12

34

5 67 8 9

0Set

Operating instructions

50425855

EJE 116/118/120

G

10.03 -

06.06

0108

.GB

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

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

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

0108

.GB

I 1

0803

.GB

Table of contentsA Correct use and application of the truck

B Truck description

1 Description of use ............................................................................... B 12 Description of assemblies and functions ............................................. B 23 Technical data - Standard version ...................................................... B 33.1 Performance data for standard trucks ................................................ B 33.2 Dimensions ......................................................................................... B 33.3 EN standards ...................................................................................... B 53.4 Conditions for application .................................................................... B 54 Labels and plates ................................................................................ B 64.1 Truck identification plate ..................................................................... B 7

C Transportation and commissioning

1 Transportation by crane ...................................................................... C 12 Commissioning .................................................................................... C 13 Moving an incapacitated truck ............................................................. C 23.1 Emergency operation with service key 741 (o) .................................. C 3

D Battery - Servicing, recharging, replacement

1 Safety regulations governing the handling of lead-acid batteries ........ D 12 Battery type ......................................................................................... D 23 Batteries and motor output: ................................................................. D 24 Exposing the battery ........................................................................... D 35 Charging the battery ............................................................................ D 35.1 Charging the battery with a stationary charging device ...................... D 35.2 Selecting the charging curves in the integrated charging device (o) ... D 46 Removing and installing the battery .................................................... D 77 Battery discharge indicator (t) ........................................................... D 8

I 1

0803

.GB

Table of contentsA Correct use and application of the truck

B Truck description

1 Description of use ............................................................................... B 12 Description of assemblies and functions ............................................. B 23 Technical data - Standard version ...................................................... B 33.1 Performance data for standard trucks ................................................ B 33.2 Dimensions ......................................................................................... B 33.3 EN standards ...................................................................................... B 53.4 Conditions for application .................................................................... B 54 Labels and plates ................................................................................ B 64.1 Truck identification plate ..................................................................... B 7

C Transportation and commissioning

1 Transportation by crane ...................................................................... C 12 Commissioning .................................................................................... C 13 Moving an incapacitated truck ............................................................. C 23.1 Emergency operation with service key 741 (o) .................................. C 3

D Battery - Servicing, recharging, replacement

1 Safety regulations governing the handling of lead-acid batteries ........ D 12 Battery type ......................................................................................... D 23 Batteries and motor output: ................................................................. D 24 Exposing the battery ........................................................................... D 35 Charging the battery ............................................................................ D 35.1 Charging the battery with a stationary charging device ...................... D 35.2 Selecting the charging curves in the integrated charging device (o) ... D 46 Removing and installing the battery .................................................... D 77 Battery discharge indicator (t) ........................................................... D 8

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I 2

E Operation

1 Safety regulations governing the operation of the fork lift truck .......... E 12 Description of the operating controls and displays .............................. E 23 Start-up of truck ................................................................................... E 44 Operation of the fork lift truck .............................................................. E 54.1 Safety regulations applicable when operating the truck ...................... E 54.2 Driving, steering, braking .................................................................... E 64.3 Picking up and setting down loads ...................................................... E 94.4 Rendering the vehicle safe when parking ........................................... E 95 Keyboard (CANCODE) (o) ................................................................. E 105.1 Code lock ............................................................................................ E 105.2 Travel programmes ............................................................................. E 125.3 Parameters .......................................................................................... E 125.4 Parameter settings .............................................................................. E 135.5 Travel parameters ............................................................................... E 176 Display instrument (CANDIS) (o) ....................................................... E 206.1 Discharge monitor function ................................................................. E 216.2 Operating hours display ...................................................................... E 216.3 Switch-on test ...................................................................................... E 216.4 Fault location ....................................................................................... E 22

F Maintenance of the fork lift truck

1 Operational safety and environmental protection ................................ F 12 Safety regulations applicable to truck maintenance ............................ F 13 Servicing and inspection ..................................................................... F 34 Maintenance Check - list EJE 116 / 118 / 120 .................................... F 45 Lubrication Schedule EJE 116 / 118 / 120 ......................................... F 65.1 Fuels, coolants and lubricants ............................................................. F 76 Instructions for the servicing operations .............................................. F 86.1 Preparing the truck for the performance of servicing and

maintenance operations ...................................................................... F 86.2 Removing the front cover .................................................................... F 86.3 Removing the drive cover ................................................................... F 86.4 Checking the electric fuses ................................................................. F 96.5 Recommissioning the truck ................................................................. F 107 Decommissioning the fork lift truck ..................................................... F 107.1 Operations to be performed prior to decommissioning ....................... F 107.2 Measures to be taken during decommissioning .................................. F 107.3 Recommissioning the truck ................................................................. F 118 Safety checks to be performed at regular intervals and following

any untoward incidents (D: Accident prevention check according to BGV D27) ....................................................................... F 11

9 Final de-commissioning, disposal ....................................................... F 11

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I 2

E Operation

1 Safety regulations governing the operation of the fork lift truck .......... E 12 Description of the operating controls and displays .............................. E 23 Start-up of truck ................................................................................... E 44 Operation of the fork lift truck .............................................................. E 54.1 Safety regulations applicable when operating the truck ...................... E 54.2 Driving, steering, braking .................................................................... E 64.3 Picking up and setting down loads ...................................................... E 94.4 Rendering the vehicle safe when parking ........................................... E 95 Keyboard (CANCODE) (o) ................................................................. E 105.1 Code lock ............................................................................................ E 105.2 Travel programmes ............................................................................. E 125.3 Parameters .......................................................................................... E 125.4 Parameter settings .............................................................................. E 135.5 Travel parameters ............................................................................... E 176 Display instrument (CANDIS) (o) ....................................................... E 206.1 Discharge monitor function ................................................................. E 216.2 Operating hours display ...................................................................... E 216.3 Switch-on test ...................................................................................... E 216.4 Fault location ....................................................................................... E 22

F Maintenance of the fork lift truck

1 Operational safety and environmental protection ................................ F 12 Safety regulations applicable to truck maintenance ............................ F 13 Servicing and inspection ..................................................................... F 34 Maintenance Check - list EJE 116 / 118 / 120 .................................... F 45 Lubrication Schedule EJE 116 / 118 / 120 ......................................... F 65.1 Fuels, coolants and lubricants ............................................................. F 76 Instructions for the servicing operations .............................................. F 86.1 Preparing the truck for the performance of servicing and

maintenance operations ...................................................................... F 86.2 Removing the front cover .................................................................... F 86.3 Removing the drive cover ................................................................... F 86.4 Checking the electric fuses ................................................................. F 96.5 Recommissioning the truck ................................................................. F 107 Decommissioning the fork lift truck ..................................................... F 107.1 Operations to be performed prior to decommissioning ....................... F 107.2 Measures to be taken during decommissioning .................................. F 107.3 Recommissioning the truck ................................................................. F 118 Safety checks to be performed at regular intervals and following

any untoward incidents (D: Accident prevention check according to BGV D27) ....................................................................... F 11

9 Final de-commissioning, disposal ....................................................... F 11

1

0506

.GB

Appendix

JH Traction Battery Operating Instructions

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

1

0506

.GB

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.

0506

.GB

2

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.GB

2

A 1

0600

.GB

A Correct use and application of the truck

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

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

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

M If these Operating Instruction are not observed the warranty becomes void. The sameapplies if improper work is carried out on the device by the customer and/or third par-ties without permission of our Customer Service.

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

A 1

0600

.GB

A Correct use and application of the truck

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

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

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

M If these Operating Instruction are not observed the warranty becomes void. The sameapplies if improper work is carried out on the device by the customer and/or third par-ties without permission of our Customer Service.

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

0600

.GB

A 2

0600

.GB

A 2

B 1

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B Truck description1 Description of use

The truck is designed for transporting goods on a level surface. Palets with an openfloor support or with lateral boards outside of the area of the load-bearing wheels ortrolleys can be transported. The load capacity can be found on the load capacity labelQmax.

Truck type, load capacity and motor output:

Type Load capacity Motor outputEJE 116 1,600 kg 1.0 kWEJE 118 1,800 kg 1.0 kWEJE 118 2,000 kg 1.0 kW

12

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5 67 8 9

0Set

B 1

0803

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B Truck description1 Description of use

The truck is designed for transporting goods on a level surface. Palets with an openfloor support or with lateral boards outside of the area of the load-bearing wheels ortrolleys can be transported. The load capacity can be found on the load capacity labelQmax.

Truck type, load capacity and motor output:

Type Load capacity Motor outputEJE 116 1,600 kg 1.0 kWEJE 118 1,800 kg 1.0 kWEJE 118 2,000 kg 1.0 kW

12

34

5 67 8 9

0Set

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.GB

B 2

2 Description of assemblies and functions

Item Designation Item Designation1 t Discharge indicator 8 t Load lifting device

o Display instrument(CANDIS)

9 o Integrated charging device24V/30A(incl. safety circuit)

2 o Keyboard(CANCODE)

10 t Battery hood

3 t Key switch 11 t Controllero Key switch

(with an additional second stage for brake release)

12 t Collision safety device

4 t Front cover 13 t Control shaft5 t Drive cover (2 sections) 14 t Battery plug (emergency stop)6 t Supporting wheels 15 t Inching speed pushbutton7 t Drive wheel

t = Standard equipment o = Optional equipment

12

3

4 5 6

7 8

0

9

Set

8

76

6

5

4

3

2

1

14

12

13

11

10

9

15

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B 2

2 Description of assemblies and functions

Item Designation Item Designation1 t Discharge indicator 8 t Load lifting device

o Display instrument(CANDIS)

9 o Integrated charging device24V/30A(incl. safety circuit)

2 o Keyboard(CANCODE)

10 t Battery hood

3 t Key switch 11 t Controllero Key switch

(with an additional second stage for brake release)

12 t Collision safety device

4 t Front cover 13 t Control shaft5 t Drive cover (2 sections) 14 t Battery plug (emergency stop)6 t Supporting wheels 15 t Inching speed pushbutton7 t Drive wheel

t = Standard equipment o = Optional equipment

12

3

4 5 6

7 8

0

9

Set

8

76

6

5

4

3

2

1

14

12

13

11

10

9

15

B 3

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3 Technical data - Standard version

Z Description of the technical data according to VDI 2198.Technical modifications and additions reserved.

3.1 Performance data for standard trucks

*) If the forks are longer, the load centre is in the middle of the fork.

3.2 Dimensions

* Load section lifted / lowered +55 mm

** Diagonally as per VDI +204 mm

Designation EJE 116 EJE 118 EJE 120Q Load capacity 1,600 1,800 2,000 kgC Load centre distance for standard

fork length *)600 600 600 mm

Travelling speed with/without load 6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 km/hLifting speed with/without load 3.4 / 4.2 3.3 / 4.2 3.2 / 4.2 cm/sLowering speed with/without load 5.3 / 3.6 5.3 / 3.6 5.3 / 3.6 cm/sMax. climbing capacity (5 min.) with/without load

10 / 20 9 / 20 8 / 20 %

Designation EJE 116 / 118 /120

Short version h3 Lifting height 122 mm h13 Load lifting device, lowered 85 mmY* Wheel base (short, long) 1,240 / 1,310 mml1 Overall length (short, long) 1,630 / 1,700 mml2 Length including back of fork (short, long) 480 / 550 mml Standard fork length 1,150 mm

b1 Truck width 700 mmWa* Turning radius 1,450 / 1,520 mmAst* Working aisle width 800 x 1200 pallets, lengthwise 1,915** / 1,985** mmAst* Working aisle width 1000 x 1200 pallets, crosswise 1,865 / 1,935 mm

a Safety distance 200 mm

B 3

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3 Technical data - Standard version

Z Description of the technical data according to VDI 2198.Technical modifications and additions reserved.

3.1 Performance data for standard trucks

*) If the forks are longer, the load centre is in the middle of the fork.

3.2 Dimensions

* Load section lifted / lowered +55 mm

** Diagonally as per VDI +204 mm

Designation EJE 116 EJE 118 EJE 120Q Load capacity 1,600 1,800 2,000 kgC Load centre distance for standard

fork length *)600 600 600 mm

Travelling speed with/without load 6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 km/hLifting speed with/without load 3.4 / 4.2 3.3 / 4.2 3.2 / 4.2 cm/sLowering speed with/without load 5.3 / 3.6 5.3 / 3.6 5.3 / 3.6 cm/sMax. climbing capacity (5 min.) with/without load

10 / 20 9 / 20 8 / 20 %

Designation EJE 116 / 118 /120

Short version h3 Lifting height 122 mm h13 Load lifting device, lowered 85 mmY* Wheel base (short, long) 1,240 / 1,310 mml1 Overall length (short, long) 1,630 / 1,700 mml2 Length including back of fork (short, long) 480 / 550 mml Standard fork length 1,150 mm

b1 Truck width 700 mmWa* Turning radius 1,450 / 1,520 mmAst* Working aisle width 800 x 1200 pallets, lengthwise 1,915** / 1,985** mmAst* Working aisle width 1000 x 1200 pallets, crosswise 1,865 / 1,935 mm

a Safety distance 200 mm

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B 4

h 13

Ast

l1

l2

Q

150

40

1268

803

h 3

55

y

c

l

a_2

a_2

700

b 5b 11

e

Wa

0803

.GB

B 4

h 13

Ast

l1

l2

Q

150

40

1268

803

h 3

55

y

c

l

a_2

a_2

700

b 5b 11

e

Wa

B 5

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3.3 EN standards

Continuous sound level: 70 dB(A)

according to EN 12053 as stipulated in ISO 4871

Z The continuous sound level is a value averaged according to standard regulations,taking the sound pressure level into account when driving, lifting and idling. Thesound pressure level is measured at the ear.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit val-ues for electromagnetic emission and interference immu-nity as well as testing of static electricity discharge ac-cording to EN 12895 and the references to otherstandards contained therein.

Z Electrical or electronic components and their arrangement may only be modified afterwritten approval by the manufacturer has been obtained.

3.4 Conditions for application

Ambient temperature:

- during operation: 5 °C to 40 °C

Z Industrial trucks must be specially equipped and approved for continuous use in en-vironments with temperatures below 5 °C or in cold stores respectively with extremetemperatures or humidity changes.

B 5

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3.3 EN standards

Continuous sound level: 70 dB(A)

according to EN 12053 as stipulated in ISO 4871

Z The continuous sound level is a value averaged according to standard regulations,taking the sound pressure level into account when driving, lifting and idling. Thesound pressure level is measured at the ear.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit val-ues for electromagnetic emission and interference immu-nity as well as testing of static electricity discharge ac-cording to EN 12895 and the references to otherstandards contained therein.

Z Electrical or electronic components and their arrangement may only be modified afterwritten approval by the manufacturer has been obtained.

3.4 Conditions for application

Ambient temperature:

- during operation: 5 °C to 40 °C

Z Industrial trucks must be specially equipped and approved for continuous use in en-vironments with temperatures below 5 °C or in cold stores respectively with extremetemperatures or humidity changes.

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B 6

4 Labels and plates

Item Designation16 Truck identification plate17 Load capacity Qmax18 Prohibition sign “Do not ride on truck”19 Lifting point for crane transportation20 Plate confirming accident prevention checks (only D)

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1816

20

19

Qmax 2000kg

17

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B 6

4 Labels and plates

Item Designation16 Truck identification plate17 Load capacity Qmax18 Prohibition sign “Do not ride on truck”19 Lifting point for crane transportation20 Plate confirming accident prevention checks (only D)

12

34

5 67 8 9

0Set

1816

20

19

Qmax 2000kg

17

B 7

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4.1 Truck identification plate

Z The load lifting device must be lifted to read the identification plate.

If you have questions concerning the truck or ordering spare parts, please indicatethe serial number (22).

Item Designation Item Designation21 Type 27 Manufacturer logo22 Serial No. 28 Min./max. battery weight in kg23 Rated capacity in kg 29 Drive power in kW24 System voltage V 30 Load centre distance in mm25 Dead weight without battery in kg 31 Year of manufacture26 Manufacturer 32 Option

27

26

2825

2924

3023

3122

3221

B 7

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4.1 Truck identification plate

Z The load lifting device must be lifted to read the identification plate.

If you have questions concerning the truck or ordering spare parts, please indicatethe serial number (22).

Item Designation Item Designation21 Type 27 Manufacturer logo22 Serial No. 28 Min./max. battery weight in kg23 Rated capacity in kg 29 Drive power in kW24 System voltage V 30 Load centre distance in mm25 Dead weight without battery in kg 31 Year of manufacture26 Manufacturer 32 Option

27

26

2825

2924

3023

3122

3221

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B 8

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B 8

C 1

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C Transportation and commissioning1 Transportation by crane

M Only use lifting equipment with sufficient load capacity.Transportation weight = dead weight + battery weight; see truck identification plate.)

Z Lifting points (1) are supplied on the chassis for transporting the truck using a crane.

– Safely park the truck (see Chapter E).– Attach the crane equipment to the lifting

points (1).

M Attach the crane equipment to the lift-ingpoints in such a manner that it absolutelycannot slip! Lifting equipment for the crane must beattached in such a manner that it does notcome into contact with components dur-ing lifting.

2 Commissioning

M Only drive the truck under battery power!A rectified alternating current damagesthe electronic components. Cable con-nections to the battery (towing cable)must be shorter than 6 m.

