bl ejc 110n-112n gb - jungheinrich.ie · 5 ejc 110n/112n lubrication schedule ... the truck...

11.09 -

Operating instructions

5115940309.16

EJC

G

EJC 110nEJC 112n

0716

.GBForewordThe present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.

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

Safety instructions and important explanations are indicated by the following graphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Friedrich-Ebert-Damm 129 22047 Hamburg - GERMANY

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

www.jungheinrich.com

0716

.GB

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

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

Safety instructions and important explanations are indicated by the following graphics:

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

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


t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright



Friedrich-Ebert-Damm 129 22047 Hamburg - GERMANY

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


0716

.GB

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I 1

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BIndexA Correct use and application

B Truck Description

1 Application ........................................................................................... B 12 Assemblies .......................................................................................... B 23 Standard Version Specifications ......................................................... B 33.1 Performance data for standard trucks ................................................. B 33.2 Dimensions ......................................................................................... B 33.3 EN norms ............................................................................................ B 53.4 Conditions of use ................................................................................ B 54 Identification points and data plates .................................................... B 64.1 Truck data plate .................................................................................. B 74.2 Capacity .............................................................................................. B 8

C Transport and Commissioning

1 Lifting by crane .................................................................................... C 12 Using the truck for the first time .......................................................... C 13 Operating the truck without its own drive system

(emergency operation) ........................................................................ C 2

D Battery Maintenance, Charging & Replacement

1 Safety regulations for handling acid batteries ..................................... D 12 Battery types ....................................................................................... D 23 Exposing the battery ........................................................................... D 24 Charge the battery .............................................................................. D 34.1 Charging the battery with an onboard charger t ............................... D 34.2 Charging the battery with a stationary charger o ............................... D 75 Battery removal and installation .......................................................... D 86 Battery charge / discharge indicator (t) ............................................. D 9

E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 12 Controls and Displays ......................................................................... E 23 Starting up the truck ............................................................................ E 64 Using the industrial truck ..................................................................... E 74.1 Safety regulations for truck operation ................................................. E 74.2 Travelling, Steering, Braking ............................................................... E 84.3 Collecting and depositing loads .......................................................... E 115 Emergency lowering ............................................................................ E 125.1 Parking the truck securely ................................................................... E 136 Keypad (CanCode) (o) ....................................................................... E 13

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B

IndexA Correct use and application

B Truck Description

1 Application ........................................................................................... B 12 Assemblies .......................................................................................... B 23 Standard Version Specifications ......................................................... B 33.1 Performance data for standard trucks ................................................. B 33.2 Dimensions ......................................................................................... B 33.3 EN norms ............................................................................................ B 53.4 Conditions of use ................................................................................ B 54 Identification points and data plates .................................................... B 64.1 Truck data plate .................................................................................. B 74.2 Capacity .............................................................................................. B 8

C Transport and Commissioning

1 Lifting by crane .................................................................................... C 12 Using the truck for the first time .......................................................... C 13 Operating the truck without its own drive system

(emergency operation) ........................................................................ C 2


1 Safety regulations for handling acid batteries ..................................... D 12 Battery types ....................................................................................... D 23 Exposing the battery ........................................................................... D 24 Charge the battery .............................................................................. D 34.1 Charging the battery with an onboard charger t ............................... D 34.2 Charging the battery with a stationary charger o ............................... D 75 Battery removal and installation .......................................................... D 86 Battery charge / discharge indicator (t) ............................................. D 9

E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 12 Controls and Displays ......................................................................... E 23 Starting up the truck ............................................................................ E 64 Using the industrial truck ..................................................................... E 74.1 Safety regulations for truck operation ................................................. E 74.2 Travelling, Steering, Braking ............................................................... E 84.3 Collecting and depositing loads .......................................................... E 115 Emergency lowering ............................................................................ E 125.1 Parking the truck securely ................................................................... E 136 Keypad (CanCode) (o) ....................................................................... E 13

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I 2

6.1 Code Lock ........................................................................................... E 136.2 Travel programs .................................................................................. E 156.3 Parameters .......................................................................................... E 156.4 Parameter Settings ............................................................................. E 166.5 Travel parameters ............................................................................... E 207 Display instrument (CanDis) (o) ......................................................... E 237.1 Operating hours display ...................................................................... E 247.2 Power up test ...................................................................................... E 248 Display (2 inch) (o).............................................................................. E 258.1 Symbols in the display ......................................................................... E 268.2 Service hour display............................................................................. E 278.3 Event Messages................................................................................... E 278.4 Power up test ....................................................................................... E 278.5 Battery Management System Automatic Cutout .................................. E 278.6 Battery Management System Discharge Monitor................................. E 279 Troubleshooting .................................................................................. E 29

F Forklift Truck Maintenance

1 Operational safety and environmental protection ................................ F 12 Maintenance Safety Regulations ........................................................ F 13 Servicing and inspection ..................................................................... F 34 Maintenance Checklist ........................................................................ F 45 EJC 110n/112n Lubrication Schedule ................................................. F 65.1 Fuels, coolants and lubricants ............................................................. F 76 Maintenance Instructions .................................................................... F 86.1 Prepare the truck for maintenance and repairs ................................... F 86.2 Removing the front panel .................................................................... F 86.3 Remove the drive panel ...................................................................... F 86.4 Checking the hydraulic oil level ........................................................... F 96.5 Check transmission oil level ................................................................ F 96.6 Flushing the gauze filter, Replacing the gauze filter ........................... F 106.7 Replacing the filter cartridge ............................................................... F 106.8 Checking electrical fuses .................................................................... F 116.9 Recommissioning ................................................................................ F 127 Decommissioning the industrial truck .................................................. F 127.1 Prior to decommissioning .................................................................... F 127.2 During decommissioning ..................................................................... F 127.3 Restoring the truck to operation after decommissioning ..................... F 138 Safety checks to be performed at regular intervals

and following any unusual incidents .................................................... F 149 Final de-commissioning, disposal ....................................................... F 14

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I 2

6.1 Code Lock ........................................................................................... E 136.2 Travel programs .................................................................................. E 156.3 Parameters .......................................................................................... E 156.4 Parameter Settings ............................................................................. E 166.5 Travel parameters ............................................................................... E 207 Display instrument (CanDis) (o) ......................................................... E 237.1 Operating hours display ...................................................................... E 247.2 Power up test ...................................................................................... E 248 Display (2 inch) (o).............................................................................. E 258.1 Symbols in the display ......................................................................... E 268.2 Service hour display............................................................................. E 278.3 Event Messages................................................................................... E 278.4 Power up test ....................................................................................... E 278.5 Battery Management System Automatic Cutout .................................. E 278.6 Battery Management System Discharge Monitor................................. E 279 Troubleshooting .................................................................................. E 29

F Forklift Truck Maintenance

1 Operational safety and environmental protection ................................ F 12 Maintenance Safety Regulations ........................................................ F 13 Servicing and inspection ..................................................................... F 34 Maintenance Checklist ........................................................................ F 45 EJC 110n/112n Lubrication Schedule ................................................. F 65.1 Fuels, coolants and lubricants ............................................................. F 76 Maintenance Instructions .................................................................... F 86.1 Prepare the truck for maintenance and repairs ................................... F 86.2 Removing the front panel .................................................................... F 86.3 Remove the drive panel ...................................................................... F 86.4 Checking the hydraulic oil level ........................................................... F 96.5 Check transmission oil level ................................................................ F 96.6 Flushing the gauze filter, Replacing the gauze filter ........................... F 106.7 Replacing the filter cartridge ............................................................... F 106.8 Checking electrical fuses .................................................................... F 116.9 Recommissioning ................................................................................ F 127 Decommissioning the industrial truck .................................................. F 127.1 Prior to decommissioning .................................................................... F 127.2 During decommissioning ..................................................................... F 127.3 Restoring the truck to operation after decommissioning ..................... F 138 Safety checks to be performed at regular intervals

and following any unusual incidents .................................................... F 149 Final de-commissioning, disposal ....................................................... F 14

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Appendix

JH Traction Battery Operating Instructions

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

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Appendix

JH Traction Battery Operating Instructions

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

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2

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2

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BA Correct use and application

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

The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual.

M Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.

Attaching accessories: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer’s approval.

Z The permissible operating conditions change if the truck is equipped with a lithium-ion battery (o), see the manufacturer's operating instructions.

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B

A Correct use and application

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

The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual.

M Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.

Attaching accessories: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer’s approval.


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BB Truck Description1 Application

The EJCn is a four wheel, tiller guided electric truck with a steered drive wheel. It is designed for use on level floors to lift and transport palletised goods. Open bottom pallets or roll cages can be lifted. The capacity can be obtained from the data plate. The capacity with respect to lift height and load centre of gravity is indicated on the capacity plate.

B 1

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B

B Truck Description1 Application

The EJCn is a four wheel, tiller guided electric truck with a steered drive wheel. It is designed for use on level floors to lift and transport palletised goods. Open bottom pallets or roll cages can be lifted. The capacity can be obtained from the data plate. The capacity with respect to lift height and load centre of gravity is indicated on the capacity plate.

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B

B 2

2 Assemblies

Item EJC 110n EJC 112n Component1 t t Key switch

2 o o CanCode keypado o ISM Access Module

3 t t Battery charge / discharge indicatoro o CanDis display instrument

4 t t Tiller and tiller arm5 t t “Shunt” button6 t t Controller7 t t Collision safety switch8 t t Mast9 t t Mast guard10 t t Battery panel11 t t Battery connector (Emergency Disconnect)12 t t Lift mechanism13 t t Front panel14 t t Caster wheel15 t t Charger16 t t Drive wheel

t = Standard equipment o = Optional equipment

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10

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12

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B

B 2

2 Assemblies

Item EJC 110n EJC 112n Component1 t t Key switch

2 o o CanCode keypado o ISM Access Module

3 t t Battery charge / discharge indicatoro o CanDis display instrument

4 t t Tiller and tiller arm5 t t “Shunt” button6 t t Controller7 t t Collision safety switch8 t t Mast9 t t Mast guard10 t t Battery panel11 t t Battery connector (Emergency Disconnect)12 t t Lift mechanism13 t t Front panel14 t t Caster wheel15 t t Charger16 t t Drive wheel

t = Standard equipment o = Optional equipment

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2

3

4

5

6 67

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13

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12

8

9

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B3 Standard Version Specifications

Z Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.

3.1 Performance data for standard trucks

3.2 Dimensions

1) for ZT mast: at 100 mm free lift (h2) u h1+ 50 mm 2) telescopic mast only (ZT) 3) ZZ mast only

Description EJC 110n EJC 112n Q Rated capacity 1000 1200 kgC Load centre distance

Standard fork length600 600 mm

Travel speed w. nominal load / w.o. load

6.0 / 6.0 6.0 / 6.0 km/h

Raise lift speed w. nominal load / w.o. load

13 / 24 12 / 21 cm/s

Lowering speed w. nominal load / w.o. load

40 / 42 40 / 42 cm/s

Max. gradeability (5 min rating) w / w.o. load

8 16 %

Component EJC 110n EJC 112nh1 Height (mast-dependent)1) 1750 - 2100 1700 - 2250 mmh2 Free lift 2) 100 100 mmh2 Free lift (duplex)3)

(mast dependent)- 1227 - 1777 mm

h3 Lift (mast-dependent) 2500 - 3200 2500 - 3600 mmh4 extended mast height

(mast-dependent)2973 - 3673 2973 - 4073 mm

h13 Load fork lowered 90 90 mmh14 Tiller height in min/max

travel position820/1310 820/1310 mm

y Wheelbase 1171 1171 mml1 Overall length 1787 1787 mml2 Length incl. fork shank 637 637 mmB Truck width 800 800 mmb5 Distance between forks, outer 560 560 mmm2 Ground clearance 30 30 mmAst Aisle width

800 x 1200 longit.2096 2096 mm

Ast Aisle width 800 x 1200 longit. (in accordance with VDI)

2234 2234 mm

Wa Turning radius in shunt mode (tiller vertical)

1383 1383 mm

B 3

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B

3 Standard Version Specifications

Z Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.

3.1 Performance data for standard trucks

3.2 Dimensions

1) for ZT mast: at 100 mm free lift (h2) u h1+ 50 mm 2) telescopic mast only (ZT) 3) ZZ mast only

Description EJC 110n EJC 112n Q Rated capacity 1000 1200 kgC Load centre distance

Standard fork length600 600 mm

Travel speed w. nominal load / w.o. load

6.0 / 6.0 6.0 / 6.0 km/h

Raise lift speed w. nominal load / w.o. load

13 / 24 12 / 21 cm/s

Lowering speed w. nominal load / w.o. load

40 / 42 40 / 42 cm/s

Max. gradeability (5 min rating) w / w.o. load

8 16 %

Component EJC 110n EJC 112nh1 Height (mast-dependent)1) 1750 - 2100 1700 - 2250 mmh2 Free lift 2) 100 100 mmh2 Free lift (duplex)3)

(mast dependent)- 1227 - 1777 mm

h3 Lift (mast-dependent) 2500 - 3200 2500 - 3600 mmh4 extended mast height

(mast-dependent)2973 - 3673 2973 - 4073 mm

h13 Load fork lowered 90 90 mmh14 Tiller height in min/max

travel position820/1310 820/1310 mm

y Wheelbase 1171 1171 mml1 Overall length 1787 1787 mml2 Length incl. fork shank 637 637 mmB Truck width 800 800 mmb5 Distance between forks, outer 560 560 mmm2 Ground clearance 30 30 mmAst Aisle width

800 x 1200 longit.2096 2096 mm

Ast Aisle width 800 x 1200 longit. (in accordance with VDI)

2234 2234 mm

Wa Turning radius in shunt mode (tiller vertical)

1383 1383 mm

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h1

h14h2

h3

h4

l1

l l2

h13 m2y

c

Q

b5

Ast

Wa

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B3.3 EN norms

Noise emission: 70 dB(A) in accordance with EN 12053 as harmonised with ISO 4871.

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

Electromagnetic compatibility (EMC) The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein.

Z No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.

3.4 Conditions of use

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

Z Special equipment and authorisation is required if the truck is to operate constantly below 5°C or in a cold store or in extreme temperatures or conditions of fluctuating air humidity.


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3.3 EN norms

Noise emission: 70 dB(A) in accordance with EN 12053 as harmonised with ISO 4871.

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

Electromagnetic compatibility (EMC) The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein.

Z No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.

3.4 Conditions of use

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

Z Special equipment and authorisation is required if the truck is to operate constantly below 5°C or in a cold store or in extreme temperatures or conditions of fluctuating air humidity.


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B

B 6

4 Identification points and data plates

Item Description18 Capacity19 Truck data plate20 Attachment point for lifting by crane (with ZZ mast in the middle)21 "Do not reach through the mast" warning22 “Do not step under the load handler” warning23 Battery data plate24 “No passengers” warning25 Test sticker (o)26 Model descriptiona Label „Equipped with Li-Ion battery“ (o)

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20 2020

21

22

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25

18

26a

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4 Identification points and data plates

Item Description18 Capacity19 Truck data plate20 Attachment point for lifting by crane (with ZZ mast in the middle)21 "Do not reach through the mast" warning22 “Do not step under the load handler” warning23 Battery data plate24 “No passengers” warning25 Test sticker (o)26 Model descriptiona Label „Equipped with Li-Ion battery“ (o)

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19

20 2020

21

22

23

24

25

18

26a

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B4.1 Truck data plate

Z For queries regarding the truck or ordering spare parts please quote the truck serial number (42).

Item Description Item Description27 Type 36 Manufacturer’s logo28 Name 37 Max. battery weight in kg29 Battery: Voltage (V) 38 Min. battery weight in kg30 Rated capacity (kg) 39 Output (kW)31 Net weight w.o. battery (kg) 40 Load centre (mm)32 Net weight with battery (kg) 41 Year of manufacture33 Manufacturer 42 Serial No.34 Production 43 Option35 Production address

38

37

31

3930

4029

4128

2743 42

32

33

34 35 36

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4.1 Truck data plate

Z For queries regarding the truck or ordering spare parts please quote the truck serial number (42).

Item Description Item Description27 Type 36 Manufacturer’s logo28 Name 37 Max. battery weight in kg29 Battery: Voltage (V) 38 Min. battery weight in kg30 Rated capacity (kg) 39 Output (kW)31 Net weight w.o. battery (kg) 40 Load centre (mm)32 Net weight with battery (kg) 41 Year of manufacture33 Manufacturer 42 Serial No.34 Production 43 Option35 Production address

38

37

31

3930

4029

4128

2743 42

32

33

34 35 36

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4.2 Capacity

F The capacity data with respect to lift height and load centre of gravity distance can be found on the truck's capacity plate (18).

