EJE 116/118/120

EJE 116/118/120

Operating instructions

50425855

06.06

10.03 -

G

7

Set

4

1

5

2

0

8

6

3

9

Foreword

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

For example: Page B 2 is the second page in chapter B.

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

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

F

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

M

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

Z

Used before notices and explanations.

t

Used to indicate standard equipment.

o

Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

Foreword

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

For example: Page B 2 is the second page in chapter B.

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

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

F

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

M

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

Z

Used before notices and explanations.

t

Used to indicate standard equipment.

o

Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

Table of contents

A Correct use and application of the truck

B Truck description

1

2

Description of use ............................................................................... B 1

Description of assemblies and functions ............................................. B 2

3 Technical data - Standard version ...................................................... B 3

3.1

Performance data for standard trucks ................................................ B 3

3.2

Dimensions ......................................................................................... B 3

3.3

EN standards ...................................................................................... B 5

3.4

Conditions for application .................................................................... B 5

4 Labels and plates ................................................................................ B 6

4.1

Truck identification plate ..................................................................... B 7

C Transportation and commissioning

1 Transportation by crane ...................................................................... C 1

2

3

Commissioning .................................................................................... C 1

Moving an incapacitated truck ............................................................. C 2

3.1

Emergency operation with service key 741 ( o ) .................................. C 3

D Battery - Servicing, recharging, replacement

3

4

5

1

2

Safety regulations governing the handling of lead-acid batteries ........ D 1

Battery type ......................................................................................... D 2

Batteries and motor output: ................................................................. D 2

Exposing the battery ........................................................................... D 3

Charging the battery ............................................................................ D 3

6

7

5.1

Charging the battery with a stationary charging device ...................... D 3

5.2

Selecting the charging curves in the integrated charging device (o) ... D 4

Removing and installing the battery .................................................... D 7

Battery discharge indicator ( t ) ........................................................... D 8

Table of contents


B Truck description

1

2

Description of use ............................................................................... B 1

Description of assemblies and functions ............................................. B 2

3 Technical data - Standard version ...................................................... B 3

3.1

Performance data for standard trucks ................................................ B 3

3.2

Dimensions ......................................................................................... B 3

3.3

EN standards ...................................................................................... B 5

3.4

Conditions for application .................................................................... B 5

4 Labels and plates ................................................................................ B 6

4.1

Truck identification plate ..................................................................... B 7


1 Transportation by crane ...................................................................... C 1

2

3

Commissioning .................................................................................... C 1

Moving an incapacitated truck ............................................................. C 2

3.1

Emergency operation with service key 741 ( o ) .................................. C 3


3

4

5

1

2

Safety regulations governing the handling of lead-acid batteries ........ D 1

Battery type ......................................................................................... D 2

Batteries and motor output: ................................................................. D 2

Exposing the battery ........................................................................... D 3

Charging the battery ............................................................................ D 3

6

7

5.1

Charging the battery with a stationary charging device ...................... D 3

5.2

Selecting the charging curves in the integrated charging device (o) ... D 4

Removing and installing the battery .................................................... D 7

Battery discharge indicator ( t ) ........................................................... D 8

I 1 I 1

I 2

E Operation

1

2

Safety regulations governing the operation of the fork lift truck .......... E 1

Description of the operating controls and displays .............................. E 2

3 Start-up of truck ................................................................................... E 4

4 Operation of the fork lift truck .............................................................. E 5

4.1

Safety regulations applicable when operating the truck ...................... E 5

4.2

Driving, steering, braking .................................................................... E 6

4.3

Picking up and setting down loads ...................................................... E 9

4.4

Rendering the vehicle safe when parking ........................................... E 9

5 Keyboard (CANCODE) ( o ) ................................................................. E 10

5.1

Code lock ............................................................................................ E 10

5.2

Travel programmes ............................................................................. E 12

5.3

Parameters .......................................................................................... E 12

5.4

Parameter settings .............................................................................. E 13

5.5

Travel parameters ............................................................................... E 17

6 Display instrument (CANDIS) ( o ) ....................................................... E 20

6.1

Discharge monitor function ................................................................. E 21

6.2

Operating hours display ...................................................................... E 21

6.3

Switch-on test ...................................................................................... E 21

6.4

Fault location ....................................................................................... E 22

F Maintenance of the fork lift truck

3

4

1

2

Operational safety and environmental protection ................................ F 1

Safety regulations applicable to truck maintenance ............................ F 1

Servicing and inspection ..................................................................... F 3

Maintenance Check - list EJE 116 / 118 / 120 .................................... F 4

5 Lubrication Schedule EJE 116 / 118 / 120 ......................................... F 6

5.1

Fuels, coolants and lubricants ............................................................. F 7

6 Instructions for the servicing operations .............................................. F 8

6.1

Preparing the truck for the performance of servicing and maintenance operations ...................................................................... F 8

6.2

Removing the front cover .................................................................... F 8

6.3

Removing the drive cover ................................................................... F 8

6.4

Checking the electric fuses ................................................................. F 9

6.5

Recommissioning the truck ................................................................. F 10

7 Decommissioning the fork lift truck ..................................................... F 10

7.1

Operations to be performed prior to decommissioning ....................... F 10

7.2

Measures to be taken during decommissioning .................................. F 10

7.3


8

9

Safety checks to be performed at regular intervals and following any untoward incidents ( D : Accident prevention check according to BGV D27) ....................................................................... F 11

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

I 2

E Operation

1

2

Safety regulations governing the operation of the fork lift truck .......... E 1

Description of the operating controls and displays .............................. E 2

3 Start-up of truck ................................................................................... E 4

4 Operation of the fork lift truck .............................................................. E 5

4.1

Safety regulations applicable when operating the truck ...................... E 5

4.2

Driving, steering, braking .................................................................... E 6

4.3

Picking up and setting down loads ...................................................... E 9

4.4

Rendering the vehicle safe when parking ........................................... E 9

5 Keyboard (CANCODE) ( o ) ................................................................. E 10

5.1

Code lock ............................................................................................ E 10

5.2

Travel programmes ............................................................................. E 12

5.3

Parameters .......................................................................................... E 12

5.4

Parameter settings .............................................................................. E 13

5.5

Travel parameters ............................................................................... E 17

6 Display instrument (CANDIS) ( o ) ....................................................... E 20

6.1

Discharge monitor function ................................................................. E 21

6.2

Operating hours display ...................................................................... E 21

6.3

Switch-on test ...................................................................................... E 21

6.4

Fault location ....................................................................................... E 22


3

4

1

2

Operational safety and environmental protection ................................ F 1

Safety regulations applicable to truck maintenance ............................ F 1

Servicing and inspection ..................................................................... F 3

Maintenance Check - list EJE 116 / 118 / 120 .................................... F 4

5 Lubrication Schedule EJE 116 / 118 / 120 ......................................... F 6

5.1

Fuels, coolants and lubricants ............................................................. F 7

6 Instructions for the servicing operations .............................................. F 8

6.1

Preparing the truck for the performance of servicing and maintenance operations ...................................................................... F 8

6.2

Removing the front cover .................................................................... F 8

6.3

Removing the drive cover ................................................................... F 8

6.4

Checking the electric fuses ................................................................. F 9

6.5


7 Decommissioning the fork lift truck ..................................................... F 10

7.1

Operations to be performed prior to decommissioning ....................... F 10

7.2

Measures to be taken during decommissioning .................................. F 10

7.3


8

9

Safety checks to be performed at regular intervals and following any untoward incidents ( D : Accident prevention check according to BGV D27) ....................................................................... F 11

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

Appendix

JH Traction Battery Operating Instructions

Z

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

Appendix

JH Traction Battery Operating Instructions

Z

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

1 1

2 2


Z

The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.

The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads.

It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.

Duties of the user: A „user“ within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties.

The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.

M

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

Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained.

Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.


Z

The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.

The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads.

It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.

Duties of the user: A „user“ within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties.

The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.

M

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

Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained.

Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.

A 1 A 1

A 2 A 2

1

B Truck description

Description of use

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

Qmax.

Truck type, load capacity and motor output:

Type

EJE 116

EJE 118

EJE 118

Load capacity

1,600 kg

1,800 kg

2,000 kg

Motor output

1.0 kW

1.0 kW

1.0 kW

1

B Truck description

Description of use

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

Qmax.