In order to make the truck operationallyready after delivery or after transport, car-ry out the following:

– Check the state and the completeness of the equipment.– If necessary, install the battery; do not damage the battery cable. – Charge the battery (see Chapter D).– The battery discharge indicator must match the battery type (to be verified by man-

ufacturer service personnel) if the customer uses a maintenance-free battery.– Put the truck into operation as described (see Chapter E).

Z After the truck is parked, the surfaces of the wheels may flatten. After a short drivingtime, this flattening disappears again.

12

34

5 67 8 9

0Set

1

C 1

0606

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C Transportation and commissioning1 Transportation by crane

M Only use lifting equipment with sufficient load capacity.Transportation weight = dead weight + battery weight; see truck identification plate.)

Z Lifting points (1) are supplied on the chassis for transporting the truck using a crane.

– Safely park the truck (see Chapter E).– Attach the crane equipment to the lifting

points (1).

M Attach the crane equipment to the lift-ingpoints in such a manner that it absolutelycannot slip! Lifting equipment for the crane must beattached in such a manner that it does notcome into contact with components dur-ing lifting.

2 Commissioning

M Only drive the truck under battery power!A rectified alternating current damagesthe electronic components. Cable con-nections to the battery (towing cable)must be shorter than 6 m.

In order to make the truck operationallyready after delivery or after transport, car-ry out the following:

– Check the state and the completeness of the equipment.– If necessary, install the battery; do not damage the battery cable. – Charge the battery (see Chapter D).– The battery discharge indicator must match the battery type (to be verified by man-

ufacturer service personnel) if the customer uses a maintenance-free battery.– Put the truck into operation as described (see Chapter E).

Z After the truck is parked, the surfaces of the wheels may flatten. After a short drivingtime, this flattening disappears again.

12

34

5 67 8 9

0Set

1

0606

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C 2

3 Moving an incapacitated truck

In order to be able to move the truck in emergency operation, the electromagneticallyoperated brake must be released.

– Remove the front hood (2) (see Chapter F).– Remove the right-hand drive cover (3) (see Chapter F).– Screw on 2 off M4x20 bolts (4) to loosen the armature plate.

The truck can now be moved.

F Remove the bolts again when you have parked the truck. Braking is now restored.!

12

3

4 5 6

7 8

0

9

Set

2

3

4

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C 2

3 Moving an incapacitated truck

In order to be able to move the truck in emergency operation, the electromagneticallyoperated brake must be released.

– Remove the front hood (2) (see Chapter F).– Remove the right-hand drive cover (3) (see Chapter F).– Screw on 2 off M4x20 bolts (4) to loosen the armature plate.

The truck can now be moved.

F Remove the bolts again when you have parked the truck. Braking is now restored.!

12

3

4 5 6

7 8

0

9

Set

2

3

4

C 3

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3.1 Emergency operation with service key 741 (o)

The EJE can be manually moved in case of faults in the electric system. A batterymust be in the truck and connected.

Set service key 741 (o) (701 is standard) to position 2 of the key switch.

Z Key 701 for normal truck operation can be turned to key switch position 1 only.

– Press and hold the “Inching speed” pushbutton.– The brake releases, i.e. the truck can be moved.

The brake brakes the truck as soon as the inching speed pushbutton is released.

C 3

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3.1 Emergency operation with service key 741 (o)

The EJE can be manually moved in case of faults in the electric system. A batterymust be in the truck and connected.

Set service key 741 (o) (701 is standard) to position 2 of the key switch.

Z Key 701 for normal truck operation can be turned to key switch position 1 only.

– Press and hold the “Inching speed” pushbutton.– The brake releases, i.e. the truck can be moved.

The brake brakes the truck as soon as the inching speed pushbutton is released.

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C 4

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C 4

D 1

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D Battery - Servicing, recharging, replace-ment

1 Safety regulations governing the handling of lead-acid batteries

The truck must be parked and rendered safe before any operations on batteries areundertaken (refer to chapter E).

Servicing staff: Recharging, servicing and replacing of batteries must only be per-formed by qualified personnel. The instructions contained in this operating manual,and the instructions of the manufacturer of the battery and of the battery rechargingstation, must be observed when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted when han-dling batteries. No inflammable substances or spark-generating materials must bepresent or stored within a distance of 2 meters of the truck parked for battery recharg-ing. The location must be well ventilated and fire fighting equipment must be keptready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-minals and cable shoes must be clean, lightly greased with pole grease and must besecurely tightened. Batteries with bare terminal posts must be covered using a non-skid insulating mat.

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

M Before closing the battery hood, make sure that the battery cable cannot be dam-aged.

F Batteries contain dissolved acid which is toxic and caustic. For this reason, protectiveclothing and goggles must be worn whenever work is undertaken on batteries. Avoidphysical contact with battery acid.If clothing, skin or eyes accidentally come into contact with battery acid, liberally flushthe affected parts with clean water. Consult a doctor when skin or eyes come into con-tact with battery acid. Spilled battery acid must be immediately neutralized.

M Only batteries with closed tray may be used.

F Battery weight and dimensions have considerable influence on operational safety ofthe truck. Changing the battery equipment is not permitted without prior approval bythe manufacturer.

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D Battery - Servicing, recharging, replace-ment

1 Safety regulations governing the handling of lead-acid batteries

The truck must be parked and rendered safe before any operations on batteries areundertaken (refer to chapter E).

Servicing staff: Recharging, servicing and replacing of batteries must only be per-formed by qualified personnel. The instructions contained in this operating manual,and the instructions of the manufacturer of the battery and of the battery rechargingstation, must be observed when performing the above operations.

Fire protection measures: Smoking and naked flames are not permitted when han-dling batteries. No inflammable substances or spark-generating materials must bepresent or stored within a distance of 2 meters of the truck parked for battery recharg-ing. The location must be well ventilated and fire fighting equipment must be keptready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-minals and cable shoes must be clean, lightly greased with pole grease and must besecurely tightened. Batteries with bare terminal posts must be covered using a non-skid insulating mat.

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

M Before closing the battery hood, make sure that the battery cable cannot be dam-aged.

F Batteries contain dissolved acid which is toxic and caustic. For this reason, protectiveclothing and goggles must be worn whenever work is undertaken on batteries. Avoidphysical contact with battery acid.If clothing, skin or eyes accidentally come into contact with battery acid, liberally flushthe affected parts with clean water. Consult a doctor when skin or eyes come into con-tact with battery acid. Spilled battery acid must be immediately neutralized.

M Only batteries with closed tray may be used.

F Battery weight and dimensions have considerable influence on operational safety ofthe truck. Changing the battery equipment is not permitted without prior approval bythe manufacturer.

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2 Battery type

For the battery weight, refer to the battery identification plate.

Depending on the use, the EJE is equipped with different types of batteries. (refer tochapter B).

M Batteries with non-insulated poles must be covered with an anti-slip insulating jacket.When changing / assembling the battery, make sure that it is properly fixed in the bat-tery compartment the truck.

3 Batteries and motor output:

Z The abbreviations “K” (short version) and “L” (long version) on the identification plateindicate the present model.

Depending on the battery type, performance-enhanced and maintenance-free bat-teries can also be used.

M When replacing/installing the battery, pay attention that it is firmly seated in the bat-tery compartment of the truck.

EJE Short version (K)

EJE Long version (L)

24 V - PzS - battery 1 PzS 126 Ah1 PzS 150 Ah

1 PzS 200 Ah

Motor output 1.0 kW 0,8 kW

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D 2

2 Battery type

For the battery weight, refer to the battery identification plate.

Depending on the use, the EJE is equipped with different types of batteries. (refer tochapter B).

M Batteries with non-insulated poles must be covered with an anti-slip insulating jacket.When changing / assembling the battery, make sure that it is properly fixed in the bat-tery compartment the truck.

3 Batteries and motor output:

Z The abbreviations “K” (short version) and “L” (long version) on the identification plateindicate the present model.

Depending on the battery type, performance-enhanced and maintenance-free bat-teries can also be used.

M When replacing/installing the battery, pay attention that it is firmly seated in the bat-tery compartment of the truck.

EJE Short version (K)

EJE Long version (L)

24 V - PzS - battery 1 PzS 126 Ah1 PzS 150 Ah

1 PzS 200 Ah

Motor output 1.0 kW 0,8 kW

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4 Exposing the battery

– Safely park the truck (see Chapter E). – Open the battery hood (2).

To do so, open the hood at the recessed grip (1) and swing it up.– If it is present, remove the isolation mat from the battery.

M The battery hood is held open only by its own weight.

5 Charging the battery

M To charge the battery, park the truck in a closed, well-ventilated room. During charg-ing, the surfaces of the battery cells must be exposed to provide sufficient aeration.No metallic objects must be laid on the battery. Before charging, check all cable andplug connections for visible damage.The safety regulations of the manufacturer of the battery and the charging stationmust be heeded.

5.1 Charging the battery with a stationary charging device

– Remove the battery plug (3).– Expose the battery (see Section 4).– Connect the battery plug (3) with the charging cable of the stationary charging de-

vice and switch on the charging device.

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4 Exposing the battery

– Safely park the truck (see Chapter E). – Open the battery hood (2).

To do so, open the hood at the recessed grip (1) and swing it up.– If it is present, remove the isolation mat from the battery.

M The battery hood is held open only by its own weight.

5 Charging the battery

M To charge the battery, park the truck in a closed, well-ventilated room. During charg-ing, the surfaces of the battery cells must be exposed to provide sufficient aeration.No metallic objects must be laid on the battery. Before charging, check all cable andplug connections for visible damage.The safety regulations of the manufacturer of the battery and the charging stationmust be heeded.

5.1 Charging the battery with a stationary charging device

– Remove the battery plug (3).– Expose the battery (see Section 4).– Connect the battery plug (3) with the charging cable of the stationary charging de-

vice and switch on the charging device.

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D 4

5.2 Selecting the charging curves in the integrated charging device (o)

F The battery charger must not be opened. If it is damaged, it has to be exchanged.

Z The switch (6) of trucks supplied without a battery is factory-set to the “0” position.The red light-emitting diode (4) flashes - the battery cannot be recharged.

Select charging curve in the integrated battery charger

Use switch (5) at the battery charger to adjust the charging curves to the appropriatebattery according to the following table.

M The power plug must be pulled before the corresponding charging curve is to be ad-justed!

M Provided that a battery is connected, a new setting can be acknowledged via theLEDs (cf. indicator) which will then be immediately effective.

Z All other switch (5) positions inhibit the charger, and the battery is not charged.

Switch (5) Position Selected charge curves (characteristics)1 Wet cell batteries: 100 - 300 Ah2 Maintenance-free: 100 -149 Ah3 Maintenance-free: 150 -199 Ah4 Maintenance-free: 200 - 300 Ah5 Wet cell batteries: 200 - 400 Ah pulse

characteristic6 Wet cell batteries: Jungheinrich 100 - 300 Ah

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D 4

5.2 Selecting the charging curves in the integrated charging device (o)

F The battery charger must not be opened. If it is damaged, it has to be exchanged.

Z The switch (6) of trucks supplied without a battery is factory-set to the “0” position.The red light-emitting diode (4) flashes - the battery cannot be recharged.

Select charging curve in the integrated battery charger

Use switch (5) at the battery charger to adjust the charging curves to the appropriatebattery according to the following table.

M The power plug must be pulled before the corresponding charging curve is to be ad-justed!

M Provided that a battery is connected, a new setting can be acknowledged via theLEDs (cf. indicator) which will then be immediately effective.

Z All other switch (5) positions inhibit the charger, and the battery is not charged.

Switch (5) Position Selected charge curves (characteristics)1 Wet cell batteries: 100 - 300 Ah2 Maintenance-free: 100 -149 Ah3 Maintenance-free: 150 -199 Ah4 Maintenance-free: 200 - 300 Ah5 Wet cell batteries: 200 - 400 Ah pulse

characteristic6 Wet cell batteries: Jungheinrich 100 - 300 Ah

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0606

.GBAdjusting the charging curve

The charging curve can be adjusted by performing the following steps:

Starting the recharging process with integrated battery charger

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

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

Mains supply

Mains voltage: 230 V (±6%)Mains frequency: 50/60 Hz (±1%)

The charger power cable (6) is laterally accessible from the outside.

– Expose the battery (refer to section 4).– Remove insulation mat from battery, if

necessary.– Battery plug must not be unplugged.– Connect power plug (6) with a power

socket.

The flashing LED indicates the chargingstatus and/or a fault (flashing codes seetable “LED display”).

Z If the power plug (6) is connected to themains, all electric functions of the truckare interrupted (electric driving lock). Nooperation of the truck is possible.

– Pull plug (6) from the power socketand place it in the battery compartment.

Z The recharge procedure is automatically continued after a power failure.The recharge procedure can be interrupted by pulling the power plug and can be con-tinued in steps.

F The mains cable must not be damaged.Before commissioning the truck, the battery hood must be properly closed.

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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Adjusting the charging curve

The charging curve can be adjusted by performing the following steps:

Starting the recharging process with integrated battery charger

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

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

Mains supply

Mains voltage: 230 V (±6%)Mains frequency: 50/60 Hz (±1%)

The charger power cable (6) is laterally accessible from the outside.

– Expose the battery (refer to section 4).– Remove insulation mat from battery, if

necessary.– Battery plug must not be unplugged.– Connect power plug (6) with a power

socket.

The flashing LED indicates the chargingstatus and/or a fault (flashing codes seetable “LED display”).

Z If the power plug (6) is connected to themains, all electric functions of the truckare interrupted (electric driving lock). Nooperation of the truck is possible.

– Pull plug (6) from the power socketand place it in the battery compartment.

Z The recharge procedure is automatically continued after a power failure.The recharge procedure can be interrupted by pulling the power plug and can be con-tinued in steps.

F The mains cable must not be damaged.Before commissioning the truck, the battery hood must be properly closed.

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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Charging times

The time required for recharging depends on the capacity of the battery.

LED display

Fill-up charge

The fill-up charge begins automatically after the recharge procedure has ended.

Partial recharging

The battery charger is designed in such a way that it automatically adapts to thecharging status of partially recharged batteries. This permits to reduce wear and tearof the battery.

Green LED(charging

status)

Red LED(fault)

Indication

is lit --- Recharge procedure is finished; battery is full. (charging break, fill-up charge or equalization charge)

flashes slowly --- Charging processflashes fast --- Indicates the start of a recharge procedure or that a

new charging curve was adjusted. The number of the flashing pulses corresponds to the adjusted charging curve.

--- is lit Excess temperature. Recharge process is interrupt-ed.

--- flashes slowly Safety charging interval exceeded. Recharge proc-ess is interrupted. Disconnection from the mains is required for restarting the charging process.

--- flashes fast charging curve setting is invalid.--- --- Power failure and/or no battery connected.

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D 6

Charging times

The time required for recharging depends on the capacity of the battery.

LED display

Fill-up charge

The fill-up charge begins automatically after the recharge procedure has ended.

Partial recharging

The battery charger is designed in such a way that it automatically adapts to thecharging status of partially recharged batteries. This permits to reduce wear and tearof the battery.

Green LED(charging

status)

Red LED(fault)

Indication

is lit --- Recharge procedure is finished; battery is full. (charging break, fill-up charge or equalization charge)

flashes slowly --- Charging processflashes fast --- Indicates the start of a recharge procedure or that a

new charging curve was adjusted. The number of the flashing pulses corresponds to the adjusted charging curve.

--- is lit Excess temperature. Recharge process is interrupt-ed.

--- flashes slowly Safety charging interval exceeded. Recharge proc-ess is interrupted. Disconnection from the mains is required for restarting the charging process.

--- flashes fast charging curve setting is invalid.--- --- Power failure and/or no battery connected.

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6 Removing and installing the battery

F The truck must stand horizontally. To prevent short circuits, batteries with open polesor connectors must be covered with a rubber mat. Lay down the battery plug and ca-ble in such a manner that they do not snag on the truck when the battery is pulled out.

Z When transporting the battery with crane equipment, pay attention that the load ca-pacity is sufficient (see battery weight on the battery identification plate on the batterytrough). The crane equipment must pull vertically. The hooks of the crane equipmentmust never fall onto the battery cells.

– Expose the battery (see Section 4).– Remove the battery plug (3).– Connect the crane equipment to the eyelets (7).– Pull the battery upwards and out of the battery trough.

M Installation occurs in the reverse sequence; pay attention that the battery is installedin the correct position and is connected properly.

– After reinstallation, check all the cable and plug connections for visible damage.

F Close the battery hood slowly and carefully.Keep your fingers away from the area between the battery hood and the chassis.

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6 Removing and installing the battery

F The truck must stand horizontally. To prevent short circuits, batteries with open polesor connectors must be covered with a rubber mat. Lay down the battery plug and ca-ble in such a manner that they do not snag on the truck when the battery is pulled out.

Z When transporting the battery with crane equipment, pay attention that the load ca-pacity is sufficient (see battery weight on the battery identification plate on the batterytrough). The crane equipment must pull vertically. The hooks of the crane equipmentmust never fall onto the battery cells.

– Expose the battery (see Section 4).– Remove the battery plug (3).– Connect the crane equipment to the eyelets (7).– Pull the battery upwards and out of the battery trough.

M Installation occurs in the reverse sequence; pay attention that the battery is installedin the correct position and is connected properly.

– After reinstallation, check all the cable and plug connections for visible damage.

F Close the battery hood slowly and carefully.Keep your fingers away from the area between the battery hood and the chassis.

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D 8

7 Battery discharge indicator (t)

The battery discharge state is indicated as soon asthe truck is switched on with the key switch or theCANCODE.

