ERC 212/214/216/Z12/Z14/Z16 02.

04 -

Operating instructions G
50434880
03.11 ERC 212
ERC 214
ERC 216
ERC Z12
ERC Z14
ERC Z16
 Declaration of Conformity Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or his authorized representative in the Community Manufacturer or his authorized representative in the Community

Type Option Serial No. Year of Type Option Serial No. Year of
construction construction
ERC 212 ERC 212
ERC Z12 ERC Z12
ERC 214 ERC 214
ERC Z14 ERC Z14
ERC 216 ERC 216
ERC Z16 ERC Z16

Additional information Additional information

Authorised signatory Authorised signatory

Date Date

G EU Declaration of Conformity G EU Declaration of Conformity

The signatories hereby certify that the specified powered industrial truck conforms to
the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-
Magnetic Compatibility, EMC) including their amendments as translated into national
legislation of the member countries. The signatories are individually empowered in
each case to compile the technical documentation.
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The signatories hereby certify that the specified powered industrial truck conforms to
the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-
Magnetic Compatibility, EMC) including their amendments as translated into national
legislation of the member countries. The signatories are individually empowered in
each case to compile the technical documentation.

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 Foreword
Notes on the operating instructions
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 and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Foreword
Notes on the operating instructions
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 and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.

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

Safety notices and text mark-ups Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following Safety instructions and important explanations are indicated by the following
graphics: graphics:

DANGER! DANGER!

Indicates an extremely hazardous situation. Failure to comply with this instruction will Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death. result in severe irreparable injury and even death.

WARNING! WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instruction Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death. may result in severe irreparable injury and even death.

CAUTION! CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result in Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury. slight to medium injury.

NOTE NOTE

Indicates a material hazard. Failure to comply with this instruction may result in Indicates a material hazard. Failure to comply with this instruction may result in
material damage. material damage.

Z Used before notices and explanations. Z Used before notices and explanations.

t Indicates standard equipment t Indicates standard equipment

o Indicates optional equipment o Indicates optional equipment
Copyright Copyright
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Copyright of these operating instructions remains with JUNGHEINRICH AG. Copyright of these operating instructions remains with JUNGHEINRICH AG.

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 Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft
Am Stadtrand 35 Am Stadtrand 35
22047 Hamburg - Germany 22047 Hamburg - Germany

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

www.jungheinrich.com www.jungheinrich.com

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 Table of Contents Table of Contents

A Correct Use and Application ................................................... 11 A Correct Use and Application ................................................... 11
1 General.................................................................................................... 11 1 General.................................................................................................... 11
2 Correct application................................................................................... 11 2 Correct application................................................................................... 11
3 Approved application conditions .............................................................. 11 3 Approved application conditions .............................................................. 11
4 Proprietor responsibilities ........................................................................ 12 4 Proprietor responsibilities ........................................................................ 12
5 Adding attachments and/or accessories.................................................. 12 5 Adding attachments and/or accessories.................................................. 12

B Truck Description .................................................................... 13 B Truck Description .................................................................... 13

1 Application ............................................................................................... 13 1 Application ............................................................................................... 13
1.1 Truck models and rated capacity............................................................. 13 1.1 Truck models and rated capacity............................................................. 13
2 Assemblies and Functional Description................................................... 14 2 Assemblies and Functional Description................................................... 14
2.1 Assembly Overview ................................................................................. 14 2.1 Assembly Overview ................................................................................. 14
2.2 Functional Description ............................................................................. 15 2.2 Functional Description ............................................................................. 15
3 Technical Specifications .......................................................................... 17 3 Technical Specifications .......................................................................... 17
3.1 Performance data .................................................................................... 17 3.1 Performance data .................................................................................... 17
3.2 Dimensions .............................................................................................. 18 3.2 Dimensions .............................................................................................. 18
3.3 Weights.................................................................................................... 20 3.3 Weights.................................................................................................... 20
3.4 Tyre type.................................................................................................. 20 3.4 Tyre type.................................................................................................. 20
3.5 EN norms................................................................................................. 21 3.5 EN norms................................................................................................. 21
3.6 Conditions of use..................................................................................... 22 3.6 Conditions of use..................................................................................... 22
3.7 Electrical requirements ............................................................................ 22 3.7 Electrical requirements ............................................................................ 22
4 Identification points and data plates ........................................................ 23 4 Identification points and data plates ........................................................ 23
4.1 Data plate ................................................................................................ 24 4.1 Data plate ................................................................................................ 24
4.2 Truck load chart....................................................................................... 25 4.2 Truck load chart....................................................................................... 25
4.3 Capacity, wheel arm lift ........................................................................... 26 4.3 Capacity, wheel arm lift ........................................................................... 26
4.4 Plate, order, inventory and service nos. .................................................. 26 4.4 Plate, order, inventory and service nos. .................................................. 26