Truck type, load capacity and motor output:

Type

EJE 116

EJE 118

EJE 118

Load capacity

1,600 kg

1,800 kg

2,000 kg

Motor output

1.0 kW

1.0 kW

1.0 kW

7

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B 1 B 1

2 Description of assemblies and functions

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Item

1

2

3

Designation t Discharge indicator o Display instrument

(CANDIS) o Keyboard

(CANCODE) t Key switch o Key switch

(with an additional second stage for brake release) t Front cover t Drive cover (2 sections) t Supporting wheels t Drive wheel t = Standard equipment

10

11

12

13

14

15

Item

8

9

Designation t Load lifting device o Integrated charging device

24V/30A

(incl. safety circuit) t Battery hood t Controller t Collision safety device t Control shaft t Battery plug (emergency stop) t Inching speed pushbutton o = Optional equipment

B 2

2 Description of assemblies and functions

11

12

13

14

15

10

9

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1

4

7

2

5

8

0

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1

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3

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7

6

7

4

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Item

1

2

3

Designation t Discharge indicator o Display instrument

(CANDIS) o Keyboard

(CANCODE) t Key switch o Key switch

(with an additional second stage for brake release) t Front cover t Drive cover (2 sections) t Supporting wheels t Drive wheel t = Standard equipment

10

11

12

13

14

15

Item

8

9

Designation t Load lifting device o Integrated charging device

24V/30A

(incl. safety circuit) t Battery hood t Controller t Collision safety device t Control shaft t Battery plug (emergency stop) t Inching speed pushbutton o = Optional equipment

B 2

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

Designation

Q Load capacity

C Load centre distance for standard fork length *)

Travelling speed with/without load

Lifting speed with/without load

Lowering speed with/without load

Max. climbing capacity (5 min.) with/without load

EJE 116 EJE 118 EJE 120

1,600 1,800 2,000

600 600 600 kg mm

6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 km/h

3.4 / 4.2 3.3 / 4.2 3.2 / 4.2 cm/s

5.3 / 3.6 5.3 / 3.6 5.3 / 3.6 cm/s

10 / 20 9 / 20 8 / 20 %

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

3.2

Dimensions

Designation EJE 116 / 118 /

120

Short version

h

3

h

13

Lifting height

Load lifting device, lowered

Y* Wheel base (short, long) l

1 l

2

Overall length (short, long)

Length including back of fork (short, long) l Standard fork length

122

85

1,240 / 1,310

1,630 / 1,700

480 / 550

1,150 mm mm mm mm mm mm b

1

Truck width

Wa* Turning radius

700 mm

1,450 / 1,520 mm

Ast* Working aisle width 800 x 1200 pallets, lengthwise 1,915** / 1,985** mm

Ast* Working aisle width 1000 x 1200 pallets, crosswise 1,865 / 1,935 mm a Safety distance 200 mm

* Load section lifted / lowered +55 mm

** Diagonally as per VDI +204 mm

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

Designation

Q Load capacity

C Load centre distance for standard fork length *)

Travelling speed with/without load

Lifting speed with/without load

Lowering speed with/without load

Max. climbing capacity (5 min.) with/without load

EJE 116 EJE 118 EJE 120

1,600 1,800 2,000

600 600 600 kg mm

6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 km/h

3.4 / 4.2 3.3 / 4.2 3.2 / 4.2 cm/s

5.3 / 3.6 5.3 / 3.6 5.3 / 3.6 cm/s

10 / 20 9 / 20 8 / 20 %

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

3.2

Dimensions

Designation EJE 116 / 118 /

120

Short version

h

3

Lifting height

h

13

Load lifting device, lowered

Y* Wheel base (short, long) l

1 l

2

Overall length (short, long)

Length including back of fork (short, long) l Standard fork length

122

85

1,240 / 1,310

1,630 / 1,700

480 / 550

1,150 mm mm mm mm mm mm b

1

Truck width

Wa* Turning radius

700 mm

1,450 / 1,520 mm

Ast* Working aisle width 800 x 1200 pallets, lengthwise 1,915** / 1,985** mm

Ast* Working aisle width 1000 x 1200 pallets, crosswise 1,865 / 1,935 mm a Safety distance 200 mm

* Load section lifted / lowered +55 mm

** Diagonally as per VDI +204 mm

B 3 B 3

c l

Q

150 l

2 y l

1 c l

Q

150 l

2 y l

1

B 4

2

W a

A st

2

B 4

2

W a

A st

2

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. The sound pressure level is measured at the ear.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other standards contained therein.

Z

Electrical or electronic components and their arrangement may only be modified after written 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 environments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.

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. The sound pressure level is measured at the ear.

Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other standards contained therein.

Z

Electrical or electronic components and their arrangement may only be modified after written 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 environments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.

B 5 B 5

4 Labels and plates

16

Q max

2000 kg

17

18

20

Set

4

1

7

8

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5

6

3

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19

4 Labels and plates

16

Q max

2000 kg

17

18

20

Set

4

1

7

0

8

2

5

9

3

6

19

B 6

Item Designation

16 Truck identification plate

17 Load capacity Qmax

18 Prohibition sign “Do not ride on truck”

19 Lifting point for crane transportation

20 Plate confirming accident prevention checks (only D )

B 6

Item Designation

16 Truck identification plate

17 Load capacity Qmax

18 Prohibition sign “Do not ride on truck”

19 Lifting point for crane transportation

20 Plate confirming accident prevention checks (only D )

4.1

Truck identification plate

21

22

23

24

25

32

31

30

29

28

27

26

Item Designation

21 Type

22 Serial No.

23 Rated capacity in kg

Item Designation

27

28

29

Manufacturer logo

Min./max. battery weight in kg

Drive power in kW

24 System voltage V 30 Load centre distance in mm

25 Dead weight without battery in kg 31 Year of manufacture

26 Manufacturer 32 Option

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 indicate the serial number (22).

4.1

Truck identification plate

21

22

23

24

25

32

31

30

29

28

27

26

Item Designation

21 Type

22 Serial No.

23 Rated capacity in kg

Item Designation

27

28

29

Manufacturer logo

Min./max. battery weight in kg

Drive power in kW

24 System voltage V 30 Load centre distance in mm

25 Dead weight without battery in kg 31 Year of manufacture

26 Manufacturer 32 Option

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 indicate the serial number (22).

B 7 B 7

B 8 B 8


1 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).

1

M

Attach the crane equipment to the lift-ing points in such a manner that it absolutely cannot slip!

Lifting equipment for the crane must be attached in such a manner that it does not come into contact with components during lifting.

Set

2 Commissioning

M

Only drive the truck under battery power!

A rectified alternating current damages the electronic components. Cable connections to the battery (towing cable) must be shorter than 6 m.

In order to make the truck operationally ready after delivery or after transport, carry 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 manufacturer 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 driving time, this flattening disappears again.


1 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.


– Attach the crane equipment to the lifting points (1).

1

M

Attach the crane equipment to the lift-ing points in such a manner that it absolutely cannot slip!

Lifting equipment for the crane must be attached in such a manner that it does not come into contact with components during lifting.

Set

2 Commissioning

M

Only drive the truck under battery power!

A rectified alternating current damages the electronic components. Cable connections to the battery (towing cable) must be shorter than 6 m.

In order to make the truck operationally ready after delivery or after transport, carry 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 manufacturer 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 driving time, this flattening disappears again.

C 1 C 1

3 Moving an incapacitated truck

In order to be able to move the truck in emergency operation, the electromagnetically operated 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.!

3 Moving an incapacitated truck

In order to be able to move the truck in emergency operation, the electromagnetically operated 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.!

1

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0

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2

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C 2 C 2

3.1

Emergency operation with service key 741 ( o )

The EJE can be manually moved in case of faults in the electric system. A battery must 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.

3.1

Emergency operation with service key 741 ( o )

The EJE can be manually moved in case of faults in the electric system. A battery must 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 C 3

C 4 C 4


1 Safety regulations governing the handling of lead-acid batteries

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

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

Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a nonskid insulating mat.

Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for the disposal must be heeded.

M

Before closing the battery hood, make sure that the battery cable cannot be damaged.

F

Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid.

If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.

M

Only batteries with closed tray may be used.

F

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


1 Safety regulations governing the handling of lead-acid batteries

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

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

Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.

Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a nonskid insulating mat.

Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for the disposal must be heeded.

M

Before closing the battery hood, make sure that the battery cable cannot be damaged.

F

Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid.

If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.

M

Only batteries with closed tray may be used.

F

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

D 1 D 1

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 to chapter 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 battery compartment the truck.

3 Batteries and motor output:

24 V - PzS - battery

EJE

Short version (K)

1 PzS 126 Ah

1 PzS 150 Ah

1.0 kW

EJE

Long version (L)

1 PzS 200 Ah

Motor output 0,8 kW

Z

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

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

M

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

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 to chapter 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 battery compartment the truck.

3 Batteries and motor output:

24 V - PzS - battery

EJE

Short version (K)

1 PzS 126 Ah

1 PzS 150 Ah

1.0 kW

EJE

Long version (L)

1 PzS 200 Ah

Motor output 0,8 kW

Z

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

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

M

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

D 2 D 2

4 Exposing the battery


– 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 charging, 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 and plug connections for visible damage.

The safety regulations of the manufacturer of the battery and the charging station must 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 device and switch on the charging device.

1 2 3

4 Exposing the battery


– 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 charging, 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 and plug connections for visible damage.

The safety regulations of the manufacturer of the battery and the charging station must be heeded.

5.1

Charging the battery with a stationary charging device



– Connect the battery plug (3) with the charging cable of the stationary charging device and switch on the charging device.

1 2 3

Set

7

1

4

0

5

8

2

9

6

3

Set

7

1

4

0

5

8

2

3

9

6

D 3 D 3

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.

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.

6

5 4

Select charging curve in the integrated battery charger

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

M

The power plug must be pulled before the corresponding charging curve is to be adjusted!

M

Provided that a battery is connected, a new setting can be acknowledged via the

LEDs (cf. indicator) which will then be immediately effective.

