F Maintenance of the truck1 Operational safety and protection of the environment

The checks and maintenance work listed in this chapter have to be performed accor-ding to the intervals of the maintenance checklists.

f Modifications of truck assemblies, especially of the safety installations, are not per-mitted. On no account must the operational speeds of the truck be changed.

m Only original spare parts have been passed by our quality assurance service. In orderto ensure safe and reliable operation only original spare parts of the manufacturermust be used. Old parts and changed consumption type materials must be disposedof in accordance with the applicable environmental protection regulations. The OilChange Service of the manufacturer is available for oil changes.

Upon completion of any checks and servicing activities, the operations contained inthe section "Recommissioning" must be performed (see section 6.8).

2 Safety regulations for repair

Servicing and maintenance personnel: Maintenance and repair of the floor con-veyors may only be performed by expert personnel of the manufacturer. The ServiceOrganisation of the manufacturer has service engineers available that have beenspecifically trained for these tasks. We therefore advise to conclude a maintenancecontract with the manufacturer’s Service Base responsible for the area.

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

Cleaning operations: No inflammable liquids must be used when cleaning the indu-strial truck. Prior to performing cleaning operations all appropriate safety measuresmust be taken to avoid sparking (e.g. due to short circuits). The battery connectormust be disconnected. Electric and electronic components must be cleaned with low-pressure air or suction air and a non-conducting, antistatic brush.

m If the truck is to be cleaned using water or a steam jet, all electric and electronic as-semblies have to be carefully covered beforehand, as humidity will cause mal-functions. Steam-cleaning is not permitted.

Upon the completion of cleaning work the operations detailed in section “Recommis-sioning” have to be performed.

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F Maintenance of the truck1 Operational safety and protection of the environment

The checks and maintenance work listed in this chapter have to be performed accor-ding to the intervals of the maintenance checklists.

f Modifications of truck assemblies, especially of the safety installations, are not per-mitted. On no account must the operational speeds of the truck be changed.

m Only original spare parts have been passed by our quality assurance service. In orderto ensure safe and reliable operation only original spare parts of the manufacturermust be used. Old parts and changed consumption type materials must be disposedof in accordance with the applicable environmental protection regulations. The OilChange Service of the manufacturer is available for oil changes.

Upon completion of any checks and servicing activities, the operations contained inthe section "Recommissioning" must be performed (see section 6.8).

2 Safety regulations for repair

Servicing and maintenance personnel: Maintenance and repair of the floor con-veyors may only be performed by expert personnel of the manufacturer. The ServiceOrganisation of the manufacturer has service engineers available that have beenspecifically trained for these tasks. We therefore advise to conclude a maintenancecontract with the manufacturer’s Service Base responsible for the area.

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

Cleaning operations: No inflammable liquids must be used when cleaning the indu-strial truck. Prior to performing cleaning operations all appropriate safety measuresmust be taken to avoid sparking (e.g. due to short circuits). The battery connectormust be disconnected. Electric and electronic components must be cleaned with low-pressure air or suction air and a non-conducting, antistatic brush.

m If the truck is to be cleaned using water or a steam jet, all electric and electronic as-semblies have to be carefully covered beforehand, as humidity will cause mal-functions. Steam-cleaning is not permitted.

Upon the completion of cleaning work the operations detailed in section “Recommis-sioning” have to be performed.

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Working on the electrical installation: All work on the electrical installation must becarried out only by electrotechnically skilled personnel. Before commencing any workon the electric system, all measures required to prevent electric shocks have to betaken. For battery-operated floor conveyors, the truck must also be depowered by re-moving the battery connector.

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

Settings: The vehicle settings must be observed when carrying out repairs and chan-ging hydraulic / electric / electronic components.