Depending on the mast fitted, the truck will have one of the following two capacity plates (18): (illustrations for reference purposes only).

The capacity plate to the right (18) shows the capacity (Q in kg) for different load centres of gravity (D in mm) in diagram form.

The lower plate (18) gives the capacity (Q in kg) of the truck as a function of the load centre of gravity distance (D in mm) and lift height (H in mm) in tabular form.

The arrow shape markings (44 and 45) on the inner mast and bottom and outer tie bar indicate to the driver when he has exceeded the height limits specified by the capacity plate (18).

18

-Nr.

Serien-Nr.

DmmHmm

Qkg

18

39 40

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4.2 Capacity

F The capacity data with respect to lift height and load centre of gravity distance can be found on the truck's capacity plate (18).

Depending on the mast fitted, the truck will have one of the following two capacity plates (18): (illustrations for reference purposes only).

The capacity plate to the right (18) shows the capacity (Q in kg) for different load centres of gravity (D in mm) in diagram form.

The lower plate (18) gives the capacity (Q in kg) of the truck as a function of the load centre of gravity distance (D in mm) and lift height (H in mm) in tabular form.

The arrow shape markings (44 and 45) on the inner mast and bottom and outer tie bar indicate to the driver when he has exceeded the height limits specified by the capacity plate (18).

18

-Nr.

Serien-Nr.

DmmHmm

Qkg

18

39 40

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C Transport and Commissioning1 Lifting by crane

F Only use lifting gear with sufficient capacity (for transport weight see truck data plate).

Z The attachment points (1) are provided for lifting the truck with crane lifting gear (in the middle with the ZZ mast).

– Park the truck securely (See Chapter E).– Strap the lifting gear onto the attachment

points (1) (in the middle with the ZZ mast).

M Fasten the harness to the lifting points so that it cannot slip! Crane slings should be fastened in such a way that they do not come into contact with any parts of the truck when it is being raised.

2 Using the truck for the first time

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

F It is forbidden to raise loads if the truck is operated via a tow lead with an external battery.

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

– Make sure the truck’s equipment is complete and in a satisfactory condition.– Install battery (where required). Do not damage battery cables

(see Chapter D).

Z Set the characteristic curve (charging curve) on the charger (see Chapter D).

– Charge the battery (see Chapter D).– If necessary, adjust the combination instrument to match the battery type (see

Chapter D).– Commission the truck in accordance with instructions

(see Chapter E).

Z When the truck is parked, the surface of the tyres will flatten. The flattening will disappear after a short period of operation.

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C Transport and Commissioning1 Lifting by crane

F Only use lifting gear with sufficient capacity (for transport weight see truck data plate).

Z The attachment points (1) are provided for lifting the truck with crane lifting gear (in the middle with the ZZ mast).

– Park the truck securely (See Chapter E).– Strap the lifting gear onto the attachment

points (1) (in the middle with the ZZ mast).

M Fasten the harness to the lifting points so that it cannot slip! Crane slings should be fastened in such a way that they do not come into contact with any parts of the truck when it is being raised.

2 Using the truck for the first time

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

F It is forbidden to raise loads if the truck is operated via a tow lead with an external battery.

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

– Make sure the truck’s equipment is complete and in a satisfactory condition.– Install battery (where required). Do not damage battery cables

(see Chapter D).

Z Set the characteristic curve (charging curve) on the charger (see Chapter D).

– Charge the battery (see Chapter D).– If necessary, adjust the combination instrument to match the battery type (see

Chapter D).– Commission the truck in accordance with instructions

(see Chapter E).

Z When the truck is parked, the surface of the tyres will flatten. The flattening will disappear after a short period of operation.

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3 Operating the truck without its own drive system (emergency operation)

F This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a failure has rendered it immobile, proceed as follows:

– Set the master switch to position “OFF”.– Set the key switch to position “OFF” (“0”) and remove the key.– Prevent the truck from rolling away.– Remove the front panel (2) (see Chapter F).– Remove the right-hand drive panel (3) (see Chapter F).– Pull up the anchor plate by screwing in two M5 screws (4, at least 35 mm long) as

far as the stop.

The brake has now been released and the truck can be moved.

F On reaching your destination, ensure that the brake is restored to its initial state. The truck must on no account be parked with the brake in the released condition.

– Remove the screws (4).

The brake is now applied again.

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3 Operating the truck without its own drive system (emergency operation)

F This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a failure has rendered it immobile, proceed as follows:

– Set the master switch to position “OFF”.– Set the key switch to position “OFF” (“0”) and remove the key.– Prevent the truck from rolling away.– Remove the front panel (2) (see Chapter F).– Remove the right-hand drive panel (3) (see Chapter F).– Pull up the anchor plate by screwing in two M5 screws (4, at least 35 mm long) as

far as the stop.

The brake has now been released and the truck can be moved.

F On reaching your destination, ensure that the brake is restored to its initial state. The truck must on no account be parked with the brake in the released condition.

– Remove the screws (4).

The brake is now applied again.

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BD Battery Maintenance, Charging &

Replacement

Z For use of lithium-ion batteries (o), see the manufacturer's operating instructions.

1 Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries (see Chapter E).

Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

Fire protection: Smoking and naked flames must be avoided when working with batteries Wherever a truck is parked for charging there shall be no inflammable material or operating fluids capable of creatings sparks within 2 metres around the truck. The area must be well ventilated. Fire protection equipment must be provided.

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

Battery Disposal: Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.

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

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

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

F The weight and dimensions of the battery have considerable affect on the operational safety of the truck. Battery equipment may only be replaced with the agreement of the manufacturer.

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Z For use of lithium-ion batteries (o), see the manufacturer's operating instructions.

1 Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries (see Chapter E).

Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

Fire protection: Smoking and naked flames must be avoided when working with batteries Wherever a truck is parked for charging there shall be no inflammable material or operating fluids capable of creatings sparks within 2 metres around the truck. The area must be well ventilated. Fire protection equipment must be provided.

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

Battery Disposal: Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.

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

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

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

F The weight and dimensions of the battery have considerable affect on the operational safety of the truck. Battery equipment may only be replaced with the agreement of the manufacturer.

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D 2

2 Battery types

Depending on the model, the EJCn comes with different battery types. The battery weights can be taken from the battery data plate.

M When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.

The following table shows which combinations are included as standard:

Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.

3 Exposing the battery

– Park the truck securely (see Chapter E).– Remove the battery connector (1).– Lift up the battery panel (2).

F When you lift up the battery panel, make sure the panel lock engages.

Z Remove the panel to replace the battery (see Section 5).

Truck type Battery

EJC 110n / 112n2 EPzS/EPzB 150 Ah2 EPzS/EPzB 200 Ah

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D 2

2 Battery types

Depending on the model, the EJCn comes with different battery types. The battery weights can be taken from the battery data plate.

M When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.

The following table shows which combinations are included as standard:

Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.

3 Exposing the battery

– Park the truck securely (see Chapter E).– Remove the battery connector (1).– Lift up the battery panel (2).

F When you lift up the battery panel, make sure the panel lock engages.

Z Remove the panel to replace the battery (see Section 5).

Truck type Battery

EJC 110n / 112n2 EPzS/EPzB 150 Ah2 EPzS/EPzB 200 Ah

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B4 Charge the battery

The EJC 110n/112n is fitted as standard with an onboard charger (for charging see section 4.1).

The EJC 110n/112n can optionally be fitted with a stationary charger (for charging see section 4.2).

To charge the battery, the truck must be parked in a closed and properly ventilated room.

4.1 Charging the battery with an onboard charger t

The charger must not be opened. If damaged, it must be replaced.

Z The switch (4) of trucks supplied without a battery is factory-set to the “0” position. The red LED (3) flashes to indicate the battery cannot be charged.

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4 Charge the battery

The EJC 110n/112n is fitted as standard with an onboard charger (for charging see section 4.1).

The EJC 110n/112n can optionally be fitted with a stationary charger (for charging see section 4.2).

To charge the battery, the truck must be parked in a closed and properly ventilated room.

4.1 Charging the battery with an onboard charger t

The charger must not be opened. If damaged, it must be replaced.

Z The switch (4) of trucks supplied without a battery is factory-set to the “0” position. The red LED (3) flashes to indicate the battery cannot be charged.

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D 4

Selecting the charging curve for the onboard charger

Use the switch (4) on the charger to adapt the charge curves to the particular battery used, in accordance with the following table.

M Remove the battery and mains connectors before setting the appropriate curve.

Z All other switch (4) positions block the charger, and the battery is not charged.

Z With 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be used. Characteristic curve 5 produces a faster charge.

Setting the charging characteristic curve

Set the characteristic curve as follows:

Switch (4) Position Selected charge curves (characteristics)1 Wet cell batteries (EPzS/EPzB):100 - 300 Ah2 Maintenance-free (EPzV): 100 - 149 Ah3 Maintenance-free (EPzV): 150 - 199 Ah4 Maintenance-free (EPzV): 200 - 300 Ah5 Wet cell batteries (EPzS/EPzB): 200 - 400 Ah pulse

characteristic6 Wet cell batteries (EPzS/EPzB): 100 - 300 Ah

Jungheinrich

Connect the battery This allows you to adjust via the charger

Turn the setting switch to the right to select the desired characteristic curve

If the characteristic curve is valid, the green LED flashes according to the set position.If invalid, the red LED flashes.

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D 4

Selecting the charging curve for the onboard charger

Use the switch (4) on the charger to adapt the charge curves to the particular battery used, in accordance with the following table.

M Remove the battery and mains connectors before setting the appropriate curve.

Z All other switch (4) positions block the charger, and the battery is not charged.

Z With 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be used. Characteristic curve 5 produces a faster charge.

Setting the charging characteristic curve

Set the characteristic curve as follows:

Switch (4) Position Selected charge curves (characteristics)1 Wet cell batteries (EPzS/EPzB):100 - 300 Ah2 Maintenance-free (EPzV): 100 - 149 Ah3 Maintenance-free (EPzV): 150 - 199 Ah4 Maintenance-free (EPzV): 200 - 300 Ah5 Wet cell batteries (EPzS/EPzB): 200 - 400 Ah pulse

characteristic6 Wet cell batteries (EPzS/EPzB): 100 - 300 Ah

Jungheinrich

Connect the battery This allows you to adjust via the charger

Turn the setting switch to the right to select the desired characteristic curve

If the characteristic curve is valid, the green LED flashes according to the set position.If invalid, the red LED flashes.

D 5

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BStarting to charge with the onboard charger

– Park the truck securely (see Chapter E).

F When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. It is essential to follow the safety regulations of the battery and charger station manufacturers.

Mains connection

Mains supply: 220 V (± 10%) Mains frequency: 50/60 Hz (± 4%)

The mains cable of the charger (5) is located in the mains cable holder in the battery compartment.

– Lift up the battery panel (2).– Where necessary remove the insulating mat from the battery.– Attach the mains connector (5) to a mains socket.

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Starting to charge with the onboard charger


F When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. It is essential to follow the safety regulations of the battery and charger station manufacturers.

Mains connection

Mains supply: 220 V (± 10%) Mains frequency: 50/60 Hz (± 4%)

The mains cable of the charger (5) is located in the mains cable holder in the battery compartment.

– Lift up the battery panel (2).– Where necessary remove the insulating mat from the battery.– Attach the mains connector (5) to a mains socket.

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D 6

The flashing LED indicates the charge status or a fault (for flashing codes see “LED Display” table).

Z If the mains connector (5) is connected to the mains, all the truck’s electrical functions will be interrupted (electrical start block). The truck cannot be operated.

– Remove the connector (5) from the socket and store it in the battery compartment.

Z Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging.

M The mains cable must not be opened.

F Before starting the truck, the battery panel must be firmly closed.

Charging times

The duration of charge depends on the battery capacity.

LED display

Compensation charge

Compensation charge starts automatically when charging is complete.

Partial charging

The charger is designed to automatically adapt to partially charged batteries. This keeps battery wear to a minimum.

Green LED (charge status)

Red LED (fault)

Display

Lit --- Charging complete, battery full. (Charging interval, compensation charge)

Flashes slowly --- ChargingRapid flash --- Display at beginning of charge or after setting a new

characteristic curve. Number of flash pulses corresponds to the characteristic curve set.

--- Lit Overtemperature. Charging is interrupted.--- Flashes slowly Safety charging time exceeded. Charging is

cancelled. Mains must be disconnected for charging to recommence.

--- Rapid flash Invalid characteristic curve setting.--- --- Mains failure and/or no battery connected.

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D 6

The flashing LED indicates the charge status or a fault (for flashing codes see “LED Display” table).

Z If the mains connector (5) is connected to the mains, all the truck’s electrical functions will be interrupted (electrical start block). The truck cannot be operated.

– Remove the connector (5) from the socket and store it in the battery compartment.

Z Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging.

M The mains cable must not be opened.

F Before starting the truck, the battery panel must be firmly closed.

Charging times

The duration of charge depends on the battery capacity.

LED display

Compensation charge

Compensation charge starts automatically when charging is complete.

Partial charging

The charger is designed to automatically adapt to partially charged batteries. This keeps battery wear to a minimum.

Green LED (charge status)

Red LED (fault)

Display

Lit --- Charging complete, battery full. (Charging interval, compensation charge)

Flashes slowly --- ChargingRapid flash --- Display at beginning of charge or after setting a new

characteristic curve. Number of flash pulses corresponds to the characteristic curve set.

--- Lit Overtemperature. Charging is interrupted.--- Flashes slowly Safety charging time exceeded. Charging is

cancelled. Mains must be disconnected for charging to recommence.

--- Rapid flash Invalid characteristic curve setting.--- --- Mains failure and/or no battery connected.

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B4.2 Charging the battery with a stationary charger o


M Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.

– Expose the battery (see Section 3).

F When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.

– Where necessary remove the insulating mat from the battery.– Connect the charging cable of the battery charging station to the battery connector

and switch on the charger.

M Charge the battery in accordance with the battery and charging station manufacturers’ instructions.

F Risk of accidents and injuries when handling lithium-ion batteries. Improper use can result in overheating, fire or a battery explosion.

1. Do not expose the lithium-ion battery for charging.

2. Observe the operating instructions for charging the lithium-ion battery.

3. Do not place any metallic objects on the lithium-ion battery.

4. The battery charger must comply with national regulations.

Procedure– Connect the charger cable of the deactivated charger to the battery plug (5a).– Switch on the battery charger. – The lithium-ion battery is charged, see the manufacturer's operating instructions. – The battery is charging.

5a

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4.2 Charging the battery with a stationary charger o


M Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.

– Expose the battery (see Section 3).

F When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.

– Where necessary remove the insulating mat from the battery.– Connect the charging cable of the battery charging station to the battery connector

and switch on the charger.

M Charge the battery in accordance with the battery and charging station manufacturers’ instructions.

F Risk of accidents and injuries when handling lithium-ion batteries. Improper use can result in overheating, fire or a battery explosion.

1. Do not expose the lithium-ion battery for charging.

2. Observe the operating instructions for charging the lithium-ion battery.

3. Do not place any metallic objects on the lithium-ion battery.

4. The battery charger must comply with national regulations.

Procedure– Connect the charger cable of the deactivated charger to the battery plug (5a).– Switch on the battery charger. – The lithium-ion battery is charged, see the manufacturer's operating instructions. – The battery is charging.

5a

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D 8

5 Battery removal and installation

– Undo the spring elements of the battery panel and remove the battery panel.

F The truck must be parked on level ground. To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or the battery cable in such a way that they will not get caught on the truck when the battery is removed.

Z When transporting batteries using a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery data plate on the battery container). The lifting gear must exert a vertical pull so that the battery container is not compressed. The hooks must be attached to the eyes (6) of the battery in such a way that they cannot fall onto the battery cells when the lifting gear is discharged.

– Attach the lifting gear to the attachment eyes (6) and lift out the battery.

F When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position.

– Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.

M After installing the battery again, check all cables and plug connections for visible signs of damage.

F Before starting the truck, the battery panel must be firmly closed. Close the battery panel carefully and slowly. Do not reach between the battery panel and the chassis.

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D 8

5 Battery removal and installation

– Undo the spring elements of the battery panel and remove the battery panel.

F The truck must be parked on level ground. To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or the battery cable in such a way that they will not get caught on the truck when the battery is removed.