Switch (5) Position

1

2

3

4

5

Selected charge curves (characteristics)

Wet cell batteries: 100 - 300 Ah

Maintenance-free: 100 -149 Ah


Maintenance-free: 200 - 300 Ah

Wet cell batteries: 200 - 400 Ah pulse characteristic

Wet cell batteries: Jungheinrich 100 - 300 Ah 6

Z

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

D 4

6

5 4

Select charging curve in the integrated battery charger

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

M

The power plug must be pulled before the corresponding charging curve is to be adjusted!

M

Provided that a battery is connected, a new setting can be acknowledged via the

LEDs (cf. indicator) which will then be immediately effective.

Switch (5) Position

1

2

3

4

5

Selected charge curves (characteristics)

Wet cell batteries: 100 - 300 Ah



Maintenance-free: 200 - 300 Ah

Wet cell batteries: 200 - 400 Ah pulse characteristic

Wet cell batteries: Jungheinrich 100 - 300 Ah 6

Z

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

D 4

Adjusting the charging curve

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

Connect the battery

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

This allows you to adjust via the charger

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

If invalid, the red LED flashes.

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 ensure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. The safety instructions provided by the battery supplier and battery 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 charging status and/or a fault (flashing codes see table “LED display”).

Z

If the power plug (6) is connected to the mains, all electric functions of the truck are interrupted (electric driving lock). No operation of the truck is possible.

7

– Pull plug (6) from the power socket and 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 continued in steps.

F

The mains cable must not be damaged.

Before commissioning the truck, the battery hood must be properly closed.

D 5

Adjusting the charging curve

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

Connect the battery

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

This allows you to adjust via the charger

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

If invalid, the red LED flashes.

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 ensure adequate ventilation. Metal objects must not be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. The safety instructions provided by the battery supplier and battery 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 charging status and/or a fault (flashing codes see table “LED display”).

Z

If the power plug (6) is connected to the mains, all electric functions of the truck are interrupted (electric driving lock). No operation of the truck is possible.

7

– Pull plug (6) from the power socket and 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 continued in steps.

F

The mains cable must not be damaged.

Before commissioning the truck, the battery hood must be properly closed.

D 5

D 6

Charging times

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

LED display

Green LED

(charging status) is lit

Red LED

(fault)

Indication flashes slowly flashes fast

---

---

---

---

---

---

--is lit

Recharge procedure is finished; battery is full.

(charging break, fill-up charge or equalization charge)

Charging process

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.

Excess temperature. Recharge process is interrupted.

flashes slowly Safety charging interval exceeded. Recharge process 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.

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 the charging status of partially recharged batteries. This permits to reduce wear and tear of the battery.

Charging times

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

LED display

Green LED

(charging status) is lit

Red LED

(fault)

Indication flashes slowly flashes fast

---

---

---

---

---

---

--is lit

Recharge procedure is finished; battery is full.

(charging break, fill-up charge or equalization charge)

Charging process

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.

Excess temperature. Recharge process is interrupted.

flashes slowly Safety charging interval exceeded. Recharge process 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.

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 the charging status of partially recharged batteries. This permits to reduce wear and tear of the battery.

D 6

6 Removing and installing the battery

F

The truck must stand horizontally. To prevent short circuits, batteries with open poles or connectors must be covered with a rubber mat. Lay down the battery plug and cable 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 capacity is sufficient (see battery weight on the battery identification plate on the battery trough). The crane equipment must pull vertically. The hooks of the crane equipment must never fall onto the battery cells.



– Connect the crane equipment to the eyelets (7).

– Pull the battery upwards and out of the battery trough.

8

3

7

Set

4

1

5

2

8

0

6

3

9

6 Removing and installing the battery

F

The truck must stand horizontally. To prevent short circuits, batteries with open poles or connectors must be covered with a rubber mat. Lay down the battery plug and cable 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 capacity is sufficient (see battery weight on the battery identification plate on the battery trough). The crane equipment must pull vertically. The hooks of the crane equipment must never fall onto the battery cells.



– Connect the crane equipment to the eyelets (7).

– Pull the battery upwards and out of the battery trough.

8

3

7

Set

1

4

0

8

5

2

9

6

3

M

Installation occurs in the reverse sequence; pay attention that the battery is installed in 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.

D 7

M

Installation occurs in the reverse sequence; pay attention that the battery is installed in 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.

D 7

7 Battery discharge indicator ( t )

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

CANCODE.

9

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

LED color green orange

Residual capacity, standard battery

Residual capacity, maintenance-free battery




Rating

40 - 100%

60 - 100%

30 - 40%

50 - 60%

20 - 30% green/orange flashing, 1Hz red




40 - 50%

0 - 20%

0 - 40%

Z

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

The display is reset to 100% if the battery capacity determined when the truck is switched on is at least 70% of a fully charged battery. Depending on the residual capacity, the display is reduced in steps of 10%. The displayed residual capacity changes 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 operated any longer. The LED flashing red signals a truck controller malfunction. The flash sequence indicates the malfunction type.

7 Battery discharge indicator ( t )

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

CANCODE.

9

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

LED color green orange






Rating

40 - 100%

60 - 100%

30 - 40%

50 - 60%

20 - 30% green/orange flashing, 1Hz red




40 - 50%

0 - 20%

0 - 40%

Z

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

The display is reset to 100% if the battery capacity determined when the truck is switched on is at least 70% of a fully charged battery. Depending on the residual capacity, the display is reduced in steps of 10%. The displayed residual capacity changes 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 operated any longer. The LED flashing red signals a truck controller malfunction. The flash sequence indicates the malfunction type.

D 8 D 8

E Operation

1 Safety regulations governing the operation of the fork lift truck

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

Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him.

If the fork lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.

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

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

Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.

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

F

Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop.

The fork lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.

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

E Operation

1 Safety regulations governing the operation of the fork lift truck

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

Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him.

If the fork lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.

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

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

Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.

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

F

Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop.

The fork lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.

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

E 1 E 1

2 Description of the operating controls and displays

Item Operating control or dis-

1

2 Battery plug (emergency

3

4

5

7

8 play

Control shaft stop)

Discharge indicator

Display instrument

(CANDIS)

Keyboard

(CANCODE)

Key switch

Key switch with second position

6 Integrated charging device

(incl. safety circuit)

Inching speed pushbutton

Controller

9 Collision safety button

10 Button for lifting load lifting device

11 Button for lowering load lifting device

12 Operating key “Horn”

EJE 116 /

118 / 120 t t t o

Function

Steers and brakes truck.

The power circuit is interrupted and all electrical functions are switched off.

Battery discharge state.

Operating hours meter.


Display of service messages and, in conjunction with CANCODE, drive parameters.

o t

Code settings.

Releasing and selecting the travel programmes.

Entering travel parameters.

Switches the control current on and off. Pulling out the key prevents unauthorised persons from switching on the truck.

o o

Releases the brake to allow a nonoperable truck to be moved.

Charges the battery; insert the power plug into a mains socket.

t t

Pressing the Inching speed push button reduces travel speed and acceleration. When the control shaft is in the upper brake area, the braking function can be bypassed by pressing this key and the truck can be moved at reduced speed.

Controls the travelling direction and speed.

t t

Truck drives away from operator.

Lifts load lifting device.

t t

Lowers load lifting device.

Gives an audible warning signal.

t = Standard equipment o = Optional equipment

E 2

2 Description of the operating controls and displays

Item Operating control or dis-

1

2 Battery plug (emergency

3

4

5

7

8 play

Control shaft stop)

Discharge indicator

Display instrument

(CANDIS)

Keyboard

(CANCODE)

Key switch

Key switch with second position

6 Integrated charging device

(incl. safety circuit)

Inching speed pushbutton

Controller

9 Collision safety button

10 Button for lifting load lifting device

11 Button for lowering load lifting device

12 Operating key “Horn”

EJE 116 /

118 / 120 t t t o

Function

Steers and brakes truck.

The power circuit is interrupted and all electrical functions are switched off.


Operating hours meter.


Display of service messages and, in conjunction with CANCODE, drive parameters.

o t

Code settings.

Releasing and selecting the travel programmes.

Entering travel parameters.

Switches the control current on and off. Pulling out the key prevents unauthorised persons from switching on the truck.

o o

Releases the brake to allow a nonoperable truck to be moved.

Charges the battery; insert the power plug into a mains socket.

t t

Pressing the Inching speed push button reduces travel speed and acceleration. When the control shaft is in the upper brake area, the braking function can be bypassed by pressing this key and the truck can be moved at reduced speed.

Controls the travelling direction and speed.

t t

Truck drives away from operator.

Lifts load lifting device.

t t

Lowers load lifting device.

Gives an audible warning signal.

t = Standard equipment o = Optional equipment

E 2

7

8 9 8

10

11

12

1

4

7

2

3

5

8

0

6

9

3

4

5

6

1

2

7

8 9 8

10

11

12

1

4

2

7

5

8

0

3

6

9

3

4

5

6

1

2

E 3 E 3

3 Start-up of truck

F

Before the truck can be started up or operated or a load can be lifted, the driver must make 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).