The colors of the LED (8) indicate the following:

Z Lifting of load units is no longer possible if the LED is lit in red. The lifting function isre-enabled at a battery capacity of at least 70 % only.

The display is reset to 100% if the battery capacity determined when the truck isswitched on is at least 70% of a fully charged battery. Depending on the residual ca-pacity, the display is reduced in steps of 10%. The displayed residual capacity chang-es by no more than 10% within 3 minutes.

The residual capacity displayed cannot rise while the truck is in operation.

The residual capacity display is reset to 100% when the battery type is defined.

Call the manufacturer service when LED flashes red and the truck cannot be operat-ed any longer. The LED flashing red signals a truck controller malfunction. The flashsequence indicates the malfunction type.

LED color Ratinggreen Residual capacity, standard battery 40 - 100%

Residual capacity, maintenance-free battery 60 - 100%orange Residual capacity, standard battery 30 - 40%

Residual capacity, maintenance-free battery 50 - 60%green/orangeflashing, 1Hz

Residual capacity, standard battery 20 - 30%

Residual capacity, maintenance-free battery 40 - 50%red Residual capacity, standard battery 0 - 20%

Residual capacity, maintenance-free battery 0 - 40%

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7 Battery discharge indicator (t)

The battery discharge state is indicated as soon asthe truck is switched on with the key switch or theCANCODE.

The colors of the LED (8) indicate the following:

Z Lifting of load units is no longer possible if the LED is lit in red. The lifting function isre-enabled at a battery capacity of at least 70 % only.

The display is reset to 100% if the battery capacity determined when the truck isswitched on is at least 70% of a fully charged battery. Depending on the residual ca-pacity, the display is reduced in steps of 10%. The displayed residual capacity chang-es by no more than 10% within 3 minutes.

The residual capacity displayed cannot rise while the truck is in operation.

The residual capacity display is reset to 100% when the battery type is defined.

Call the manufacturer service when LED flashes red and the truck cannot be operat-ed any longer. The LED flashing red signals a truck controller malfunction. The flashsequence indicates the malfunction type.

LED color Ratinggreen Residual capacity, standard battery 40 - 100%

Residual capacity, maintenance-free battery 60 - 100%orange Residual capacity, standard battery 30 - 40%

Residual capacity, maintenance-free battery 50 - 60%green/orangeflashing, 1Hz

Residual capacity, standard battery 20 - 30%

Residual capacity, maintenance-free battery 40 - 50%red Residual capacity, standard battery 0 - 20%

Residual capacity, maintenance-free battery 0 - 40%

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E Operation1 Safety regulations governing the operation of the fork lift truck

Driving permission: The fork lift truck must only be operated by persons who havebeen trained in the operation of trucks, who have demonstrated to the user or his rep-resentative their capability of moving and handling loads, and who have expresslybeen charged by the user or his representative with the operation of the truck.

Rights, duties and conduct of the driver: The driver must be: informed of his rightsand duties; trained in the operation of the fork lift truck; and familiar with the contentsof these operating instructions. All necessary rights must be granted to him.If the fork lift truck can be used in the pedestrian-controlled mode, the driver mustwear safety boots when operating the truck.

Prohibition of unauthorised use: The driver is responsible for the fork lift truck dur-ing working time. He must forbid unauthorised persons to drive or operate the fork lifttruck. The transport or lifting of persons is forbidden.

Damage and defects: Damage or defects noted on the fork lift truck or on the attach-ments must immediately be brought to the notice of the person in charge. fork lifttrucks that cannot be safely operated (e.g. due to worn tyres or defective brakes)must not be used until they have been properly repaired.

Repairs: Without specific training and express authorisation, the driver is not allowedto perform any repairs or modifications on the fork lift truck. Under no circumstancesmust the driver change the setting of switches or safety installations or render themineffective.

Danger area: A “danger area” is considered to be the area within which persons areendangered by the travelling or lifting movements of the fork lift truck or its load liftingdevices (e.g. fork or attachments), or by the loads being transported. This also in-cludes the area within reach of falling loads or falling / lowering truck attachments.

F Unauthorised persons must be asked to leave the danger area. The driver must givea warning signal whenever a situation presenting danger to persons might develop.The fork lift truck must immediately be brought to a standstill if persons, althoughasked, do not leave the danger area.

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

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E Operation1 Safety regulations governing the operation of the fork lift truck

Driving permission: The fork lift truck must only be operated by persons who havebeen trained in the operation of trucks, who have demonstrated to the user or his rep-resentative their capability of moving and handling loads, and who have expresslybeen charged by the user or his representative with the operation of the truck.

Rights, duties and conduct of the driver: The driver must be: informed of his rightsand duties; trained in the operation of the fork lift truck; and familiar with the contentsof these operating instructions. All necessary rights must be granted to him.If the fork lift truck can be used in the pedestrian-controlled mode, the driver mustwear safety boots when operating the truck.

Prohibition of unauthorised use: The driver is responsible for the fork lift truck dur-ing working time. He must forbid unauthorised persons to drive or operate the fork lifttruck. The transport or lifting of persons is forbidden.

Damage and defects: Damage or defects noted on the fork lift truck or on the attach-ments must immediately be brought to the notice of the person in charge. fork lifttrucks that cannot be safely operated (e.g. due to worn tyres or defective brakes)must not be used until they have been properly repaired.

Repairs: Without specific training and express authorisation, the driver is not allowedto perform any repairs or modifications on the fork lift truck. Under no circumstancesmust the driver change the setting of switches or safety installations or render themineffective.

Danger area: A “danger area” is considered to be the area within which persons areendangered by the travelling or lifting movements of the fork lift truck or its load liftingdevices (e.g. fork or attachments), or by the loads being transported. This also in-cludes the area within reach of falling loads or falling / lowering truck attachments.

F Unauthorised persons must be asked to leave the danger area. The driver must givea warning signal whenever a situation presenting danger to persons might develop.The fork lift truck must immediately be brought to a standstill if persons, althoughasked, do not leave the danger area.

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

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E 2

2 Description of the operating controls and displays

Item Operating control or dis-play

EJE 116 / 118 / 120

Function

1 Control shaft t Steers and brakes truck.2 Battery plug (emergency

stop)t The power circuit is interrupted and

all electrical functions are switched off.

3 Discharge indicator t Battery discharge state.Display instrument(CANDIS)

o Operating hours meter.Battery discharge state.Display of service messages and, in conjunction with CANCODE, drive parameters.

4 Keyboard(CANCODE)

o Code settings. Releasing and selecting the travel programmes.Entering travel parameters.

5 Key switch t Switches the control current on and off. Pulling out the key prevents un-authorised persons from switching on the truck.

Key switch with second position

o Releases the brake to allow a non-operable truck to be moved.

6 Integrated charging device (incl. safety circuit)

o Charges the battery; insert the pow-er plug into a mains socket.

7 Inching speed pushbutton t Pressing the Inching speed push button reduces travel speed and ac-celeration. When the control shaft is in the upper brake area, the braking function can be bypassed by press-ing this key and the truck can be moved at reduced speed.

8 Controller t Controls the travelling direction and speed.

9 Collision safety button t Truck drives away from operator.10 Button for lifting load lifting

devicet Lifts load lifting device.

11 Button for lowering load lift-ing device

t Lowers load lifting device.

12 Operating key “Horn” t Gives an audible warning signal.

t = Standard equipment o = Optional equipment

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E 2

2 Description of the operating controls and displays

Item Operating control or dis-play

EJE 116 / 118 / 120

Function

1 Control shaft t Steers and brakes truck.2 Battery plug (emergency

stop)t The power circuit is interrupted and

all electrical functions are switched off.

3 Discharge indicator t Battery discharge state.Display instrument(CANDIS)

o Operating hours meter.Battery discharge state.Display of service messages and, in conjunction with CANCODE, drive parameters.

4 Keyboard(CANCODE)

o Code settings. Releasing and selecting the travel programmes.Entering travel parameters.

5 Key switch t Switches the control current on and off. Pulling out the key prevents un-authorised persons from switching on the truck.

Key switch with second position

o Releases the brake to allow a non-operable truck to be moved.

6 Integrated charging device (incl. safety circuit)

o Charges the battery; insert the pow-er plug into a mains socket.

7 Inching speed pushbutton t Pressing the Inching speed push button reduces travel speed and ac-celeration. When the control shaft is in the upper brake area, the braking function can be bypassed by press-ing this key and the truck can be moved at reduced speed.

8 Controller t Controls the travelling direction and speed.

9 Collision safety button t Truck drives away from operator.10 Button for lifting load lifting

devicet Lifts load lifting device.

11 Button for lowering load lift-ing device

t Lowers load lifting device.

12 Operating key “Horn” t Gives an audible warning signal.

t = Standard equipment o = Optional equipment

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E 4

3 Start-up of truck

F Before the truck can be started up or operated or a load can be lifted, the driver mustmake sure that no-one is in the danger zone.

Tests and duties before the daily start-up

– Check the entire truck (especially the tyres and the load lifting device) for damage.– Check the battery holder and the cable connections.

Switching on the truck

– Check that the battery plug (2) is plugged in.– Insert the key in the key switch (5) and turn it all the way to the right to position “I”

or enter the CANCODE (o) release code(see section 5).

– Press the warning signal pushbutton (12) to test its function.

The truck is now ready for operation.

o The battery discharge indicator (3) indicates the remaining battery capacity.

– Check the braking function of the control shaft (1) (see Section 4.2).

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E 4

3 Start-up of truck

F Before the truck can be started up or operated or a load can be lifted, the driver mustmake sure that no-one is in the danger zone.

Tests and duties before the daily start-up

– Check the entire truck (especially the tyres and the load lifting device) for damage.– Check the battery holder and the cable connections.

Switching on the truck

– Check that the battery plug (2) is plugged in.– Insert the key in the key switch (5) and turn it all the way to the right to position “I”

or enter the CANCODE (o) release code(see section 5).

– Press the warning signal pushbutton (12) to test its function.

The truck is now ready for operation.

o The battery discharge indicator (3) indicates the remaining battery capacity.

– Check the braking function of the control shaft (1) (see Section 4.2).

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4 Operation of the fork lift truck

4.1 Safety regulations applicable when operating the truck

Driving lanes and work areas: Only such lanes and routes that are specially allo-cated for truck traffic must be used. Unauthorized persons must stay away from workareas. Loads must only be stored at places specially provided for this purpose.

Driving conduct: The travelling speed must be adapted to the prevailing local con-ditions. The truck must be driven at slow speed when negotiating bends or narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways observe an adequate braking distance between the fork lift truck and the vehiclein front and he must be in control of his truck at all times. Sudden stopping (except inemergencies), rapid U-turns and overtaking at dangerous or blind spots is not permit-ted. It is forbidden to lean out of or reach beyond the working and operating area.

Visibility: The driver must look in the direction of travel and must always have a clearview of the route ahead. When loads blocking the view are carried, the fork lift truckmust be driven with the load at the rear. If this is not possible, a second person mustwalk in front of the fork lift truck to give suitable warnings.

Negotiating slopes and inclines: Negotiating of slopes and inclines is permittedonly when they are recognised lanes, when they are clean and non-slipping, andwhen the technical specification of the truck permits safe driving on such slopes orinclines. Loads must always be carried at that end of the truck facing uphill. U-turns,cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes orinclines is not permitted. Inclines must only be negotiated at slow speed, with the driv-er ready to brake at any moment.

Use of lifts and driving on loading platforms: Lifts and loading platforms must onlybe used if they are of adequate load bearing capacity, if suitable for driving on, and ifauthorised by the user of the truck for truck traffic. The fork lift truck driver has to sat-isfy himself accordingly before driving into lifts or on to loading platforms. The truckmust enter lifts with the load in front and must take up a position which does not allowit to come into contact with the walls of the lift shaft.Persons riding in the lift together with the fork lift truck must only enter the lift after thefork lift truck has come safely to a standstill, and must leave the lift before the fork lifttruck.

Nature of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Only carry loads that are positioned safely and carefully. Usesuitable precautions, e.g. a load guard, to prevent parts of the load from tipping orfalling down.

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4 Operation of the fork lift truck

4.1 Safety regulations applicable when operating the truck

Driving lanes and work areas: Only such lanes and routes that are specially allo-cated for truck traffic must be used. Unauthorized persons must stay away from workareas. Loads must only be stored at places specially provided for this purpose.

Driving conduct: The travelling speed must be adapted to the prevailing local con-ditions. The truck must be driven at slow speed when negotiating bends or narrowpassages, when passing through swing doors and at blind spots. The driver must al-ways observe an adequate braking distance between the fork lift truck and the vehiclein front and he must be in control of his truck at all times. Sudden stopping (except inemergencies), rapid U-turns and overtaking at dangerous or blind spots is not permit-ted. It is forbidden to lean out of or reach beyond the working and operating area.

Visibility: The driver must look in the direction of travel and must always have a clearview of the route ahead. When loads blocking the view are carried, the fork lift truckmust be driven with the load at the rear. If this is not possible, a second person mustwalk in front of the fork lift truck to give suitable warnings.

Negotiating slopes and inclines: Negotiating of slopes and inclines is permittedonly when they are recognised lanes, when they are clean and non-slipping, andwhen the technical specification of the truck permits safe driving on such slopes orinclines. Loads must always be carried at that end of the truck facing uphill. U-turns,cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes orinclines is not permitted. Inclines must only be negotiated at slow speed, with the driv-er ready to brake at any moment.

Use of lifts and driving on loading platforms: Lifts and loading platforms must onlybe used if they are of adequate load bearing capacity, if suitable for driving on, and ifauthorised by the user of the truck for truck traffic. The fork lift truck driver has to sat-isfy himself accordingly before driving into lifts or on to loading platforms. The truckmust enter lifts with the load in front and must take up a position which does not allowit to come into contact with the walls of the lift shaft.Persons riding in the lift together with the fork lift truck must only enter the lift after thefork lift truck has come safely to a standstill, and must leave the lift before the fork lifttruck.

Nature of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Only carry loads that are positioned safely and carefully. Usesuitable precautions, e.g. a load guard, to prevent parts of the load from tipping orfalling down.

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4.2 Driving, steering, braking

F It is not admissible to stay on the vehicle during driving.

Emergency stop

– Pull out the battery plug (6).

All electrical functions are switched off.

Forced braking

When the control shaft is released, forced braking occurs - the control shaft automat-ically moves into the upper braking area (B).

F If the control shaft moves slowly into the braking position, the cause must be eliminat-ed. If necessary, the gas pressure spring is to be replaced.

Driving

M Travelling with raised forks / raised load beyond 500 mm above the ground isprohibited.

M Drive only with closed and properly locked hoods.

– Start the truck up (see Section 3).

The travelling speed is controlled with the controller (8).

– Lower the control shaft (1) into the travel direction (F) and set the drive controller(8) to the desired direction (V or R, forward or backward).

Inching

F The driver must be particularly careful when using the “Inching” pushbutton (7).

The truck can be shunted with the control shaft (1) in the vertical position (e.g. in con-fined spaces / elevators):

– Press the “Inching” pushbutton (7).– Set the travel direction switch (8) to the desired direction (V or R, forward or back-

ward).

Parking brake is released. The truck starts moving slowly.

M The brake is applied when the “Inching” pushbutton is released only; at inchingspeed, braking is possible with the counter-current brake only (travel direction switch(8)).

F To brake the truck in an emergency, release the “Inching” pushbutton (7) immediate-ly.

Pressing the “Inching speed” push button in the drive section (F) causes the truck totravel at reduced speed and acceleration.

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4.2 Driving, steering, braking

F It is not admissible to stay on the vehicle during driving.

Emergency stop

– Pull out the battery plug (6).

All electrical functions are switched off.

Forced braking

When the control shaft is released, forced braking occurs - the control shaft automat-ically moves into the upper braking area (B).

F If the control shaft moves slowly into the braking position, the cause must be eliminat-ed. If necessary, the gas pressure spring is to be replaced.

Driving

M Travelling with raised forks / raised load beyond 500 mm above the ground isprohibited.

M Drive only with closed and properly locked hoods.

– Start the truck up (see Section 3).

The travelling speed is controlled with the controller (8).

– Lower the control shaft (1) into the travel direction (F) and set the drive controller(8) to the desired direction (V or R, forward or backward).

Inching

F The driver must be particularly careful when using the “Inching” pushbutton (7).

The truck can be shunted with the control shaft (1) in the vertical position (e.g. in con-fined spaces / elevators):

– Press the “Inching” pushbutton (7).– Set the travel direction switch (8) to the desired direction (V or R, forward or back-

ward).

Parking brake is released. The truck starts moving slowly.

M The brake is applied when the “Inching” pushbutton is released only; at inchingspeed, braking is possible with the counter-current brake only (travel direction switch(8)).

F To brake the truck in an emergency, release the “Inching” pushbutton (7) immediate-ly.

Pressing the “Inching speed” push button in the drive section (F) causes the truck totravel at reduced speed and acceleration.

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Steering

– Swing the control shaft (1) to the left or right.

12

34

5 67 8 9

0Set

0

R

RV

B

F

B

V

8

1

7

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Steering

– Swing the control shaft (1) to the left or right.

12

34

5 67 8 9

0Set

0

R

RV

B

F

B

V

8

1

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Braking

F The braking behaviour of the truck strongly depends on the road surface conditions.The driver must take this into account in his driving behaviour.

Braking with the service brake:

– Raise or lower the control shaft (1) to one of thebrake positions (B).

M The service brake is the regenerative brake. Themechanical brake is applied only if this brake doesnot reach the required deceleration.