C Transport and Commissioning ................................................ 27 C Transport and Commissioning ................................................ 27

1 Lifting by crane ........................................................................................ 27 1 Lifting by crane ........................................................................................ 27
2 Transport ................................................................................................. 28 2 Transport ................................................................................................. 28
3 Using the Truck for the First Time ........................................................... 29 3 Using the Truck for the First Time ........................................................... 29

D Battery - Servicing, Recharging, Replacement ....................... 31 D Battery - Servicing, Recharging, Replacement ....................... 31
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 31 1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 31
2 Battery types............................................................................................ 32 2 Battery types............................................................................................ 32
3 Exposing the battery ................................................................................ 33 3 Exposing the battery................................................................................ 33
4 Charging the battery ................................................................................ 35 4 Charging the battery ................................................................................ 35
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 4.1 Charging the battery with an on-board charger ....................................... 37 4.1 Charging the battery with an on-board charger ....................................... 37
5 Battery removal and installation .............................................................. 42 5 Battery removal and installation .............................................................. 42
5.1 Changing the battery from the top, trucks without wheel arm lift ............. 43 5.1 Changing the battery from the top, trucks without wheel arm lift ............. 43
5.2 Changing the battery from the top, trucks with wheel arm lift .................. 44 5.2 Changing the battery from the top, trucks with wheel arm lift .................. 44
5.3 Removing the battery from the side......................................................... 45 5.3 Removing the battery from the side......................................................... 45

E Operation ................................................................................ 47 E Operation ................................................................................ 47

1 Safety Regulations for the Operation of the Forklift Truck....................... 47 1 Safety Regulations for the Operation of the Forklift Truck....................... 47
2 Displays and Controls.............................................................................. 48 2 Displays and Controls.............................................................................. 48
2.1 Battery discharge indicator ...................................................................... 51 2.1 Battery discharge indicator ...................................................................... 51
3 Starting up the truck ................................................................................ 52 3 Starting up the truck ................................................................................ 52
3.1 Checks and operations to be performed before starting daily operation . 52 3.1 Checks and operations to be performed before starting daily operation . 52
3.2 Preparing the truck for operation ............................................................. 53 3.2 Preparing the truck for operation ............................................................. 53
3.3 Parking the truck securely ....................................................................... 55 3.3 Parking the truck securely ....................................................................... 55
3.4 Battery discharge monitor........................................................................ 55 3.4 Battery discharge monitor........................................................................ 55
4 Industrial Truck Operation ....................................................................... 57 4 Industrial Truck Operation ....................................................................... 57
4.1 Safety regulations for truck operation...................................................... 57 4.1 Safety regulations for truck operation...................................................... 57
4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 59 4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 59
4.3 Lifting, transporting and depositing loads ................................................ 64 4.3 Lifting, transporting and depositing loads ................................................ 64
4.4 Switch Matrix / Safety Switch Height ....................................................... 67 4.4 Switch Matrix / Safety Switch Height ....................................................... 67
5 Troubleshooting....................................................................................... 68 5 Troubleshooting....................................................................................... 68
5.1 Truck does not start................................................................................. 68 5.1 Truck does not start................................................................................. 68
5.2 Load cannot be lifted ............................................................................... 68 5.2 Load cannot be lifted ............................................................................... 68
6 Operating the truck without its own drive system .................................... 69 6 Operating the truck without its own drive system .................................... 69
7 Load handler emergency lowering .......................................................... 71 7 Load handler emergency lowering .......................................................... 71
8 Optional equipment ................................................................................. 72 8 Optional equipment ................................................................................. 72
8.1 CanCode keypad..................................................................................... 72 8.1 CanCode keypad..................................................................................... 72
8.2 Parameter................................................................................................ 78 8.2 Parameter................................................................................................ 78
8.3 CANDIS display instrument ..................................................................... 80 8.3 CANDIS display instrument ..................................................................... 80