12

1

4

7

2

5

8

0

3

6

9

1

2

3

4

5

3 Start-up of truck

F

Before the truck can be started up or operated or a load can be lifted, the driver must make 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).

12

1

4

7

2

5

8

0

3

6

9

1

2

3

4

5

E 4 E 4

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 allocated for truck traffic must be used. Unauthorized persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.

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

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

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

Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft.

Persons riding in the lift together with the fork lift truck must only enter the lift after the fork lift truck has come safely to a standstill, and must leave the lift before the fork lift truck.

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

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 allocated for truck traffic must be used. Unauthorized persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.

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

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

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

Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft.

Persons riding in the lift together with the fork lift truck must only enter the lift after the fork lift truck has come safely to a standstill, and must leave the lift before the fork lift truck.

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

E 5 E 5

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 automatically moves into the upper braking area (B).

F

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

Driving

M

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

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 confined spaces / elevators):

– Press the “Inching” pushbutton (7).

– Set the travel direction switch (8) to the desired direction (V or R, forward or backward).

Parking brake is released. The truck starts moving slowly.

M

The brake is applied when the “Inching” pushbutton is released only; at inching speed, 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) immediately.

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

E 6

4.2

Driving, steering, braking

F

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

Emergency stop


All electrical functions are switched off.

Forced braking

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

F

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

Driving

M

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

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 confined spaces / elevators):

– Press the “Inching” pushbutton (7).

– Set the travel direction switch (8) to the desired direction (V or R, forward or backward).

Parking brake is released. The truck starts moving slowly.

M

The brake is applied when the “Inching” pushbutton is released only; at inching speed, 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) immediately.

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

E 6

0

R

V

8

1

B

F

Set

B

7

V

R

Steering

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

0

R

V

8

1

B

F

Set

B

7

V

R

Steering

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

E 7 E 7

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 the brake positions (B).

M

The service brake is the regenerative brake. The mechanical brake is applied only if this brake does not reach the required deceleration.

Braking using the countercurrent brake: 7

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

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

Braking with the coasting brake

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

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 is set to “0” (the controller detects the truck rolling down). With the drive controller you release the service brake and control the speed and the travel direction as desired.

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 the brake positions (B).

M

The service brake is the regenerative brake. The mechanical brake is applied only if this brake does not reach the required deceleration.

Braking using the countercurrent brake: 7

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

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

Braking with the coasting brake

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

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 is set to “0” (the controller detects the truck rolling down). With the drive controller you release the service brake and control the speed and the travel direction as desired.

E 8 E 8

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 paletted and 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 is reached.

Lowering

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

(14)).

14

13 10

11

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 paletted and 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 is reached.

Lowering

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

(14)).

14

13 10

11

5

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”.

E 9

5

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”.

E 9

5 Keyboard (CANCODE) ( o )

The operator keyboard is composed of 10 numeric keys, a Set key and an o -key.

Activation of the travel programs by means of switches 1,2,3 is indicated by green LEDs.

The o -key indicates operating conditions by a red/green LED.

1 2 3

4 5 6

It has the following functions:

7 8

– Code lock function (setting the truck into operation).

– Selecting the travel program.

– Setting the travel and battery parameters, only in conjunction with the indicator instrument

(CANDIS ( o )).

Set 0

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

9

5.1

Code lock

After entering the correct code, the truck is ready for operation. It is possible to assign an 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 indicated on a removable sticker.

M

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

5 Keyboard (CANCODE) ( o )

The operator keyboard is composed of 10 numeric keys, a Set key and an o -key.

Activation of the travel programs by means of switches 1,2,3 is indicated by green LEDs.

The o -key indicates operating conditions by a red/green LED.

1 2 3

4 5 6

It has the following functions:

7 8

– Code lock function (setting the truck into operation).

– Selecting the travel program.

– Setting the travel and battery parameters, only in conjunction with the indicator instrument

(CANDIS ( o )).

Set 0

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

9

5.1

Code lock

After entering the correct code, the truck is ready for operation. It is possible to assign an 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 indicated on a removable sticker.

M

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

E 10 E 10

Commissioning

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

After entering the correct operator code (factory setting 2-5-8-0) the LED (15) lights up 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 the o key (20).

Z

The truck can be switched off automatically after a preset time. For that purpose the corresponding code lock parameter must be set

(refer to section 5.4).

17 18 19

1

4

7

Set

2

5

8

0

3

6

9

16

20

15

Commissioning

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

After entering the correct operator code (factory setting 2-5-8-0) the LED (15) lights up 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 the o key (20).

Z

The truck can be switched off automatically after a preset time. For that purpose the corresponding code lock parameter must be set

(refer to section 5.4).

17 18 19

1

4

7

Set

2

5

8

0

3

6

9

16

20

15

E 11 E 11

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 corresponding key.

Z

The travel programmes differ with respect to travelling speed, acceleration, and deceleration.

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 functions and the adaption of the travel programmes. Additionally, the battery parameters can be set.

Z

For trucks without indicator instrument (CANDIS ( can be set.

o )) only the code lock parameters

Parameter groups

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

No. Parameter group

0xx Code lock settings

(Codes, travel programme enable, automatic switch-off, etc.)

1xx Travel programme 1 parameters

(Acceleration, coasting brake, speed, etc.)





4xx Programme-independent parameters

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 corresponding key.

Z

The travel programmes differ with respect to travelling speed, acceleration, and deceleration.

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 functions and the adaption of the travel programmes. Additionally, the battery parameters can be set.

Z

For trucks without indicator instrument (CANDIS ( can be set.

o )) only the code lock parameters

Parameter groups

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

No. Parameter group

0xx Code lock settings

(Codes, travel programme enable, automatic switch-off, etc.)







4xx Programme-independent parameters

E 12 E 12

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 (refer to 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 indicator instrument (CANDIS ( o )). If in doubt, the setting procedure must be cancelled by pressing the o -key (20).

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

Entering the master code:

– Press the o -key

– Enter master code

Operating hours are indicated

Display instrument

(CANDIS)

284 .

0

LED (15) o -key green flashing

LED (17)

Key 1 off

LED (18)

Key 2 off

LED (19)

Key 3 off

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. After entering the parameter number again, the setting value can be entered or changed.

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

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 (refer to 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 indicator instrument (CANDIS ( o )). If in doubt, the setting procedure must be cancelled by pressing the o -key (20).

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

Entering the master code:

– Press the o -key

– Enter master code

Operating hours are indicated

Display instrument

(CANDIS)

284 .

0

LED (15) o -key green flashing

LED (17)

Key 1 off

LED (18)

Key 2 off

LED (19)

Key 3 off

Code lock parameters

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



Set key (16).

Z



E 13 E 13

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


– 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 restart from the beginning.


Set key (16).

Z



The following parameters can be entered:

Code lock parameter list

No.

Function Range

Setting value

Default

Setting value

Comments

Work flow

Code lock

000 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 - 9999 or

00000 - 99999 or

000000 - 999999

7295 (LED 17 flashes)

Enter the current code confirm (Set)

(LED 18 flashes)

Enter a new code

001 Add operator code

(max. 600)

0000 - 9999 or

00000 - 99999 or

000000 - 999999

2580 confirm (Set)

(LED 19 flashes)

Repeat new code

Confirm (Set)

(LED 18 flashes)

Enter a code confirm (Set)

(LED 19 flashes)

Repeat the code entry

Confim (Set)

E 14

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


– 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 restart from the beginning.


Set key (16).

Z




Code lock parameter list

No.

Function Range

Setting value

Default

Setting value

Comments

Work flow

Code lock

000 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 - 9999 or

00000 - 99999 or

000000 - 999999

7295 (LED 17 flashes)

Enter the current code confirm (Set)

(LED 18 flashes)

Enter a new code

001 Add operator code

(max. 600)

0000 - 9999 or

00000 - 99999 or

000000 - 999999

2580 confirm (Set)

(LED 19 flashes)

Repeat new code

Confirm (Set)

(LED 18 flashes)

Enter a code confirm (Set)

(LED 19 flashes)


Confim (Set)

E 14

No.

Function Range

Setting value

Default

Setting value

Comments

Work flow

Code lock

002 Change operator code 0000 - 9999 or

00000 - 99999 or

000000 - 999999

(LED 17 flashes)

Enter the current code

Confirm (Set)

(LED 18 flashes)

Enter a new code

Confirm (Set)

(LED 19 flashes)


Confirm

(LED 18 flashes)

Enter a code

003 Delete operator code 0000 - 9999 or

00000 - 99999 or

000000 - 999999

Confirm (Set)

(LED 19 flashes)


004 Clear code memory

(deletes all operator codes)

010 automatic switch-off

3265

00 - 31 00

Confirm (Set)

3265 = delete other entry = do not delete

00 = none

Switch-off

01 to 30 =

Switch-off time in minutes

31 = switch-off after

10 seconds

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

E 15

No.