Braking using the countercurrent brake:

– While driving, the controller (8) can be used toswitch to the opposite direction.

– The truck is braked by the countercurrent until driving in the opposite directiontakes affect.

Braking with the coasting brake

The truck is braked with the regenerative brake when the drive controller is in the 0-position.

F Bring the control shaft into the braking position in an emergency.

Driving at inclines

M Transport the load pointing uphill!

Securing the truck against “rolling down”:

The brake is automatically applied with a short jolt when the drive direction switch isset to “0” (the controller detects the truck rolling down). With the drive controller yourelease the service brake and control the speed and the travel direction as desired.

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Braking

F The braking behaviour of the truck strongly depends on the road surface conditions.The driver must take this into account in his driving behaviour.

Braking with the service brake:

– Raise or lower the control shaft (1) to one of thebrake positions (B).

M The service brake is the regenerative brake. Themechanical brake is applied only if this brake doesnot reach the required deceleration.

Braking using the countercurrent brake:

– While driving, the controller (8) can be used toswitch to the opposite direction.

– The truck is braked by the countercurrent until driving in the opposite directiontakes affect.

Braking with the coasting brake

The truck is braked with the regenerative brake when the drive controller is in the 0-position.

F Bring the control shaft into the braking position in an emergency.

Driving at inclines

M Transport the load pointing uphill!

Securing the truck against “rolling down”:

The brake is automatically applied with a short jolt when the drive direction switch isset to “0” (the controller detects the truck rolling down). With the drive controller yourelease the service brake and control the speed and the travel direction as desired.

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4.3 Picking up and setting down loads

m Before a load can be picked up, the driver must make sure that it is properly palettedand does not exceed the permitted load capacity of the truck.Loading long goods transversely is not permitted.

– Drive the truck’s fork tines completely under the load.

Z The lifting and lowering speeds are preset.

Lifting

– Press the “Lift load lifting device” pushbutton (10) (for left-handed operation o (13))until the desired height is reached.

m Release the button immediately when the end stop of the load lifting device isreached.

Lowering

– Press the “Lower load lifting device” pushbutton (11) (for left-handed operation o(14)).

4.4 Rendering the vehicle safe when parking

F Always render the truck safe when parking it.Do not park the truck on an incline.The load lifting device must always be entirely lowered.

– Lower the load lifting device.– Set key switch (5) to position “0” and remove the key or press CANCODE “Off”.

12

3

4 5 6

7 8

0

9

Set

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4.3 Picking up and setting down loads

m Before a load can be picked up, the driver must make sure that it is properly palettedand does not exceed the permitted load capacity of the truck.Loading long goods transversely is not permitted.

– Drive the truck’s fork tines completely under the load.

Z The lifting and lowering speeds are preset.

Lifting

– Press the “Lift load lifting device” pushbutton (10) (for left-handed operation o (13))until the desired height is reached.

m Release the button immediately when the end stop of the load lifting device isreached.

Lowering

– Press the “Lower load lifting device” pushbutton (11) (for left-handed operation o(14)).

4.4 Rendering the vehicle safe when parking

F Always render the truck safe when parking it.Do not park the truck on an incline.The load lifting device must always be entirely lowered.

– Lower the load lifting device.– Set key switch (5) to position “0” and remove the key or press CANCODE “Off”.

12

3

4 5 6

7 8

0

9

Set

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5 Keyboard (CANCODE) (o)

The operator keyboard is composed of 10 nume-ric keys, a Set key and an o-key.Activation of the travel programs by means ofswitches 1,2,3 is indicated by green LEDs.The o-key indicates operating conditions by ared/green LED.

It has the following functions:

– Code lock function (setting the truck into oper-ation).

– Selecting the travel program.– Setting the travel and battery parameters, only

in conjunction with the indicator instrument(CANDIS (o)).

The o-key has top priority and reset the truckfrom any condition to the basic condition without modifying any settings.

5.1 Code lock

After entering the correct code, the truck is ready for operation. It is possible to assignan individual code to every truck, operator or even operator group.

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

M Change the master and operator codes when setting the truck into operation for thefirst time! (refer to section 5.4).

1 2 3

4 5 6

7 8 9

0Set

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5 Keyboard (CANCODE) (o)

The operator keyboard is composed of 10 nume-ric keys, a Set key and an o-key.Activation of the travel programs by means ofswitches 1,2,3 is indicated by green LEDs.The o-key indicates operating conditions by ared/green LED.

It has the following functions:

– Code lock function (setting the truck into oper-ation).

– Selecting the travel program.– Setting the travel and battery parameters, only

in conjunction with the indicator instrument(CANDIS (o)).

The o-key has top priority and reset the truckfrom any condition to the basic condition without modifying any settings.

5.1 Code lock

After entering the correct code, the truck is ready for operation. It is possible to assignan individual code to every truck, operator or even operator group.

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

M Change the master and operator codes when setting the truck into operation for thefirst time! (refer to section 5.4).

1 2 3

4 5 6

7 8 9

0Set

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The LED (15) lights up red after the battery plug has been plugged in and, if applica-ble, the key switch has been switched on.

After entering the correct operator code (factory setting 2-5-8-0) the LED (15) lightsup red.

When an incorrect code has been entered, LED (15) lights up red for two seconds.After that you can enter a new code.

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

Switching off

The truck is switched off by actuating theo -key (20).

Z The truck can be switched off automaticallyafter a preset time. For that purpose the cor-responding code lock parameter must be set(refer to section 5.4).

1 2 3

4 5 6

7 8 9

0Set

17

16

15

20

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Commissioning

The LED (15) lights up red after the battery plug has been plugged in and, if applica-ble, the key switch has been switched on.

After entering the correct operator code (factory setting 2-5-8-0) the LED (15) lightsup red.

When an incorrect code has been entered, LED (15) lights up red for two seconds.After that you can enter a new code.

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

Switching off

The truck is switched off by actuating theo -key (20).

Z The truck can be switched off automaticallyafter a preset time. For that purpose the cor-responding code lock parameter must be set(refer to section 5.4).

1 2 3

4 5 6

7 8 9

0Set

17

16

15

20

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5.2 Travel programmes

By actuating the numeric keys 1, 2, and 3 you can select three travel programmes.The activated programme is indicated by the green LEDs (17), (18), (19) in the cor-responding key.

Z The travel programmes differ with respect to travelling speed, acceleration, and de-celeration.

Factory settings:

– Programme 1: Soft running– Programme 2: Normal operation– Programme 3: Power operation (preset for commissioning)

Z The travel programs can be adapted individually to the truck (refer to section 5.5).

5.3 Parameters

In programming mode, the operator keyboard allows the setting of the code lock func-tions and the adaption of the travel programmes. Additionally, the battery parameterscan be set.

Z For trucks without indicator instrument (CANDIS (o)) only the code lock parameterscan be set.

Parameter groups

The parameter number is composed of three digits. The first digit designated the pa-rameter group according to table 1. The second and third digits are sequentially num-bered from 00 to 99.

No. Parameter group0xx Code lock settings

(Codes, travel programme enable, automatic switch-off, etc.)1xx Travel programme 1 parameters

(Acceleration, coasting brake, speed, etc.)2xx Travel programme 2 parameters

(Acceleration, coasting brake, speed, etc.)3xx Travel programme 3 parameters

(Acceleration, coasting brake, speed, etc.)4xx Programme-independent parameters

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5.2 Travel programmes

By actuating the numeric keys 1, 2, and 3 you can select three travel programmes.The activated programme is indicated by the green LEDs (17), (18), (19) in the cor-responding key.

Z The travel programmes differ with respect to travelling speed, acceleration, and de-celeration.

Factory settings:

– Programme 1: Soft running– Programme 2: Normal operation– Programme 3: Power operation (preset for commissioning)

Z The travel programs can be adapted individually to the truck (refer to section 5.5).

5.3 Parameters

In programming mode, the operator keyboard allows the setting of the code lock func-tions and the adaption of the travel programmes. Additionally, the battery parameterscan be set.

Z For trucks without indicator instrument (CANDIS (o)) only the code lock parameterscan be set.

Parameter groups

The parameter number is composed of three digits. The first digit designated the pa-rameter group according to table 1. The second and third digits are sequentially num-bered from 00 to 99.

No. Parameter group0xx Code lock settings

(Codes, travel programme enable, automatic switch-off, etc.)1xx Travel programme 1 parameters

(Acceleration, coasting brake, speed, etc.)2xx Travel programme 2 parameters

(Acceleration, coasting brake, speed, etc.)3xx Travel programme 3 parameters

(Acceleration, coasting brake, speed, etc.)4xx Programme-independent parameters

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5.4 Parameter settings

To change the truck settings the master code must be entered.

Z The master code is factory-set to 7-2-9-5.

M Change the master code when setting the truck into operation for the first time (referto section 5.1).

F Safety notes for trucks with indicator instrument (CANDIS (o))

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

– Every setting procedure must be monitored on the LC display of the indicatorinstrument (CANDIS (o)). If in doubt, the setting procedure must be cancelled bypressing the o-key (20).

– Since the truck's travel behaviour is changed, you must perform a trial in a speciallyassigned and suitable working area run after changing any of the parameters.

Entering the master code:

– Press the o-key– Enter master code

Code lock parameters

Setting procedure for trucks without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (16).– Enter or change the setting value according to the parameter list and confirm with

Set key (16).

Z When the input is incorrect, the LED (15) of the o-key (20) lights up red. Afterentering the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (20).

Display instrument (CANDIS)

LED (15)o-key

LED (17)Key 1

LED (18)Key 2

LED (19)Key 3

Operating hoursare indicated 284.0 green

flashingoff off off

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5.4 Parameter settings

To change the truck settings the master code must be entered.

Z The master code is factory-set to 7-2-9-5.

M Change the master code when setting the truck into operation for the first time (referto section 5.1).

F Safety notes for trucks with indicator instrument (CANDIS (o))

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

– Every setting procedure must be monitored on the LC display of the indicatorinstrument (CANDIS (o)). If in doubt, the setting procedure must be cancelled bypressing the o-key (20).

– Since the truck's travel behaviour is changed, you must perform a trial in a speciallyassigned and suitable working area run after changing any of the parameters.

Entering the master code:

– Press the o-key– Enter master code

Code lock parameters

Setting procedure for trucks without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (16).– Enter or change the setting value according to the parameter list and confirm with

Set key (16).

Z When the input is incorrect, the LED (15) of the o-key (20) lights up red. Afterentering the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (20).

Display instrument (CANDIS)

LED (15)o-key

LED (17)Key 1

LED (18)Key 2

LED (19)Key 3

Operating hoursare indicated 284.0 green

flashingoff off off

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Setting procedure for trucks with and without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (16).– The indicator instrument (CANDIS (o)) continues to display the operating hours. If

the display changes, cancel the setting procedure with the o-key (20) and restartfrom the beginning.

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

Z When the input is incorrect, the LED (15) of the o-key (20) lights up red. After enter-ing the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (20).

The following parameters can be entered:

Code lock parameter list

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Code lock000 Change master code

The length of the master code (4 to 6 digits) also determines the length (4 to 6 digits) of the operator code. As long as operator codes have been programmed, only new codes with the same length can be entered. If the code length is to be changed, all operator codes must be deleted first.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 17 flashes)Enter the current

code

confirm (Set)

(LED 18 flashes)Enter a 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)Enter a code

confirm (Set)

(LED 19 flashes)Repeat the code en-

try

Confim (Set)

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Setting procedure for trucks with and without indicator instrument (CANDIS (o)):

– Enter the three-digit parameter number and confirm with Set key (16).– The indicator instrument (CANDIS (o)) continues to display the operating hours. If

the display changes, cancel the setting procedure with the o-key (20) and restartfrom the beginning.

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

Z When the input is incorrect, the LED (15) of the o-key (20) lights up red. After enter-ing the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters. To terminate the input, press theo-key (20).

The following parameters can be entered:

Code lock parameter list

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Code lock000 Change master code

The length of the master code (4 to 6 digits) also determines the length (4 to 6 digits) of the operator code. As long as operator codes have been programmed, only new codes with the same length can be entered. If the code length is to be changed, all operator codes must be deleted first.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 17 flashes)Enter the current

code

confirm (Set)

(LED 18 flashes)Enter a 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)Enter a code

confirm (Set)

(LED 19 flashes)Repeat the code en-

try

Confim (Set)

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LED 17-19 are located in the key pad fields 1-3 (refer to section 5.2).

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Code lock002 Change operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 17 flashes)Enter the current

code

Confirm (Set)

(LED 18 flashes)Enter a new code

Confirm (Set)

(LED 19 flashes)Repeat the code en-

try

Confirm003 Delete operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 18 flashes)Enter a code

Confirm (Set)

(LED 19 flashes)Repeat the code en-

try

Confirm (Set)004 Clear code memory

(deletes all operator codes)

3265 3265 = delete

other entry = do not delete

010 automatic switch-off 00 - 31 00 00 = noneSwitch-off

01 to 30 =Switch-off time in

minutes

31 = switch-off after 10 seconds

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LED 17-19 are located in the key pad fields 1-3 (refer to section 5.2).

No. Function RangeSetting value

DefaultSetting value

CommentsWork flow

Code lock002 Change operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 17 flashes)Enter the current

code

Confirm (Set)

(LED 18 flashes)Enter a new code

Confirm (Set)

(LED 19 flashes)Repeat the code en-

try

Confirm003 Delete operator code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 18 flashes)Enter a code

Confirm (Set)

(LED 19 flashes)Repeat the code en-

try

Confirm (Set)004 Clear code memory

(deletes all operator codes)

3265 3265 = delete

other entry = do not delete

010 automatic switch-off 00 - 31 00 00 = noneSwitch-off

01 to 30 =Switch-off time in

minutes

31 = switch-off after 10 seconds

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*) only in conjunction with indicator instrument (CANDIS (o))

Keyboard error messages

The following errors are indicated by a red flashing LED (15):

– 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 an existing code.– Operator code to be deleted does not exist.– Code memory full.

No. Function RangeSetting value

DefaultSetting val-

ue

CommentsWork flow

Code lock021 Travel programme 1*)

Enable0 or 1 1 0 = Travel pro-

gramme not ena-bled

1 = Travel pro-gramme enabled

022 Travel programme 2*)

Enable0 or 1 1 0 = Travel pro-

gramme not ena-bled

1 = Travel pro-gramme enabled

023 Travel programme 3*)

Enable0 or 1 1 0 = Travel pro-

gramme not ena-bled

1 = Travel pro-gramme enabled

030 Display of the number of used operator codes*)

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*) only in conjunction with indicator instrument (CANDIS (o))

Keyboard error messages

The following errors are indicated by a red flashing LED (15):

– 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 an existing code.– Operator code to be deleted does not exist.– Code memory full.

No. Function RangeSetting value

DefaultSetting val-

ue

CommentsWork flow

Code lock021 Travel programme 1*)

Enable0 or 1 1 0 = Travel pro-

gramme not ena-bled

1 = Travel pro-gramme enabled

022 Travel programme 2*)

Enable0 or 1 1 0 = Travel pro-

gramme not ena-bled

1 = Travel pro-gramme enabled

023 Travel programme 3*)

Enable0 or 1 1 0 = Travel pro-

gramme not ena-bled

1 = Travel pro-gramme enabled

030 Display of the number of used operator codes*)

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5.5 Travel parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

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

Acceleration example

– Enter the three-digit parameter number (101) and confirm with the Set key (16).– Check the LC display of the indicator instrument (CANDIS (o)) (parameter number

and current parameter value are displayed).

Z If there is no input for approx. 5 seconds, the display switches back to operating hoursindication.

F If another parameter number than the one displayed is desired, you must wait untilthe operating hours are displayed again.

– Enter or change the parameter value according to the parameter list.– Check the LC display of the indicator instrument (CANDIS (o))(confirm with the Set

key (16)).– The LED (15) of the o-key (20) switches briefly to steady light and start flashing

again after approx. 2 seconds.

Z When the input is incorrect, the LED (15) of the o-key (20) lights up red. After enter-ing the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters as soon as the LED (15) of the o-key (20) flashes. To terminate the input, press the o-key (20).

Z During the parameter input the travel function is switched off. If the setting value is tobe checked in travel operation, follow this sequence:

– Select the modified travel programme after entering the parameter value, confirmwith the Set key (16).

– The truck is now in travel operation and can be checked.– To continue the setting operation, confirm with the Set key (16) again.

Display instrument (CANDIS)

LED (15)o-key

LED (17)Key 1

LED (18)Key 2

LED (19)Key 3

current setting is displayed 101 6

greenflashing

off off off

changed setting is displayed 101 8

greenflashing

off off off

Parameter number

Parame-ter setting

value

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5.5 Travel parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

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

Acceleration example

– Enter the three-digit parameter number (101) and confirm with the Set key (16).– Check the LC display of the indicator instrument (CANDIS (o)) (parameter number

and current parameter value are displayed).

Z If there is no input for approx. 5 seconds, the display switches back to operating hoursindication.

F If another parameter number than the one displayed is desired, you must wait untilthe operating hours are displayed again.

– Enter or change the parameter value according to the parameter list.– Check the LC display of the indicator instrument (CANDIS (o))(confirm with the Set

key (16)).– The LED (15) of the o-key (20) switches briefly to steady light and start flashing

again after approx. 2 seconds.

Z When the input is incorrect, the LED (15) of the o-key (20) lights up red. After enter-ing the parameter number again, the setting value can be entered or changed.

Repeat the procedure to enter further parameters as soon as the LED (15) of the o-key (20) flashes. To terminate the input, press the o-key (20).