F Industrial Truck Maintenance .................................................. 83 F Industrial Truck Maintenance .................................................. 83

1 Operational Safety and Environmental Protection................................... 83 1 Operational Safety and Environmental Protection................................... 83
2 Maintenance Safety Regulations ............................................................. 83 2 Maintenance Safety Regulations............................................................. 83
3 Servicing and Inspection ......................................................................... 87 3 Servicing and Inspection ......................................................................... 87
4 Maintenance checklist ............................................................................. 88 4 Maintenance checklist ............................................................................. 88
5 Lubricants and Lubrication Schedule ...................................................... 91 5 Lubricants and Lubrication Schedule ...................................................... 91
5.1 Handling consumables safely .................................................................. 91 5.1 Handling consumables safely .................................................................. 91
5.2 Lubrication Schedule ............................................................................... 93 5.2 Lubrication Schedule ............................................................................... 93
5.3 Consumables........................................................................................... 94 5.3 Consumables........................................................................................... 94
6 Maintenance and repairs ......................................................................... 95 6 Maintenance and repairs ......................................................................... 95
6.1 Preparing the truck for maintenance and repairs .................................... 95 6.1 Preparing the truck for maintenance and repairs .................................... 95
6.2 Removing the front panel ........................................................................ 96 6.2 Removing the front panel ........................................................................ 96
6.3 Checking the hydraulic oil level ............................................................... 97 6.3 Checking the hydraulic oil level ............................................................... 97
6.4 Check the gear oil level ........................................................................... 98 6.4 Check the gear oil level ........................................................................... 98
6.5 Tightening the wheel nuts........................................................................ 99 6.5 Tightening the wheel nuts........................................................................ 99
6.6 Checking electrical fuses ......................................................................... 100 6.6 Checking electrical fuses......................................................................... 100
6.7 Restoring the truck to service after maintenance and repairs ................. 101 6.7 Restoring the truck to service after maintenance and repairs ................. 101
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7 Safety tests to be performed at intervals and after unusual incidents ..... 102 7 Safety tests to be performed at intervals and after unusual incidents ..... 102
8 Decommissioning the industrial truck ...................................................... 103 8 Decommissioning the industrial truck ...................................................... 103

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 8.1 Prior to decommissioning ........................................................................ 103 8.1 Prior to decommissioning ........................................................................ 103
8.2 Action to be taken during decommissioning ............................................ 104 8.2 Action to be taken during decommissioning ............................................ 104
8.3 Restoring the truck to service after decommissioning ............................. 105 8.3 Restoring the truck to service after decommissioning ............................. 105
9 Final de-commissioning, disposal............................................................ 105 9 Final de-commissioning, disposal............................................................ 105
10 Human vibration measurement ............................................................... 106 10 Human vibration measurement ............................................................... 106
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 Appendix Appendix

JH Traction Battery Operating Instructions 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.
Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB

0506.GB

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0506.GB

0506.GB
 A Correct Use and Application A Correct Use and Application
1 General 1 General
The industrial truck described in the present operating instructions is designed for The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units. lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions. It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property. personnel, the industrial truck or property.

2 Correct application 2 Correct application

NOTE NOTE

The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.
The maximum load and load distance are indicated on the load chart and must not be
exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks.

– Lifting and lowering of loads. – Lifting and lowering of loads.

– Transporting lowered loads. – Transporting lowered loads.
– Do not travel with a raised load (>500 mm). – Do not travel with a raised load (>500 mm).
– Do not carry or lift passengers. – Do not carry or lift passengers.
– Do push or pull load units. – Do push or pull load units.

3 Approved application conditions 3 Approved application conditions

– Operation in industrial and commercial environments.
– Permissible temperature range +5°C to +40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor.
– Negotiating inclines up to a maximum of 15 %.
– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
– Operation in partially public traffic.
Z Special equipment and authorisation are required if the truck is to be used in
extreme conditions.
The truck is not authorised for use in areas at risk of explosion.
03.11 EN
– Operation in industrial and commercial environments.
– Permissible temperature range +5°C to +40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor.
– Negotiating inclines up to a maximum of 15 %.
– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
– Operation in partially public traffic.
Z Special equipment and authorisation are required if the truck is to be used in
extreme conditions.
The truck is not authorised for use in areas at risk of explosion.