Z When transporting batteries using a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery data plate on the battery container). The lifting gear must exert a vertical pull so that the battery container is not compressed. The hooks must be attached to the eyes (6) of the battery in such a way that they cannot fall onto the battery cells when the lifting gear is discharged.

– Attach the lifting gear to the attachment eyes (6) and lift out the battery.

F When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position.

– Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.

M After installing the battery again, check all cables and plug connections for visible signs of damage.

F Before starting the truck, the battery panel must be firmly closed. Close the battery panel carefully and slowly. Do not reach between the battery panel and the chassis.

6

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B6 Battery charge / discharge indicator (t)

When the truck has been released via the keyswitch or CanCode, the battery charge status is displayed.

The colours of the LEDs (8) represent the following conditions:

Z If the LED is red, load units can no longer be lifted. Lifting is only released when the battery connected is at least 70% charged.

If the charge status calculated when the truck is switched on is at least 70% of that of a fully charged battery, the display is reset to 100%. The display reduces in increments of 10% depending on the charge status. The displayed status is reduced to a maximum of 10% within 3 minutes.

The displayed status cannot rise again during the present operation.

The status display is reset to 100% when the battery type is adjusted.

If the LED flashes red and the truck is not ready for operation, inform the manufacturer's service department. Red flashing is a fault code of the truck controller. The flashing sequence indicates the type of fault.

LED colour RatingGreen Capacitance 40 - 100 %

Orange Capacitance 30 - 40 %Green/orangeFlashing. 1Hz

Capacitance 20 - 30 %

Red Capacitance 0 - 20 %

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6 Battery charge / discharge indicator (t)

When the truck has been released via the keyswitch or CanCode, the battery charge status is displayed.

The colours of the LEDs (8) represent the following conditions:

Z If the LED is red, load units can no longer be lifted. Lifting is only released when the battery connected is at least 70% charged.

If the charge status calculated when the truck is switched on is at least 70% of that of a fully charged battery, the display is reset to 100%. The display reduces in increments of 10% depending on the charge status. The displayed status is reduced to a maximum of 10% within 3 minutes.

The displayed status cannot rise again during the present operation.

The status display is reset to 100% when the battery type is adjusted.

If the LED flashes red and the truck is not ready for operation, inform the manufacturer's service department. Red flashing is a fault code of the truck controller. The flashing sequence indicates the type of fault.

LED colour RatingGreen Capacitance 40 - 100 %

Orange Capacitance 30 - 40 %Green/orangeFlashing. 1Hz

Capacitance 20 - 30 %

Red Capacitance 0 - 20 %

8

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E 1

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BE Operation1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation: The forklift truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn with pedestrian operated trucks. Travel with a raised load is prohibited (max. height above ground = 500 mm).

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

Damage and Faults: The supervisor must be immediately informed of any damage or faults to the forklift truck. Trucks not safe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authoristion to do so. On no account may the driver disable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded in good time. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.

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

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E Operation1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation: The forklift truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn with pedestrian operated trucks. Travel with a raised load is prohibited (max. height above ground = 500 mm).

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

Damage and Faults: The supervisor must be immediately informed of any damage or faults to the forklift truck. Trucks not safe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authoristion to do so. On no account may the driver disable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded in good time. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.

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

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E 2

2 Controls and Displays

Item Control / Display

EJC 110n

EJC 112n

Function

1 Battery connector(Emergency Stop)

t t The circuit is interrupted, all electrical functions are cut out. The truck automatically brakes.

2 Switch switch t t Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.

3 Keypad (CanCode)

o o Switches control current on and off. Code settings. Releasing and selecting the travel programs.Entering travel parameters.

ISM access module o o Code settings. Releasing and selecting the travel programs.Entering travel parameters.

4 Battery charge / discharge indicator

t t Indicates the charge/discharge status of the battery.

Display instrument (CanDis)

o o Operating hours meter.Battery charge status.Displays service messages and travel parameters in combination with CanCode.

Display unit o o Displays for:– Lithium ion battery charge status– Lithium ion battery discharge

status– Service hours– Event messages

5 Tiller t t Is used to steer the truck.6 “Shunt” switch t t If the tiller is in the upper braking

zone, braking can be overriden by pressing the switch, and the truck can move with reduced speed (shunting).

7 Controller t t Controls travel direction and speed.

t = Standard equipment o = Optional Equipment

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E 2

2 Controls and Displays


EJC 110n

EJC 112n

Function

1 Battery connector(Emergency Stop)

t t The circuit is interrupted, all electrical functions are cut out. The truck automatically brakes.

2 Switch switch t t Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.

3 Keypad (CanCode)

o o Switches control current on and off. Code settings. Releasing and selecting the travel programs.Entering travel parameters.

ISM access module o o Code settings. Releasing and selecting the travel programs.Entering travel parameters.

4 Battery charge / discharge indicator

t t Indicates the charge/discharge status of the battery.


o o Operating hours meter.Battery charge status.Displays service messages and travel parameters in combination with CanCode.

Display unit o o Displays for:– Lithium ion battery charge status– Lithium ion battery discharge

status– Service hours– Event messages

5 Tiller t t Is used to steer the truck.6 “Shunt” switch t t If the tiller is in the upper braking

zone, braking can be overriden by pressing the switch, and the truck can move with reduced speed (shunting).

7 Controller t t Controls travel direction and speed.


E 3

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2

1

12

3

4

5

6

87 79

10

11

87 79

10

11

910

t

o

E 3

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1

12

3

4

5

6

87 79

10

11

87 79

10

11

910

t

o

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E 4


EJC 110n

EJC 112n

Function

7 Controller t t Controls travel direction and speed.8 Collision safety

switcht t Truck moves away from the operator

and stops.9 Load fork raise

switcht t Raises the forks.

The lift speed can be infinitely controlled via the distance the button is moved (8 mm).

10 Load fork lower switch

t t Lowers the forks.The lowering speed can be infinitely controlled by the distance the button is moved (8 mm).

11 Warning signal (horn) button

t t Triggers a warning signal.

12 On-board charger t t Used to charge the battery (see Chapter D).


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E 4


EJC 110n

EJC 112n

Function

7 Controller t t Controls travel direction and speed.8 Collision safety

switcht t Truck moves away from the operator

and stops.9 Load fork raise

switcht t Raises the forks.

The lift speed can be infinitely controlled via the distance the button is moved (8 mm).

10 Load fork lower switch

t t Lowers the forks.The lowering speed can be infinitely controlled by the distance the button is moved (8 mm).

11 Warning signal (horn) button

t t Triggers a warning signal.

12 On-board charger t t Used to charge the battery (see Chapter D).


E 5

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12

3

4

5

6

87 79

10

11

87 79

10

11

910

t

o

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3

4

5

6

87 79

10

11

87 79

10

11

910

t

o

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E 6

3 Starting up the truck

F Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.

Checks and operations to be performed before starting daily work

– Visually inspect the entire truck (in particular wheels and load handler) for obvious damage.

– Visually inspect the battery attachment and cable connections.

Switching on the truck

– Make sure the battery is connected (1).– Insert the key in the key switch (2) and turn it to the right as far as it will go (position

“I”) or for CanCode (3, o) enter the release code. (see section 5).

– Test the warning signal switch (11).

The truck is now operational.

The battery charge / discharge indicator (4) or the CanDis (o) or the display unit (o) shows the available battery capacity.

– Test the braking operation of the tiller (5) (see section 4.2).

2

3

4

5

1

11

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E 6

3 Starting up the truck

F Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.


– Visually inspect the entire truck (in particular wheels and load handler) for obvious damage.

– Visually inspect the battery attachment and cable connections.

Switching on the truck

– Make sure the battery is connected (1).– Insert the key in the key switch (2) and turn it to the right as far as it will go (position

“I”) or for CanCode (3, o) enter the release code. (see section 5).

– Test the warning signal switch (11).

The truck is now operational.

The battery charge / discharge indicator (4) or the CanDis (o) or the display unit (o) shows the available battery capacity.

– Test the braking operation of the tiller (5) (see section 4.2).

2

3

4

5

1

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B4 Using the industrial truck

4.1 Safety regulations for truck operation

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

Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area.

Visibility when travelling: The driver must look in the direction of travel and must always have a clear view of the route ahead. When carrying loads which affect visibility, these must be stored at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.

Negotiating slopes and inclines: Slopes or inclines may only be negotiated if they are designated traffic routes, are clean and have a non-slip surface and providing they can be safely negotiated in accordance with the technical specifications of the truck. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must leave the lift before the truck.

Type of loads to be carried: Only transport properly secured loads. Never transport loads stacked higher than the top of the fork carriage or the load guard.

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4 Using the industrial truck

4.1 Safety regulations for truck operation

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

Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area.

Visibility when travelling: The driver must look in the direction of travel and must always have a clear view of the route ahead. When carrying loads which affect visibility, these must be stored at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.

Negotiating slopes and inclines: Slopes or inclines may only be negotiated if they are designated traffic routes, are clean and have a non-slip surface and providing they can be safely negotiated in accordance with the technical specifications of the truck. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must leave the lift before the truck.

Type of loads to be carried: Only transport properly secured loads. Never transport loads stacked higher than the top of the fork carriage or the load guard.

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4.2 Travelling, Steering, Braking

F Never carry passengers.

Emergency Stop

– Remove the battery connector (1).All electrical functions are deactivated.

Automatic braking

Automatic braking occurs when the tiller is released – the tiller automatically sets itself to the upper brake zone (B).

F If the tiller moves slowly to the upper brake zone, the cause of this fault must be rectified. If necessary, replace the gas pressure spring.

Travel

M Travel with raised forks / raised load beyond 500 mm above the ground is prohibited.

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

– Start up the truck (refer to section 3).

The travel speed is governed by the travel switch (7).

– Set the tiller (5) to the travel range (F) and press the travel switch (7) in the desired direction (fwd. or rev.).

0

B

F

B

7 6

1

5

R

R

V

V

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E 8

4.2 Travelling, Steering, Braking

F Never carry passengers.

Emergency Stop

– Remove the battery connector (1).All electrical functions are deactivated.

Automatic braking

Automatic braking occurs when the tiller is released – the tiller automatically sets itself to the upper brake zone (B).

F If the tiller moves slowly to the upper brake zone, the cause of this fault must be rectified. If necessary, replace the gas pressure spring.

Travel

M Travel with raised forks / raised load beyond 500 mm above the ground is prohibited.

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

– Start up the truck (refer to section 3).

The travel speed is governed by the travel switch (7).

– Set the tiller (5) to the travel range (F) and press the travel switch (7) in the desired direction (fwd. or rev.).

0

B

F

B

7 6

1

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R

V

V

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BCrawl speed

F The driver must be particularly careful when applying the “Crawl speed” switch (6).

The truck can be operated with a vertical tiller (5) (e.g. in congested areas / travel seat).

– Press the crawl speed switch (6).– Set the travel switch (7) to the required direction (fwd. or rev.).

The brake is released. The truck travels at slow speed.

M The brake is only activated with the crawl speed switch is released; with crawl speed you can only brake by plugging (travel switch (7)).

F In hazardous situations brake the truck by immediately releasing the crawl speed switch (6).

When you apply the crawl speed switch in the travel range (F) the truck travels at reduced speed and acceleration.

Steering

– Apply the tiller (5) to the left or right.

0

B

F

B

7 6

1

5

R

R

V

V

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Crawl speed

F The driver must be particularly careful when applying the “Crawl speed” switch (6).

The truck can be operated with a vertical tiller (5) (e.g. in congested areas / travel seat).

– Press the crawl speed switch (6).– Set the travel switch (7) to the required direction (fwd. or rev.).

The brake is released. The truck travels at slow speed.

M The brake is only activated with the crawl speed switch is released; with crawl speed you can only brake by plugging (travel switch (7)).

F In hazardous situations brake the truck by immediately releasing the crawl speed switch (6).

When you apply the crawl speed switch in the travel range (F) the truck travels at reduced speed and acceleration.

Steering

– Apply the tiller (5) to the left or right.

0

B

F

B

7 6

1

5

R

R

V

V

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Braking

F The braking pattern of the truck depends largely on the track conditions. The driver must take this into account when operating the truck.

Braking with the Service Brake:

– Set the tiller (5) up or down to one of the brake zones (B).

M The service brake is the generator brake. Only when this brake fails to achieve the necessary brake force is the mechanical brake applied.

Plugging:

– You can set the travel switch (7) to the opposite direction when traveling.

– The truck braked regeneratively until it starts to move in the opposite direction.

Braking with the Coasting Brake:

If the travel switch is set to 0, the truck automatically brakes regeneratively.

F In hazardous situations set the tiller to the brake position.

Driving on inclines

M Loads must always be carried on the end of the truck facing uphill.

Preventing the truck from “rolling downhill”:

– With the travel switch set to zero, the brake is automatically applied after a short jerk (the controller detects the truck is rolling back on the slope). The service brake is released again via the travel switch, which is also used to select the speed and the travel direction.

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Braking

F The braking pattern of the truck depends largely on the track conditions. The driver must take this into account when operating the truck.

Braking with the Service Brake:

– Set the tiller (5) up or down to one of the brake zones (B).

M The service brake is the generator brake. Only when this brake fails to achieve the necessary brake force is the mechanical brake applied.

Plugging:

– You can set the travel switch (7) to the opposite direction when traveling.

– The truck braked regeneratively until it starts to move in the opposite direction.

Braking with the Coasting Brake:

If the travel switch is set to 0, the truck automatically brakes regeneratively.

F In hazardous situations set the tiller to the brake position.

Driving on inclines

M Loads must always be carried on the end of the truck facing uphill.

Preventing the truck from “rolling downhill”:

– With the travel switch set to zero, the brake is automatically applied after a short jerk (the controller detects the truck is rolling back on the slope). The service brake is released again via the travel switch, which is also used to select the speed and the travel direction.

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B4.3 Collecting and depositing loads

Z Before lifting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded.

– Drive the truck with forks as far as possible underneath the load.

Z With the two-stage Duplex mast (ZZ) a short, centre-mounted free lift cylinder initially lifts the load carriage (free lift) without changing the overall height of the truck.

Lifting

– Press the “Raise Load Forks” switch (9) until the required lifting height has been reached.

Z The lift speed can be infinitely controlled via the switch stroke (8 mm).

Short switch stroke= slow lift Long switch stroke= fast lift

Lower

– Press the “Lower Load Forks” switch (10) until the required lifting height has been reached.

Z The lowering speed can be infinitely controlled via the switch stroke (8 mm).

Short switch stroke= slow lower Long switch stroke= fast lower

M Avoid fast and sudden depositing of the load.

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4.3 Collecting and depositing loads

Z Before lifting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded.

– Drive the truck with forks as far as possible underneath the load.

Z With the two-stage Duplex mast (ZZ) a short, centre-mounted free lift cylinder initially lifts the load carriage (free lift) without changing the overall height of the truck.

Lifting

– Press the “Raise Load Forks” switch (9) until the required lifting height has been reached.

Z The lift speed can be infinitely controlled via the switch stroke (8 mm).

Short switch stroke= slow lift Long switch stroke= fast lift

Lower

– Press the “Lower Load Forks” switch (10) until the required lifting height has been reached.

Z The lowering speed can be infinitely controlled via the switch stroke (8 mm).

Short switch stroke= slow lower Long switch stroke= fast lower

M Avoid fast and sudden depositing of the load.

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9

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5 Emergency lowering

F Keep all personnel out of the hazardous area when applying emergency lowering.

If the mast cannot be lowered any further due to a fault in the combination controller, manually apply the valve (14) on the hydraulic unit.

– Set key switch (2) to “0”.– Disconnect the battery (see chapter

D).– Open the front panel (see Chapter F,

Section 6.3).– Unscrew the cap (14.1).– Retract the valve slide (14.2) as far as

the stop.– Push in the valve slide (14.3) and pin

(3mm) gradually and keep it pressed down.

The lifting device lowers.

– Insert the valve slide (14.2) as far as the stop.– Fit the cap (14.1).

F Only operate the truck once the fault has been removed.

14.114.2

14.3

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5 Emergency lowering

F Keep all personnel out of the hazardous area when applying emergency lowering.

If the mast cannot be lowered any further due to a fault in the combination controller, manually apply the valve (14) on the hydraulic unit.

– Set key switch (2) to “0”.– Disconnect the battery (see chapter

D).– Open the front panel (see Chapter F,

Section 6.3).– Unscrew the cap (14.1).– Retract the valve slide (14.2) as far as

the stop.– Push in the valve slide (14.3) and pin

(3mm) gradually and keep it pressed down.