Function Range

Setting value

Default

Setting value

Comments

Work flow

Code lock

002 Change operator code 0000 - 9999 or

00000 - 99999 or

000000 - 999999

(LED 17 flashes)

Enter the current code

Confirm (Set)

(LED 18 flashes)

Enter a new code

Confirm (Set)

(LED 19 flashes)


Confirm

(LED 18 flashes)

Enter a code

003 Delete operator code 0000 - 9999 or

00000 - 99999 or

000000 - 999999

Confirm (Set)

(LED 19 flashes)


004 Clear code memory

(deletes all operator codes)

010 automatic switch-off

3265

00 - 31 00

Confirm (Set)

3265 = delete other entry = do not delete

00 = none

Switch-off

01 to 30 =

Switch-off time in minutes

31 = switch-off after

10 seconds

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

E 15

E 16

No.

Code lock

021 Travel programme 1*

Enable


Enable

Function


Enable

)

)

)

Range

Setting value

Default

Setting value

0 or 1 1

0 or 1

0 or 1

1

1

Comments

Work flow

0 = Travel programme not enabled

1 = Travel programme enabled





030 Display of the number of used operator codes*

)

*

) 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.

Code lock


Enable


Enable

Function


Enable

)

)

)

Range

Setting value

Default

Setting value

0 or 1 1

0 or 1

0 or 1

1

1

Comments

Work flow







030 Display of the number of used operator codes*

)

*

) 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.

E 16

5.5

Travel parameters

Z

For trucks without indicator instrument (CANDIS ( only be set by the manufacturer's service.

o )) the code lock parameters can

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

Acceleration example current setting is displayed changed setting is displayed

Display instrument

(CANDIS)

101 6

101 8

Parameter number

Parameter setting value

LED (15) o -key green flashing green flashing

LED (17)

Key 1 off off

LED (18)

Key 2 off

LED (19)

Key 3 off off off

– 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 hours indication.

F

If another parameter number than the one displayed is desired, you must wait until the 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


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 to be checked in travel operation, follow this sequence:

– Select the modified travel programme after entering the parameter value, confirm with 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.

E 17

5.5

Travel parameters

Z



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

Acceleration example current setting is displayed changed setting is displayed

Display instrument

(CANDIS)

101 6

101 8

Parameter number

Parameter setting value

LED (15) o -key green flashing green flashing

LED (17)

Key 1 off off

LED (18)

Key 2 off

LED (19)

Key 3 off off off

– 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 hours indication.

F

If another parameter number than the one displayed is desired, you must wait until the 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


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 to be checked in travel operation, follow this sequence:

– Select the modified travel programme after entering the parameter value, confirm with 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.

E 17

E 18


Travel programmes

No.

Function Range

Setting value

Standard

Setting value

Travel Programme 1

101 Acceleration

102 Coasting brake

104 Maximum speed in drive direction via controller

108 Maximum speed in fork direction via controller

0 - 9

(0,2 - 2,0 m/s

2

)

0 - 9

(0,2 - 1,1 m/s

2

)

0 - 9

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

0 - 9

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

3

(0,8 m/s

2

)

3

(0,5 m/s

2

)

3

(4,8 km/h)

3

(4,8 km/h)

Comments depending on controller depending on controller

No.

Function Range

Setting value

Standard

Setting value


201 Acceleration

202 Coasting brake



0 - 9

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

0 - 9

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

0 - 9

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

0 - 9

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

6

(1,4 m/s)

6

(0,8 m/s)

8

(6,0 km/h)

8

(6,0 km/h)



Travel programmes

No.

Function Range

Setting value

Standard

Setting value


101 Acceleration

102 Coasting brake



0 - 9

(0,2 - 2,0 m/s

2

)

0 - 9

(0,2 - 1,1 m/s

2

)

0 - 9

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

0 - 9

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

3

(0,8 m/s

2

)

3

(0,5 m/s

2

)

3

(4,8 km/h)

3

(4,8 km/h)


No.

Function Range

Setting value

Standard

Setting value


201 Acceleration

202 Coasting brake



0 - 9

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

0 - 9

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

0 - 9

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

0 - 9

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

6

(1,4 m/s)

6

(0,8 m/s)

8

(6,0 km/h)

8

(6,0 km/h)


E 18

No.

Function Range

Setting value

Standard

Setting value

Comments


301 Acceleration

302 Coasting brake



0 - 9

(0,2 - 2,0 m/s

2

)

0 - 9

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

0 - 9

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

0 - 9

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

9

(2,0 m/s

2

)

9

(1,1 m/s 2 )

8

(6,0 km/h)

8

(6,0 km/h) depending on controller depending on controller

Battery parameters

Z



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


No.

Function Range

Setting value

Standard

Setting value

Comments


411 Battery type

(normal/high-power/dry)

0 - 2 0 0 = Normal (wet)

1 = High-power (wet)

2 = Dry

(maintenance-free)

412 Discharge monitor function

0 / 1 1

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

No.

Function Range

Setting value

Standard

Setting value

Comments


301 Acceleration

302 Coasting brake



0 - 9

(0,2 - 2,0 m/s

2

)

0 - 9

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

0 - 9

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

0 - 9

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

9

(2,0 m/s

2

)

9

(1,1 m/s 2 )

8

(6,0 km/h)

8

(6,0 km/h) depending on controller depending on controller


Z



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


No.

Function Range

Setting value

Standard

Setting value

Comments


411 Battery type

(normal/high-power/dry)

0 - 2 0 0 = Normal (wet)

1 = High-power (wet)

2 = Dry

(maintenance-free)

412 Discharge monitor function

0 / 1 1

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

E 19 E 19

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 electronic components and parameter changes are indicated.

21

22

23

24

Discharge status indication

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

Number

Bars

10

9

8

7

6

Charging condition

90.1- 100%

80.1 - 90%

70.1 - 80%

60.1 - 70%

50.1 - 60%

Wet battery

LED (yellow)

Warning

LED (red)

Stop

Off

Off

Off

Off

Off

Off

Off

Off

Off

Off

Maintenance-free battery

LED (yellow)

Warning

Off

Off

Off

Off

Off

3

2

5

4

40.1 - 50%

30.1 - 40%

20.1 - 30%

10.1 - 20%

Off

Off

On

On

Off

Off

Off

On

On

On

On

On

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

LED (red)

Stop

Off

Off

Off

Off

Off

Off

On

On

On

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 electronic components and parameter changes are indicated.

21

22

23

24

Discharge status indication

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

Number

Bars

10

9

8

7

6

Charging condition

90.1- 100%

80.1 - 90%

70.1 - 80%

60.1 - 70%

50.1 - 60%

Wet battery

LED (yellow)

Warning

LED (red)

Stop

Off

Off

Off

Off

Off

Off

Off

Off

Off

Off

Maintenance-free battery

LED (yellow)

Warning

Off

Off

Off

Off

Off

3

2

5

4

40.1 - 50%

30.1 - 40%

20.1 - 30%

10.1 - 20%

Off

Off

On

On

Off

Off

Off

On

On

On

On

On

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

LED (red)

Stop

Off

Off

Off

Off

Off

Off

On

On

On

E 20 E 20

6.1

Discharge monitor function

With the discharge monitor function enabled, the lifting function switches of when reaching the discharge limit (the Stop LED switches on). Travelling and lowering is still possible. For wet batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. At 30% for wet batteries resp. 50% for maintenance-free batteries the batteries 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 are logged. 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 displayed in 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 displayed as long as they are present (always in combination Cxxx / Exxx).

Errors are displayed as long as they persist. The operating hours display is overwritten with an error message. Most errors cause the emergency stop to be triggered. The error display is maintained until the control circuit is switched off (Code lock).

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

Z

Detailed component descriptions including error codes are available at the manufacturers 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 the parameter 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

6.1

Discharge monitor function

With the discharge monitor function enabled, the lifting function switches of when reaching the discharge limit (the Stop LED switches on). Travelling and lowering is still possible. For wet batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. At 30% for wet batteries resp. 50% for maintenance-free batteries the batteries 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 are logged. 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 displayed in 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 displayed as long as they are present (always in combination Cxxx / Exxx).

Errors are displayed as long as they persist. The operating hours display is overwritten with an error message. Most errors cause the emergency stop to be triggered. The error display is maintained until the control circuit is switched off (Code lock).

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

Z

Detailed component descriptions including error codes are available at the manufacturers 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 the parameter 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

6.4

Fault location

Fault

Truck does not move

Load cannot be lifted

Possible cause

– Battery connector not connected.

– Key switch in position “0”.

– Incorrect CANCODE code

– Battery exhausted.

– Fuse defective.

– Truck is being charged

– Battery capacity below

20 / 40%

– Truck not operative.

Remedial action

– Check the battery connector and connect 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

– Charging the battery

– Hydraulic oil level too low.

– Fuse defective.

– Perform all remedial actions listed under the fault “Truck does not move”.

– Check the hydraulic oil level

– Check fuse 2F1

Z

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

6.4

Fault location

Fault

Truck does not move

Load cannot be lifted

Possible cause

– Battery connector not connected.

– Key switch in position “0”.

– Incorrect CANCODE code

– Battery exhausted.

– Fuse defective.

– Truck is being charged

– Battery capacity below

20 / 40%

– Truck not operative.

– Hydraulic oil level too low.

– Fuse defective.

Remedial action

– Check the battery connector and connect 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

– Charging the battery

– Perform all remedial actions listed under the fault “Truck does not move”.

– Check the hydraulic oil level

– Check fuse 2F1

Z

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

E 22 E 22


1 Operational safety and environmental protection

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

F

Modifications of fork lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.