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4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.
5 Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
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4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.
5 Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
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 B Truck Description
1 Application
The industrial truck is an electric pallet truck with a folding platform.
It is designed for lifting and transporting goods on level floors. Wheel arm lift
(ERC Z12/Z14/Z16 only) increases the ground clearance when transporting goods
on uneven surfaces. Loads can be stacked or unstacked up to 5.35m high and
transported over long distances. The rated capacity of the truck is shown on the data
plate or the data capacity plate Qmax.
Due to its high travel speed the ERC 214/216 has side restraints.
B Truck Description
1 Application
The industrial truck is an electric pallet truck with a folding platform.
It is designed for lifting and transporting goods on level floors. Wheel arm lift
(ERC Z12/Z14/Z16 only) increases the ground clearance when transporting goods
on uneven surfaces. Loads can be stacked or unstacked up to 5.35m high and
transported over long distances. The rated capacity of the truck is shown on the data
plate or the data capacity plate Qmax.
Due to its high travel speed the ERC 214/216 has side restraints.

1.1 Truck models and rated capacity 1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from The rated capacity depends on the model. The rated capacity can be derived from
the model name. the model name.

Type Capacity Motor output Type Capacity Motor output

ERC 212 / Z12 1200 kg 2,0 kW ERC 212 / Z12 1200 kg 2,0 kW
ERC 214 / Z14 1400 kg 2,0 kW ERC 214 / Z14 1400 kg 2,0 kW
ERC 216 / Z16 1600 kg 2,0 kW ERC 216 / Z16 1600 kg 2,0 kW

The rated capacity does not generally match the permissible capacity. The capacity The rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack. can be found on the load chart attached to the rack.
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2 Assemblies and Functional Description 2 Assemblies and Functional Description
2.1 Assembly Overview 2.1 Assembly Overview

1 1
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3 3
4 4

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ItemName Item Name ItemName Item Name

1 t Mast 9 o Folding side restraint *) 1 t Mast 9 o Folding side restraint *)
2 t Travel switch 10 t Wheel arms 2 t Travel switch 10 t Wheel arms
4 t Tiller 11 t Drive wheel 4 t Tiller 11 t Drive wheel
5 t Key switch 12 o Lift linkage (wheel arm lift only) 5 t Key switch 12 o Lift linkage (wheel arm lift only)
6 o CanDis 13 o Charger 6 o CanDis 13 o Charger
7 o CanCode 14 t Folding operator platform 7 o CanCode 14 t Folding operator platform
8 t Emergency Disconnect (main 3 t Mast guard 8 t Emergency Disconnect (main 3 t Mast guard
switch) switch)
15 t Castor wheel o Load backrest (for cold store 15 t Castor wheel o Load backrest (for cold store
operation) operation)
t = Standard version o = Option t = Standard version o = Option
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*) Not on trucks with 1200 kg capacity. *) Not on trucks with 1200 kg capacity.