The lifting device lowers.

– Insert the valve slide (14.2) as far as the stop.– Fit the cap (14.1).

F Only operate the truck once the fault has been removed.

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B5.1 Parking the truck securely

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

F Do not park the truck on a slope. The load forks must always be lowered to the ground.

– Lower the load forks.– Set the key switch (2) to “0” and remove the key or press “o” for CanCode.

6 Keypad (CanCode) (o)

The keypad consists of 10 number keys, a Set key and an extra key o. Activation of the travel programs via switches 1,2,3 is indicated by green LEDs. The o key indicates operating statuses via a red/ green LED.

It contains the following functions:

– Code lock function (commissioning the truck).– Travel program selection.– Setting the travel and battery parameters, only in conjunction with the display

instrument (CanDis (o)).

The o key has top priority and resets the truck from any condition to its default condition without modifying any settings.

6.1 Code Lock

When the correct code has been entered, the machine is ready for use. You can allocate an individual code to each truck, driver or group of drivers.

M When delivered from the factory, the operator code (factory setting 2-5-8-0) is indicated on a removable sticker.

Z When starting the truck for the first time, change the master and operating codes. (refer to section 6.4).

1 2 3

4 5 6

7 8 9

0Set

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5.1 Parking the truck securely

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

F Do not park the truck on a slope. The load forks must always be lowered to the ground.

– Lower the load forks.– Set the key switch (2) to “0” and remove the key or press “o” for CanCode.

6 Keypad (CanCode) (o)

The keypad consists of 10 number keys, a Set key and an extra key o. Activation of the travel programs via switches 1,2,3 is indicated by green LEDs. The o key indicates operating statuses via a red/ green LED.

It contains the following functions:

– Code lock function (commissioning the truck).– Travel program selection.– Setting the travel and battery parameters, only in conjunction with the display

instrument (CanDis (o)).

The o key has top priority and resets the truck from any condition to its default condition without modifying any settings.

6.1 Code Lock

When the correct code has been entered, the machine is ready for use. You can allocate an individual code to each truck, driver or group of drivers.

M When delivered from the factory, the operator code (factory setting 2-5-8-0) is indicated on a removable sticker.

Z When starting the truck for the first time, change the master and operating codes. (refer to section 6.4).

1 2 3

4 5 6

7 8 9

0Set

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Starting the truck for the first time

The LED (15) goes red when you connect the battery and if necessary switch on the key switch.

When you enter the correct operator code (factory setting 2-5-8-0) the LED (15) turns green.

If the wrong code is entered LED (15) flashes red for two seconds. The correct code can then be entered.

Z The Set key (16) has no function in operating mode.

Switching off

To switch the truck off, press the o key (20).

Z The truck can switch off automatically after a pre-determined time. To do this, you need to set the corresponding code lock parameter. (see section 6.4).

1 2 3

4 5 6

7 8 9

0Set

17

16

15

20

1918

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Starting the truck for the first time

The LED (15) goes red when you connect the battery and if necessary switch on the key switch.

When you enter the correct operator code (factory setting 2-5-8-0) the LED (15) turns green.

If the wrong code is entered LED (15) flashes red for two seconds. The correct code can then be entered.

Z The Set key (16) has no function in operating mode.

Switching off

To switch the truck off, press the o key (20).

Z The truck can switch off automatically after a pre-determined time. To do this, you need to set the corresponding code lock parameter. (see section 6.4).

1 2 3

4 5 6

7 8 9

0Set

17

16

15

20

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B6.2 Travel programs

Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated program is indicated by the green LEDs (17), (18), (19) in the corresponding key.

Z The travel programs differ with respect to travel speed, acceleration and deceleration force.

Factory settings:

– Program 1: Soft running– Program 2: Normal mode (pre-selected when using the truck for the first time)– Program 3: Power mode

Z The travel programs can be individually adapted (see Section 6.5).

6.3 Parameters

In programming mode, the operator keypad enables you to set the code lock functions and adapt travel programs. In addition, the battery parameters can also be set.

M For trucks without a display instrument (CanDis (o)) the parameters must be adjusted with great care to avoid errors.

The internal parameter numbers for the code lock are comprised of three digits.

All other parameter numbers are comprised of four digits.

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6.2 Travel programs

Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated program is indicated by the green LEDs (17), (18), (19) in the corresponding key.

Z The travel programs differ with respect to travel speed, acceleration and deceleration force.

Factory settings:

– Program 1: Soft running– Program 2: Normal mode (pre-selected when using the truck for the first time)– Program 3: Power mode

Z The travel programs can be individually adapted (see Section 6.5).

6.3 Parameters

In programming mode, the operator keypad enables you to set the code lock functions and adapt travel programs. In addition, the battery parameters can also be set.

M For trucks without a display instrument (CanDis (o)) the parameters must be adjusted with great care to avoid errors.

The internal parameter numbers for the code lock are comprised of three digits.

All other parameter numbers are comprised of four digits.

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6.4 Parameter Settings

To change the truck setting you must enter the master code.

Z The factory setting for the master code is 7-2-9-5.

M When starting the truck for the first time, change the master code.

F Safety instructions for trucks with a display instrument (CanDis (o))

– Parameter settings must be made carefully and only by special trained personnel. If in doubt, consult the manufacturer's service department.

– Each setting must be monitored on the LC display of the display instrument (CanDis (o)). If in doubt, cancel the setting by pressing the o-key (20).

– Since changing any parameter will affect the truck's travel pattern, you must carry out a test run in a specially designated work area.

To enter the master code:

– Press the o key– Enter master code

Code Lock Parameters

Setting procedure for trucks with a display instrument (CanDis (o)):

– Enter the parameter number and confirm with set key (16).– Enter the subindex “2” and confirm with the set key (16).– The display instrument (CanDis (o)) continues to display the operating hours. If the

display changes, cancel the setting with the o key (20) and restart from the beginning.

– Enter the setting according to the parameter list or change and confirm with the Set key (16).

Z If the entry is incorrect, the LED (15) of the o key (20) flashes red. If you enter the parameter number again the setting can be entered or changed. If the entry is correct, the parameter and the subindex will be displayed alternating with theentry.

– To enter further parameters the procedure is repeated. – When all the parameters have been entered, carry out the “SaveParameter”

function by pressing keys 1-2-3-Set.– To finish entering, press the o key (19).


LED (15)o key

LED (17)Key 1

LED (18)Key 2

LED (19)Key 3

Service hours are indicated 284.0 Green

flashingOff Off Off

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6.4 Parameter Settings

To change the truck setting you must enter the master code.

Z The factory setting for the master code is 7-2-9-5.

M When starting the truck for the first time, change the master code.

F Safety instructions for trucks with a display instrument (CanDis (o))

– Parameter settings must be made carefully and only by special trained personnel. If in doubt, consult the manufacturer's service department.

– Each setting must be monitored on the LC display of the display instrument (CanDis (o)). If in doubt, cancel the setting by pressing the o-key (20).

– Since changing any parameter will affect the truck's travel pattern, you must carry out a test run in a specially designated work area.

To enter the master code:

– Press the o key– Enter master code

Code Lock Parameters

Setting procedure for trucks with a display instrument (CanDis (o)):

– Enter the parameter number and confirm with set key (16).– Enter the subindex “2” and confirm with the set key (16).– The display instrument (CanDis (o)) continues to display the operating hours. If the

display changes, cancel the setting with the o key (20) and restart from the beginning.

– Enter the setting according to the parameter list or change and confirm with the Set key (16).

Z If the entry is incorrect, the LED (15) of the o key (20) flashes red. If you enter the parameter number again the setting can be entered or changed. If the entry is correct, the parameter and the subindex will be displayed alternating with theentry.


function by pressing keys 1-2-3-Set.– To finish entering, press the o key (19).


LED (15)o key

LED (17)Key 1

LED (18)Key 2

LED (19)Key 3

Service hours are indicated 284.0 Green

flashingOff Off Off

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BSetting procedure for trucks without a display instrument (CanDis (o)):

– Enter the parameter number and confirm with the Set key (16).– Enter the subindex “2” and confirm with the Set key (16).– Enter the setting according to the parameter list or change and confirm with the Set

key (16).

Z If the entry is incorrect, the LED (15) of the o key (20) turns red. When you enter the parameter number again the setting can be entered or changed.


function by pressing keys 1-2-3-Set.– To finish entering, press the o key (20) again.

The following parameters may be entered.

Code Lock Parameter List

No. Function Setting Range StandardSetting

CommentsProcedure

Code Lock000 Change Master Code

The length (4-6 digits) of the master code also pre-determines the length of the operator code (4-6 digits). Provided the operator codes are programmed, only news codes of the same length can be entered. If the code length is changed, all operator codes must be deleted beforehand.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 17 flashes)Enter

current code

Confirm (Set)

(LED 18 flashes)Enter

new code

Confirm (Set)

(LED 19 flashes)Repeat new code

Confirm (Set)001 Add operator code (max.

600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 18 flashes)Entercode

Confirm (Set)

(LED 19 flashes)Repeat

code entry

Confirm (Set)

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Setting procedure for trucks without a display instrument (CanDis (o)):

– Enter the parameter number and confirm with the Set key (16).– Enter the subindex “2” and confirm with the Set key (16).– Enter the setting according to the parameter list or change and confirm with the Set

key (16).

Z If the entry is incorrect, the LED (15) of the o key (20) turns red. When you enter the parameter number again the setting can be entered or changed.


function by pressing keys 1-2-3-Set.– To finish entering, press the o key (20) again.


Code Lock Parameter List


CommentsProcedure

Code Lock000 Change Master Code

The length (4-6 digits) of the master code also pre-determines the length of the operator code (4-6 digits). Provided the operator codes are programmed, only news codes of the same length can be entered. If the code length is changed, all operator codes must be deleted beforehand.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 17 flashes)Enter

current code

Confirm (Set)


new code

Confirm (Set)

(LED 19 flashes)Repeat new code

Confirm (Set)001 Add operator code (max.

600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 18 flashes)Entercode

Confirm (Set)


code entry

Confirm (Set)

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LEDs 17-19 are located in key fields 1-3 (see Section 6.2).

No. Function Settingrange

Standard setting

CommentsWork Sequence

Code Lock002 Change user code 0000 - 9999

or00000 - 99999

or000000 - 999999


current code

confirm (Set)

(LED 18 flashes)Enter a

new code

Confirm (Set)

(LED 19 flashes)Repeat code

entry

Confirm003 Delete user code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 18 flashes)Enter acode

Confirm (Set)


code entry

Confirm (Set)004 Delete code log

(Deletes all user codes )3265 3265 = delete

other inputs= do not delete

010 Automatic timeout 00 - 31 00 00 = No cutout

01 to 30 = Cutout time in

minutes

31 = cutout in 10 seconds

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LEDs 17-19 are located in key fields 1-3 (see Section 6.2).


Standard setting


Code Lock002 Change user code 0000 - 9999

or00000 - 99999

or000000 - 999999


current code

confirm (Set)

(LED 18 flashes)Enter a

new code

Confirm (Set)

(LED 19 flashes)Repeat code

entry

Confirm003 Delete user code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 18 flashes)Enter acode

Confirm (Set)


code entry

Confirm (Set)004 Delete code log

(Deletes all user codes )3265 3265 = delete

other inputs= do not delete

010 Automatic timeout 00 - 31 00 00 = No cutout

01 to 30 = Cutout time in

minutes

31 = cutout in 10 seconds

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The travel programs are connected to the user code. The travel programs can be individually released or blocked for each user code. A start travel program can be assigned to each user code.

Once a user code has been set up, all travel programs are globally releasted, the valid start travel program is program 2. The user code configuration can then be changed with program number 024.

024 - SET – user code - SET - configuration (4-digit) - SET – confirm configuration (4-digit) - SET

1. digit: travel program 1 release (0 or 1) 2nd digit: travel program 2 release (0 or 1) 3rd digit: travel program 3 release (0 or 1) 4th digit: start travel program (0, I, 2 or 3)

Error messages on keypad

LED (15) flashes red to indicate the following errors:

– New master code is already operator code.– New operator code is already master code.– Operator code to be changed does not exist.– Tried to change the operator code to another user code that already exists.– Operator code to be deleted does not exist.– Code memory full.


Standard setting


Code Lock024 User code configuration 1112

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The travel programs are connected to the user code. The travel programs can be individually released or blocked for each user code. A start travel program can be assigned to each user code.

Once a user code has been set up, all travel programs are globally releasted, the valid start travel program is program 2. The user code configuration can then be changed with program number 024.

024 - SET – user code - SET - configuration (4-digit) - SET – confirm configuration (4-digit) - SET

1. digit: travel program 1 release (0 or 1) 2nd digit: travel program 2 release (0 or 1) 3rd digit: travel program 3 release (0 or 1) 4th digit: start travel program (0, I, 2 or 3)

Error messages on keypad

LED (15) flashes red to indicate the following errors:

– New master code is already operator code.– New operator code is already master code.– Operator code to be changed does not exist.– Tried to change the operator code to another user code that already exists.– Operator code to be deleted does not exist.– Code memory full.


Standard setting


Code Lock024 User code configuration 1112

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6.5 Travel parameters

Z For trucks without a display instrument (CanDis (o)) the code lock parameters can only be set by the manufacturer's service department.

The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101).

Acceleration example

– Enter the four-digit parameter number (0256) and confirm with the Set key (16).– Enter the subindex “2” and confirm with the set key (16).

Z No display of the parameter setting via the display instrument LCD (CanDis (o)) ist.

– Enter the parameter according to the parameter list and confirm with the Set key (16).

– The LED (14) of the o key (20) switches briefly to a steady light and starts flashing again after approx. 2 seconds.

– The parameter and subindex are displayed alternating with the entry (0256-2 <-> 0000-5).

Z If the entry is incorrect, the LED (15) of the o key (20) flashes red. Enter the parameter number again to repeat the setting.

Repeat the process to enter more parameters as soon as the LED (15) of the o key (20) flashes.

Z Travel is disabled while the parameters are being entered. If the setting is to be checked in programming mode, follow this sequence:

– Select the edited travel program after entering the parameter, and confirm with the Set key (16).

– The truck is now in travel mode and can be checked.– To continue setting, confirm with the Set key (16) again.– To enter further parameters the procedure is repeated. – When all the parameters have been entered, carry out the “SaveParameter”

function by pressing keys “1-2-3-Set”.– To finish entering, press the Enter o key (20) again.

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6.5 Travel parameters

Z For trucks without a display instrument (CanDis (o)) the code lock parameters can only be set by the manufacturer's service department.

The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101).

Acceleration example

– Enter the four-digit parameter number (0256) and confirm with the Set key (16).– Enter the subindex “2” and confirm with the set key (16).

Z No display of the parameter setting via the display instrument LCD (CanDis (o)) ist.

– Enter the parameter according to the parameter list and confirm with the Set key (16).

– The LED (14) of the o key (20) switches briefly to a steady light and starts flashing again after approx. 2 seconds.

– The parameter and subindex are displayed alternating with the entry (0256-2 <-> 0000-5).

Z If the entry is incorrect, the LED (15) of the o key (20) flashes red. Enter the parameter number again to repeat the setting.

Repeat the process to enter more parameters as soon as the LED (15) of the o key (20) flashes.

Z Travel is disabled while the parameters are being entered. If the setting is to be checked in programming mode, follow this sequence:

– Select the edited travel program after entering the parameter, and confirm with the Set key (16).

– The truck is now in travel mode and can be checked.– To continue setting, confirm with the Set key (16) again.– To enter further parameters the procedure is repeated. – When all the parameters have been entered, carry out the “SaveParameter”

function by pressing keys “1-2-3-Set”.– To finish entering, press the Enter o key (20) again.

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BThe following parameters may be entered.