Tire equipment: The quality of the tires greatly affects the stability and the drivingbehaviour of the fork-lift truck. Modifications must only be carried out after discussionwith the manufacturer. When replacing wheels or tires, it must be ensured that thetruck remains level (tires and wheels must always be replaced in pairs, i.e. left andright together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals stated in theservice checklist apply for use in normal environment. For applications in aggravatedconditions (dust, temperature), frequent re-lubrication must be performed. Use thecorrect chain spray oil as prescribed. If grease is only externally applied, no sufficientlubrication can be realised.

Hydraulic hoses: The hoses must be replaced after a service life of six years. Whenreplacing hydraulic components the hoses in this hydraulic system should be repla-ced.

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Working on the electrical installation: All work on the electrical installation must becarried out only by electrotechnically skilled personnel. Before commencing any workon the electric system, all measures required to prevent electric shocks have to betaken. For battery-operated floor conveyors, the truck must also be depowered by re-moving the battery connector.

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

Settings: The vehicle settings must be observed when carrying out repairs and chan-ging hydraulic / electric / electronic components.

Tire equipment: The quality of the tires greatly affects the stability and the drivingbehaviour of the fork-lift truck. Modifications must only be carried out after discussionwith the manufacturer. When replacing wheels or tires, it must be ensured that thetruck remains level (tires and wheels must always be replaced in pairs, i.e. left andright together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals stated in theservice checklist apply for use in normal environment. For applications in aggravatedconditions (dust, temperature), frequent re-lubrication must be performed. Use thecorrect chain spray oil as prescribed. If grease is only externally applied, no sufficientlubrication can be realised.

Hydraulic hoses: The hoses must be replaced after a service life of six years. Whenreplacing hydraulic components the hoses in this hydraulic system should be repla-ced.

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3 Maintenance and service

Thorough and expert servicing is one of the most important preconditions for safeoperation of the fork-lift truck. The neglect of regular servicing intervals can lead tofork-lift failure and constitutes a potential hazard to personnel and operation.

m The indicated servicing intervals are based on single-shift operation under normaloperating conditions. For applications in dusty environments, or involving large tem-perature fluctuations or multiple-shift operation, the servicing intervals must be shor-tened accordingly.

The following servicing checklist indicates the operations to be performed and the re-spective intervals to be observed. The following maintenance intervals are defined:

W1 = Every 50 operating hours, at least, however, once a weekM3 = Every 500 operating hours, at least, however, every 3 monthsM6 = Every 1000 operating hours, at least, however, every 6 monthsM12 = Every 2000 operating hours, at least, however, every 12 months

In the running-in phase of the truck, the following additional operations have to be car-ried out:

After the first 100 operating hours:

– Check the wheel nuts for security and retighten, if required.– Check the hydraulic connections for leaks and retighten, if required.

After the first 500 operating hours:

– Changing hydraulic oil and filter cartridge– Flush the the coarse sieve, if required exchange it (see section 6.6).

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3 Maintenance and service

Thorough and expert servicing is one of the most important preconditions for safeoperation of the fork-lift truck. The neglect of regular servicing intervals can lead tofork-lift failure and constitutes a potential hazard to personnel and operation.

m The indicated servicing intervals are based on single-shift operation under normaloperating conditions. For applications in dusty environments, or involving large tem-perature fluctuations or multiple-shift operation, the servicing intervals must be shor-tened accordingly.

The following servicing checklist indicates the operations to be performed and the re-spective intervals to be observed. The following maintenance intervals are defined:

W1 = Every 50 operating hours, at least, however, once a weekM3 = Every 500 operating hours, at least, however, every 3 monthsM6 = Every 1000 operating hours, at least, however, every 6 monthsM12 = Every 2000 operating hours, at least, however, every 12 months

In the running-in phase of the truck, the following additional operations have to be car-ried out:

After the first 100 operating hours:

– Check the wheel nuts for security and retighten, if required.– Check the hydraulic connections for leaks and retighten, if required.

After the first 500 operating hours:

– Changing hydraulic oil and filter cartridge– Flush the the coarse sieve, if required exchange it (see section 6.6).