M

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

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

2 Safety regulations applicable to truck maintenance

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

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

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

M

If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning.

Cleaning by means of a steam jet is not permitted.

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

F 1


1 Operational safety and environmental protection

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

F

Modifications of fork lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.

M

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

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

2 Safety regulations applicable to truck maintenance

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

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

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

M

If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning.

Cleaning by means of a steam jet is not permitted.

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

F 1

F 2

Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork lift trucks, the truck must also be depowered by removing the battery plug.

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

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

Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. The factory-mounted tyres must only be replaced by original spare parts of the manufacturer, since otherwise the specification of the data sheet cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified.

The external application of grease does not provide sufficient lubrication.

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

Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork lift trucks, the truck must also be depowered by removing the battery plug.

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

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

Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. The factory-mounted tyres must only be replaced by original spare parts of the manufacturer, since otherwise the specification of the data sheet cannot be met. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).

Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified.

The external application of grease does not provide sufficient lubrication.

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

F 2

3 Servicing and inspection

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

M

The application conditions of an industrial truck have a considerable impact on the wear of the service components.

We recommend that a Jungheinrich customer adviser carries out an application analysis 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 operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.

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

W = every 50 operating hours, but at least once per week

A = every 500 operating hours, or at least every six months

B = every 1000 operating hours, or at least annually

C = 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 owner must check the wheel nuts/bolts and re-tighten if necessary.

3 Servicing and inspection

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

M

The application conditions of an industrial truck have a considerable impact on the wear of the service components.

We recommend that a Jungheinrich customer adviser carries out an application analysis 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 operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.

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

W = every 50 operating hours, but at least once per week

A = every 500 operating hours, or at least every six months

B = every 1000 operating hours, or at least annually

C = 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 owner must check the wheel nuts/bolts and re-tighten if necessary.

F 3 F 3

4 Maintenance Check - list EJE 116 / 118 / 120

Maintenance intervals

Chassis and superstruct.:

Drive unit:

Wheels:

Steering:

Brake system:

Standard = t W A B C

Cold store = k

1.1 Check all load bearing elements for damage

1.2 Check all bolted connections

2.1 Check the transmission for noises and leakage

2.2 Check the transmission oil level

2.3 Change the transmission oil t t t t k t

3.1 Check for wear and damage

3.2 Check the wheel bearings and ensure t k t secure fastening of wheels

4.1 Check the steering wheel play

5.1 Performance and adjustment check

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

Lifting device:

Hydraulic system:

5.3 Check the brake linings for wear

5.4 Check the brake linkage; adjust and grease, if necessary


6.2 Perform sight check of rollers, sliding elements, and stops

7.1 Performance check

7.2 Check all connections for leakage and damage

7.3 Check hydraulic cylinders for leakage, damage k t k t

6.3 Check fork tines and fork carrier for wear and damage k t k t k t k t and secure attachment

7.4 Check the oil level k t

7.5 Change hydraulic oil and filter cartridge k t k t

Electrical system:

Electric

7.6 Check the pressure relief valves for correct functioning


8.2 Check all cables for secure connection and damage t t

8.3 Check the fuses for correct amperage

8.4 Check switches and trip cams for secure attachment t and correct functioning

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

8.6 Check the warning installation for correct functioning k t

9.1 Check the motor for secure attachment t t motors:

4 Maintenance Check - list EJE 116 / 118 / 120


Chassis and superstruct.:

Drive unit:

Wheels:

Steering:

Brake system:


Cold store = k

1.1 Check all load bearing elements for damage

1.2 Check all bolted connections

2.1 Check the transmission for noises and leakage

2.2 Check the transmission oil level

2.3 Change the transmission oil t t t t k t

3.1 Check for wear and damage

3.2 Check the wheel bearings and ensure t k t secure fastening of wheels

4.1 Check the steering wheel play


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

Lifting device:

Hydraulic system:

5.3 Check the brake linings for wear

5.4 Check the brake linkage; adjust and grease, if necessary


6.2 Perform sight check of rollers, sliding elements, and stops


7.2 Check all connections for leakage and damage

7.3 Check hydraulic cylinders for leakage, damage k t k t

6.3 Check fork tines and fork carrier for wear and damage k t k t k t k t and secure attachment

7.4 Check the oil level k t

7.5 Change hydraulic oil and filter cartridge k t k t

Electrical system:

Electric

7.6 Check the pressure relief valves for correct functioning


8.2 Check all cables for secure connection and damage t t

8.3 Check the fuses for correct amperage

8.4 Check switches and trip cams for secure attachment t and correct functioning

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

8.6 Check the warning installation for correct functioning k t

9.1 Check the motor for secure attachment t t motors:

F 4 F 4

Battery:

Lubrication:


10.2 Check the terminals for secure attachment and apply grease


Cold store = k

10.1 Check acid density, acid level and cell voltage l t l t

10.3 Clean the battery connections; check for tight fitting

10.4 Check the battery cables for damage, renew if necessary

11.1 Grease the vehicle in accordance with the lubrication schedule l t t l t

General measurements:

12.1 Check the electrical system for a grounding fault

12.2 Check the driving speed and braking distance

12.3 Check the lifting and lowering speed t t t

Demonstration:

12.4 Check safety and shutdown devices

13.1 Perform a trial run under a nominal load

13.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible t t l t

Battery:

Lubrication:


10.2 Check the terminals for secure attachment and apply grease


Cold store = k

10.1 Check acid density, acid level and cell voltage l t l t

10.3 Clean the battery connections; check for tight fitting

10.4 Check the battery cables for damage, renew if necessary

11.1 Grease the vehicle in accordance with the lubrication schedule l t t l t

General measurements:

12.1 Check the electrical system for a grounding fault

12.2 Check the driving speed and braking distance

12.3 Check the lifting and lowering speed t t t

Demonstration:

12.4 Check safety and shutdown devices

13.1 Perform a trial run under a nominal load

13.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible t t l t

F 5 F 5

5 Lubrication Schedule EJE 116 / 118 / 120

1

2

4

7

5

8

0

3

6

9

E

E

E 0,55 l

F 6 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

1)

Cold store usage

Compound for cold store usage 1:1

1)

5 Lubrication Schedule EJE 116 / 118 / 120

1

2

4

7

5

8

0

3

6

9

E

E

E 0,55 l

F 6 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

1)

Cold store usage

Compound for cold store usage 1:1

1)

5.1

Fuels, coolants and lubricants

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

F

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

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

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

Code Order-no.

Supply Qty Designation

A 50 449 669 5,0 l

Used for:

H-LP 46, DIN 51524 Hydraulic system

B 50 380 904 5,0 l Fuchs Titan Gear

HSY 75W-90

Transmission

C 29 200 810

E 29 202 050

5,0 l

1.0 kg


Grease, Polylub

GA352P

Lubrication

Grease Data

Code Saponification Dropp. point

° C

E Lithium >220

Worked penetr. at 25 ° C

280 - 310

NLG1 class

2

Service temperat.

° C

-35 / +120

5.1

Fuels, coolants and lubricants

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

F

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

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

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

Code Order-no.

Supply Qty Designation

A 50 449 669 5,0 l

Used for:


B 50 380 904 5,0 l Fuchs Titan Gear

HSY 75W-90

Transmission

C 29 200 810

E 29 202 050

5,0 l

1.0 kg


Grease, Polylub

GA352P

Lubrication

Grease Data

Code Saponification Dropp. point

° C

E Lithium >220

Worked penetr. at 25 ° C

280 - 310

NLG1 class

2

Service temperat.

° C

-35 / +120

F 7 F 7

6 Instructions for the servicing operations

6.1

Preparing the truck for the performance of servicing and maintenance operations

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



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 fork or truck. When lifting the truck, the instructions contained in chapter “Transportation and commissioning” have to be observed.

When performing work on the parking brake, the truck must be secured against moving.

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).

1

Set

7

4

1

8

0

2

5

9

3

6

6

6 Instructions for the servicing operations

6.1

Preparing the truck for the performance of servicing and maintenance operations

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



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 fork or truck. When lifting the truck, the instructions contained in chapter “Transportation and commissioning” have to be observed.

When performing work on the parking brake, the truck must be secured against moving.

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).

1

Set

7

4

1

5

2

0

8

9

3

6

6

4

3 2

4

3 2

F 8 F 8

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, replace fuses.

7 8

7

Set

4

1

5

2

8

0

9

6

3

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, replace fuses.

7 8

7

Set

1

4

0

8

5

2

9

6

3

10

Item Designation Protection of:

7 F10 Integrated charging device (option)

8

9

10

F1

1F1

2F1

Entire control circuit

Drive motor

Pump motor

9

Value

10 A

10 A T

100 A

100 A

10

Item Designation Protection of:

7 F10 Integrated charging device (option)

8

9

10

F1

1F1

2F1

Entire control circuit

Drive motor

Pump motor

9

Value

10 A

10 A T

100 A

100 A

F 9 F 9

6.5

Recommissioning the truck

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

– Check the horn for proper functioning.

– Check the 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 be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.

M

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

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

7.1

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:


M

Battery-operated fork lift trucks:

Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.