Travel programs


Comments

Travel program 10256 Acceleration 0 - 9

(0.2 - 2.0 m/s2)1

(0.4 m/s2)0260 Coasting brake 0 - 9

(0.2 - 1.1 m/s2) 3

(0.5 m/s2)0264 Maximum speed in drive

direction via travel switch0 - 9

(2.8 - 6.2 km/h)4

(4.4 km/h)depending on

controller0268 Maximum speed in fork


(2.8 - 6.2 km/h)3


controller


Comments


(0.2 - 2.0 m/s2)2


(0.2 - 1.1 m/s2)4

(0.6 m/s2)0280 Maximum speed in tiller


(2.8 - 6.2 km/h)7




(2.8 - 6.2 km/h)7

(5.6 km/h)depending ontravel switch


Comments


(0.2 - 2.0 m/s2)4


(0.2 - 1.1 m/s2)6



(2.8 - 6.2 km/h)8




(2.8 - 6.2 km/h)8


E 21

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Travel programs


Comments


(0.2 - 2.0 m/s2)1


(0.2 - 1.1 m/s2) 3

(0.5 m/s2)0264 Maximum speed in drive


(2.8 - 6.2 km/h)4




(2.8 - 6.2 km/h)3


controller


Comments


(0.2 - 2.0 m/s2)2


(0.2 - 1.1 m/s2)4



(2.8 - 6.2 km/h)7




(2.8 - 6.2 km/h)7



Comments


(0.2 - 2.0 m/s2)4


(0.2 - 1.1 m/s2)6



(2.8 - 6.2 km/h)8




(2.8 - 6.2 km/h)8


09.1

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Comments

Z For trucks without a display instrument (CanDis (o)) the CODE lock parameters can only be set by the manufacturer's service department.

The parameters are set in the same way as for the travel parameters.


Setting 0 / 1 is to be interpreted as: 0 = off 1 = on

No. Function Range ofSetting

StandardSetting

Comments

Comments1377 Battery parameters

Battery type (normal/high-power/dry)

0 - 2 1 0 = Normal (wet) 1 = High-power (wet)

2 = Dry (maintenance-free)

1389 Discharge monitor function

0 / 1 1

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Comments

Z For trucks without a display instrument (CanDis (o)) the CODE lock parameters can only be set by the manufacturer's service department.

The parameters are set in the same way as for the travel parameters.


Setting 0 / 1 is to be interpreted as: 0 = off 1 = on

No. Function Range ofSetting

StandardSetting

Comments

Comments1377 Battery parameters

Battery type (normal/high-power/dry)

0 - 2 1 0 = Normal (wet) 1 = High-power (wet)

2 = Dry (maintenance-free)

1389 Discharge monitor function

0 / 1 1

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B7 Display instrument (CanDis) (o)

The instrument indicates:

In addition, service messages for the elec-tronic components and parameter changes are displayed.

Discharge status indication

Setting limits for the additional “Warning” (25) and “Stop” (22) displays will depend on the battery type set.

The available capacity is shown via 8 LED bars. The two bottom bars are always off.

The current battery capacity is shown by the illuminated LED bars. 8 bars correspond to full capacity, 1 bar to the minimum batterycapacity.

If only one LED bar is lit, the battery capacity is almost depleted and the “Warning” indicator (25) is lit. The battery must be charged immediately.

If no more LED bars are illuminated, the “Stop” indicator (22) lights up. Lifting is now inhibited. The battery must be charged.

21 Capacity display bars Battery residual charge

22 Stop symbol; lift cutout, battery charge required

23 6 digit LCD display; hourmeter; entry display; error display

24 T symbol appears during operation when the discharge indicator is set to maintenance-free battery

25 Attention pre-warning symbol, battery charge required

26 Battery charge display (on board charger only)

25

24

26 21

22

23

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7 Display instrument (CanDis) (o)

The instrument indicates:

In addition, service messages for the elec-tronic components and parameter changes are displayed.

Discharge status indication

Setting limits for the additional “Warning” (25) and “Stop” (22) displays will depend on the battery type set.

The available capacity is shown via 8 LED bars. The two bottom bars are always off.

The current battery capacity is shown by the illuminated LED bars. 8 bars correspond to full capacity, 1 bar to the minimum batterycapacity.

If only one LED bar is lit, the battery capacity is almost depleted and the “Warning” indicator (25) is lit. The battery must be charged immediately.

If no more LED bars are illuminated, the “Stop” indicator (22) lights up. Lifting is now inhibited. The battery must be charged.

21 Capacity display bars Battery residual charge

22 Stop symbol; lift cutout, battery charge required

23 6 digit LCD display; hourmeter; entry display; error display

24 T symbol appears during operation when the discharge indicator is set to maintenance-free battery

25 Attention pre-warning symbol, battery charge required

26 Battery charge display (on board charger only)

25

24

26 21

22

23

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7.1 Operating hours display

Display range between 0.0 and 99,999.0 hours. This is a backlit display.

Z For maintenance-free batteries a “T” symbol is shown in the operating hours display (24).

Error messages

The operating hours display is also used for indicating errors. The error display begins with an “E” for Error and a three-digit error number. if several errors occur at the same time, they are displayed in turn. The errors are displayed until they are rectified. Error messages overwrite the service hour display. Most errors cause the emergency stop to be triggered. The error display remains until the control circuit is switched off (Code lock).

If no CanDis is present, the error code is displayed by the flashing of the charge/discharge indicator LED.

Z The manufacturer’s service department has detailed component descriptions with error codes.

Display for parameter changes (travel programs)

The LC display (24) is used in conjunction with the operator keypad (CanCode (o)) to display the setting parameters. The parameter number and subindex are displayed alternating with the parameter. Display: 0280-2 (max. speed) <-> 0000-8 (value)

Z Settings of parameter group 0XX (code lock) are not displayed.

Hourmeter

Service hours are counted while the truck is operational and one of the following controls is applied:

– Tiller in travel zone "F"– "Slow travel button"– "Lift" button – "Lower" button

7.2 Power up test

On power up the display shows:

– the software version of the display instrument (briefly),– the operating hours– the charge status

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7.1 Operating hours display

Display range between 0.0 and 99,999.0 hours. This is a backlit display.

Z For maintenance-free batteries a “T” symbol is shown in the operating hours display (24).

Error messages

The operating hours display is also used for indicating errors. The error display begins with an “E” for Error and a three-digit error number. if several errors occur at the same time, they are displayed in turn. The errors are displayed until they are rectified. Error messages overwrite the service hour display. Most errors cause the emergency stop to be triggered. The error display remains until the control circuit is switched off (Code lock).

If no CanDis is present, the error code is displayed by the flashing of the charge/discharge indicator LED.

Z The manufacturer’s service department has detailed component descriptions with error codes.

Display for parameter changes (travel programs)

The LC display (24) is used in conjunction with the operator keypad (CanCode (o)) to display the setting parameters. The parameter number and subindex are displayed alternating with the parameter. Display: 0280-2 (max. speed) <-> 0000-8 (value)

Z Settings of parameter group 0XX (code lock) are not displayed.

Hourmeter

Service hours are counted while the truck is operational and one of the following controls is applied:

– Tiller in travel zone "F"– "Slow travel button"– "Lift" button – "Lower" button

7.2 Power up test

On power up the display shows:

– the software version of the display instrument (briefly),– the operating hours– the charge status

E 25

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B8 Display (2 Inch) (o)

1 Display element is animated when energy is recovered during regenerative braking.

Item Control or display

Function

30 Information field Displays event messages31 Battery capacity display1 Lithium ion battery discharge status32 Icon field Displays the icons, see page E26.33 Service hours Service hours are counted while the truck is

operational and one of the following controls is applied:

– Tiller in travel zone "F"– Slow travel button– Lift button– Lower button

345

32

30

31

33

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8 Display (2 Inch) (o)

1 Display element is animated when energy is recovered during regenerative braking.

Item Control or display

Function

30 Information field Displays event messages31 Battery capacity display1 Lithium ion battery discharge status32 Icon field Displays the icons, see page E26.33 Service hours Service hours are counted while the truck is

operational and one of the following controls is applied:

– Tiller in travel zone "F"– Slow travel button– Lift button– Lower button

345

32

30

31

33

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8.1 Symbols in the display

Any number of pictograms can be displayed in the pictogram field (32). Which pictograms are shown in the pictogram field depends on the operating and truck status.

2 The lithium ion battery cuts out immediately.3 The lithium ion battery needs to be charged soon.4 The lithium ion battery needs to be charged immediately.

Symbol Meaning Colour FunctionStop notice Red Functional cutout following truck

malfunctions2

Warning Red Flashing:– Lithium ion battery malfunction– Battery management system

malfunction

Charging process Green Battery charge display (on-board charger only):– Flashing:

Charging in progress– Steady light:

Charging completedBattery indicator, low residual capacity

Yellow Charge status display– Steady light:

Residual capacity < 15% 3

– Flashing: Residual capacity < 10% 4

Red Charge status display– Steady light:

Battery is discharged.4

Overtemperature Red Flashing:– Lithium ion battery overtemperature

detected

Low temperature Red Flashing:– Lithium ion battery low temperature

detected

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8.1 Symbols in the display

Any number of pictograms can be displayed in the pictogram field (32). Which pictograms are shown in the pictogram field depends on the operating and truck status.

2 The lithium ion battery cuts out immediately.3 The lithium ion battery needs to be charged soon.4 The lithium ion battery needs to be charged immediately.

Symbol Meaning Colour FunctionStop notice Red Functional cutout following truck

malfunctions2

Warning Red Flashing:– Lithium ion battery malfunction– Battery management system

malfunction

Charging process Green Battery charge display (on-board charger only):– Flashing:

Charging in progress– Steady light:

Charging completedBattery indicator, low residual capacity

Yellow Charge status display– Steady light:

Residual capacity < 15% 3

– Flashing: Residual capacity < 10% 4

Red Charge status display– Steady light:

Battery is discharged.4

Overtemperature Red Flashing:– Lithium ion battery overtemperature

detected

Low temperature Red Flashing:– Lithium ion battery low temperature

detected

E 27

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B8.2 Service hour display

The service hour display range is between 0.0 and 99,999.0 hours. The display (33) has background lighting.

8.3 Event Messages

Event message start with an ”E” for Event and a four-digit error number. The event message is displayed as long as the fault persists. If there are several event messages they are displayed consecutively. Most event messages result in the Emergency Stop being activated.

Z Remedies, see page E29.

8.4 Power up test

Once the truck has become operational the following displays appear:

– Brief flashing of status messages and system information– Service hours– Lithium ion battery charge status

8.5 Battery Management System Automatic Cutout

If no energy consumption from travel, steering or hydraulic operations is detected within a period of 60 minutes, the battery management system automatically cuts out the lithium ion battery.

When the truck has been switched off and on with the key switch the lithium ion battery is available again to energise the truck.

Z The presetting cannot be changed.

8.6 Battery Management System Discharge Monitor

M Applying maximum braking can result in accidents! Switching off the discharge monitor will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury.

– Do not travel at maximum speed when the battery charge is low.

Z The standard setting for the battery discharge monitor cannot be altered.

A buzzer is activated in the battery when the charge reaches a critical level.

The truck is switched off by the battery management system when the residual capacity falls below the required level. When the truck has been switched off and on with the key switch, all truck functions are briefly available again as emergency functions - through release of residual capacity - until the battery management system activates a full shutdown.

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8.2 Service hour display

The service hour display range is between 0.0 and 99,999.0 hours. The display (33) has background lighting.

8.3 Event Messages

Event message start with an ”E” for Event and a four-digit error number. The event message is displayed as long as the fault persists. If there are several event messages they are displayed consecutively. Most event messages result in the Emergency Stop being activated.

Z Remedies, see page E29.

8.4 Power up test

Once the truck has become operational the following displays appear:

– Brief flashing of status messages and system information– Service hours– Lithium ion battery charge status

8.5 Battery Management System Automatic Cutout

If no energy consumption from travel, steering or hydraulic operations is detected within a period of 60 minutes, the battery management system automatically cuts out the lithium ion battery.

When the truck has been switched off and on with the key switch the lithium ion battery is available again to energise the truck.

Z The presetting cannot be changed.

8.6 Battery Management System Discharge Monitor

M Applying maximum braking can result in accidents! Switching off the discharge monitor will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury.

– Do not travel at maximum speed when the battery charge is low.

Z The standard setting for the battery discharge monitor cannot be altered.

A buzzer is activated in the battery when the charge reaches a critical level.

The truck is switched off by the battery management system when the residual capacity falls below the required level. When the truck has been switched off and on with the key switch, all truck functions are briefly available again as emergency functions - through release of residual capacity - until the battery management system activates a full shutdown.

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NOTE

Z Discharge can damage the battery. If the battery is not used for a long period of time, it can become damaged through discharge.

– Before a long period of inactivity, the battery must be fully charged.– To ensure a long battery life, we recommend checking and charging the battery

every 4 weeks when it is not being used.

Z Charge the battery see page D3.

Z If the truck is used temporarily with a suitable standard battery, the traction controller battery discharge monitor is restored to operation.

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NOTE

Z Discharge can damage the battery. If the battery is not used for a long period of time, it can become damaged through discharge.

– Before a long period of inactivity, the battery must be fully charged.– To ensure a long battery life, we recommend checking and charging the battery

every 4 weeks when it is not being used.

Z Charge the battery see page D3.

Z If the truck is used temporarily with a suitable standard battery, the traction controller battery discharge monitor is restored to operation.

E 29

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B9 Troubleshooting

This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table.

Z If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service department, as any further troubleshooting can only be performed by specially trained and qualified service personnel.

Fault Possible cause ActionTruck does not start.

– Battery plug not connected. – Check the battery plug and connect if necessary.

– Key switch in "0" position – Set key switch to "I"– Incorrect CanCode code – Check code– Battery charge too low. – Check battery charge, charge

battery if necessary– Tiller not set to travel range (F) – Set tiller to travel range (F)– Faulty fuse. – Check fuses F1 and F15– On board charger connected – Disconnect on board charger

from mainsLoad cannot be lifted

– Truck not operational – Carry out all remedial actions listed under “Truck does not start”.

– Hydraulic oil level too low – Check the hydraulic oil level– Faulty fuse. – Check fuse F15– Load is too heavy – Note maximum capacity (see

data plate)– Charge capacity below

20 / 40%– Charge the battery

E 29

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9 Troubleshooting

This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table.

Z If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service department, as any further troubleshooting can only be performed by specially trained and qualified service personnel.

Fault Possible cause ActionTruck does not start.

– Battery plug not connected. – Check the battery plug and connect if necessary.

– Key switch in "0" position – Set key switch to "I"– Incorrect CanCode code – Check code– Battery charge too low. – Check battery charge, charge

battery if necessary– Tiller not set to travel range (F) – Set tiller to travel range (F)– Faulty fuse. – Check fuses F1 and F15– On board charger connected – Disconnect on board charger

from mainsLoad cannot be lifted

– Truck not operational – Carry out all remedial actions listed under “Truck does not start”.

– Hydraulic oil level too low – Check the hydraulic oil level– Faulty fuse. – Check fuse F15– Load is too heavy – Note maximum capacity (see

data plate)– Charge capacity below

20 / 40%– Charge the battery

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F 1

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F Forklift Truck Maintenance1 Operational safety and environmental protection

The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists.

F Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.

M Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the forklift truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.

Upon completion of inspection and servicing, the tasks contained in the “Recommissioning” section must be performed (see chapter F).

2 Maintenance Safety Regulations

Maintenance personnel: Industrial trucks must only be serviced and maintained by the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.

Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath a raised load handler if it is supported by a sufficiently strong chain.

Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, all safety measures required to prevent sparking (e.g. through short circuits) must be taken. For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies.

M If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical and electronic components must be carefully covered beforehand as moisture can cause malfunctions. Do not clean with pressurised water.

After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.

F 1

1109

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F Forklift Truck Maintenance1 Operational safety and environmental protection

The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists.

F Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.

M Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the forklift truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.

Upon completion of inspection and servicing, the tasks contained in the “Recommissioning” section must be performed (see chapter F).

2 Maintenance Safety Regulations

Maintenance personnel: Industrial trucks must only be serviced and maintained by the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.

Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath a raised load handler if it is supported by a sufficiently strong chain.

Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, all safety measures required to prevent sparking (e.g. through short circuits) must be taken. For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies.

M If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical and electronic components must be carefully covered beforehand as moisture can cause malfunctions. Do not clean with pressurised water.

After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.

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F 2

Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.

Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.

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

Tyres: The quality of tyres affects the stability and performance of the truck. When replacing factory fitted tyres only used original manufacturer’s spare parts, as otherwise the data plate specifications will not be kept. When changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing wheels always left and right simultaneously).

Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.

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F 2

Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.

Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.

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

Tyres: The quality of tyres affects the stability and performance of the truck. When replacing factory fitted tyres only used original manufacturer’s spare parts, as otherwise the data plate specifications will not be kept. When changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing wheels always left and right simultaneously).

Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.

F 3

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3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.