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 2.2 Functional Description
Safety Mechanisms
– An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck.
– The wheels are surrounded by a solid skirt.
– Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations.
Hydraulic system
– Lifting and lowering are activated via the lift and lower buttons.
– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder.
Emergency Stop safety feature
– The emergency stop is activated by the traction controller.
– The steering controller sends a system status signal which is monitored by the
traction controller. If the signal fails to appear or a fault is identified the truck
automatically brakes to a halt. Control displays on the driver’s display indicate the
emergency stop.
– Each time the truck is switched on the system performed an automatic diagnosis.
Operator Position
– All travel and lift operations can be performed sensitively without having to reach.
– Tiller for reliable control of the industrial truck.
– The industrial truck has a folding standing platform and movable side arm. The
industrial truck can also optionally be equipped with a fixed standing platform and
rigid side arm.
Operator platform
– Travel functions are only released when the driver stands on the operator platform.
Drive system
– A fixed DC motor actuates the drive wheel via a bevel spur gearbox.
– The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking.
Steering
– The driver steers with a tiller.
– The steering motion is transmitted directly from the steering controller via a steer
motor directly to the ring gear of the pivoted drive system.
– The progressive electric steering allows for a 90° turn of the drive wheel when the
tiller is turned only 70°.
Electric steering (o)
– The electric steering system is self-monitoring.
The steering controller permanently monitors the entire steering system. If an error
is detected the traction controller interrupts travel and the magnetic brake is
applied.
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2.2 Functional Description
Safety Mechanisms
– An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck.
– The wheels are surrounded by a solid skirt.
– Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations.
Hydraulic system
– Lifting and lowering are activated via the lift and lower buttons.
– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder.
Emergency Stop safety feature
– The emergency stop is activated by the traction controller.
– The steering controller sends a system status signal which is monitored by the
traction controller. If the signal fails to appear or a fault is identified the truck
automatically brakes to a halt. Control displays on the driver’s display indicate the
emergency stop.
– Each time the truck is switched on the system performed an automatic diagnosis.
Operator Position
– All travel and lift operations can be performed sensitively without having to reach.
– Tiller for reliable control of the industrial truck.
– The industrial truck has a folding standing platform and movable side arm. The
industrial truck can also optionally be equipped with a fixed standing platform and
rigid side arm.
Operator platform
– Travel functions are only released when the driver stands on the operator platform.
Drive system
– A fixed DC motor actuates the drive wheel via a bevel spur gearbox.
– The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking.
Steering
– The driver steers with a tiller.
– The steering motion is transmitted directly from the steering controller via a steer
motor directly to the ring gear of the pivoted drive system.
– The progressive electric steering allows for a 90° turn of the drive wheel when the
tiller is turned only 70°.
Electric steering (o)
– The electric steering system is self-monitoring.
The steering controller permanently monitors the entire steering system. If an error
is detected the traction controller interrupts travel and the magnetic brake is
applied.

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Electrical System Electrical System

– 24 volt system. – 24 volt system.

15 15
 – Standard electronic traction, lift and steering control are standard.
Controls and displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of travel
operations.
– The battery discharge indicator shows the available battery capacity.
– The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and error messages.
Mast
– The maximum strength steel sections are narrow, allowing for outstanding fork
visibility in particular with the three-stage mast.
– The lift rails and the fork carriage run on permanently-lubricated and hence
maintenance-free angled rollers.
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16
– Standard electronic traction, lift and steering control are standard.
Controls and displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of travel
operations.
– The battery discharge indicator shows the available battery capacity.
– The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and error messages.
Mast
– The maximum strength steel sections are narrow, allowing for outstanding fork
visibility in particular with the three-stage mast.
– The lift rails and the fork carriage run on permanently-lubricated and hence
maintenance-free angled rollers.
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 3 Technical Specifications 3 Technical Specifications
Z Technical specification details in accordance with VDI 2198. Technical Z Technical specification details in accordance with VDI 2198. Technical
modifications and additions reserved. modifications and additions reserved.

3.1 Performance data 3.1 Performance data

ERC 212 / ERC 214 / ERC 216 / ERC 212 / ERC 214 / ERC 216 /
Z12 Z14 Z16 Z12 Z14 Z16
Q Rated capacity 1200 1400 1600 kg Q Rated capacity 1200 1400 1600 kg
c Load centre distance with 600 600 600 c Load centre distance with 600 600 600
mm mm
standard fork length standard fork length
Travel speed with restraint 9,0 / 9,0 9,0 / 9,0 9,0 / 9,0 Travel speed with restraint 9,0 / 9,0 9,0 / 9,0 9,0 / 9,0
system km/h system km/h
w / w.o. rated load w / w.o. rated load
Lift speed with / without rated 0,13 / 0,22 0,16 / 0,25 0,15 / 0,25 m/s Lift speed with / without rated 0,13 / 0,22 0,16 / 0,25 0,15 / 0,25 m/s
load (adjustable (ZT)) load (adjustable (ZT))
Lower speed with / without rated 0,43/0,37 0,37/0,34 0,37/0,34 m/s Lower speed with / without rated 0,43/0,37 0,37/0,34 0,37/0,34 m/s
load (adjustable (ZT)) load (adjustable (ZT))
Max. gradeability (over 5 mins) w 10/16 9 / 16 8 / 16 % Max. gradeability (over 5 mins) w 10/16 9 / 16 8 / 16 %
/ w.o. load / w.o. load
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3.2
h3
b5
h2
b11 h13
s h5