F 10

6.5


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

– Check the horn for proper functioning.

– Check the 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 be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.

M

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

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

7.1

Operations to be performed prior to decommissioning


– 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).


– 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:


M


Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.

F 10

7.3



– 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.


– 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


If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.

F

Perform several brake tests immediately after recommissioning the truck.

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

At least once yearly, or after any untoward incident, the fork lift truck has to be chekked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork lift trucks.

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

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

Z

The manufacturer has set up a special safety service with specially qualified staff. As visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to 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 in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

F 11

7.3



– 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.


– 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


If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.

F

Perform several brake tests immediately after recommissioning the truck.

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

At least once yearly, or after any untoward incident, the fork lift truck has to be chekked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experienced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the inspection of fork lift trucks.

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

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

Z

The manufacturer has set up a special safety service with specially qualified staff. As visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to 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 in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

F 11

F 12 F 12

Instructions for use

Jungheinrich traction battery

Table of contents

1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB ..........................................2-6

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

Instruction for use

Aquamatic/BFS III water refilling system ......................................................8-12

2 Jungheinrich traction battery

Maintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17


Instructions for use

Jungheinrich traction battery

Table of contents

1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB ..........................................2-6


Instruction for use

Aquamatic/BFS III water refilling system ......................................................8-12

2 Jungheinrich traction battery

Maintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17


1 1

1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB

Rating Data

1. Nominal capacity C5:

2. Nominal voltage:

3. Discharge current::

4. Nominal S.G. of electrolyte*

Type EPzS:

Type EPzB:

5. Rated temperature:

6. Nominal electrolyte level:

See type plate

2,0 V x No of cells

C5/5h

1,29 kg/l

1,29 kg/l

30° C up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles.

•Pay attention to the operation instruction and fix them close to the battery!

•Work on batteries to be carried out by skilled personnel only!

•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 metal objects on the battery!

2

1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB

Rating Data


2. Nominal voltage:

3. Discharge current::

4. Nominal S.G. of electrolyte*

Type EPzS:

Type EPzB:


6. Nominal electrolyte level:

See type plate

2,0 V x No of cells

C5/5h

1,29 kg/l

1,29 kg/l

30° C up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles.

•Pay attention to the operation instruction and fix them close to the battery!

•Work on batteries to be carried out by skilled personnel only!

•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 metal objects on the battery!

2

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

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

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

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

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

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

M 10

steel

23 ± 1 Nm

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

The 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 applies 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 circuit condition.

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

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

2.2 Charging

Only direct current must be used for charging. All charging procedures in accordance with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts, unacceptable gassing and the escape of electrolyte from the cells.

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

3

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


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


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

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

M 10

steel

23 ± 1 Nm

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

The battery is then charged as in item 2.2.

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

2. Operation


2.1 Discharging

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



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

2.2 Charging

Only direct current must be used for charging. All charging procedures in accordance with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts, unacceptable gassing and the escape of electrolyte from the cells.

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

3

4

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

With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the electrolyte rises by about 10°C, so charging should only begin if the electrolyte temperature is below 45°C. The electrolyte temperature of batteries should be at least +10°C before charging otherwise a full charge will not be achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltage have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with

EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past.

2.3 Equalising charge

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

Watch the temperature!

2.4 Temperature

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

2.5 Electrolyte

The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.

The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.

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

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

With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the electrolyte rises by about 10°C, so charging should only begin if the electrolyte temperature is below 45°C. The electrolyte temperature of batteries should be at least +10°C before charging otherwise a full charge will not be achieved.

A charge is finished when the specific gravity of the electrolyte and the battery voltage have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with

EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past.


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


2.4 Temperature

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

2.5 Electrolyte

The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it.

The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.

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

4

3. Maintenance

3.1 Daily

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

3.2 Weekly

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

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measured with the charger switched on, and recorded. After charging has ended the specific gravity and the temperature of the electrolyte in all cells should be measured and recorded.

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

3.4 Annually

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

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

The insulation resistance of the battery thus determined must not be below a value of

50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

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

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of

Vehicle Traction batteries».

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

5

3. Maintenance

3.1 Daily

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

3.2 Weekly

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

3.3 Monthly

At the end of the charge the voltages of all cells or bloc batteries should be measured with the charger switched on, and recorded. After charging has ended the specific gravity and the temperature of the electrolyte in all cells should be measured and recorded.

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

3.4 Annually


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







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

5

6

5. Storage

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

1. a monthly equalising charge as in point 2.3

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

6. Malfunctions

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

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 be disposed of as hazardous waste!

We reserve the right make technical modification.

5. Storage

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

1. a monthly equalising charge as in point 2.3

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

6. Malfunctions

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






6

7. Type plate, Jungheinrich traction battery

2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5

Batteriegewicht min/max

Battery mass min/max

8

7

8

9

Hersteller

9

Manufacturer

Jungheinrich AG, D-22047 Hamburg, Germany

Pb Pb

6

5

11

13

1

14

Item Designation

1 Logo

2 Battery designation

3 Battery type

4 Battery number

5 Battery tray number

6 Delivery date

7 Battery manufacturer's logo


8

9

10

11

Recycling symbol

Dustbin/material

Nominal battery voltage

Nominal battery capacity

12 Number of battery cells

13 Battery weight

14 Safety instructions and warnings

* CE mark is only for batteries with a nominal voltage greater than 75 volt.


2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5


8


7

8

9

Hersteller

Manufacturer


Pb Pb

6

5

11

13

1

14


1 Logo


3 Battery type

4 Battery number


6 Delivery date



8

9

10

11

Recycling symbol

Dustbin/material



12 Number of battery cells

13 Battery weight



7 7

Aquamatic/BFS III water refilling system for Jungheinrich traction battery with

EPzS and EPzB cells with tubular positive plates

Aquamatic plug arrangement for the Operating Instructions

Cell series*

EPzS EPzB

2/120 – 10/ 600 2/ 42 – 12/ 252

2/160 – 10/ 800 2/ 64 – 12/ 384

– 2/ 84 – 12/ 504

–

–

–

–

–

2/110 – 12/ 660

2/130 – 12/ 780

2/150 – 12/ 900

2/172 – 12/1032

2/200 – 12/1200

–

2/180 – 10/900

2/210 – 10/1050

2/230 – 10/1150

2/250 – 10/1250

2/280 – 10/1400

2/310 – 10/1550

2/216 – 12/1296

–

–

–

–

–

–

Aquamatic plug type

Frötek

(yellow)

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

72,0 mm

72,0 mm

(length)

BFS

(black)

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

66,0 mm

66,0 mm

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column

EPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.

2 EPzS 120.

Aquamatic/BFS III water refilling system for Jungheinrich traction battery with

EPzS and EPzB cells with tubular positive plates

Aquamatic plug arrangement for the Operating Instructions

Cell series*

EPzS EPzB

2/120 – 10/ 600 2/ 42 – 12/ 252

2/160 – 10/ 800 2/ 64 – 12/ 384

– 2/ 84 – 12/ 504

–

–

–

–

–

2/110 – 12/ 660

2/130 – 12/ 780

2/150 – 12/ 900

2/172 – 12/1032

2/200 – 12/1200

–

2/180 – 10/900

2/210 – 10/1050

2/230 – 10/1150

2/250 – 10/1250

2/280 – 10/1400

2/310 – 10/1550

2/216 – 12/1296

–

–

–

–

–

–

Aquamatic plug type

Frötek

(yellow)

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

72,0 mm

72,0 mm

(length)

BFS

(black)

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

66,0 mm

66,0 mm

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column

EPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.

2 EPzS 120.

8

Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

Non-adherence to the operating instructions, repairs carried out with non-original spare parts, unauthorised interference, and the use of additives for the electrolytes

(alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).

8

Aquamatic plug with diagnostics hole

Aquamatic plug BFS III with diagnostics hole

Non-adherence to the operating instructions, repairs carried out with non-original spare parts, unauthorised interference, and the use of additives for the electrolytes

(alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).

Diagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with solenoid 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 adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases which arise during charging. In addition to the optical level indicator, the plug systems also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing coupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries for forklift trucks. The water refilling system is provided with a central water connection for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection sleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve located in the plug in combination with the float and the float rods. In the Aquamatic System the existing water pressure at the valve turns off the water supply and ensures that the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times the buoyant force and consequently interrupt the water supply reliably.

9

Diagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with solenoid 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 adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases which arise during charging. In addition to the optical level indicator, the plug systems also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing coupler through the hose connections in the individual Aquamatic/BFS plugs.

2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries for forklift trucks. The water refilling system is provided with a central water connection for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection sleeves located on the T or < pieces.

3. Function

The quantity of water required in the refilling process is controlled by the valve located in the plug in combination with the float and the float rods. In the Aquamatic System the existing water pressure at the valve turns off the water supply and ensures that the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times the buoyant force and consequently interrupt the water supply reliably.

9

10

4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week.

5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in the water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair the system's functional reliability. This wide pressure range permits three types of filling.

5.1 Falling water

The height of the tank is chosen to suit whichever water refilling system is used. For the Aquamatic System the installation height is 2 m to 6 m and for the BFS system the installation height is 3 m to 18 m over the battery surface.