Z During the parameter input the travel function is switched off. If the setting value is tobe checked in travel operation, follow this sequence:

– Select the modified travel programme after entering the parameter value, confirmwith the Set key (16).

– The truck is now in travel operation and can be checked.– To continue the setting operation, confirm with the Set key (16) again.

Display instrument (CANDIS)

LED (15)o-key

LED (17)Key 1

LED (18)Key 2

LED (19)Key 3

current setting is displayed 101 6

greenflashing

off off off

changed setting is displayed 101 8

greenflashing

off off off

Parameter number

Parame-ter setting

value

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The following parameters can be entered:

Travel programmes

No. Function RangeSetting value

StandardSetting val-

ue

Comments

Travel Programme 1101 Acceleration 0 - 9

(0,2 - 2,0 m/s2)3

(0,8 m/s2)102 Coasting brake 0 - 9

(0,2 - 1,1 m/s2) 3

(0,5 m/s2)104 Maximum speed in drive

direction via controller0 - 9

(2,8 - 6,2 km/h)3

(4,8 km/h)depending on

controller108 Maximum speed in fork di-

rection via controller0 - 9

(2,8 - 6,2 km/h)3

(4,8 km/h)depending on

controller

No. Function RangeSetting value

StandardSetting val-

ue

Comments

Travel Programme 2201 Acceleration 0 - 9

(0,2 - 2,0 m/s)6

(1,4 m/s)202 Coasting brake 0 - 9

(0,2 - 2,0 m/s)6

(0,8 m/s)204 Maximum speed in drive

direction via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller208 Maximum speed in fork

direction via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller

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The following parameters can be entered:

Travel programmes

No. Function RangeSetting value

StandardSetting val-

ue

Comments

Travel Programme 1101 Acceleration 0 - 9

(0,2 - 2,0 m/s2)3

(0,8 m/s2)102 Coasting brake 0 - 9

(0,2 - 1,1 m/s2) 3

(0,5 m/s2)104 Maximum speed in drive

direction via controller0 - 9

(2,8 - 6,2 km/h)3

(4,8 km/h)depending on

controller108 Maximum speed in fork di-

rection via controller0 - 9

(2,8 - 6,2 km/h)3

(4,8 km/h)depending on

controller

No. Function RangeSetting value

StandardSetting val-

ue

Comments

Travel Programme 2201 Acceleration 0 - 9

(0,2 - 2,0 m/s)6

(1,4 m/s)202 Coasting brake 0 - 9

(0,2 - 2,0 m/s)6

(0,8 m/s)204 Maximum speed in drive

direction via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller208 Maximum speed in fork

direction via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller

E 19

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Battery parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

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

The following parameters can be entered:

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

No. Function RangeSetting value

StandardSetting val-

ue

Comments

Travel Programme 3301 Acceleration 0 - 9

(0,2 - 2,0 m/s2)9

(2,0 m/s2)302 Coasting brake 0 - 9

(0,2 - 2,0 m/s2)9

(1,1 m/s2)304 Maximum speed in drive

direction via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller308 Maximum speed in fork di-

rection via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller

No. Function RangeSetting value

StandardSetting value

Comments

Battery parameters411 Battery type

(normal/high-power/dry)0 - 2 0 0 = Normal (wet)

1 = High-power (wet)

2 = Dry(maintenance-free)

412 Discharge monitorfunction

0 / 1 1

E 19

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Battery parameters

Z For trucks without indicator instrument (CANDIS (o)) the code lock parameters canonly be set by the manufacturer's service.

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

The following parameters can be entered:

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

No. Function RangeSetting value

StandardSetting val-

ue

Comments

Travel Programme 3301 Acceleration 0 - 9

(0,2 - 2,0 m/s2)9

(2,0 m/s2)302 Coasting brake 0 - 9

(0,2 - 2,0 m/s2)9

(1,1 m/s2)304 Maximum speed in drive

direction via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller308 Maximum speed in fork di-

rection via controller0 - 9

(2,8 - 6,2 km/h)8

(6,0 km/h)depending on

controller

No. Function RangeSetting value

StandardSetting value

Comments

Battery parameters411 Battery type

(normal/high-power/dry)0 - 2 0 0 = Normal (wet)

1 = High-power (wet)

2 = Dry(maintenance-free)

412 Discharge monitorfunction

0 / 1 1

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6 Display instrument (CANDIS) (o)

The instrument indicates:

– Remaining battery charge(LED bars (22))

– Operating hours (LC display (24)).

In addition, service messages from the elec-tronic components and parameter changesare indicated.

Discharge status indication

Depending on the battery type set, switch-on limits for the additional “Warning” (21)and “Stop” (23) indicators may result.

NumberBars

Charging condition

Wet battery Maintenance-free batteryLED (yellow)

WarningLED (red)

StopLED (yellow)

WarningLED (red)

Stop10 90.1- 100% Off Off Off Off9 80.1 - 90% Off Off Off Off8 70.1 - 80% Off Off Off Off7 60.1 - 70% Off Off Off Off6 50.1 - 60% Off Off Off Off5 40.1 - 50% Off Off On Off4 30.1 - 40% Off Off On On3 20.1 - 30% On Off On On2 10.1 - 20% On On On On

Avoid falling below the 20% limit for wet batteries resp. 40% limitfor maintenance-free batteries.

21

22

23

24

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6 Display instrument (CANDIS) (o)

The instrument indicates:

– Remaining battery charge(LED bars (22))

– Operating hours (LC display (24)).

In addition, service messages from the elec-tronic components and parameter changesare indicated.

Discharge status indication

Depending on the battery type set, switch-on limits for the additional “Warning” (21)and “Stop” (23) indicators may result.

NumberBars

Charging condition

Wet battery Maintenance-free batteryLED (yellow)

WarningLED (red)

StopLED (yellow)

WarningLED (red)

Stop10 90.1- 100% Off Off Off Off9 80.1 - 90% Off Off Off Off8 70.1 - 80% Off Off Off Off7 60.1 - 70% Off Off Off Off6 50.1 - 60% Off Off Off Off5 40.1 - 50% Off Off On Off4 30.1 - 40% Off Off On On3 20.1 - 30% On Off On On2 10.1 - 20% On On On On

Avoid falling below the 20% limit for wet batteries resp. 40% limitfor maintenance-free batteries.

21

22

23

24

E 21

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6.1 Discharge monitor function

With the discharge monitor function enabled, the lifting function switches of whenreaching the discharge limit (the Stop LED switches on). Travelling and lowering isstill possible. For wet batteries the residual capacity is 20%, for maintenance-free bat-teries it is 40%. At 30% for wet batteries resp. 50% for maintenance-free batteries thebatteries should be recharged (the yellow LED lights up as warning indication).

6.2 Operating hours display

Display range between 0.0 and 99,999.0 hours. Travel and lifting movements arelogged. 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 is displayedin two parts and starts with a “C” for component and a three-digit component number,then an “E” for error with alternating three-digit error number.If several errors occur they are displayed one after the other. The errors are displayedas long as they are present (always in combination Cxxx / Exxx). Errors are displayedas long as they persist. The operating hours display is overwritten with an error mes-sage. Most errors cause the emergency stop to be triggered. The error display ismaintained until the control circuit is switched off (Code lock).

When CANDIS is not available, the error code is signaled by the flashing dischargeindicator LED.

Z Detailed component descriptions including error codes are available at the manufac-turers service.

Display for parameter changes (travel programmes)

The LC display (24) is used in conjunction with the operator keyboard (CANCODE(o)) to display the setting parameters. The first three digits of the display show theparameter numbers, the last three digits indicate the parameter value.

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

6.3 Switch-on test

After switching on the display shows:

– the software version of the display instrument (short-term), – the operating hours– the charging condition

E 21

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6.1 Discharge monitor function

With the discharge monitor function enabled, the lifting function switches of whenreaching the discharge limit (the Stop LED switches on). Travelling and lowering isstill possible. For wet batteries the residual capacity is 20%, for maintenance-free bat-teries it is 40%. At 30% for wet batteries resp. 50% for maintenance-free batteries thebatteries should be recharged (the yellow LED lights up as warning indication).

6.2 Operating hours display

Display range between 0.0 and 99,999.0 hours. Travel and lifting movements arelogged. 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 is displayedin two parts and starts with a “C” for component and a three-digit component number,then an “E” for error with alternating three-digit error number.If several errors occur they are displayed one after the other. The errors are displayedas long as they are present (always in combination Cxxx / Exxx). Errors are displayedas long as they persist. The operating hours display is overwritten with an error mes-sage. Most errors cause the emergency stop to be triggered. The error display ismaintained until the control circuit is switched off (Code lock).

When CANDIS is not available, the error code is signaled by the flashing dischargeindicator LED.

Z Detailed component descriptions including error codes are available at the manufac-turers service.

Display for parameter changes (travel programmes)

The LC display (24) is used in conjunction with the operator keyboard (CANCODE(o)) to display the setting parameters. The first three digits of the display show theparameter numbers, the last three digits indicate the parameter value.

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

6.3 Switch-on test

After switching on the display shows:

– the software version of the display instrument (short-term), – the operating hours– the charging condition

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6.4 Fault location

Z If the fault could not be eliminated after performing the “Remedial actions” contact thecustomer service of the manufacturer since all follow-up troubleshooting can only beperformed by specially trained and qualified service staff.

Fault Possible cause Remedial actionTruck does not move

– Battery connector not con-nected.

– Key switch in position “0”.– Incorrect CANCODE code– Battery exhausted.

– Fuse defective.– Truck is being charged

– Check the battery connector andconnect if necessary.Set the key switch to position “I”

– Verify code– Check the charging condition of the

battery and recharge if necessary– Check fuses F1 and 1F1– Interrupt charging process

Load cannot be lifted

– Battery capacity below 20 / 40%

– Truck not operative.

– Hydraulic oil level too low.– Fuse defective.

– Charging the battery

– Perform all remedial actions listedunder the fault “Truck does notmove”.

– Check the hydraulic oil level– Check fuse 2F1

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6.4 Fault location

Z If the fault could not be eliminated after performing the “Remedial actions” contact thecustomer service of the manufacturer since all follow-up troubleshooting can only beperformed by specially trained and qualified service staff.

Fault Possible cause Remedial actionTruck does not move

– Battery connector not con-nected.

– Key switch in position “0”.– Incorrect CANCODE code– Battery exhausted.

– Fuse defective.– Truck is being charged

– Check the battery connector andconnect if necessary.Set the key switch to position “I”

– Verify code– Check the charging condition of the

battery and recharge if necessary– Check fuses F1 and 1F1– Interrupt charging process

Load cannot be lifted

– Battery capacity below 20 / 40%

– Truck not operative.

– Hydraulic oil level too low.– Fuse defective.

– Charging the battery

– Perform all remedial actions listedunder the fault “Truck does notmove”.

– Check the hydraulic oil level– Check fuse 2F1

F 1

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F Maintenance of the fork lift truck1 Operational safety and environmental protection

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

F Modifications of fork lift truck assemblies, especially of the safety installations, are notpermitted. On no account must the operational speeds of the truck be changed.

M Only original spare parts have been certified by our quality assurance service. To en-sure safe and reliable operation of the fork lift truck, only spare parts of the manufac-turer must be used. Used parts, oils and fuels must be disposed of in accordance withthe applicable environmental protection regulations. For oil changes, the oil serviceof the manufacturer is available to you.

Upon completion of any checking and servicing activities, the operations contained inthe section “Recommissioning” must be performed (refer to chapter F).

2 Safety regulations applicable to truck maintenance

Servicing and maintenance personnel: The fork lift truck must only be serviced andmaintained by trained personnel of the manufacturer. The service organization of themanufacturer has external technicians trained especially for these assignments. Wethus recommend signing a maintenance contract with the relevant service location ofthe manufacturer.

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

Cleaning operations: No inflammable liquids must be used when cleaning the forklift truck. Prior to commencing cleaning operations, all safety measures that are re-quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-oper-ated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com-pressed air and non-conducting, antistatic brushes must be used for the cleaning ofelectric or electronic assemblies.

M If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, allelectric and electronic components must be carefully covered beforehand becausemoisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.

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

F 1

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F Maintenance of the fork lift truck1 Operational safety and environmental protection

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

F Modifications of fork lift truck assemblies, especially of the safety installations, are notpermitted. On no account must the operational speeds of the truck be changed.

M Only original spare parts have been certified by our quality assurance service. To en-sure safe and reliable operation of the fork lift truck, only spare parts of the manufac-turer must be used. Used parts, oils and fuels must be disposed of in accordance withthe applicable environmental protection regulations. For oil changes, the oil serviceof the manufacturer is available to you.

Upon completion of any checking and servicing activities, the operations contained inthe section “Recommissioning” must be performed (refer to chapter F).

2 Safety regulations applicable to truck maintenance

Servicing and maintenance personnel: The fork lift truck must only be serviced andmaintained by trained personnel of the manufacturer. The service organization of themanufacturer has external technicians trained especially for these assignments. Wethus recommend signing a maintenance contract with the relevant service location ofthe manufacturer.

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

Cleaning operations: No inflammable liquids must be used when cleaning the forklift truck. Prior to commencing cleaning operations, all safety measures that are re-quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-oper-ated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com-pressed air and non-conducting, antistatic brushes must be used for the cleaning ofelectric or electronic assemblies.

M If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, allelectric and electronic components must be carefully covered beforehand becausemoisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.

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

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F 2

Work on the electric system: Work on the electric system of the truck must only beperformed by personnel specially trained for such operations. Before commencingany work on the electric system, all measures required to prevent electric shockshave to be taken. For battery-operated fork lift trucks, the truck must also be depow-ered by removing the battery plug.

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

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, all truck-specific settings have to be retained.

Tyres: The quality of the tyres greatly affects the stability and the driving behaviourof the fork-lift truck. The factory-mounted tyres must only be replaced by originalspare parts of the manufacturer, since otherwise the specification of the data sheetcannot be met. When replacing wheels or tyres, it must be ensured that the fork-lifttruck remains level (tyres and wheels must always be replaced in pairs, i.e. left andright together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the servicechecklist apply to normal duty. If requirements are higher (dust, temperature), lubri-cation is required more often. The specified chain spray must be used as specified.The external application of grease does not provide sufficient lubrication.

Hydraulic hoses: The hoses must be renewed every six years. When replacing hy-draulic components, also renew the hoses in this hydraulic system.

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F 2

Work on the electric system: Work on the electric system of the truck must only beperformed by personnel specially trained for such operations. Before commencingany work on the electric system, all measures required to prevent electric shockshave to be taken. For battery-operated fork lift trucks, the truck must also be depow-ered by removing the battery plug.

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

Settings: When repairing or replacing hydraulic, electric or electronic components orassemblies, all truck-specific settings have to be retained.

Tyres: The quality of the tyres greatly affects the stability and the driving behaviourof the fork-lift truck. The factory-mounted tyres must only be replaced by originalspare parts of the manufacturer, since otherwise the specification of the data sheetcannot be met. When replacing wheels or tyres, it must be ensured that the fork-lifttruck remains level (tyres and wheels must always be replaced in pairs, i.e. left andright together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the servicechecklist apply to normal duty. If requirements are higher (dust, temperature), lubri-cation is required more often. The specified chain spray must be used as specified.The external application of grease does not provide sufficient lubrication.

Hydraulic hoses: The hoses must be renewed every six years. When replacing hy-draulic components, also renew the hoses in this hydraulic system.

F 3

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3 Servicing and inspection

Thorough and expert servicing is one of the most important preconditions for safe op-eration of the fork lift truck. The neglect of regular servicing intervals can lead to forklift truck failure and constitutes a potential hazard to personnel and equipment.

M The application conditions of an industrial truck have a considerable impact on thewear of the service components. We recommend that a Jungheinrich customer adviser carries out an application anal-ysis on site to work out specific service intervals to prevent damage due to wear.The indicated servicing intervals are based on single-shift operation under normal op-erating conditions. For applications in dusty environments, or involving large temper-ature fluctuations or multiple-shift operation, the servicing intervals must beshortened accordingly.

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

W = every 50 operating hours, but at least once per weekA = every 500 operating hours, or at least every six monthsB = every 1000 operating hours, or at least annuallyC = every 2000 operating hours, or at least annually

Z The W maintenance intervals must be carried out by the operator / customer.

In the run-in period - after approx. 100 service hours - or after repair work, the ownermust 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 preconditions for safe op-eration of the fork lift truck. The neglect of regular servicing intervals can lead to forklift truck failure and constitutes a potential hazard to personnel and equipment.

M The application conditions of an industrial truck have a considerable impact on thewear of the service components. We recommend that a Jungheinrich customer adviser carries out an application anal-ysis on site to work out specific service intervals to prevent damage due to wear.The indicated servicing intervals are based on single-shift operation under normal op-erating conditions. For applications in dusty environments, or involving large temper-ature fluctuations or multiple-shift operation, the servicing intervals must beshortened accordingly.

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

W = every 50 operating hours, but at least once per weekA = every 500 operating hours, or at least every six monthsB = every 1000 operating hours, or at least annuallyC = every 2000 operating hours, or at least annually

Z The W maintenance intervals must be carried out by the operator / customer.