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4 Maintenance checklist

a) First check of the wheel nuts after approx. 100 operating hours for tight fit. Re-tighten ifnecessary. For starting torque, see maintenance plan.

b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours;tighten, if necessary.

c) 1. exchange after 500 hours of operation / if required, change coarse sieve.d) Check the wheel arm fastening screws for the first time after approx. 100 operating hours

and re-tighten, if necessary. For starting torque, see maintenance plan.

A The maintenance intervals refer to normal service conditions. If you are working un-der difficult conditions, reduce the intervals, if required.

Maintenance intervalsStandard = t W M M MCold-stora-ge depot

= k 1 3 6 12

Chassis/Design:

1.1 Check all load bearing elements for damage t1.2 Check all bolted connections d) t

Drive unit: 2.1 Check the transmission for noises and leakage t2.2 Check the transmission oil level t2.3 Change the gear oil k t

Wheels: 3.1 Check for wear and damage t3.2 Check seating and attachment a) k t

Steering: 4.1 Check the steering clearance tBrake system:

5.1 Check for correct function and adjustment k t5.2 Check the return spring for repositioning function and

damaget

5.3 Check the brake linings for wear t5.4 Check the brake linkage; adjust and grease,

if necessaryk t

Hoist frame: 6.1 Visual check of rollers, slide pieces and stops k t6.2 Check fork tines and fork carrier for wear and damage k t6.3 Check secure attachment of hoist frame t6.4 Check lift chains and chain guide for wear, adjust and

grease them.t

6.5 Check the lateral clearance of the mast profiles and whether they are parallel to each other

t

6.6 Check safety devices for proper attachment and damages

k t

Lifting device: 7.1 Check function, wear and tear and adjustment t7.2 Visual check of rollers, slide pieces and stops k t7.3 Check fork tines and fork carrier for wear and damage k t

Hydr. system: 8.1 Check function k t8.2 Check all connections for leakage and damage b) k t8.3 Check hydraulic cylinders for leakage, damage and

secure attachmentk t

8.4 Check the oil level k t8.5 Change hydraulic oil c) k t8.6 Change filter t8.7 Check the pressure relief valves for correct functioning k t

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4 Maintenance checklist

a) First check of the wheel nuts after approx. 100 operating hours for tight fit. Re-tighten ifnecessary. For starting torque, see maintenance plan.

b) Hydraulic connections to be first checked for leakage after approx. 100 operating hours;tighten, if necessary.

c) 1. exchange after 500 hours of operation / if required, change coarse sieve.d) Check the wheel arm fastening screws for the first time after approx. 100 operating hours

and re-tighten, if necessary. For starting torque, see maintenance plan.

A The maintenance intervals refer to normal service conditions. If you are working un-der difficult conditions, reduce the intervals, if required.

Maintenance intervalsStandard = t W M M MCold-stora-ge depot

= k 1 3 6 12

Chassis/Design:

1.1 Check all load bearing elements for damage t1.2 Check all bolted connections d) t

Drive unit: 2.1 Check the transmission for noises and leakage t2.2 Check the transmission oil level t2.3 Change the gear oil k t

Wheels: 3.1 Check for wear and damage t3.2 Check seating and attachment a) k t

Steering: 4.1 Check the steering clearance tBrake system:

5.1 Check for correct function and adjustment k t5.2 Check the return spring for repositioning function and

damaget

5.3 Check the brake linings for wear t5.4 Check the brake linkage; adjust and grease,

if necessaryk t

Hoist frame: 6.1 Visual check of rollers, slide pieces and stops k t6.2 Check fork tines and fork carrier for wear and damage k t6.3 Check secure attachment of hoist frame t6.4 Check lift chains and chain guide for wear, adjust and

grease them.t

6.5 Check the lateral clearance of the mast profiles and whether they are parallel to each other

t

6.6 Check safety devices for proper attachment and damages

k t

Lifting device: 7.1 Check function, wear and tear and adjustment t7.2 Visual check of rollers, slide pieces and stops k t7.3 Check fork tines and fork carrier for wear and damage k t