M The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as:

W = Every 50 service hours, at least weekly A = Every 500 operating hours B = Every 1000 operating hours, or at least annually C = Every 2000 operating hours, or at least annually

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

In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.

F 3

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3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.

M The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as:

W = Every 50 service hours, at least weekly A = Every 500 operating hours B = Every 1000 operating hours, or at least annually C = Every 2000 operating hours, or at least annually

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

In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.

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F 4

4 Maintenance Checklist

Maintenance intervalsStandard = t W A B CCold Store = k

Brake 1.1 Check magnetic brake air gap k t

Electrics 2.1 Test instruments, displays and control switches t2.2 Test warning and safety device. k t2.3 Check fuse ratings. t2.4 Make sure wire connections are secure and check for

damage.t

2.5 Test micro switch setting t2.6 Check contactors and relays. t2.7 Safety switch t2.8 Wire and motor attachment t2.9 Check carbon brush wear, replace if necessary t

Energy supply 3.1 Visually inspect battery. k t3.2 Check battery cable connections are secure, grease

terminals if necessary.k t

3.3 Check acid density, acid level and battery voltage k t

Travel 4.1 Check transmission for noise and leakage t4.2 Test and lubricate travel mechanisms, carry out tiller

recuperation test.k t

4.3 Check wheels for wear and damage k t4.4 Check wheel suspension and attachment. k t

Truck Design 5.1 Check mast attachment t5.2 Check chassis for damage. t5.3 Check labels. (see Chapter B) t

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F 4

4 Maintenance Checklist


Brake 1.1 Check magnetic brake air gap k t

Electrics 2.1 Test instruments, displays and control switches t2.2 Test warning and safety device. k t2.3 Check fuse ratings. t2.4 Make sure wire connections are secure and check for

damage.t

2.5 Test micro switch setting t2.6 Check contactors and relays. t2.7 Safety switch t2.8 Wire and motor attachment t2.9 Check carbon brush wear, replace if necessary t

Energy supply 3.1 Visually inspect battery. k t3.2 Check battery cable connections are secure, grease

terminals if necessary.k t

3.3 Check acid density, acid level and battery voltage k t

Travel 4.1 Check transmission for noise and leakage t4.2 Test and lubricate travel mechanisms, carry out tiller

recuperation test.k t

4.3 Check wheels for wear and damage k t4.4 Check wheel suspension and attachment. k t

Truck Design 5.1 Check mast attachment t5.2 Check chassis for damage. t5.3 Check labels. (see Chapter B) t

F 5

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Hydraulic operation

6.1 Check mast bearings t6.2 Check setting of slide pieces and stops, and adjust if

necessaryt

6.3 Visually inspect the mast rollers and check contact surface wear level

k t

6.4 Check lateral clearance of mast connections and of fork carriage

t

6.5 Check load chain settings and tighten if necessary t6.6 Check forks for wear and damage k t6.7 Check mast tilt angle t6.8 Test hydraulic system. k t6.9 Check that hose and pipe lines and their connections

are secure, check for leaks and damage.k t

6.10 Check cylinders and piston rods for damage and leaks, and make sure they are secure

k t

6.11 Check hydraulic oil level. k t6.12 Replace hydraulic oil. (This may have to be performed

via a specialist environmental service truck)k t

6.13 Replace the hydraulic oil filter t6.14 Tie rods (EJC-Z only) t

Agreed performance levels

7.1 Lubricate truck in accordance with Lubrication Schedule.

k t

7.2 Test run t7.3 Demonstration after servicing k t

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Hydraulic operation

6.1 Check mast bearings t6.2 Check setting of slide pieces and stops, and adjust if

necessaryt

6.3 Visually inspect the mast rollers and check contact surface wear level

k t

6.4 Check lateral clearance of mast connections and of fork carriage

t

6.5 Check load chain settings and tighten if necessary t6.6 Check forks for wear and damage k t6.7 Check mast tilt angle t6.8 Test hydraulic system. k t6.9 Check that hose and pipe lines and their connections

are secure, check for leaks and damage.k t

6.10 Check cylinders and piston rods for damage and leaks, and make sure they are secure

k t

6.11 Check hydraulic oil level. k t6.12 Replace hydraulic oil. (This may have to be performed

via a specialist environmental service truck)k t

6.13 Replace the hydraulic oil filter t6.14 Tie rods (EJC-Z only) t

Agreed performance levels

7.1 Lubricate truck in accordance with Lubrication Schedule.

k t

7.2 Test run t7.3 Demonstration after servicing k t

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5 EJC 110n/112n Lubrication Schedule

g Contact surfaces

h Hydraulic oil filler neck

c Hydraulic oil drain plug

b Transmission oil filler neck

Transmission oil overflow and control screw

a Transmission oil drain plug

0,55 l

G

E

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5 EJC 110n/112n Lubrication Schedule

g Contact surfaces

h Hydraulic oil filler neck

c Hydraulic oil drain plug

b Transmission oil filler neck

Transmission oil overflow and control screw

a Transmission oil drain plug

0,55 l

G

E

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5.1 Fuels, coolants and lubricants

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

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

Only use clean containers when filling up with consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Manual.

Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be disposed of in accordance with regulations.

Code Order no. Quantity Description Used forA 29200670 5.0 l H-LP 46, DIN 51524 Hydraulic systemB 50380904 5.0 l Fuchs Titan Gear

HSY 75W-90Transmission

E 29202050 1.0 kg Polylub GA 352P LubricationG 29201280 0.4 l Chain spray Chains

Code Saponification Dew point°C

Worked penetr. at 25°C

NLG1 class

Service temperat.

Application Temperature °C

E Lithium > 220 280 - 310 2 -35 / +120

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5.1 Fuels, coolants and lubricants

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

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

Only use clean containers when filling up with consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Manual.

Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be disposed of in accordance with regulations.

Code Order no. Quantity Description Used forA 29200670 5.0 l H-LP 46, DIN 51524 Hydraulic systemB 50380904 5.0 l Fuchs Titan Gear

HSY 75W-90Transmission

E 29202050 1.0 kg Polylub GA 352P LubricationG 29201280 0.4 l Chain spray Chains

Code Saponification Dew point°C

Worked penetr. at 25°C

NLG1 class

Service temperat.

Application Temperature °C

E Lithium > 220 280 - 310 2 -35 / +120

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6 Maintenance Instructions

6.1 Prepare the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:

– Park the truck securely (see Chapter E).– Disconnect the battery (1) to prevent the truck from accidentally starting.

F When working under a raised lift truck, secure it to prevent it from tipping or sliding away. When raising the truck also refer to the instructions in the “Transport and Commissioning” section.

6.2 Removing the front panel

– Open the battery panel.– Remove the two screws (6).– Carefully lift off the front panel (2).

6.3 Remove the drive panel

The drive panel consists of two halves (3 and 4).

– Turn the tiller to the left stop.– Unscrew the two screws (5) with the Allen key size 6 (in accordance with DIN 911).– Carefully remove the first panel half (3).– Turn the tiller to the right stop.– Unscrew the second panel half (4) and carefully remove it.

1234

5

6

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6 Maintenance Instructions

6.1 Prepare the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:

– Park the truck securely (see Chapter E).– Disconnect the battery (1) to prevent the truck from accidentally starting.

F When working under a raised lift truck, secure it to prevent it from tipping or sliding away. When raising the truck also refer to the instructions in the “Transport and Commissioning” section.

6.2 Removing the front panel

– Open the battery panel.– Remove the two screws (6).– Carefully lift off the front panel (2).

6.3 Remove the drive panel

The drive panel consists of two halves (3 and 4).

– Turn the tiller to the left stop.– Unscrew the two screws (5) with the Allen key size 6 (in accordance with DIN 911).– Carefully remove the first panel half (3).– Turn the tiller to the right stop.– Unscrew the second panel half (4) and carefully remove it.

1234

5

6

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6.4 Checking the hydraulic oil level

– Prepare the truck for maintenance and repairs (see Chapter 6.1). – Remove the front panel (see section 6.2).– Check hydraulic oil level in hydraulic reservoir.

M There are markings on the hydraulic reservoir. The oil level must be checked when the load forks are lowered.

– If necessary add hydraulic oil of the correct grade (see Section 5) – see table.

M Installation is the reverse order.

6.5 Check transmission oil level

– Prepare the truck for maintenance and repairs (see Chapter 6.1). – Remove the front panel (see section 6.2).– Turn the tiller to the right stop.– Check the transmission oil level – it should be at the control plug level (see

Section 5).– If necessary add transmission oil of the correct grade (see Section 5).


Tank Marking

Marking 1 2

110n ZT up to 320

112n ZT up to 360

112n ZZ up to 360

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6.4 Checking the hydraulic oil level

– Prepare the truck for maintenance and repairs (see Chapter 6.1). – Remove the front panel (see section 6.2).– Check hydraulic oil level in hydraulic reservoir.

M There are markings on the hydraulic reservoir. The oil level must be checked when the load forks are lowered.

– If necessary add hydraulic oil of the correct grade (see Section 5) – see table.


6.5 Check transmission oil level

– Prepare the truck for maintenance and repairs (see Chapter 6.1). – Remove the front panel (see section 6.2).– Turn the tiller to the right stop.– Check the transmission oil level – it should be at the control plug level (see

Section 5).– If necessary add transmission oil of the correct grade (see Section 5).


Tank Marking

Marking 1 2

110n ZT up to 320

112n ZT up to 360

112n ZZ up to 360

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6.6 Flushing the gauze filter, Replacing the gauze filter

– Prepare the truck for maintenance and repairs (see Section 6.1). – Remove the front panel (see Section 6.2).– Undo the union (8). – Remove connection and take out the gauze filter– Insert a clean / new filter

M Assembly is the reverse order.

6.7 Replacing the filter cartridge

– Prepare the truck for maintenance and repairs (see section 6.1). – Remove the front panel (see Section 6.2).– Unscrew the reservoir lid (7) and remove filter cartridge from the filter cone.


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6.6 Flushing the gauze filter, Replacing the gauze filter

– Prepare the truck for maintenance and repairs (see Section 6.1). – Remove the front panel (see Section 6.2).– Undo the union (8). – Remove connection and take out the gauze filter– Insert a clean / new filter


6.7 Replacing the filter cartridge

– Prepare the truck for maintenance and repairs (see section 6.1). – Remove the front panel (see Section 6.2).– Unscrew the reservoir lid (7) and remove filter cartridge from the filter cone.


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6.8 Checking electrical fuses

– Prepare the truck for maintenance and repairs (see Section 6.1).– Remove the front panel (see Section 6.2).– Check the fuse rating and condition in accordance with the table; replace if

necessary.

Item To protect: EJC 110n/112n

9 Overall control fuse F1 10 A

10 Hourmeter control fuse 6F2 2 A

11 Travel/Lift fuse F15 200 A

9

10

11

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6.8 Checking electrical fuses

– Prepare the truck for maintenance and repairs (see Section 6.1).– Remove the front panel (see Section 6.2).– Check the fuse rating and condition in accordance with the table; replace if

necessary.

Item To protect: EJC 110n/112n

9 Overall control fuse F1 10 A

10 Hourmeter control fuse 6F2 2 A

11 Travel/Lift fuse F15 200 A

9

10

11

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6.9 Recommissioning

The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed.

– Test horn.– Test EMERGENCY DISCONNECT switch.– Test brake.– Lubricate the truck in accordance with the maintenance schedule.

7 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.

M On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.

If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.

7.1 Prior to decommissioning

– Thoroughly clean the truck.– Check the brakes.– Check the hydraulic oil level and replenish as necessary (see Chapter F).– Apply a thin layer of oil or grease to any non-painted mechanical components.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Charge the battery (see Chapter D).– Disconnect the battery, clean it and apply grease to the terminals.

Z In addition, follow the battery manufacturer’s instructions.

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

7.2 During decommissioning

Every 2 months:

– Charge the battery (see Chapter D).

M Battery powered trucks: The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.

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6.9 Recommissioning

The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed.

– Test horn.– Test EMERGENCY DISCONNECT switch.– Test brake.– Lubricate the truck in accordance with the maintenance schedule.

7 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.

M On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.

If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.

7.1 Prior to decommissioning

– Thoroughly clean the truck.– Check the brakes.– Check the hydraulic oil level and replenish as necessary (see Chapter F).– Apply a thin layer of oil or grease to any non-painted mechanical components.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Charge the battery (see Chapter D).– Disconnect the battery, clean it and apply grease to the terminals.

Z In addition, follow the battery manufacturer’s instructions.

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

7.2 During decommissioning

Every 2 months:

– Charge the battery (see Chapter D).

M Battery powered trucks: The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.

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7.3 Restoring the truck to operation after decommissioning

– Thoroughly clean the truck.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Clean the battery, grease the terminals and connect the battery.– Charge the battery (see Chapter D).– Check transmission oil for condensed water and replace if necessary.– Check hydraulic oil for condensed water and replace if necessary.– Start up the truck (see Chapter E).

Z Battery powered trucks: If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.

F Perform several brake tests immediately after re-commissioning the truck.

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7.3 Restoring the truck to operation after decommissioning

– Thoroughly clean the truck.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Clean the battery, grease the terminals and connect the battery.– Charge the battery (see Chapter D).– Check transmission oil for condensed water and replace if necessary.– Check hydraulic oil for condensed water and replace if necessary.– Start up the truck (see Chapter E).

Z Battery powered trucks: If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.

F Perform several brake tests immediately after re-commissioning the truck.

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8 Safety checks to be performed at regular intervals and following any unusual incidents

Z Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.

The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified.

Z A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.

9 Final de-commissioning, disposal

Z Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

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8 Safety checks to be performed at regular intervals and following any unusual incidents

Z Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.

The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified.

Z A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.

9 Final de-commissioning, disposal

Z Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

3

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Foreword

Notes to the operating instructions

The present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the traction battery. The information ispresented in a precise and clear manner. The chapters are arranged by letter and thepages are numbered continuously.

The operating instructions detail different battery variants and their optionalequipment. When operating and servicing the battery, make sure that the particularsection applies to your battery model.

Our traction batteries and their optional equipment are subject to ongoingdevelopment. We reserve the right to alter the design, features and technical aspectsof the equipment. No guarantee of particular features of the traction battery shouldtherefore be assumed from the present operating instructions.

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the followinggraphics:

DANGER!

Indicates an extremely hazardous situation. Failure to comply with this instruction willresult in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instructionmay result in severe irreparable injury and even death.

CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result inslight to medium injury.

NOTE

Indicates a material hazard. Failure to comply with this instruction may result inmaterial damage.


t Indicates standard equipmento Indicates optional equipment

3

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Foreword

Notes to the operating instructions

The present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the traction battery. The information ispresented in a precise and clear manner. The chapters are arranged by letter and thepages are numbered continuously.

The operating instructions detail different battery variants and their optionalequipment. When operating and servicing the battery, make sure that the particularsection applies to your battery model.

Our traction batteries and their optional equipment are subject to ongoingdevelopment. We reserve the right to alter the design, features and technical aspectsof the equipment. No guarantee of particular features of the traction battery shouldtherefore be assumed from the present operating instructions.

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the followinggraphics:

DANGER!

Indicates an extremely hazardous situation. Failure to comply with this instruction willresult in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instructionmay result in severe irreparable injury and even death.

CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result inslight to medium injury.