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

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F 4

4 Maintenance Check - list EJE 116 / 118 / 120

Maintenance intervalsStandard = t W A B CCold store = k

Chassis andsuperstruct.:

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

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

Wheels: 3.1 Check for wear and damage t3.2 Check the wheel bearings and ensure

secure fastening of wheelsk t

Steering: 4.1 Check the steering wheel play k tBrake system: 5.1 Performance and adjustment check t

5.2 Check gas pressure spring for proper resetting function, for leaks and damage

t

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

if necessaryk t

Lifting device: 6.1 Performance and adjustment check t6.2 Perform sight check of rollers, sliding elements, and

stopsk t

6.3 Check fork tines and fork carrier for wear and damage k tHydraulic system:

7.1 Performance check k t7.2 Check all connections for leakage and damage k t7.3 Check hydraulic cylinders for leakage, damage

and secure attachmentk t

7.4 Check the oil level k t7.5 Change hydraulic oil and filter cartridge k t7.6 Check the pressure relief valves for correct functioning k t

Electrical system:

8.1 Performance check t8.2 Check all cables for secure connection and damage t8.3 Check the fuses for correct amperage t8.4 Check switches and trip cams for secure attachment

and correct functioningt

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

t

8.6 Check the warning installation for correct functioning k tElectric motors:

9.1 Check the motor for secure attachment t

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F 4

4 Maintenance Check - list EJE 116 / 118 / 120

Maintenance intervalsStandard = t W A B CCold store = k

Chassis andsuperstruct.:

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

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

Wheels: 3.1 Check for wear and damage t3.2 Check the wheel bearings and ensure

secure fastening of wheelsk t

Steering: 4.1 Check the steering wheel play k tBrake system: 5.1 Performance and adjustment check t

5.2 Check gas pressure spring for proper resetting function, for leaks and damage

t

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

if necessaryk t

Lifting device: 6.1 Performance and adjustment check t6.2 Perform sight check of rollers, sliding elements, and

stopsk t

6.3 Check fork tines and fork carrier for wear and damage k tHydraulic system:

7.1 Performance check k t7.2 Check all connections for leakage and damage k t7.3 Check hydraulic cylinders for leakage, damage

and secure attachmentk t

7.4 Check the oil level k t7.5 Change hydraulic oil and filter cartridge k t7.6 Check the pressure relief valves for correct functioning k t

Electrical system:

8.1 Performance check t8.2 Check all cables for secure connection and damage t8.3 Check the fuses for correct amperage t8.4 Check switches and trip cams for secure attachment

and correct functioningt

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

t

8.6 Check the warning installation for correct functioning k tElectric motors:

9.1 Check the motor for secure attachment t

F 5

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Maintenance intervalsStandard = t W A B CCold store = k

Battery: 10.1 Check acid density, acid level and cell voltage l t10.2 Check the terminals for secure attachment and apply

greasel t

10.3 Clean the battery connections; check for tight fitting l t10.4 Check the battery cables for damage, renew if necessary t

Lubrication: 11.1 Grease the vehicle in accordance with the lubrication schedule

l t

General measure-ments:

12.1 Check the electrical system for a grounding fault t12.2 Check the driving speed and braking distance t12.3 Check the lifting and lowering speed t12.4 Check safety and shutdown devices t

Demon-stration:

13.1 Perform a trial run under a nominal load t13.2 Upon completion of servicing operations, demonstrate the

vehicle to the person responsiblel t

F 5

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Maintenance intervalsStandard = t W A B CCold store = k

Battery: 10.1 Check acid density, acid level and cell voltage l t10.2 Check the terminals for secure attachment and apply

greasel t

10.3 Clean the battery connections; check for tight fitting l t10.4 Check the battery cables for damage, renew if necessary t

Lubrication: 11.1 Grease the vehicle in accordance with the lubrication schedule

l t

General measure-ments:

12.1 Check the electrical system for a grounding fault t12.2 Check the driving speed and braking distance t12.3 Check the lifting and lowering speed t12.4 Check safety and shutdown devices t

Demon-stration:

13.1 Perform a trial run under a nominal load t13.2 Upon completion of servicing operations, demonstrate the

vehicle to the person responsiblel t

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F 6

5 Lubrication Schedule EJE 116 / 118 / 120

g Gliding surfaces

s Grease nipples

Filler plug hydraulic oil

b Filler plug gear oil

a Drain plug gear oil

Gear oil overflow/filler neck and inspection plug

Cold store usage

Compound for cold store usage 1:1

12

3

4 5 6

7 8

0

9

Set

0,55 lE

E

E

1)

1)

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F 6

5 Lubrication Schedule EJE 116 / 118 / 120

g Gliding surfaces

s Grease nipples

Filler plug hydraulic oil

b Filler plug gear oil

a Drain plug gear oil

Gear oil overflow/filler neck and inspection plug

Cold store usage

Compound for cold store usage 1:1

12

3

4 5 6

7 8

0

9

Set

0,55 lE

E

E

1)

1)

F 7

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5.1 Fuels, coolants and lubricants

Handling consumption type material: Consumption type material must always behandled properly. Manufacturer's instructions to be observed.

F Improper handling is injurious to health, life, and environment. Consumption type ma-terials must be stored in adequate containers. They might be inflammable and, there-fore, must not come into contact with hot components or open fire.

When filling in consumption type materials use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualitiies resp., except if mix-ing is expressively prescribed in these operating instructions.

Avoid spilling. Spilt liquid must be removed immediately using a suitable bindingagent, and the mixture of consumption type material and binding agent is to be dis-posed of according to the regulations.

Grease Data

Code Order-no. Supply Qty Designation Used for:A 50 449 669 5,0 l H-LP 46, DIN 51524 Hydraulic systemB 50 380 904 5,0 l Fuchs Titan Gear

HSY 75W-90Transmission

C 29 200 810 5,0 l H-LP 10, DIN 51524 Hydraulic systemE 29 202 050 1.0 kg Grease, Polylub

GA352PLubrication

Code Saponification Dropp. point °C

Worked penetr. at 25° C

NLG1 class

Service temperat. °C

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

F 7

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5.1 Fuels, coolants and lubricants

Handling consumption type material: Consumption type material must always behandled properly. Manufacturer's instructions to be observed.

F Improper handling is injurious to health, life, and environment. Consumption type ma-terials must be stored in adequate containers. They might be inflammable and, there-fore, must not come into contact with hot components or open fire.

When filling in consumption type materials use clean containers only. It is prohibitedto mix consumption type materials of different grades or qualitiies resp., except if mix-ing is expressively prescribed in these operating instructions.

Avoid spilling. Spilt liquid must be removed immediately using a suitable bindingagent, and the mixture of consumption type material and binding agent is to be dis-posed of according to the regulations.

Grease Data

Code Order-no. Supply Qty Designation Used for:A 50 449 669 5,0 l H-LP 46, DIN 51524 Hydraulic systemB 50 380 904 5,0 l Fuchs Titan Gear

HSY 75W-90Transmission

C 29 200 810 5,0 l H-LP 10, DIN 51524 Hydraulic systemE 29 202 050 1.0 kg Grease, Polylub

GA352PLubrication

Code Saponification Dropp. point °C

Worked penetr. at 25° C

NLG1 class

Service temperat. °C

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

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F 8

6 Instructions for the servicing operations

6.1 Preparing the truck for the performance of servicing and maintenance opera-tions

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

– Safely park the truck (see Chapter E).– Pull out the battery plug (1).

F When work has to be performed under the raised fork or under the jacked up truck,suitable measures must be taken to prevent any dropping, tilting or slipping of the forkor truck. When lifting the truck, the instructions contained in chapter “Transportationand commissioning” have to be observed. When performing work on the parking brake, the truck must be secured against mov-ing.

6.2 Removing the front cover

– Unscrew two screws (6).– Carefully remove the front cover (3).

6.3 Removing the drive cover

The drive cover consists of two halves (3/4).

– Turn the control shaft to the right-hand stop position.– Remove the 2 screws (2).– Carefully remove the first cover half (3).– Turn the control shaft to the left-hand stop position.– Carefully unscrew and remove the second cover half (4).

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F 8

6 Instructions for the servicing operations

6.1 Preparing the truck for the performance of servicing and maintenance opera-tions

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

– Safely park the truck (see Chapter E).– Pull out the battery plug (1).

F When work has to be performed under the raised fork or under the jacked up truck,suitable measures must be taken to prevent any dropping, tilting or slipping of the forkor truck. When lifting the truck, the instructions contained in chapter “Transportationand commissioning” have to be observed. When performing work on the parking brake, the truck must be secured against mov-ing.

6.2 Removing the front cover

– Unscrew two screws (6).– Carefully remove the front cover (3).

6.3 Removing the drive cover

The drive cover consists of two halves (3/4).

– Turn the control shaft to the right-hand stop position.– Remove the 2 screws (2).– Carefully remove the first cover half (3).– Turn the control shaft to the left-hand stop position.– Carefully unscrew and remove the second cover half (4).

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6.4 Checking the electric fuses

– Prepare the truck for servicing and maintenance operations (see Section 6.1).– Remove the front cover (see Section 6.2).– Check the correct value (according to the table) of all of the fuses; if necessary, re-

place fuses.

Item Designation Protection of: Value7 F10 Integrated charging device (option) 10 A8 F1 Entire control circuit 10 A T9 1F1 Drive motor 100 A

10 2F1 Pump motor 100 A

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6.4 Checking the electric fuses

– Prepare the truck for servicing and maintenance operations (see Section 6.1).– Remove the front cover (see Section 6.2).– Check the correct value (according to the table) of all of the fuses; if necessary, re-

place fuses.

Item Designation Protection of: Value7 F10 Integrated charging device (option) 10 A8 F1 Entire control circuit 10 A T9 1F1 Drive motor 100 A

10 2F1 Pump motor 100 A

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6.5 Recommissioning the truck

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

– Check the horn for proper functioning.– Check the emergency stop connector for correct functioning.– Check the brake for correct functioning.– Lubricate truck according to lubrication schedule.

7 Decommissioning the fork lift truck

If the fork lift truck is to be decommissioned for more than two months, it must beparked in a frost-free and dry location and all measures to be taken before, during andfollowing decommissioning must be performed as detailed below.

M During decommissioning, the fork lift truck must be jacked up, ensuring that thewheels are clear of the ground. Only this measure will ensure that wheels and wheelbearings do not suffer damage.

If the fork lift truck is to be decommissioned for more than 6 months, additional meas-ures must be discussed with the Service Department of the manufacturer.

7.1 Operations to be performed prior to decommissioning

– Thoroughly clean the fork lift truck.– Check the brakes for correct function.– Check the hydraulic oil level and top up if required (see Section 5).– Apply a thin film of oil or grease to all parts not protected by a paint coating.– Grease the fork lift truck as detailed in the lubrication chart (see Section 5).– Recharge the battery (refer to chapter D).– Disconnect and clean the battery. Apply pole grease to the battery poles.

Z In addition to this, all instructions given by the battery supplier must be observed.

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

7.2 Measures to be taken during decommissioning

Every 2 months:

– Recharge the battery (refer to chapter D).

M Battery-operated fork lift trucks:Regular recharging of the battery is very important; otherwise, exhaustive depletionof the battery caused by self-discharging would occur. Owing to sulfatisation, this willresult in the destruction of the battery.

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6.5 Recommissioning the truck

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

– Check the horn for proper functioning.– Check the emergency stop connector for correct functioning.– Check the brake for correct functioning.– Lubricate truck according to lubrication schedule.

7 Decommissioning the fork lift truck

If the fork lift truck is to be decommissioned for more than two months, it must beparked in a frost-free and dry location and all measures to be taken before, during andfollowing decommissioning must be performed as detailed below.

M During decommissioning, the fork lift truck must be jacked up, ensuring that thewheels are clear of the ground. Only this measure will ensure that wheels and wheelbearings do not suffer damage.

If the fork lift truck is to be decommissioned for more than 6 months, additional meas-ures must be discussed with the Service Department of the manufacturer.

7.1 Operations to be performed prior to decommissioning

– Thoroughly clean the fork lift truck.– Check the brakes for correct function.– Check the hydraulic oil level and top up if required (see Section 5).– Apply a thin film of oil or grease to all parts not protected by a paint coating.– Grease the fork lift truck as detailed in the lubrication chart (see Section 5).– Recharge the battery (refer to chapter D).– Disconnect and clean the battery. Apply pole grease to the battery poles.

Z In addition to this, all instructions given by the battery supplier must be observed.

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

7.2 Measures to be taken during decommissioning

Every 2 months:

– Recharge the battery (refer to chapter D).

M Battery-operated fork lift trucks:Regular recharging of the battery is very important; otherwise, exhaustive depletionof the battery caused by self-discharging would occur. Owing to sulfatisation, this willresult in the destruction of the battery.

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7.3 Recommissioning the truck

– Thoroughly clean the fork lift truck.– Lubricate the fork lift truck according to the lubrication chart (see Section 5).– Clean the battery. Grease the pole screws using pole grease and reconnect the

battery.– Recharge the battery (refer to chapter D).– Check if the gear oil contains condensed water and change if required.– Check if the hydraulic oil contains condensed water and change if required.– Start up the fork lift truck (refer to chapter E).

Z Battery-operated fork lift trucks:If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove any oxide layer on the contacts of the operatingcontrols by repeated operation.

F Perform several brake tests immediately after recommissioning the truck.

8 Safety checks to be performed at regular intervals and following any untowardincidents (D: Accident prevention check according to BGV D27)

At least once yearly, or after any untoward incident, the fork lift truck has to be chek-ked by a qualified inspector. The inspector must assess the condition of the truck froma standpoint purely concerned with safety aspects, uninfluenced by any company oreconomic circumstances. The inspector must be adequately informed and experi-enced to be able to assess the condition of the fork lift truck and the effectiveness ofthe safety installations based on the technical rules and principles governing the in-spection of fork lift trucks.

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

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

Z The manufacturer has set up a special safety service with specially qualified staff. Asvisual proof that the fork lift truck has passed the safety inspection, a plaque is affixedto it. This plaque indicates in which month of which year the next test will be due.

9 Final de-commissioning, disposal

Z Final, correct de-commissioning or disposal of the truck must be performed inaccordance with the regulations of the country of use. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

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7.3 Recommissioning the truck

– Thoroughly clean the fork lift truck.– Lubricate the fork lift truck according to the lubrication chart (see Section 5).– Clean the battery. Grease the pole screws using pole grease and reconnect the

battery.– Recharge the battery (refer to chapter D).– Check if the gear oil contains condensed water and change if required.– Check if the hydraulic oil contains condensed water and change if required.– Start up the fork lift truck (refer to chapter E).

Z Battery-operated fork lift trucks:If switching troubles are experienced in the electric system, spray the exposed con-tacts with contact spray and remove any oxide layer on the contacts of the operatingcontrols by repeated operation.

F Perform several brake tests immediately after recommissioning the truck.

8 Safety checks to be performed at regular intervals and following any untowardincidents (D: Accident prevention check according to BGV D27)

At least once yearly, or after any untoward incident, the fork lift truck has to be chek-ked by a qualified inspector. The inspector must assess the condition of the truck froma standpoint purely concerned with safety aspects, uninfluenced by any company oreconomic circumstances. The inspector must be adequately informed and experi-enced to be able to assess the condition of the fork lift truck and the effectiveness ofthe safety installations based on the technical rules and principles governing the in-spection of fork lift trucks.

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

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

Z The manufacturer has set up a special safety service with specially qualified staff. Asvisual proof that the fork lift truck has passed the safety inspection, a plaque is affixedto it. This plaque indicates in which month of which year the next test will be due.

9 Final de-commissioning, disposal

Z Final, correct de-commissioning or disposal of the truck must be performed inaccordance with the regulations of the country of use. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

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Instructions for use

Jungheinrich traction battery

Table of contents1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB..........................................2-6

Type plate Jungheinrich traction battery............................................7

Instruction for useAquamatic/BFS III water refilling system ......................................................8-12

2 Jungheinrich traction batteryMaintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17

Type plate Jungheinrich traction battery............................................17

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Instructions for use

Jungheinrich traction battery

Table of contents1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB..........................................2-6

Type plate Jungheinrich traction battery............................................7

Instruction for useAquamatic/BFS III water refilling system ......................................................8-12

2 Jungheinrich traction batteryMaintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17

Type plate Jungheinrich traction battery............................................17

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1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB

Rating Data

1. Nominal capacity C5: See type plate2. Nominal voltage: 2,0 V x No of cells3. Discharge current:: C5/5h4. Nominal S.G. of electrolyte*

Type EPzS: 1,29 kg/lType EPzB: 1,29 kg/l

5. Rated temperature: 30° C6. Nominal electrolyte level: up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles.

•Pay attention to the operation instruction and fix them close to the battery!•Work on batteries to be carried out by skilled personnel only!

•Use protective glasses and clothes when working on batteries!•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN 50110-1!

•No smoking!•Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the battery to explode!

•Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately!•Clothing contaminated by acid should be washed in water.

•Risk of explosion and fire, avoid short circuits!

•Electrolyte is highly corrosive!

•Batteries and cells are heavy!•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.

•Dangerous electrical voltage!•Caution! Metal parts of the battery are always live. Do not place tools or other me-tal objects on the battery!

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1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB

Rating Data

1. Nominal capacity C5: See type plate2. Nominal voltage: 2,0 V x No of cells3. Discharge current:: C5/5h4. Nominal S.G. of electrolyte*

Type EPzS: 1,29 kg/lType EPzB: 1,29 kg/l

5. Rated temperature: 30° C6. Nominal electrolyte level: up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles.

•Pay attention to the operation instruction and fix them close to the battery!•Work on batteries to be carried out by skilled personnel only!

•Use protective glasses and clothes when working on batteries!•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN 50110-1!

•No smoking!•Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the battery to explode!

•Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately!•Clothing contaminated by acid should be washed in water.

•Risk of explosion and fire, avoid short circuits!

•Electrolyte is highly corrosive!

•Batteries and cells are heavy!•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.

•Dangerous electrical voltage!•Caution! Metal parts of the battery are always live. Do not place tools or other me-tal objects on the battery!

3

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For batteries in classes I and II the instructions for maintaining the appropriateprotection class during operation must be complied with (see relevant certificate).

1. Commissioning filled and charged batteries. For commissioning of unfilledbatteries see separate instructions!

The battery should be inspected to ensure it is in perfect physical condition.

The charger cables must be connected to ensure a good contact, taking care that thepolarity is correct. Otherwise battery, vehicle or charger could be damaged.

The specified torque loading for the polscrews of the charger cables and connectorsare:

The level of the electrolyte must be checked. If it is below the antisurge baffle or thetop of the separator it must first be topped up to this height with purified water.

The battery is then charged as in item 2.2.

The electrolyte should be topped up to the specified level with purified water.

2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-plies to the operation traction batteries in industrial trucks.

2.1 Discharging

Be sure that all breather holes are not sealed or covered.

Electrical connections (e.g. plugs) must only be made or broken in the open circuitcondition.

To achieve the optimum life for the battery, operating discharges of more than 80%of the rated capacity should be avoided (deep discharge).

This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-scharge. Discharged batteries must be recharged immediately and must not be leftdischarged. This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. All charging procedures in accordancewith DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned toa charger, suitable for the size of battery, in order to avoid overloading of the electriccables and contacts, unacceptable gassing and the escape of electrolyte from thecells.

In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-ded. If the charger was not purchased together with the battery it is best to have itssuitability checked by the manufacturers service department. When charging, properprovision must be made for venting of the charging gases.

steel M 10 23 ± 1 Nm

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Ignoring the operation instructions, repair with non-original parts or using additives forthe electrolyte will render the warranty void.

For batteries in classes I and II the instructions for maintaining the appropriateprotection class during operation must be complied with (see relevant certificate).

1. Commissioning filled and charged batteries. For commissioning of unfilledbatteries see separate instructions!

The battery should be inspected to ensure it is in perfect physical condition.

The charger cables must be connected to ensure a good contact, taking care that thepolarity is correct. Otherwise battery, vehicle or charger could be damaged.

The specified torque loading for the polscrews of the charger cables and connectorsare:

The level of the electrolyte must be checked. If it is below the antisurge baffle or thetop of the separator it must first be topped up to this height with purified water.

The battery is then charged as in item 2.2.

The electrolyte should be topped up to the specified level with purified water.

2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-plies to the operation traction batteries in industrial trucks.

2.1 Discharging

Be sure that all breather holes are not sealed or covered.

Electrical connections (e.g. plugs) must only be made or broken in the open circuitcondition.

To achieve the optimum life for the battery, operating discharges of more than 80%of the rated capacity should be avoided (deep discharge).

This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-scharge. Discharged batteries must be recharged immediately and must not be leftdischarged. This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. All charging procedures in accordancewith DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned toa charger, suitable for the size of battery, in order to avoid overloading of the electriccables and contacts, unacceptable gassing and the escape of electrolyte from thecells.

In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-ded. If the charger was not purchased together with the battery it is best to have itssuitability checked by the manufacturers service department. When charging, properprovision must be made for venting of the charging gases.

steel M 10 23 ± 1 Nm

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Battery container lids and the covers of battery compartments must be opened or re-moved. The vent plugs should stay on the cells and remain closed.

With the charger switched off connect up the battery, ensuring that the polarity is cor-rect. (positive to positive, negative to negative). Now switch on the charger. Whencharging the temperature of the electrolyte rises by about 10°C, so charging shouldonly begin if the electrolyte temperature is below 45°C. The electrolyte temperatureof batteries should be at least +10°C before charging otherwise a full charge will notbe achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltagehave remained constant for two hours. Special instructions for the operation of batte-ries in hazardous areas. This concerns batteries which are used in accordance withEN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-tentially explosive areas). During charging and subsequent gassing the container lidsmust be removed or opened so that the explosive mixture of gases loses its flamma-bility due to adequate ventilation. The containers for batteries with plate protectionpacks must not be closed until at least half an hour after charging has past.

2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. They are necessary after deep discharges, repeated incomplete rechargesand charges to an IU characteristic curve. Equalising charges are carried out follo-wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-pacity (end of charge - see point 2.2).

Watch the temperature!

2.4 Temperature

An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-peratures shorten the life of the battery, lower temperatures reduce the capacity avai-lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-perature.

2.5 Electrolyte

The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°Cand the nominal electrolyte level in the cell in fully charged condition. Higher tempe-ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specificgravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.

The electrolyte must conform to the purity regulations in DIN 43530 part 2.

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Battery container lids and the covers of battery compartments must be opened or re-moved. The vent plugs should stay on the cells and remain closed.

With the charger switched off connect up the battery, ensuring that the polarity is cor-rect. (positive to positive, negative to negative). Now switch on the charger. Whencharging the temperature of the electrolyte rises by about 10°C, so charging shouldonly begin if the electrolyte temperature is below 45°C. The electrolyte temperatureof batteries should be at least +10°C before charging otherwise a full charge will notbe achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltagehave remained constant for two hours. Special instructions for the operation of batte-ries in hazardous areas. This concerns batteries which are used in accordance withEN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-tentially explosive areas). During charging and subsequent gassing the container lidsmust be removed or opened so that the explosive mixture of gases loses its flamma-bility due to adequate ventilation. The containers for batteries with plate protectionpacks must not be closed until at least half an hour after charging has past.

2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. They are necessary after deep discharges, repeated incomplete rechargesand charges to an IU characteristic curve. Equalising charges are carried out follo-wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-pacity (end of charge - see point 2.2).

Watch the temperature!

2.4 Temperature

An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-peratures shorten the life of the battery, lower temperatures reduce the capacity avai-lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-perature.

2.5 Electrolyte

The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°Cand the nominal electrolyte level in the cell in fully charged condition. Higher tempe-ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specificgravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.

The electrolyte must conform to the purity regulations in DIN 43530 part 2.

5

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3.1 Daily

Charge the battery after every discharge. Towards the end of charge the electrolytelevel should be checked and if necessary topped up to the specified level with purifiedwater. The electrolyte level must not fall below the anti-surge baffle or the top of theseparator or the electrolyte „min“ level mark.

3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-tery is charged regularly with a IU characteristic curve an equalising charge must becarried out (see point 2.3).

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measuredwith the charger switched on, and recorded. After charging has ended the specificgravity and the temperature of the electrolyte in all cells should be measured and re-corded.

If significant changes from earlier measurements or differences between the cells orbloc batteries are found further testing and maintenance by the service departmentshould be requested.

3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance ofthe truck and the battery must be checked by an electrical specialist.

The tests on the insulation resistance of the battery must be conducted in accordancewith DIN EN 60254-1.

The insulation resistance of the battery thus determined must not be below a value of50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea-ning must be done in accordance with the ZVEI code of practice «The Cleaning ofVehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man-ner. Damage to the insulation of the tray should be repaired after cleaning, to ensurethat the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call in our service department for this.

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3. Maintenance

3.1 Daily

Charge the battery after every discharge. Towards the end of charge the electrolytelevel should be checked and if necessary topped up to the specified level with purifiedwater. The electrolyte level must not fall below the anti-surge baffle or the top of theseparator or the electrolyte „min“ level mark.

3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-tery is charged regularly with a IU characteristic curve an equalising charge must becarried out (see point 2.3).

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measuredwith the charger switched on, and recorded. After charging has ended the specificgravity and the temperature of the electrolyte in all cells should be measured and re-corded.

If significant changes from earlier measurements or differences between the cells orbloc batteries are found further testing and maintenance by the service departmentshould be requested.

3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance ofthe truck and the battery must be checked by an electrical specialist.

The tests on the insulation resistance of the battery must be conducted in accordancewith DIN EN 60254-1.

The insulation resistance of the battery thus determined must not be below a value of50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea-ning must be done in accordance with the ZVEI code of practice «The Cleaning ofVehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man-ner. Damage to the insulation of the tray should be repaired after cleaning, to ensurethat the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call in our service department for this.

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5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room. To ensure the battery is always readyfor use a choice of charging methods can be made:

1. a monthly equalising charge as in point 2.3

2. float charging at a charging voltage of 2.23 V x the number of cells. The storagetime should be taken into account when considering the life of the battery.

6. Malfunctions

If malfunctions are found on the battery or the charger our service department shouldbe called in without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.

A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer!

Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must bedisposed of as hazardous waste!

We reserve the right make technical modification.

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5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room. To ensure the battery is always readyfor use a choice of charging methods can be made:

1. a monthly equalising charge as in point 2.3

2. float charging at a charging voltage of 2.23 V x the number of cells. The storagetime should be taken into account when considering the life of the battery.

6. Malfunctions

If malfunctions are found on the battery or the charger our service department shouldbe called in without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.

A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer!

Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must bedisposed of as hazardous waste!

We reserve the right make technical modification.

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0506

.GB7.Type plate, Jungheinrich traction battery

* CE mark is only for batteries with a nominal voltage greater than 75 volt.

Item Designation Item Designation1 Logo 8 Recycling symbol2 Battery designation 9 Dustbin/material3 Battery type 10 Nominal battery voltage4 Battery number 11 Nominal battery capacity5 Battery tray number 12 Number of battery cells6 Delivery date 13 Battery weight7 Battery manufacturer's logo 14 Safety instructions and warnings

Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7

Number of CellsBatteriegewicht min/max 8

Battery mass min/max

Serien-Nr.3

Serial-Nr.Lieferanten Nr. 4

Supplier No.

Baujahr 2

Year of manufacture

Jungheinrich AG, D-22047 Hamburg, Germany

5

Pb Pb

2/3 651113

1

14

41012

7

8

9

7

0506

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7.Type plate, Jungheinrich traction battery

* CE mark is only for batteries with a nominal voltage greater than 75 volt.

Item Designation Item Designation1 Logo 8 Recycling symbol2 Battery designation 9 Dustbin/material3 Battery type 10 Nominal battery voltage4 Battery number 11 Nominal battery capacity5 Battery tray number 12 Number of battery cells6 Delivery date 13 Battery weight7 Battery manufacturer's logo 14 Safety instructions and warnings

Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7

Number of CellsBatteriegewicht min/max 8

Battery mass min/max

Serien-Nr.3

Serial-Nr.Lieferanten Nr. 4

Supplier No.

Baujahr 2

Year of manufacture

Jungheinrich AG, D-22047 Hamburg, Germany

5

Pb Pb

2/3 651113

1

14

41012

7

8

9

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8

Aquamatic/BFS III water refilling system for Jungheinrich traction battery withEPzS and EPzB cells with tubular positive plates

Aquamatic plug arrangement for the Operating Instructions

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. columnEPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.2 EPzS 120.

Non-adherence to the operating instructions, repairs carried out with non-originalspare parts, unauthorised interference, and the use of additives for the electrolytes(alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the in-structions on maintaining the respective protection class during operation (see asso-ciated certification).

Cell series* Aquamatic plug type (length)

EPzS EPzB Frötek (yellow) BFS (black)

2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm

– 2/ 84 – 12/ 504 50,5 mm 51,0 mm– 2/110 – 12/ 660 50,5 mm 51,0 mm– 2/130 – 12/ 780 50,5 mm 51,0 mm– 2/150 – 12/ 900 50,5 mm 51,0 mm– 2/172 – 12/1032 50,5 mm 51,0 mm– 2/200 – 12/1200 56,0 mm 56,0 mm– 2/216 – 12/1296 56,0 mm 56,0 mm

2/180 – 10/900 – 61,0 mm 61,0 mm2/210 – 10/1050 – 61,0 mm 61,0 mm2/230 – 10/1150 – 61,0 mm 61,0 mm2/250 – 10/1250 – 61,0 mm 61,0 mm2/280 – 10/1400 – 72,0 mm 66,0 mm2/310 – 10/1550 – 72,0 mm 66,0 mm

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Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

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Aquamatic/BFS III water refilling system for Jungheinrich traction battery withEPzS and EPzB cells with tubular positive plates

Aquamatic plug arrangement for the Operating Instructions

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. columnEPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.2 EPzS 120.

Non-adherence to the operating instructions, repairs carried out with non-originalspare parts, unauthorised interference, and the use of additives for the electrolytes(alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the in-structions on maintaining the respective protection class during operation (see asso-ciated certification).

Cell series* Aquamatic plug type (length)

EPzS EPzB Frötek (yellow) BFS (black)

2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm

– 2/ 84 – 12/ 504 50,5 mm 51,0 mm– 2/110 – 12/ 660 50,5 mm 51,0 mm– 2/130 – 12/ 780 50,5 mm 51,0 mm– 2/150 – 12/ 900 50,5 mm 51,0 mm– 2/172 – 12/1032 50,5 mm 51,0 mm– 2/200 – 12/1200 56,0 mm 56,0 mm– 2/216 – 12/1296 56,0 mm 56,0 mm

2/180 – 10/900 – 61,0 mm 61,0 mm2/210 – 10/1050 – 61,0 mm 61,0 mm2/230 – 10/1150 – 61,0 mm 61,0 mm2/250 – 10/1250 – 61,0 mm 61,0 mm2/280 – 10/1400 – 72,0 mm 66,0 mm2/310 – 10/1550 – 72,0 mm 66,0 mm

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Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

9

0506

.GBDiagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with sole-noid valve

5. Charger

6. Sealing coupler

7. Closing nipple

8. Ion exchange cartridge with conductance meter and solenoid valve

9. Connection for untreated water

10. Charging lead

1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically adjus-ting the nominal electrolyte level. Venting holes are provided for letting off the gaseswhich arise during charging. In addition to the optical level indicator, the plug systemsalso have a diagnostics hole for measuring the temperature and the electrolyte den-sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-matic/BFS filling systems. The water can be refilled by means of a central sealingcoupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries forforklift trucks. The water refilling system is provided with a central water connectionfor the water supply. Soft PVC hose is used for this connection and for the hose con-nections for the individual plugs. The hose ends are put onto the hose connectionsleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve locatedin the plug in combination with the float and the float rods. In the Aquamatic Systemthe existing water pressure at the valve turns off the water supply and ensures thatthe valve closes securely. When the maximum filling level is reached in the BFS sys-tem, the float and the float rods through a lever system close the valve with five timesthe buoyant force and consequently interrupt the water supply reliably.

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9

0506

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Diagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with sole-noid valve

5. Charger

6. Sealing coupler

7. Closing nipple

8. Ion exchange cartridge with conductance meter and solenoid valve

9. Connection for untreated water

10. Charging lead

1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically adjus-ting the nominal electrolyte level. Venting holes are provided for letting off the gaseswhich arise during charging. In addition to the optical level indicator, the plug systemsalso have a diagnostics hole for measuring the temperature and the electrolyte den-sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-matic/BFS filling systems. The water can be refilled by means of a central sealingcoupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries forforklift trucks. The water refilling system is provided with a central water connectionfor the water supply. Soft PVC hose is used for this connection and for the hose con-nections for the individual plugs. The hose ends are put onto the hose connectionsleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve locatedin the plug in combination with the float and the float rods. In the Aquamatic Systemthe existing water pressure at the valve turns off the water supply and ensures thatthe valve closes securely. When the maximum filling level is reached in the BFS sys-tem, the float and the float rods through a lever system close the valve with five timesthe buoyant force and consequently interrupt the water supply reliably.

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4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the batterycharging comes to an end; this ensures that the refilled water quantity is mixed withthe electrolyte. In normal operation it is usually sufficient to fill once a week.

5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in thewater pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operatingpressure range of between 0.2 bars and 0.6 bars. The BFS system has an operatingpressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impairthe system's functional reliability. This wide pressure range permits three types of fil-ling.

5.1 Falling water

The height of the tank is chosen to suit whichever water refilling system is used. Forthe Aquamatic System the installation height is 2 m to 6 m and for the BFS systemthe installation height is 3 m to 18 m over the battery surface.

5.2 Pressurised water

The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 barsand from 0.3 bars to 1.8 bars in the BFS system.

5.3 Water Refill Trolley (serviceMobil)

The submergible pump located in the ServiceMobil's tank generates the necessaryfilling pressure. No difference in height is permitted between the standing level of theServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under whichthe battery is used, the ambient temperatures and the type of filling and/or the fillingpressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-ter feed pipe must be separated from the battery after filling.

7. Water quality

Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fillthe batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kindof dirt which could impair the functional reliability of the Aquamatic/BFS plug. Forsafety reasons it is recommendable to insert a filter element (optional) with a max.passage opening of 100 to 300 µm into the battery's main supply pipe.

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4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the batterycharging comes to an end; this ensures that the refilled water quantity is mixed withthe electrolyte. In normal operation it is usually sufficient to fill once a week.

5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in thewater pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operatingpressure range of between 0.2 bars and 0.6 bars. The BFS system has an operatingpressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impairthe system's functional reliability. This wide pressure range permits three types of fil-ling.

5.1 Falling water

The height of the tank is chosen to suit whichever water refilling system is used. Forthe Aquamatic System the installation height is 2 m to 6 m and for the BFS systemthe installation height is 3 m to 18 m over the battery surface.

5.2 Pressurised water

The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 barsand from 0.3 bars to 1.8 bars in the BFS system.