Hydr. system: 8.1 Check function k t8.2 Check all connections for leakage and damage b) k t8.3 Check hydraulic cylinders for leakage, damage and

secure attachmentk t

8.4 Check the oil level k t8.5 Change hydraulic oil c) k t8.6 Change filter t8.7 Check the pressure relief valves for correct functioning k t

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Maintenance intervalsStandard = t W M M MCold-stora-ge depot

= k 1 3 6 12

Electr. system:

9.1 Check function t9.2 Check all cables for secure connection and damage t9.3 Check the fuses for correct amperage t9.4 Check switches and trip cams for proper functioning and

seatingt

9.5 Check contactors and relays, replace wearing parts, if necessary

t

9.6 Check functioning of warning devices and safety circuits k tElectric motors:

10.1 Check wear of carbon brushes t10.2 Check the motor for secure attachment t10.3 Suck out engine block, check wear of collector k t

Battery: 11.1 Check acid density, acid level and cell voltage k t11.2 Check the terminals for secure attachment and apply

pole greasek t

11.3 Clean battery connections, check for tight fit k t11.4 Check the battery cables for damage and replace,

if necessaryt

Lubrication service:

12.1 Grease truck according to lubrication schedule k t

General mea-surements:

13.1 Check electrical system for short to ground t13.2 Check driving speed and braking distance t13.3 Check lifting and lowering speed t13.4 Check safety facilities and switch-off devices t

Demonstrati-on:

14.1 Perform a trial run under a nominal load t14.2 Demonstrate the truck to a person charged with inspec-

tion upon completion of the maintenance of the truckk t

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Maintenance intervalsStandard = t W M M MCold-stora-ge depot

= k 1 3 6 12

Electr. system:

9.1 Check function t9.2 Check all cables for secure connection and damage t9.3 Check the fuses for correct amperage t9.4 Check switches and trip cams for proper functioning and

seatingt

9.5 Check contactors and relays, replace wearing parts, if necessary

t

9.6 Check functioning of warning devices and safety circuits k tElectric motors:

10.1 Check wear of carbon brushes t10.2 Check the motor for secure attachment t10.3 Suck out engine block, check wear of collector k t

Battery: 11.1 Check acid density, acid level and cell voltage k t11.2 Check the terminals for secure attachment and apply

pole greasek t

11.3 Clean battery connections, check for tight fit k t11.4 Check the battery cables for damage and replace,

if necessaryt

Lubrication service:

12.1 Grease truck according to lubrication schedule k t

General mea-surements:

13.1 Check electrical system for short to ground t13.2 Check driving speed and braking distance t13.3 Check lifting and lowering speed t13.4 Check safety facilities and switch-off devices t

Demonstrati-on:

14.1 Perform a trial run under a nominal load t14.2 Demonstrate the truck to a person charged with inspec-

tion upon completion of the maintenance of the truckk t

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5 Lubrication schedule

g Slide facess Grease nipple

Filler neck for hydraulic oilb Filler neck Gear oila Drain plug Gear oil1) Mixing proportion for application in cold-storage depots 1:12) Filling level see "Check hydraulic oil level"

a

b

B1,4l

MA = 105 Nm

B+C1)

G

A A+C1)

2)

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5 Lubrication schedule

g Slide facess Grease nipple

Filler neck for hydraulic oilb Filler neck Gear oila Drain plug Gear oil1) Mixing proportion for application in cold-storage depots 1:12) Filling level see "Check hydraulic oil level"

a

b

B1,4l

MA = 105 Nm

B+C1)

G

A A+C1)

2)

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5.1 Operating material

Handling operating material: Consumption type material must always be handledproperly. Manufacturer's instructions to be observed.

f Improper handling endangers health, life and environment. Operating material mustonly be stored in containers conforming to specification. They might be inflammableand must not come into contact with hot components or open fire.