a/2
R
Dimensions

l
e

Q
x
c

m2

Ast
Wa
l1
y
l2

a/2
188
428

167
983
500 h14 min
b1 h14 max
h1
h4

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18
3.2

h3
b5
h2
b11 h13
s h5
a/2

R
Dimensions

e
Q
x
c

m2
Ast
Wa
l1
y
l2

a/2
188
428

167
983
500 h14 min
b1 h14 max
h1
h4

03.11 EN
 ERC ERC ERC ERC ERC ERC
212/212Z 214/214Z 216/216Z 212/212Z 214/214Z 216/216Z
l1 Overall length 2046 2067 2067 mm l1 Overall length 2046 2067 2067 mm
l2 Headlength 896 917 917 mm l2 Headlength 896 917 917 mm
h1 Mast height retracted 1950 1950 1950 mm h1 Mast height retracted 1950 1950 1950 mm
h2 Free lift 100 100 100 h2 Free lift 100 100 100
h3 Lift 2900 2900 2800 mm h3 Lift 2900 2900 2800 mm
h4 Mast height extended 3375 3375 3325 mm h4 Mast height extended 3375 3375 3325 mm
h5 Initial lift 122 122 122 mm h5 Initial lift 122 122 122 mm
h13 Lowered fork height 90 90 90 mm h13 Lowered fork height 90 90 90 mm
Tiller height in min./max. 1158/1414 1158/1414 1158/1414 mm Tiller height in min./max. 1158/1414 1158/1414 1158/1414 mm
h14 h14
travel position travel position
y Wheelbase 1336 1357 1357 mm y Wheelbase 1336 1357 1357 mm
x Load distance 688 688 688 mm x Load distance 688 688 688 mm
b1 Overall width 800 800 800 mm b1 Overall width 800 800 800 mm
b5 Outside straddle 570 570 570 mm b5 Outside straddle 570 570 570 mm
b10 Track width, front 507 507 507 mm b10 Track width, front 507 507 507 mm
b11 Track width, rear 400 400 400 mm b11 Track width, rear 400 400 400 mm
s/e/l Fork spread 56/185/1150 56/185/1150 56/185/1150 mm s/e/l Fork spread 56/185/1150 56/185/1150 56/185/1150 mm
Ground clearance centre 30 30 30 mm Ground clearance centre 30 30 30 mm
m2 m2
wheelbase wheelbase
Wa Turning radius 1597 1618 1618 mm Wa Turning radius 1597 1618 1618 mm
Ast Working aisle width for 2414*) / 2414*) / 2414**)/ mm Ast Working aisle width for 2414*) / 2414*) / 2414**)/ mm
pallets 1000 x 1200 2483*) 2483*) 2483**) pallets 1000 x 1200 2483*) 2483*) 2483**)
Ast Working aisle width for 2441*) / 2441*) / 2441**) / mm Ast Working aisle width for 2441*) / 2441*) / 2441**) / mm
pallets 1000 x 1200 2565*) 2565*) 2565**) pallets 1000 x 1200 2565*) 2565*) 2565**)
Net weight: See truck data plate Net weight: See truck data plate
*) for DZ + 35 *) for DZ + 35

**) for DZ +43 **) for DZ +43

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3.3 Weights 3.3 Weights

Name ERC 212 / Z12 ERC 214 / Z14 ERC 216 / Z16 Name ERC 212 / Z12 ERC 214 / Z14 ERC 216 / Z16
Standard 290 ZT mast 280 ZT Standard 290 ZT mast 280 ZT
Net weight (including 1220 1230 Net weight (including 1220 1230
1160 kg 1160 kg
battery) battery)
Axle load, w. load 970/1650 990/1840 Axle load, w. load 970/1650 990/1840
900/1460 kg 900/1460 kg
front / rear front / rear
Axle load, w.o. load 840/320 880/340 880/350 Axle load, w.o. load 840/320 880/340 880/350
kg kg
front / rear front / rear