5.3 Water Refill Trolley (serviceMobil)

The submergible pump located in the ServiceMobil's tank generates the necessaryfilling pressure. No difference in height is permitted between the standing level of theServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under whichthe battery is used, the ambient temperatures and the type of filling and/or the fillingpressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-ter feed pipe must be separated from the battery after filling.

7. Water quality

Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fillthe batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kindof dirt which could impair the functional reliability of the Aquamatic/BFS plug. Forsafety reasons it is recommendable to insert a filter element (optional) with a max.passage opening of 100 to 300 µm into the battery's main supply pipe.

11

0506

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Hose connections for the individual plugs are laid along the existing electric circuit.No changes may be made.

9. Operating temperature

The temperature limit for battery operation is set at 55° C. Exceeding this temperaturedamages the batteries. The battery filling systems may be operated within a tempe-rature range of > 0° C to a maximum of 55° C.

CAUTION:Batteries with automatic water refilling systems may only be operated in roomswith temperatures > 0° C (as there is otherwise a danger that the systems mayfreeze).

9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling sys-tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a7.5 mm-diameter (BFS plugs).

9.2 Float

Different floats are used depending on the cell design and type.

9.3 Cleaning

The plug systems may only be cleaned with water. No parts of the plugs may comein contact with soap or fabrics which contain solvents.

10. Accessories

10.1 Flow indicator

To monitor the filling process, a flow indicator can be inserted into the water feed pipeon the battery side. During the filling process, the paddlewheel is turned by the flowingwater. When the filling process ends, the wheel stops and this indicates the end ofthe filling process. (ident no.: 50219542).

10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug sys-tems (plug lifter). The greatest of care must be employed when prising out the plug toprevent any damage to the plug systems.

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8. Battery hose connections

Hose connections for the individual plugs are laid along the existing electric circuit.No changes may be made.

9. Operating temperature

The temperature limit for battery operation is set at 55° C. Exceeding this temperaturedamages the batteries. The battery filling systems may be operated within a tempe-rature range of > 0° C to a maximum of 55° C.

CAUTION:Batteries with automatic water refilling systems may only be operated in roomswith temperatures > 0° C (as there is otherwise a danger that the systems mayfreeze).

9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling sys-tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a7.5 mm-diameter (BFS plugs).

9.2 Float

Different floats are used depending on the cell design and type.

9.3 Cleaning

The plug systems may only be cleaned with water. No parts of the plugs may comein contact with soap or fabrics which contain solvents.

10. Accessories

10.1 Flow indicator

To monitor the filling process, a flow indicator can be inserted into the water feed pipeon the battery side. During the filling process, the paddlewheel is turned by the flowingwater. When the filling process ends, the wheel stops and this indicates the end ofthe filling process. (ident no.: 50219542).

10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug sys-tems (plug lifter). The greatest of care must be employed when prising out the plug toprevent any damage to the plug systems.

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12

10.2.1 Clamping ring tool

The clamping ring tool is used to push on a clamping ring to increase the contact pres-sure of the hose connection on the plugs' hose couplings and to loosen it again.

10.3 Filter element

For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-ry's main supply pipe for supplying battery water. This filter element has a maximumpassage cross-section of 100 to 300 µm and is designed as a bag filter.

10.4 Sealing coupler

The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-tral supply pipe. This is connected to the water supply system at the battery chargingstation by means of a sealing coupler system. On the battery side a closing nipple(ident no.: 50219538) is mounted and the customer must place a sealing couplerconstruction on the water supply side (obtainable under ident. no.: 50219537).

11. Functional data

PS - self-sealing pressure: Aquamatic > 1.2 bars

BFS system none

D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min

D1 - maximum permissible leakage rate in the closed valve when the pressure is at0.1 bars: 2 ml/min

T - permissible temperature range: 0° C to a maximum of 65° C

Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system andoperating pressure range: 0.3 to 1.8 bars in the BFS system.

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10.2.1 Clamping ring tool

The clamping ring tool is used to push on a clamping ring to increase the contact pres-sure of the hose connection on the plugs' hose couplings and to loosen it again.

10.3 Filter element

For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-ry's main supply pipe for supplying battery water. This filter element has a maximumpassage cross-section of 100 to 300 µm and is designed as a bag filter.

10.4 Sealing coupler

The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-tral supply pipe. This is connected to the water supply system at the battery chargingstation by means of a sealing coupler system. On the battery side a closing nipple(ident no.: 50219538) is mounted and the customer must place a sealing couplerconstruction on the water supply side (obtainable under ident. no.: 50219537).

11. Functional data

PS - self-sealing pressure: Aquamatic > 1.2 bars

BFS system none

D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min

D1 - maximum permissible leakage rate in the closed valve when the pressure is at0.1 bars: 2 ml/min

T - permissible temperature range: 0° C to a maximum of 65° C

Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system andoperating pressure range: 0.3 to 1.8 bars in the BFS system.

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2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular platestype EPzV and EPzV-BS

Rating Data

1. Nominal capacity C5: See type plate

2. Nominal voltage: 2,0 Volt x No of cells

3. Discharge current: C5/5h

4. Rated temperature: 30° C

EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe-re a water refilling isn’t permitted during the whole battery life. Instead of a vent plugthere are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements asfor vented cells apply to protect against hazards from electric current, from explosionof electrolytic gas and in case of the cell container is damaged, from the corrosiveelectrolyte.

• Pay attention to the operation instruction and fix them close to the battery!• Work on batteries to be carried out by skilled personnel only!

• Use protective glasses and clothes when working on batteries!• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN

50110-1!

• No smoking!• Do not expose batteries to naked flames, glowing embers or sparks, as it may

cause the battery to explode!

• Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately!

• Clothing contaminated by acid should be washed in water.

• Risk of explosion and fire, avoid short circuits!

• Electrolyte is highly corrosive!• In the normal operation of this batteries a contact with acid isn´t possible. If the

cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid) is corrosive like the liquid electrolyte.

• Batteries and cells are heavy!• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear

in accordance with VDI 3616.

• Dangerous electrical voltage!• Caution! Metal parts of the battery are always live. Do not place tools or other

metal objects on the battery!

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0506

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2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular platestype EPzV and EPzV-BS

Rating Data

1. Nominal capacity C5: See type plate

2. Nominal voltage: 2,0 Volt x No of cells

3. Discharge current: C5/5h

4. Rated temperature: 30° C

EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe-re a water refilling isn’t permitted during the whole battery life. Instead of a vent plugthere are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements asfor vented cells apply to protect against hazards from electric current, from explosionof electrolytic gas and in case of the cell container is damaged, from the corrosiveelectrolyte.

• Pay attention to the operation instruction and fix them close to the battery!• Work on batteries to be carried out by skilled personnel only!

• Use protective glasses and clothes when working on batteries!• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN

50110-1!

• No smoking!• Do not expose batteries to naked flames, glowing embers or sparks, as it may

cause the battery to explode!

• Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately!

• Clothing contaminated by acid should be washed in water.

• Risk of explosion and fire, avoid short circuits!

• Electrolyte is highly corrosive!• In the normal operation of this batteries a contact with acid isn´t possible. If the

cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid) is corrosive like the liquid electrolyte.

• Batteries and cells are heavy!• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear

in accordance with VDI 3616.

• Dangerous electrical voltage!• Caution! Metal parts of the battery are always live. Do not place tools or other

metal objects on the battery!

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Ignoring the operation instructions, repair with non-original parts and non authorisedinterventions will render the warranty void.

For batteries in classes I and II the instructions for maintaining the appropriateprotection class during operation must be complied with (see relevant certificate).

1. Commissioning

The battery should be inspected to ensure it is in perfect physical condition.

The battery end cables must have a good contact to terminals, check that the polarityis correct.

Otherwise battery, vehicle or charger could be destroyed.

The battery has to be charged according to item 2.2

The specified torque loading for the pole screws of the end cables and connectorsare:

2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-plies to the operation traction batteries in industrial trucks.

2.1 Discharging

Ventilation openings must not be sealed or covered.

Electrical connections (e.g. plugs) must only be made or broken in the open circuitcondition.

To achieve the optimum life for the battery, operating discharges of more than 60%of the rated capacity should be avoided (deep discharge).

They reduce the battery life considerable. To measure the state of discharge use onlythe battery manufacturer recommended discharge indicators.

Discharged batteries must be recharged immediately and must not be left dischar-ged.

This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. Charging procedures according to DIN41773 and DIN 41774 must only be applied in the manufacturer approved modifica-tions. Therefore only battery manufacturer approved chargers must be used. Onlyconnect the battery assigned to a charger, suitable for the size of battery, in order toavoid overloading of the electric cables and contacts and unacceptable gassing of thecells. EPzV batteries have a low gas emission.

When charging, proper provision must be made for venting of the charging gases.Battery container lids and the covers of battery compartments must be opened or re-moved.

steel M 10 23 ± 1 Nm

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14

Ignoring the operation instructions, repair with non-original parts and non authorisedinterventions will render the warranty void.

For batteries in classes I and II the instructions for maintaining the appropriateprotection class during operation must be complied with (see relevant certificate).

1. Commissioning

The battery should be inspected to ensure it is in perfect physical condition.

The battery end cables must have a good contact to terminals, check that the polarityis correct.

Otherwise battery, vehicle or charger could be destroyed.

The battery has to be charged according to item 2.2

The specified torque loading for the pole screws of the end cables and connectorsare:

2. Operation

DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-plies to the operation traction batteries in industrial trucks.

2.1 Discharging

Ventilation openings must not be sealed or covered.

Electrical connections (e.g. plugs) must only be made or broken in the open circuitcondition.

To achieve the optimum life for the battery, operating discharges of more than 60%of the rated capacity should be avoided (deep discharge).

They reduce the battery life considerable. To measure the state of discharge use onlythe battery manufacturer recommended discharge indicators.

Discharged batteries must be recharged immediately and must not be left dischar-ged.

This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. Charging procedures according to DIN41773 and DIN 41774 must only be applied in the manufacturer approved modifica-tions. Therefore only battery manufacturer approved chargers must be used. Onlyconnect the battery assigned to a charger, suitable for the size of battery, in order toavoid overloading of the electric cables and contacts and unacceptable gassing of thecells. EPzV batteries have a low gas emission.

When charging, proper provision must be made for venting of the charging gases.Battery container lids and the covers of battery compartments must be opened or re-moved.

steel M 10 23 ± 1 Nm

15

0506

.GBWith the charger switched off connect up the battery, ensuring that the polarity is cor-rect (positive to positive, negative to negative). Now switch on the charger. Whencharging the temperature of the battery rises by about 15° C, so charging should onlybegin if the battery temperature is below 35° C. The battery temperature should be atleast +15°C before charging otherwise a full charge will not be achieved. Are the tem-peratures a longer time higher than +40° C or lower than +15° C, so the chargersneed a temperatures regulated voltage.

The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.

Special instructions for the operation of batteries in hazardous areas.

This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).The attention pictograms has to be respected.

2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. Equalising charges are carried out following normal charging.

They are necessary after deep discharges and repeated incomplete recharges. Forthe equalising charges has to be used only the battery manufacturer prescribed char-gers.

Watch the temperature!

2.4 Temperature

A battery temperature of 30°C is specified as the rated temperature. Higher tempera-tures shorten the life of the battery, lower temperatures reduce the available capacity.45° C is the upper temperature limit and is not acceptable as an operating tempera-ture.

2.5 Electrolyte

The electrolyte is immobilised in a gel. The density of the electrolyte can not bemeasured.

3. Maintenance

Don’t refill water!

3.1 Daily

Charge the battery immediately after every discharge.

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With the charger switched off connect up the battery, ensuring that the polarity is cor-rect (positive to positive, negative to negative). Now switch on the charger. Whencharging the temperature of the battery rises by about 15° C, so charging should onlybegin if the battery temperature is below 35° C. The battery temperature should be atleast +15°C before charging otherwise a full charge will not be achieved. Are the tem-peratures a longer time higher than +40° C or lower than +15° C, so the chargersneed a temperatures regulated voltage.

The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.

Special instructions for the operation of batteries in hazardous areas.

This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170/ 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas).The attention pictograms has to be respected.

2.3 Equalising charge

Equalising charges are used to safeguard the life of the battery and to maintain itscapacity. Equalising charges are carried out following normal charging.

They are necessary after deep discharges and repeated incomplete recharges. Forthe equalising charges has to be used only the battery manufacturer prescribed char-gers.

Watch the temperature!

2.4 Temperature

A battery temperature of 30°C is specified as the rated temperature. Higher tempera-tures shorten the life of the battery, lower temperatures reduce the available capacity.45° C is the upper temperature limit and is not acceptable as an operating tempera-ture.

2.5 Electrolyte

The electrolyte is immobilised in a gel. The density of the electrolyte can not bemeasured.

3. Maintenance

Don’t refill water!

3.1 Daily

Charge the battery immediately after every discharge.

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3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage.

3.3 Quarterly

After the end of the charge and a rest time of 5 h following should be measured andrecorded:

• the voltages of the battery

• the voltages of every cells

If significant changes from earlier measurements or differences between the cells orbloc batteries are found, further testing and maintenance by the service departmentshould be requested.

3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance ofthe truck and the battery must be checked by an electrical specialist.

The tests on the insulation resistance of the battery must be conducted in accordancewith DIN 43539-1.

The insulation resistance of the battery thus determined must not be below a value of50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea-ning must be done in accordance with the ZVEI code of practice «The Cleaning ofVehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man-ner.

Damage to the insulation of the tray should be repaired after cleaning, to ensure thatthe insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call our service department for this.

5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room.

To ensure the battery is always ready for use a choice of charging methods can bemade:

1.a quarterly full charging like charge as in point 2.2. If any consumer is connectedwith, e.g. measure or controlling systems, it can be, that this charging is necessaryevery 14 days.

2. float charging at a charging voltage of 2.25 V x the number of cells.

The storage time should be taken into account when considering the life of the batte-ry.

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3.2 Weekly

Visual inspection after recharging for signs of dirt and mechanical damage.

3.3 Quarterly

After the end of the charge and a rest time of 5 h following should be measured andrecorded:

• the voltages of the battery

• the voltages of every cells

If significant changes from earlier measurements or differences between the cells orbloc batteries are found, further testing and maintenance by the service departmentshould be requested.

3.4 Annually

In accordance with DIN VDE 0117 at least once per year, the insulation resistance ofthe truck and the battery must be checked by an electrical specialist.

The tests on the insulation resistance of the battery must be conducted in accordancewith DIN 43539-1.

The insulation resistance of the battery thus determined must not be below a value of50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Clea-ning must be done in accordance with the ZVEI code of practice «The Cleaning ofVehicle Traction batteries».

Any liquid in the battery tray must be extracted and disposed of in the prescribed man-ner.

Damage to the insulation of the tray should be repaired after cleaning, to ensure thatthe insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If itis necessary to remove cells it is best to call our service department for this.

5. Storage

If batteries are taken out of service for a lengthy period they should be stored in thefully charged condition in a dry, frost-free room.

To ensure the battery is always ready for use a choice of charging methods can bemade:

1.a quarterly full charging like charge as in point 2.2. If any consumer is connectedwith, e.g. measure or controlling systems, it can be, that this charging is necessaryevery 14 days.

2. float charging at a charging voltage of 2.25 V x the number of cells.

The storage time should be taken into account when considering the life of the batte-ry.

17

0506

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If malfunctions are found on the battery or the charger our service department shouldbe called without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.

A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer!

Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must bedisposed of as hazardous waste!

We reserve the right make technical modification.

7.Type plate, Jungheinrich traction battery

* CE mark is only for batteries with a nominal voltage greater than 75 volt.

Item Designation Item Designation1 Logo 8 Recycling symbol2 Battery designation 9 Dustbin/material3 Battery type 10 Nominal battery voltage4 Battery number 11 Nominal battery capacity5 Battery tray number 12 Number of battery cells6 Delivery date 13 Battery weight7 Battery manufacturer's logo 14 Safety instructions and warnings

Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7

Number of CellsBatteriegewicht min/max 8

Battery mass min/max

Serien-Nr.3

Serial-Nr.Lieferanten Nr. 4

Supplier No.

Baujahr 2

Year of manufacture

Jungheinrich AG, D-22047 Hamburg, Germany

5

Pb Pb

2/3 651113

1

14

41012

7

8

9

17

0506

.GB

6. Malfunctions

If malfunctions are found on the battery or the charger our service department shouldbe called without delay. The measurements taken in point 3.3 will facilitate fault fin-ding and their elimination.

A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer!

Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must bedisposed of as hazardous waste!

We reserve the right make technical modification.

7.Type plate, Jungheinrich traction battery

* CE mark is only for batteries with a nominal voltage greater than 75 volt.

Item Designation Item Designation1 Logo 8 Recycling symbol2 Battery designation 9 Dustbin/material3 Battery type 10 Nominal battery voltage4 Battery number 11 Nominal battery capacity5 Battery tray number 12 Number of battery cells6 Delivery date 13 Battery weight7 Battery manufacturer's logo 14 Safety instructions and warnings

Typ1

Type

Nennspannung5

Nominal Voltage

Hersteller9

Manufacturer

Kapazität 6

Capacity

Zellenzahl7

Number of CellsBatteriegewicht min/max 8

Battery mass min/max

Serien-Nr.3

Serial-Nr.Lieferanten Nr. 4

Supplier No.

Baujahr 2

Year of manufacture

Jungheinrich AG, D-22047 Hamburg, Germany

5

Pb Pb

2/3 651113

1

14

41012

7

8

9

0506

.GB

18

0506

.GB

18