When filling in consumption type materials, use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualities, except if mixing isexpressively prescribed in these operating instructions. -This instruction may only beignored, if another mixing ratio is explicitly prescribed in this manual.

Avoid any spilling. Spilled liquid must be removed immediately using a suitable bin-ding agent, and the mixture of consumption type material and binding agent is to bedisposed of according to the regulations.

Code Order-no. Supplied quantity

Description Used for:

A 092 006 708 5.0 l H-LP 46, DIN 51524 Hydraulic systemB 092 006 801 5.0 l CLP 100, DIN 51517 TransmissionC 092 008 102 5.0 l H-LP 10, DIN 51524 Transmission

hydraulic systemE 092 014 307 1.0 kg Grease, DIN 51825 Lubrication serviceF 092 001 006 1.0 kg Grease, TTF52 Lubrication service

Grease standard valuesCode Type of

SaponificationDropping point °C

Worked penetrationat 25°C

NLG1 Class

Service temperature °C

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

F 7

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.GB

5.1 Operating material

Handling operating material: Consumption type material must always be handledproperly. Manufacturer's instructions to be observed.

f Improper handling endangers health, life and environment. Operating material mustonly be stored in containers conforming to specification. They might be inflammableand must not come into contact with hot components or open fire.

When filling in consumption type materials, use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualities, except if mixing isexpressively prescribed in these operating instructions. -This instruction may only beignored, if another mixing ratio is explicitly prescribed in this manual.

Avoid any spilling. Spilled liquid must be removed immediately using a suitable bin-ding agent, and the mixture of consumption type material and binding agent is to bedisposed of according to the regulations.

Code Order-no. Supplied quantity

Description Used for:

A 092 006 708 5.0 l H-LP 46, DIN 51524 Hydraulic systemB 092 006 801 5.0 l CLP 100, DIN 51517 TransmissionC 092 008 102 5.0 l H-LP 10, DIN 51524 Transmission

hydraulic systemE 092 014 307 1.0 kg Grease, DIN 51825 Lubrication serviceF 092 001 006 1.0 kg Grease, TTF52 Lubrication service

Grease standard valuesCode Type of

SaponificationDropping point °C

Worked penetrationat 25°C

NLG1 Class

Service temperature °C

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

0999

.GB

F 8

6 Notes on maintenance

6.1 Preparation of the truck for servicing and maintenance operation

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

– Park the truck and render it safe (refer to chapter E).– Disconnect the battery connector to prevent accidental or unauthorised truck ope-

ration.

f When work has to be performed under the jacked-up truck, suitable measures mustbe taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck,the instructions included in chapter “Transportation and Commissioning” have to beobserved.

6.2 Open the battery hood

See chapter D.

6.3 Open the front hood

– Turn the control shaft to the truck outer edge or incline it slightly.– Release the hood locking mechanism (1); the key (2) can be found in the battery

compartment.– Raise the hood (3) and place it next to the truck.

A Mounting is performed in reverse order.

1

4

3

2

5

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6 Notes on maintenance

6.1 Preparation of the truck for servicing and maintenance operation

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

– Park the truck and render it safe (refer to chapter E).– Disconnect the battery connector to prevent accidental or unauthorised truck ope-

ration.

f When work has to be performed under the jacked-up truck, suitable measures mustbe taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck,the instructions included in chapter “Transportation and Commissioning” have to beobserved.

6.2 Open the battery hood

See chapter D.

6.3 Open the front hood

– Turn the control shaft to the truck outer edge or incline it slightly.– Release the hood locking mechanism (1); the key (2) can be found in the battery

compartment.– Raise the hood (3) and place it next to the truck.

A Mounting is performed in reverse order.