NOTE

Indicates a material hazard. Failure to comply with this instruction may result inmaterial damage.


t Indicates standard equipmento Indicates optional equipment

02.1

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4

Copyright



Friedrich-Ebert-Damm 12922047 Hamburg - Germany

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


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4

Copyright



Friedrich-Ebert-Damm 12922047 Hamburg - Germany

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


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Contents

A Traction battery ....................................................................... 7

1 Correct Use and Application.................................................................... 72 Data plate ................................................................................................ 73 Safety Instructions, Warning Indications and other Notes....................... 94 Lead acid batteries with armour plated cells and liquid electrolyte.......... 104.1 Description............................................................................................... 104.2 Operation................................................................................................. 124.3 Servicing lead-acid batteries with armour plated cells............................. 155 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 175.1 Description............................................................................................... 175.2 Operation................................................................................................. 185.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated

cells ......................................................................................................... 216 Aquamatik water replenishment system.................................................. 226.1 Water replenishment system design ....................................................... 226.2 Functional Description ............................................................................. 236.3 Adding water............................................................................................ 236.4 Water pressure ........................................................................................ 236.5 Filling time ............................................................................................... 246.6 Water quality............................................................................................ 246.7 Battery tubing .......................................................................................... 246.8 Operating temperature ............................................................................ 246.9 Cleaning measures.................................................................................. 246.10 Service mobile vehicle............................................................................. 247 Electrolyte circulation............................................................................... 257.1 Functional Description ............................................................................. 258 Cleaning batteries.................................................................................... 279 Storing the battery ................................................................................... 2910 Troubleshooting....................................................................................... 2911 Disposal................................................................................................... 29

5

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Contents

A Traction battery ....................................................................... 7

1 Correct Use and Application.................................................................... 72 Data plate ................................................................................................ 73 Safety Instructions, Warning Indications and other Notes....................... 94 Lead acid batteries with armour plated cells and liquid electrolyte.......... 104.1 Description............................................................................................... 104.2 Operation................................................................................................. 124.3 Servicing lead-acid batteries with armour plated cells............................. 155 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 175.1 Description............................................................................................... 175.2 Operation................................................................................................. 185.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated

cells ......................................................................................................... 216 Aquamatik water replenishment system.................................................. 226.1 Water replenishment system design ....................................................... 226.2 Functional Description ............................................................................. 236.3 Adding water............................................................................................ 236.4 Water pressure ........................................................................................ 236.5 Filling time ............................................................................................... 246.6 Water quality............................................................................................ 246.7 Battery tubing .......................................................................................... 246.8 Operating temperature ............................................................................ 246.9 Cleaning measures.................................................................................. 246.10 Service mobile vehicle............................................................................. 247 Electrolyte circulation............................................................................... 257.1 Functional Description ............................................................................. 258 Cleaning batteries.................................................................................... 279 Storing the battery ................................................................................... 2910 Troubleshooting....................................................................................... 2911 Disposal................................................................................................... 29

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6

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6

7

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A Traction battery

1 Correct Use and Application

Z This appendix does not apply to trucks with lithium-ion batteries. Furtherdocumentation for lithium-ion batteries can be obtained from the supplieddocuments.

Failure to observe the operating instructions, carrying out repairs with non-originalspare parts, tampering with the battery or using electrolyte additives will invalidate thewarranty.

Observe the instructions for maintaining the safety rating during operation forbatteries in accordance with Ex I and Ex II (see relevant certification).

2 Data plate

1

3

7

9

11

5

2

4

8

6

13 12

14

10

1 Model (battery name)2 Production week / production year3 Serial number4 Supplier number5 Rated voltage6 Capacity7 Number of cells8 Weight9 Part no.10 Acid quantity11 Manufacturer12 Manufacturer's logo13 CE mark (for batteries above 75 V only)

7

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A Traction battery

1 Correct Use and Application

Z This appendix does not apply to trucks with lithium-ion batteries. Furtherdocumentation for lithium-ion batteries can be obtained from the supplieddocuments.

Failure to observe the operating instructions, carrying out repairs with non-originalspare parts, tampering with the battery or using electrolyte additives will invalidate thewarranty.

Observe the instructions for maintaining the safety rating during operation forbatteries in accordance with Ex I and Ex II (see relevant certification).

2 Data plate

1

3

7

9

11

5

2

4

8

6

13 12

14

10

1 Model (battery name)2 Production week / production year3 Serial number4 Supplier number5 Rated voltage6 Capacity7 Number of cells8 Weight9 Part no.10 Acid quantity11 Manufacturer12 Manufacturer's logo13 CE mark (for batteries above 75 V only)

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8

14 Safety instructions and warning information

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8

14 Safety instructions and warning information

9

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N3 Safety Instructions, Warning Indications and other Notes

Used batteries must be treated as hazardous waste.

These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste.

Buy-back terms and type of recycling are to be agreed with the manufacturer as described in § 8 of the battery legislation.

Do not smoke!

No naked flames, glowing embers or sparks near the battery - fire and explosion hazard!

Avoid fire and explosion hazards and short circuits due to overheating!

Keep away from naked flames and strong heat sources.

Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries.Always wash your hands after completing the work. Use only insulated tools. Do not mechanically machine the battery, strike, crush, compress, notch, dent or modify it in any way.

Hazardous electric voltage! The metal parts of the battery cells are permanently live. Therefore do not place any foreign objects or tools on the battery.Observe national health and safety regulations.

If the materials leak, do not inhale the fumes. Wear safety gloves.

Follow the user instructions and keep them in a visible position in the charging area.

Work on the batteries should be performed only as instructed by specialist personnel.

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3 Safety Instructions, Warning Indications and other Notes

Used batteries must be treated as hazardous waste.

These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste.

Buy-back terms and type of recycling are to be agreed with the manufacturer as described in § 8 of the battery legislation.

Do not smoke!

No naked flames, glowing embers or sparks near the battery - fire and explosion hazard!

Avoid fire and explosion hazards and short circuits due to overheating!

Keep away from naked flames and strong heat sources.

Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries.Always wash your hands after completing the work. Use only insulated tools. Do not mechanically machine the battery, strike, crush, compress, notch, dent or modify it in any way.

Hazardous electric voltage! The metal parts of the battery cells are permanently live. Therefore do not place any foreign objects or tools on the battery.Observe national health and safety regulations.

If the materials leak, do not inhale the fumes. Wear safety gloves.

Follow the user instructions and keep them in a visible position in the charging area.

Work on the batteries should be performed only as instructed by specialist personnel.

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4 Lead acid batteries with armour plated cells and liquid electrolyte

4.1 Description

Jungheinrich traction batteries are lead acid batteries with armour plated cells andliquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.

Electrolyte

The rated density of the electrolyte assumes a temperature of 30°C and the ratedelectrolyte level is fully charged. Higher temperatures will reduce, lowertemperatures will increase the electrolyte density.The corresponding adjustment factor is ± 0.0007 kg/l per K, e. g. electrolyte density1.28 kg/l at 45 °C corresponds to a density of 1,29 kg/l at 30 °C.

The electrolyte must comply with the purity regulations of DIN 43530 Part 2.

Name Explanation

PzS– Lead acid battery with "Standard" armour plated cells and liquid

electrolyte– Battery cell width: 198 mm

PzB– Lead acid battery with "British Standard" armour plated cells

and liquid electrolyte– Battery cell width: 158 mm

PzS Lib – Lead acid battery with "Standard" armour plated cells and liquid electrolyte

– Lead acid battery with extended maintenance interval– Battery cell width: 198 mm

PzM

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4 Lead acid batteries with armour plated cells and liquid electrolyte

4.1 Description

Jungheinrich traction batteries are lead acid batteries with armour plated cells andliquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.

Electrolyte

The rated density of the electrolyte assumes a temperature of 30°C and the ratedelectrolyte level is fully charged. Higher temperatures will reduce, lowertemperatures will increase the electrolyte density.The corresponding adjustment factor is ± 0.0007 kg/l per K, e. g. electrolyte density1.28 kg/l at 45 °C corresponds to a density of 1,29 kg/l at 30 °C.

The electrolyte must comply with the purity regulations of DIN 43530 Part 2.

Name Explanation

PzS– Lead acid battery with "Standard" armour plated cells and liquid

electrolyte– Battery cell width: 198 mm

PzB– Lead acid battery with "British Standard" armour plated cells

and liquid electrolyte– Battery cell width: 158 mm

PzS Lib – Lead acid battery with "Standard" armour plated cells and liquid electrolyte

– Lead acid battery with extended maintenance interval– Battery cell width: 198 mm

PzM

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1. Product Traction battery

2. Nominal voltage 2.0 V x number of cells

3. Rated capacity C5 See data plate

4. Discharge current C5/5h

5. Nominal electrolyte density1

1. Reached within the first 10 cycles.

1.29 kg/l

6. Nominal temperature2

2. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

30 °C

7. System rated electrolyte level up to "Max" electrolyte level marking

Limit temperature3

3. Not permissible as operating temperature.

55 °C

11

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4.1.1 Battery nominal data





5. Nominal electrolyte density1

1. Reached within the first 10 cycles.

1.29 kg/l

6. Nominal temperature2


30 °C

7. System rated electrolyte level up to "Max" electrolyte level marking

Limit temperature3

3. Not permissible as operating temperature.

55 °C

02.1

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12

4.2 Operation

4.2.1 Commissioning unfilled batteries

Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.

4.2.2 Commissioning filled and charged batteries


Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)

and check that contacts on the battery terminal conducting system are secure.• Check the M10 terminal screws of the conductors and connectors are secure and

if necessary torque to 23 ±1 Nm.• Charge the battery, see page 13.• Check the electrolyte level of each battery cell after charging and top up if

necessary:• Open the plug (15).

Z The electrolyte level should not be less than the "Min" electrolyte marking (16)and must not exceed the "Max" (17) marking.

• If necessary, add electrolyte with pure water up to the "Max" electrolyte levelmarking (17), see page 15.

• Close the plug (15).

The test is now complete.

Battery cell cross section Top view of a battery cell

15 16 17

15 16 17

02.1

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12

4.2 Operation

4.2.1 Commissioning unfilled batteries


4.2.2 Commissioning filled and charged batteries




if necessary torque to 23 ±1 Nm.• Charge the battery, see page 13.• Check the electrolyte level of each battery cell after charging and top up if

necessary:• Open the plug (15).

Z The electrolyte level should not be less than the "Min" electrolyte marking (16)and must not exceed the "Max" (17) marking.

• If necessary, add electrolyte with pure water up to the "Max" electrolyte levelmarking (17), see page 15.

• Close the plug (15).



15 16 17

15 16 17

13

02.1

6 E

N4.2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% ofnominal capacity (full discharge). This corresponds to a minimum electrolytedensity of 1.13 kg/l at the end of the discharge.Fully or partially discharged batteries must be re-charged immediately and not leftunattended.

4.2.4 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the

charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity

and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure

sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.

Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of2000 mm from the truck.

Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station

manufacturers.

NOTE

The battery must only be charged with DC current. All charging procedures inaccordance with DIN 41773 and DIN 41774 are permissible.

13

02.1

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N

4.2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% ofnominal capacity (full discharge). This corresponds to a minimum electrolytedensity of 1.13 kg/l at the end of the discharge.Fully or partially discharged batteries must be re-charged immediately and not leftunattended.


WARNING!








manufacturers.

NOTE

The battery must only be charged with DC current. All charging procedures inaccordance with DIN 41773 and DIN 41774 are permissible.

02.1

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14

Z The electrolyte temperature rises by approx. 10°C during charging. Chargingshould therefore only begin when the electrolyte temperature is below 45°C. Theelectrolyte temperature of batteries must be at least +10°C before charging.Otherwise the battery will not charge correctly. Below 10°C the battery isinsufficiently charged with standard charging systems.

Charging the battery

Requirements– Permissible electrolyte temperature 10°C to 45°C).

Procedure• Open or take off the tray lid or covers from the battery compartment.

Z Deviations are outlined in the truck's operating instructions. The plugs remain onthe cells or remain closed.

• Connect the battery to the switched off charger, ensuring the terminals are connect(positive to positive and negative to negative).

• Switch on the charger.

The battery is charged.

Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging. The maximum compensationcharge current is 5 A/100 Ah rated capacity.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which reduce the usefullife of the batteries.

Z Trickle charges should only be performed when the charge level is below 60 %. Usereplacement batteries instead of regular trickle charging.

02.1

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14

Z The electrolyte temperature rises by approx. 10°C during charging. Chargingshould therefore only begin when the electrolyte temperature is below 45°C. Theelectrolyte temperature of batteries must be at least +10°C before charging.Otherwise the battery will not charge correctly. Below 10°C the battery isinsufficiently charged with standard charging systems.


Requirements– Permissible electrolyte temperature 10°C to 45°C).

Procedure• Open or take off the tray lid or covers from the battery compartment.

Z Deviations are outlined in the truck's operating instructions. The plugs remain onthe cells or remain closed.

• Connect the battery to the switched off charger, ensuring the terminals are connect(positive to positive and negative to negative).

• Switch on the charger.




Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging. The maximum compensationcharge current is 5 A/100 Ah rated capacity.


Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which reduce the usefullife of the batteries.

Z Trickle charges should only be performed when the charge level is below 60 %. Usereplacement batteries instead of regular trickle charging.

15

02.1

6 E

N4.3 Servicing lead-acid batteries with armour plated cells

4.3.1 Quality of Water for Adding Electrolyte

Z The quality of the water used to add electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

4.3.2 Daily

– Charge the battery after each discharge.– After charging, check the electrolyte level of each battery cell and replenish as

required:

– Open the plug (15).– If necessary, add electrolyte with pure water up to the "Max" electrolyte level

marking (17).– Close the plug (15).

Z The electrolyte level should not be less than the "Min" electrolyte marking (16) andmust not exceed the "Max" (17) marking.


15 16 17

15 16 17

15

02.1

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4.3 Servicing lead-acid batteries with armour plated cells

4.3.1 Quality of Water for Adding Electrolyte

Z The quality of the water used to add electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

4.3.2 Daily

– Charge the battery after each discharge.– After charging, check the electrolyte level of each battery cell and replenish as

required:

– Open the plug (15).– If necessary, add electrolyte with pure water up to the "Max" electrolyte level

marking (17).– Close the plug (15).

Z The electrolyte level should not be less than the "Min" electrolyte marking (16) andmust not exceed the "Max" (17) marking.


15 16 17

15 16 17

02.1

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16

4.3.3 Weekly

– After re-charging, carry out a visual inspection for dirt and physical damage.– If the battery is charged regularly according to the IU characteristic, carry out a

compensation charge.

4.3.4 Monthly

– Towards the end of the charging process measure and record the voltages of allthe cells with the charger switched on.

– After charging measure and record the electrolyte density and the electrolytetemperature in all the cells.

– Compare the results with the previous ones.

Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.

4.3.5 Annually

– Measure the insulation resistance of the truck in accordance with EN 1175-1.– Measure the insulation resistance of the battery in accordance with DIN EN 1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.

02.1

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16

4.3.3 Weekly

– After re-charging, carry out a visual inspection for dirt and physical damage.– If the battery is charged regularly according to the IU characteristic, carry out a

compensation charge.

4.3.4 Monthly

– Towards the end of the charging process measure and record the voltages of allthe cells with the charger switched on.

– After charging measure and record the electrolyte density and the electrolytetemperature in all the cells.

– Compare the results with the previous ones.


4.3.5 Annually



17

02.1

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N5 PzV and PzV-BS lead-acid batteries with sealed armour

plated cells

5.1 Description

PzV batteries are sealed batteries with fixed electrolytes, to which no water can beadded over the entire lifespan of the battery. Relief valves are used as plugs whichare destroyed when opened. During operation the same safety requirements apply tothe sealed batteries as for batteries with liquid electrolyte. This is to avoid electricshock, explosion of the electrolyte charging gases or hazardous electrolyte burns ifthe cell vessels are destroyed.

Z PzV batteries are low gassing, but not gassing-free.

Electrolyte

The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolytecannot be measured.


Name Explanation

PzV– Lead acid battery with "Standard" closed armour plated cells

and electrolyte in gel compound– Battery cell width: 198 mm

PzV-BS– Lead acid battery with "British Standard" closed armour plated

cells and electrolyte in gel compound– Battery cell width: 158 mm





5. Rated temperature 30°C

Limit temperature1


45°C, not permissible as operating temperature

6. Rated density of the electrolyte Cannot be measured

7. System rated electrolyte level Cannot be measured

17

02.1

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5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells

5.1 Description

PzV batteries are sealed batteries with fixed electrolytes, to which no water can beadded over the entire lifespan of the battery. Relief valves are used as plugs whichare destroyed when opened. During operation the same safety requirements apply tothe sealed batteries as for batteries with liquid electrolyte. This is to avoid electricshock, explosion of the electrolyte charging gases or hazardous electrolyte burns ifthe cell vessels are destroyed.

Z PzV batteries are low gassing, but not gassing-free.

Electrolyte

The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolytecannot be measured.


Name Explanation

PzV– Lead acid battery with "Standard" closed armour plated cells

and electrolyte in gel compound– Battery cell width: 198 mm

PzV-BS– Lead acid battery with "British Standard" closed armour plated

cells and electrolyte in gel compound– Battery cell width: 158 mm





5. Rated temperature 30°C

Limit temperature1


45°C, not permissible as operating temperature

6. Rated density of the electrolyte Cannot be measured

7. System rated electrolyte level Cannot be measured

02.1

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18

5.2 Operation

5.2.1 Commissioning




if necessary torque to 23 ±1 Nm.• Charge the battery, see page 18.



Z To achieve an optimum useful life avoid operational discharges of more than 60%of nominal capacity.