5.2 Pressurised water

The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars and from 0.3 bars to 1.8 bars in the BFS system.

5.3 Water Refill Trolley (serviceMobil)

The submergible pump located in the ServiceMobil's tank generates the necessary filling pressure. No difference in height is permitted between the standing level of the

ServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under which the battery is used, the ambient temperatures and the type of filling and/or the filling pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.

7. Water quality

Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For safety reasons it is recommendable to insert a filter element (optional) with a max.

passage opening of 100 to 300 µm into the battery's main supply pipe.

4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week.

5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in the water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair the system's functional reliability. This wide pressure range permits three types of filling.

5.1 Falling water

The height of the tank is chosen to suit whichever water refilling system is used. For the Aquamatic System the installation height is 2 m to 6 m and for the BFS system the installation height is 3 m to 18 m over the battery surface.

5.2 Pressurised water

The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars and from 0.3 bars to 1.8 bars in the BFS system.

5.3 Water Refill Trolley (serviceMobil)

The submergible pump located in the ServiceMobil's tank generates the necessary filling pressure. No difference in height is permitted between the standing level of the

ServiceMobil and the standing level of the battery.

6. Filling duration

The length of time needed to fill the batteries depends on the conditions under which the battery is used, the ambient temperatures and the type of filling and/or the filling pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.

7. Water quality

Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For safety reasons it is recommendable to insert a filter element (optional) with a max.

passage opening of 100 to 300 µm into the battery's main supply pipe.

10

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 temperature damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.

CAUTION:

Batteries with automatic water refilling systems may only be operated in rooms with temperatures > 0° C (as there is otherwise a danger that the systems may freeze).

9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a

7.5 mm-diameter (BFS plugs).

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 come in 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 pipe on the battery side. During the filling process, the paddlewheel is turned by the flowing water. When the filling process ends, the wheel stops and this indicates the end of the filling process. (ident no.: 50219542).

10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to prevent any damage to the plug systems.

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 temperature damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.

CAUTION:

Batteries with automatic water refilling systems may only be operated in rooms with temperatures > 0° C (as there is otherwise a danger that the systems may freeze).

9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a

7.5 mm-diameter (BFS plugs).

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 come in 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 pipe on the battery side. During the filling process, the paddlewheel is turned by the flowing water. When the filling process ends, the wheel stops and this indicates the end of the filling process. (ident no.: 50219542).

10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to prevent any damage to the plug systems.

11 11

12

10.2.1 Clamping ring tool

The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.

10.3 Filter element

For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum passage cross-section of 100 to 300 µm and is designed as a bag filter.

10.4 Sealing coupler

The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging station by means of a sealing coupler system. On the battery side a closing nipple

(ident no.: 50219538) is mounted and the customer must place a sealing coupler construction on the water supply side (obtainable under ident. no.: 50219537).

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 at

0.1 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 and operating pressure range: 0.3 to 1.8 bars in the BFS system.

10.2.1 Clamping ring tool

The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.

10.3 Filter element

For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum passage cross-section of 100 to 300 µm and is designed as a bag filter.

10.4 Sealing coupler

The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging station by means of a sealing coupler system. On the battery side a closing nipple

(ident no.: 50219538) is mounted and the customer must place a sealing coupler construction on the water supply side (obtainable under ident. no.: 50219537).

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 at

0.1 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 and operating pressure range: 0.3 to 1.8 bars in the BFS system.

12

2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS

Rating Data


2. Nominal voltage:

3. Discharge current:


See type plate

2,0 Volt x No of cells

C5/5h

30° C

EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug there are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements as for vented cells apply to protect against hazards from electric current, from explosion of electrolytic gas and in case of the cell container is damaged, from the corrosive electrolyte.

• 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!

13

2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS

Rating Data


2. Nominal voltage:

3. Discharge current:


See type plate

2,0 Volt x No of cells

C5/5h

30° C

EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug there are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements as for vented cells apply to protect against hazards from electric current, from explosion of electrolytic gas and in case of the cell container is damaged, from the corrosive electrolyte.

• 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!

13

14

Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void.


1. Commissioning


The battery end cables must have a good contact to terminals, check that the polarity is correct.

Otherwise battery, vehicle or charger could be destroyed.

The battery has to be charged according to item 2.2

The specified torque loading for the pole screws of the end cables and connectors are:

M 10

steel

23 ± 1 Nm

2. Operation


2.1 Discharging

Ventilation openings must not be sealed or covered.



They reduce the battery life considerable. To measure the state of discharge use only the battery manufacturer recommended discharge indicators.

Discharged batteries must be recharged immediately and must not be left discharged.

This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. Charging procedures according to DIN

41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts and unacceptable gassing of the cells. EPzV batteries have a low gas emission.

When charging, proper provision must be made for venting of the charging gases.

Battery container lids and the covers of battery compartments must be opened or removed.

14

Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void.


1. Commissioning


The battery end cables must have a good contact to terminals, check that the polarity is correct.

Otherwise battery, vehicle or charger could be destroyed.

The battery has to be charged according to item 2.2

The specified torque loading for the pole screws of the end cables and connectors are:

M 10

steel

23 ± 1 Nm

2. Operation


2.1 Discharging

Ventilation openings must not be sealed or covered.



They reduce the battery life considerable. To measure the state of discharge use only the battery manufacturer recommended discharge indicators.

Discharged batteries must be recharged immediately and must not be left discharged.

This also applies to partially discharged batteries.

2.2 Charging

Only direct current must be used for charging. Charging procedures according to DIN

41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts and unacceptable gassing of the cells. EPzV batteries have a low gas emission.

When charging, proper provision must be made for venting of the charging gases.

Battery container lids and the covers of battery compartments must be opened or removed.

With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35° C. The battery temperature should be at least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers need a temperatures regulated voltage.

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.


Equalising charges are used to safeguard the life of the battery and to maintain its capacity. Equalising charges are carried out following normal charging.

They are necessary after deep discharges and repeated incomplete recharges. For the equalising charges has to be used only the battery manufacturer prescribed chargers.


2.4 Temperature

A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.

45° C is the upper temperature limit and is not acceptable as an operating temperature.

2.5 Electrolyte

The electrolyte is immobilised in a gel. The density of the electrolyte can not be measured.

3. Maintenance

Don’t refill water!

3.1 Daily

Charge the battery immediately after every discharge.

With the charger switched off connect up the battery, ensuring that the polarity is correct (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35° C. The battery temperature should be at least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers need a temperatures regulated voltage.

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.


Equalising charges are used to safeguard the life of the battery and to maintain its capacity. Equalising charges are carried out following normal charging.

They are necessary after deep discharges and repeated incomplete recharges. For the equalising charges has to be used only the battery manufacturer prescribed chargers.


2.4 Temperature

A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity.

45° C is the upper temperature limit and is not acceptable as an operating temperature.

2.5 Electrolyte

The electrolyte is immobilised in a gel. The density of the electrolyte can not be measured.

3. Maintenance

Don’t refill water!

3.1 Daily

Charge the battery immediately after every discharge.

15 15

16

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 and recorded:

• the voltages of the battery

• the voltages of every cells

If significant changes from earlier measurements or differences between the cells or bloc batteries are found, further testing and maintenance by the service department should be requested.

3.4 Annually


The tests on the insulation resistance of the battery must be conducted in accordance with DIN 43539-1.







Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.

Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call our service department for this.

5. Storage

If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room.

To ensure the battery is always ready for use a choice of charging methods can be made:

1. a quarterly full charging like charge as in point 2.2. If any consumer is connected with, e.g. measure or controlling systems, it can be, that this charging is necessary every 14 days.

2. float charging at a charging voltage of 2.25 V x the number of cells.

The storage time should be taken into account when considering the life of the battery.

16

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 and recorded:

• the voltages of the battery

• the voltages of every cells

If significant changes from earlier measurements or differences between the cells or bloc batteries are found, further testing and maintenance by the service department should be requested.

3.4 Annually


The tests on the insulation resistance of the battery must be conducted in accordance with DIN 43539-1.







Any liquid in the battery tray must be extracted and disposed of in the prescribed manner.

Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call our service department for this.

5. Storage

If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room.

To ensure the battery is always ready for use a choice of charging methods can be made:

1. a quarterly full charging like charge as in point 2.2. If any consumer is connected with, e.g. measure or controlling systems, it can be, that this charging is necessary every 14 days.

2. float charging at a charging voltage of 2.25 V x the number of cells.

The storage time 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 should be called without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.







2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5



8

7

8

9

Hersteller

9

Manufacturer


Pb Pb

6

5

11

13

1

14


1 Logo


3 Battery type

4 Battery number


6 Delivery date



8 Recycling symbol

9 Dustbin/material

10

11

12



Number of battery cells

13 Battery weight



17

6. Malfunctions

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







2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5


8


7

8

9

Hersteller

Manufacturer


Pb Pb

6

5

11

13

1

14


1 Logo


3 Battery type

4 Battery number


6 Delivery date



8 Recycling symbol

9 Dustbin/material

10

11

12



Number of battery cells

13 Battery weight



17

18 18

EJE 116/118/120

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