1

4

3

2

5

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6.4 Check hydraulic oil level

– Prepare the truck for servicing and maintenance operations (see section 6.1). – Open the front hood (see section 6.3).– Check the hydraulic oil level of the hydraulic tank (see section 5).

A There are markings on the hydraulic tank (see section 5). The oil level must be chek-ked with the lifting device being lowered.

– If required, top up with hydraulic oil with the required characteristics(see section 5.1; see table)

A Mounting is performed in reverse order.

6.5 Check the transmission oil level

– Prepare the truck for servicing and maintenance operations (see section 6.1). – Open the front hood (see section 6.3).– Loosen 2 x screws (5) using the key (2).– Remove carefully the wheel cover (4).– Check gear-oil level - oil level must reach the filler neck

(see section 5).– If required, top up with gear oil with the required characteristics (see section 5.1).

A Mounting is performed in reverse order.

6.6 Exchanging the coarse sieve

– Preparation of the truck for servicingand maintenance operations (refer section 6.1).

– Open the front hood (see chapter F,section 6.3).

– Loosen the screwed connection (6). – Pull off the connection (7) and remove

the coarse sieve.– Insert a new coarse sieve.

m Mounting is performed in reverse order.

m Tighten screwed connection (6) withmax. 60+10 Nm.

Marking Litre Lifting heights (h3)E ZT ZZ DZ

Upper edge approx. 10.5 - - - up to 53504 approx. 10 - - - -3 approx. 8.3 - - up to 4300 up to 43002 approx. 6.8 - up to 4300 up to 3600 -1 approx. 5.1 all up to 3200 up to 2500 -

6 7

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6.4 Check hydraulic oil level

– Prepare the truck for servicing and maintenance operations (see section 6.1). – Open the front hood (see section 6.3).– Check the hydraulic oil level of the hydraulic tank (see section 5).

A There are markings on the hydraulic tank (see section 5). The oil level must be chek-ked with the lifting device being lowered.

– If required, top up with hydraulic oil with the required characteristics(see section 5.1; see table)

A Mounting is performed in reverse order.

6.5 Check the transmission oil level

– Prepare the truck for servicing and maintenance operations (see section 6.1). – Open the front hood (see section 6.3).– Loosen 2 x screws (5) using the key (2).– Remove carefully the wheel cover (4).– Check gear-oil level - oil level must reach the filler neck

(see section 5).– If required, top up with gear oil with the required characteristics (see section 5.1).

A Mounting is performed in reverse order.

6.6 Exchanging the coarse sieve

– Preparation of the truck for servicingand maintenance operations (refer section 6.1).

– Open the front hood (see chapter F,section 6.3).

– Loosen the screwed connection (6). – Pull off the connection (7) and remove

the coarse sieve.– Insert a new coarse sieve.

m Mounting is performed in reverse order.

m Tighten screwed connection (6) withmax. 60+10 Nm.

Marking Litre Lifting heights (h3)E ZT ZZ DZ

Upper edge approx. 10.5 - - - up to 53504 approx. 10 - - - -3 approx. 8.3 - - up to 4300 up to 43002 approx. 6.8 - up to 4300 up to 3600 -1 approx. 5.1 all up to 3200 up to 2500 -

6 7

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F 10

6.7 Checking the electric fuses

– Preparation of the truck for servicing and maintenance operations (see section 6.1).

– Open the front hood(see section 6.3).

– Referring to the table, check all fuses for correct rating and replace, where required.

Item Description Protection of: Value8 F1 Total control fuse 10 A9 1F1 Drive motor (in parallel to 1F10) 150 A

10 2F1 Pump motor 150 A11 1F10 Drive motor (in parallel to 1F1) 40 A12 6F1 Discharge indicator/operating hour meter 10 A

12

11

10 9

8

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6.7 Checking the electric fuses

– Preparation of the truck for servicing and maintenance operations (see section 6.1).

– Open the front hood(see section 6.3).