Z If the battery is discharged during operation by more than 80% of rated capacity theuseful life of the battery will reduce significantly. Fully or partially dischargedbatteries must be re-charged immediately and not left unattended.


WARNING!








manufacturers.

02.1

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18

5.2 Operation

5.2.1 Commissioning




if necessary torque to 23 ±1 Nm.• Charge the battery, see page 18.



Z To achieve an optimum useful life avoid operational discharges of more than 60%of nominal capacity.

Z If the battery is discharged during operation by more than 80% of rated capacity theuseful life of the battery will reduce significantly. Fully or partially dischargedbatteries must be re-charged immediately and not left unattended.


WARNING!








manufacturers.

19

02.1

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NOTE

Charging the battery incorrectly can result in material damage.Incorrect battery charging can result in overloading of the electric wires and contacts,hazardous gas formation and electrolyte leakage from the battery cell.Always charge the battery with DC current.All DIN 41773 charging procedures are permitted in the format approved by the

manufacturer.Always connect the battery to a charger that is appropriate to the size and type of

the battery.If necessary have the charger checked by the manufacturer's customer service

department for suitability.Do not exceed the limit curents in accordance with DIN EN 50272-3 in the gassing

area.

19

02.1

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NOTE

Charging the battery incorrectly can result in material damage.Incorrect battery charging can result in overloading of the electric wires and contacts,hazardous gas formation and electrolyte leakage from the battery cell.Always charge the battery with DC current.All DIN 41773 charging procedures are permitted in the format approved by the

manufacturer.Always connect the battery to a charger that is appropriate to the size and type of

the battery.If necessary have the charger checked by the manufacturer's customer service

department for suitability.Do not exceed the limit curents in accordance with DIN EN 50272-3 in the gassing

area.

02.1

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20


Requirements– Electrolyte temperature between +15°C and +35°C

Procedure• Open or take off the tray lid or covers from the battery compartment.• Connect the battery to the switched off charger, ensuring the terminals are connect

(positive to positive and negative to negative). • Switch on the charger.

Z The electrolyte temperature rises by approx. 10°C during charging. If thetemperatures are permanently higher than 40°C or lower than 15°C, a temperature-dependent constant voltage control of the charger is required. The adjustmentfactor must be applied with -0.004 V/C per °C.




Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging.


Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which can reduce theuseful life of the batteries.

Z Trickle charges should only be performed when the charge level is below 50%.Use replacement batteries instead of regular trickle charging.

Z Avoid trickle charging with PzV batteries.

02.1

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20


Requirements– Electrolyte temperature between +15°C and +35°C

Procedure• Open or take off the tray lid or covers from the battery compartment.• Connect the battery to the switched off charger, ensuring the terminals are connect

(positive to positive and negative to negative). • Switch on the charger.

Z The electrolyte temperature rises by approx. 10°C during charging. If thetemperatures are permanently higher than 40°C or lower than 15°C, a temperature-dependent constant voltage control of the charger is required. The adjustmentfactor must be applied with -0.004 V/C per °C.




Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging.


Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which can reduce theuseful life of the batteries.

Z Trickle charges should only be performed when the charge level is below 50%.Use replacement batteries instead of regular trickle charging.

Z Avoid trickle charging with PzV batteries.

21

02.1

6 E

N5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour

plated cells

Z Do not add water!

5.3.1 Daily

– Charge the battery after each discharge.

5.3.2 Weekly

– Visually inspect for dirt and physical damage.

5.3.3 Every three months

– Measure and record the overall voltage.– Measure and record the individual voltages.– Compare the results with the previous ones.

Z Carry out the measurements after full charging and subsequent resting for at least5 hours.


5.3.4 Annually



21

02.1

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5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells

Z Do not add water!

5.3.1 Daily

– Charge the battery after each discharge.

5.3.2 Weekly

– Visually inspect for dirt and physical damage.

5.3.3 Every three months

– Measure and record the overall voltage.– Measure and record the individual voltages.– Compare the results with the previous ones.

Z Carry out the measurements after full charging and subsequent resting for at least5 hours.


5.3.4 Annually



02.1

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22

6 Aquamatik water replenishment system

6.1 Water replenishment system design

18 Water container19 Tap connection with ball cock20 Flow indicator21 Shut-off cock22 Locking coupling 23 Battery lock connector

18

19

20

21

22

23

> 3 m

+ -

02.1

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22

6 Aquamatik water replenishment system

6.1 Water replenishment system design

18 Water container19 Tap connection with ball cock20 Flow indicator21 Shut-off cock22 Locking coupling 23 Battery lock connector

18

19

20

21

22

23

> 3 m

+ -

23

02.1

6 E

N6.2 Functional Description

The Aquamatik water replenishment system is used to adjust the rated electrolytelevel automatically on traction batteries for industrial trucks.

The battery cells are interconnected through hoses and are attached to the watersupply (e.g. water container) through a plug connection. When the shut-off cock isopened all the cells are filled with water. The Aquamatik plug controls the amount ofwater required and, at the relevant water pressures, ensures the water supply is shutoff and the valve is closed securely.

The plug systems have an optical level indicator, a diagnostic port to measure thetemperature and electrolyte density and a degassing port.

6.3 Adding water

Water should be added to the batteries just before the battery is fully charged. Thisensures that the amount of water added is mixed with the electrolyte.

6.4 Water pressure

The water replenishment system must be operated with a water pressure in the waterline of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges willaffect the operation of the systems.

Water drop

Assembly height above battery surface is between 3 - 18 m.1 m corresponds to 0.1 bar.

Pressure water

The pressure regulating valve is adjusted to suit the system and must lie between 0.3- 1.8 bar.

23

02.1

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6.2 Functional Description

The Aquamatik water replenishment system is used to adjust the rated electrolytelevel automatically on traction batteries for industrial trucks.

The battery cells are interconnected through hoses and are attached to the watersupply (e.g. water container) through a plug connection. When the shut-off cock isopened all the cells are filled with water. The Aquamatik plug controls the amount ofwater required and, at the relevant water pressures, ensures the water supply is shutoff and the valve is closed securely.

The plug systems have an optical level indicator, a diagnostic port to measure thetemperature and electrolyte density and a degassing port.

6.3 Adding water

Water should be added to the batteries just before the battery is fully charged. Thisensures that the amount of water added is mixed with the electrolyte.

6.4 Water pressure

The water replenishment system must be operated with a water pressure in the waterline of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges willaffect the operation of the systems.

Water drop

Assembly height above battery surface is between 3 - 18 m.1 m corresponds to 0.1 bar.

Pressure water

The pressure regulating valve is adjusted to suit the system and must lie between 0.3- 1.8 bar.

02.1

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24

6.5 Filling time

The filling time for a battery depends on the electrolyte level, the ambient temperatureand the filling pressure. Filling ends automatically. The water supply line must bedisconnected from the battery when the water has been filled.

6.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

6.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit. Nochanges should be made.

6.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in roomswith temperatures > 0°C, as otherwise the systems could freeze.

6.9 Cleaning measures

The plug systems must only be cleaned with purified water in accordance with DIN43530-4. No parts of the plugs must come into contact with solvent-based materialsor soap.

6.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. Theimmersion pump in the container generates the necessary filling pressure. Theservice mobile must be at exactly the same height as the battery base.

02.1

6 E

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24

6.5 Filling time

The filling time for a battery depends on the electrolyte level, the ambient temperatureand the filling pressure. Filling ends automatically. The water supply line must bedisconnected from the battery when the water has been filled.

6.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

6.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit. Nochanges should be made.

6.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in roomswith temperatures > 0°C, as otherwise the systems could freeze.

6.9 Cleaning measures

The plug systems must only be cleaned with purified water in accordance with DIN43530-4. No parts of the plugs must come into contact with solvent-based materialsor soap.

6.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. Theimmersion pump in the container generates the necessary filling pressure. Theservice mobile must be at exactly the same height as the battery base.

25

02.1

6 E

N7 Electrolyte circulation


Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,thereby preventing any acid layer, shortening the charge time (charge factor approx.1.07) and reducing the formation of gas during charging. The charger must besuitable for the battery and electrolyte circulation.

A pump in the charger produces the necessary compressed air which is introducedto the battery cells via a hose system. The electrolyte is circulated via the inlet air andthe electrolyte density level is constant over the entire length of the electrode.

Pump

In the event of a fault, e.g. if the pressure control system responds for an unknownreason, the filters must be checked and replaced if necessary.

Battery connection

A hose is attached to the pump module which together with the charge leads is routedfrom the charger to the charging connector. The air is passed on to the battery via theelectrolyte circulation coupling ducts in the connector. When routing make sure thehose is not bent.

Pressure-monitoring module

The electrolyte circulation pump is activated when charging begins. The pressuremonitoring module monitors the build-up of pressure during charging. This ensuresthat the required air pressure is provided for electrolyte circulation charging.

In the event of malfunctions, a visual error message appears on the battery charger.Some examples of malfunctions are listed below:– No connection between the air coupling of the battery and the recirculation module

(for separate coupling) or faulty air coupling– Leaking or faulty hose connections on battery– Contaminated intake filter

25

02.1

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7 Electrolyte circulation


Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,thereby preventing any acid layer, shortening the charge time (charge factor approx.1.07) and reducing the formation of gas during charging. The charger must besuitable for the battery and electrolyte circulation.

A pump in the charger produces the necessary compressed air which is introducedto the battery cells via a hose system. The electrolyte is circulated via the inlet air andthe electrolyte density level is constant over the entire length of the electrode.

Pump

In the event of a fault, e.g. if the pressure control system responds for an unknownreason, the filters must be checked and replaced if necessary.

Battery connection

A hose is attached to the pump module which together with the charge leads is routedfrom the charger to the charging connector. The air is passed on to the battery via theelectrolyte circulation coupling ducts in the connector. When routing make sure thehose is not bent.

Pressure-monitoring module

The electrolyte circulation pump is activated when charging begins. The pressuremonitoring module monitors the build-up of pressure during charging. This ensuresthat the required air pressure is provided for electrolyte circulation charging.

In the event of malfunctions, a visual error message appears on the battery charger.Some examples of malfunctions are listed below:– No connection between the air coupling of the battery and the recirculation module

(for separate coupling) or faulty air coupling– Leaking or faulty hose connections on battery– Contaminated intake filter

02.1

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26

NOTE

If an installed electrolyte circulation system is seldom used or not used at all, or if thebattery is subjected to severe temperature fluctuations, the electrolyte may flow backinto the hose system.Attach a separate coupling system to the air inlet line, such as: locking coupling

to the battery side and through-coupling to the air supply side.

Schematic illustration

Electrolyte circulation on the battery and air supply via the charger.

02.1

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26

NOTE

If an installed electrolyte circulation system is seldom used or not used at all, or if thebattery is subjected to severe temperature fluctuations, the electrolyte may flow backinto the hose system.Attach a separate coupling system to the air inlet line, such as: locking coupling

to the battery side and through-coupling to the air supply side.

Schematic illustration

Electrolyte circulation on the battery and air supply via the charger.

27

02.1

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N8 Cleaning batteries

Batteries and trays must be cleaned in order to – Maintain cell insulation and protect cells from ground or external conductive parts.– Avoid damage from corrosion and stray currents.– Avoid excessive and varying automatic discharge of the individual cells or block

batteries due to stray currents.– Avoid electric sparking due to stray currents.

When cleaning the batteries make sure that:– The assembly site chosen for cleaning is close to a drainage system for processing

the electrolytic rinsing water.– All health and safety as well as water and waste disposal regulations are observed

when disposing of used electrolyte or rinsing water.– Protective goggles and clothing are worn.– Cell plugs are not removed or opened.– Clean the plastic components of the battery, in particular the cell containers, only

with water or water-based cloths without any additives.– After cleaning, the top of the battery is dried with suitable equipment, e.g.

compressed air or cloths.– Any fluid that has entered the battery tray must be suctioned off and disposed of in

accordance with the above-mentioned regulations.

27

02.1

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N

8 Cleaning batteries

Batteries and trays must be cleaned in order to – Maintain cell insulation and protect cells from ground or external conductive parts.– Avoid damage from corrosion and stray currents.– Avoid excessive and varying automatic discharge of the individual cells or block

batteries due to stray currents.– Avoid electric sparking due to stray currents.

When cleaning the batteries make sure that:– The assembly site chosen for cleaning is close to a drainage system for processing

the electrolytic rinsing water.– All health and safety as well as water and waste disposal regulations are observed

when disposing of used electrolyte or rinsing water.– Protective goggles and clothing are worn.– Cell plugs are not removed or opened.– Clean the plastic components of the battery, in particular the cell containers, only

with water or water-based cloths without any additives.– After cleaning, the top of the battery is dried with suitable equipment, e.g.

compressed air or cloths.– Any fluid that has entered the battery tray must be suctioned off and disposed of in

accordance with the above-mentioned regulations.

02.1

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28

Cleaning the battery with a high pressure cleaner

Requirements– Cell connectors tight, plugged in securely– Cell plugs closed

Procedure• Follow the high pressure cleaner's user instructions.• Do not use any cleaning additives.• Observe the permissible cleaning device temperature setting of 140°C.

Z This generally ensures that the temperature does not exceed 60°C at a distance of30cm behind the outlet nozzle.

• Observe the maximum operating pressure of 50 bar.• Observe a minimum distance of 30 cm from the top of the battery.• The battery should be sprayed over its entire surface to avoid localised

overheating.Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the

maximum battery surface temperature of 60°C.• After cleaning dry the battery surface with suitable materials e.g. compressed air or

cleaning cloths.

Battery cleaned.

02.1

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28

Cleaning the battery with a high pressure cleaner

Requirements– Cell connectors tight, plugged in securely– Cell plugs closed

Procedure• Follow the high pressure cleaner's user instructions.• Do not use any cleaning additives.• Observe the permissible cleaning device temperature setting of 140°C.

Z This generally ensures that the temperature does not exceed 60°C at a distance of30cm behind the outlet nozzle.

• Observe the maximum operating pressure of 50 bar.• Observe a minimum distance of 30 cm from the top of the battery.• The battery should be sprayed over its entire surface to avoid localised

overheating.Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the

maximum battery surface temperature of 60°C.• After cleaning dry the battery surface with suitable materials e.g. compressed air or

cleaning cloths.

Battery cleaned.

29

02.1

6 E

N9 Storing the battery

NOTE

The battery should not be stored for longer than 3 months without charging asotherwise it will no longer be functional.

If the battery is to be taken out of service for a long period, it should be stored fullycharged in a dry room protected from frost. To ensure the availability of the batterythe following charges can be selected:

– Monthly compensation charge for PzS and PzB batteries or 4-monthly full chargefor PzV batteries.

– Trickle charge for a charging voltage of 2.23 V x number of cells for PzS, PzM andPzB batteries or 2.25 V x number of cells for PzV batteries.

If the battery is to be taken out of service for a long period ( > 3 months), it should, asfar as possible, be charged to 50% of its charge level and stored in a dry roomprotected from frost.

10 Troubleshooting

If any faults are found on the battery or charger, contact the manufacturer's customerservice department immediately.


11 Disposal

Batteries marked with the recycling symbol and the sign showing acrossed-out rubbish bin should not be disposed of with ordinaryhousehold waste.

Buy-back terms and type of recycling are to be agreed with themanufacturer as described in § 8 of the battery legislation.

29

02.1

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9 Storing the battery

NOTE

The battery should not be stored for longer than 3 months without charging asotherwise it will no longer be functional.

If the battery is to be taken out of service for a long period, it should be stored fullycharged in a dry room protected from frost. To ensure the availability of the batterythe following charges can be selected:

– Monthly compensation charge for PzS and PzB batteries or 4-monthly full chargefor PzV batteries.

– Trickle charge for a charging voltage of 2.23 V x number of cells for PzS, PzM andPzB batteries or 2.25 V x number of cells for PzV batteries.

If the battery is to be taken out of service for a long period ( > 3 months), it should, asfar as possible, be charged to 50% of its charge level and stored in a dry roomprotected from frost.

10 Troubleshooting

If any faults are found on the battery or charger, contact the manufacturer's customerservice department immediately.


11 Disposal

Batteries marked with the recycling symbol and the sign showing acrossed-out rubbish bin should not be disposed of with ordinaryhousehold waste.

Buy-back terms and type of recycling are to be agreed with themanufacturer as described in § 8 of the battery legislation.

bl ejc 110n-112n gb - jungheinrich.ie · 5 ejc 110n/112n lubrication schedule ... the truck...

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