– Referring to the table, check all fuses for correct rating and replace, where required.

Item Description Protection of: Value8 F1 Total control fuse 10 A9 1F1 Drive motor (in parallel to 1F10) 150 A

10 2F1 Pump motor 150 A11 1F10 Drive motor (in parallel to 1F1) 40 A12 6F1 Discharge indicator/operating hour meter 10 A

12

11

10 9

8

F 11

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6.8 Recommissioning the truck

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

– Check the horn for proper functioning.– Check the main switch (Emergency-STOP) for correct function.– Check the brake for correct function.

7 Taking the floor conveyor out of service

If the floor conveyor is to be taken out of service for more than two months, it must beparked in a frost-free and dry location and all required measures are to be taken be-fore, during and following decommisioning.

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

If the floor conveyor is to be taken out of service for periods exceeding six months,the service of the manufacturer must be contacted for further measures to be taken.

7.9 Operations to be performed prior to decommissioning

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

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

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

7.10 Measures to be taken during decommissioning

Every 2 months:

– Recharge the battery (see chapter D).

m For battery-driven trucks:Regular recharging of the battery is very important. Otherwise, excessive depletionof the battery would occur caused by self-discharging, which will result in the destruc-tion of the battery caused by sulfatisation.

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6.8 Recommissioning the truck

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

– Check the horn for proper functioning.– Check the main switch (Emergency-STOP) for correct function.– Check the brake for correct function.

7 Taking the floor conveyor out of service

If the floor conveyor is to be taken out of service for more than two months, it must beparked in a frost-free and dry location and all required measures are to be taken be-fore, during and following decommisioning.

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

If the floor conveyor is to be taken out of service for periods exceeding six months,the service of the manufacturer must be contacted for further measures to be taken.

7.9 Operations to be performed prior to decommissioning

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

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

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

7.10 Measures to be taken during decommissioning

Every 2 months:

– Recharge the battery (see chapter D).

m For battery-driven trucks:Regular recharging of the battery is very important. Otherwise, excessive depletionof the battery would occur caused by self-discharging, which will result in the destruc-tion of the battery caused by sulfatisation.

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7.11 Recommissioning the truck

– Thoroughly clean the truck.– Grease the truck as detailed in the lubrication chart (see section 5).– Clean the battery. Grease the terminal screws using pole grease and reconnect the

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

A For battery-driven trucks:If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove any oxide layer on the contacts of the control equip-ment by operating it several times.

A Upon recommissioning of the truck perform several brake tests immediately.

8 Safety checks to be performed at regular intervals and following any untowardincidents (D: UVV according to VBG 36)

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

The inspection must comprise a comprehensive check of the technical condition ofthe fork-lift truck with regard to accident prevention aspects. Apart from this, the floorconveyor must be thoroughly inspected for damage possibly caused by inappropriateuse. The inspection results must be recorded in an inspection report. The report mustbe kept available for a period spanning at least the next two inspection intervals.

The user has to ensure that all defects are eliminated without delay.

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

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F 12

7.11 Recommissioning the truck

– Thoroughly clean the truck.– Grease the truck as detailed in the lubrication chart (see section 5).– Clean the battery. Grease the terminal screws using pole grease and reconnect the

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

A For battery-driven trucks:If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove any oxide layer on the contacts of the control equip-ment by operating it several times.

A Upon recommissioning of the truck perform several brake tests immediately.

8 Safety checks to be performed at regular intervals and following any untowardincidents (D: UVV according to VBG 36)

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

The inspection must comprise a comprehensive check of the technical condition ofthe fork-lift truck with regard to accident prevention aspects. Apart from this, the floorconveyor must be thoroughly inspected for damage possibly caused by inappropriateuse. The inspection results must be recorded in an inspection report. The report mustbe kept available for a period spanning at least the next two inspection intervals.

The user has to ensure that all defects are eliminated without delay.

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