3.4 Tyre type 3.4 Tyre type

Name ERC 212 / Z12 ERC 214 / Z14 ERC 216 / Z16 Name ERC 212 / Z12 ERC 214 / Z14 ERC 216 / Z16
Tyre size, front 230/77 mm Tyre size, front 230/77 mm
Tyre size, rear (single / 85x110 / 85x110 / 85x110 / mm Tyre size, rear (single / 85x110 / 85x110 / 85x110 / mm
tandem) 85x85 85x85 85x85 tandem) 85x85 85x85 85x85
Castor wheel 140x54 mm Castor wheel 140x54 mm
Wheels, number front/rear Wheels, number front/rear
1x+1/ 2 1x+1/ 2
(x = driven) (x = driven)

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 3.5 EN norms
Noise emission level
– ERC 212/214/216/Z12/Z14/Z16: 68 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
– ERC 212/214/216/Z12/Z14/Z16: 0,96 m/s²
in accordance with EN 13059
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over thresholds
at constant speed. These recordings were taken on a single occasion and must not
be confused with the human vibrations of the "2002/44/EC/Vibrations" operator
directive. The manufacturer offers a special service to measure these human
vibrations, (see "Human vibration measurement" on page 106).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
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21
3.5 EN norms
Noise emission level
– ERC 212/214/216/Z12/Z14/Z16: 68 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
– ERC 212/214/216/Z12/Z14/Z16: 0,96 m/s²
in accordance with EN 13059
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over thresholds
at constant speed. These recordings were taken on a single occasion and must not
be confused with the human vibrations of the "2002/44/EC/Vibrations" operator
directive. The manufacturer offers a special service to measure these human
vibrations, (see "Human vibration measurement" on page 106).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
21
3.6 Conditions of use 3.6 Conditions of use
Ambient temperature Ambient temperature
– operating at +5°C to +40°C – operating at +5°C to +40°C
Z Special equipment and authorisation are required if the truck is to be constantly Z Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations. used in conditions of extreme temperature or air humidity fluctuations.

3.7 Electrical requirements 3.7 Electrical requirements

The manufacturer certifies compliance with the requirements for the design and The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose. Electrical Requirements", provided the truck is used according to its purpose.

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22 22
 4 Identification points and data plates 4 Identification points and data plates

16 16
17 17
Xxx Xxx
Xxxx Xxxx

Xxxxxxx Xxxxxx Xxxxxxx Xxxxxx

Xxxxxxxxx Xxxxxx Xxxxxxxxx Xxxxxx

Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx

Xxxxxxxxxx kg Xxxxxxxxxxxxxxxxx mm Xxxxxxxxxxxxxxxxxxx kg Xxxxxxxxxx kg Xxxxxxxxxxxxxxxxx mm Xxxxxxxxxxxxxxxxxxx kg

Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx Xxxxxxxxx Xxxxxxxxxxxxxxxxxxx xxxxxxxxxx

Xxxxxxxxxx V Xxxxxxxxxxxxxxxxx kW xxxxxxxx kg Xxxxxxxxxx V Xxxxxxxxxxxxxxxxx kW xxxxxxxx kg

Xxxxxxx
Xxxxxx

Xxxxx Xxxxxxxxxxxxxxxx
18 Xxxxxxx
Xxxxxx

Xxxxx Xxxxxxxxxxxxxxxx
18
Xxxx Xxxxxxxxxxxxxxxxxx Xxxx Xxxxxxxxxxxxxxxxxx

19 19

20 20
21 11 1
21 11 1
12 0 12 0

9
2000 2000

8 7

8 7
1

1
2

2
6

6
5 4 3 5 4 3

17 17
22 22

23 23
17 17

24 24

Item Name Item Name

16 “Do not step under the load handler” warning 16 “Do not step under the load handler” warning
17 Strap points for crane lifting 17 Strap points for crane lifting
18 "Do not reach through the mast" warning 18 "Do not reach through the mast" warning
19 Data plate 19 Data plate
20 Capacity Qmax (ERC Z12/Z14/Z16 only) 20 Capacity Qmax (ERC Z12/Z14/Z16 only)
21 Test plaque 21 Test plaque
22 Capacity Qmax 22 Capacity Qmax
23 Serial number 23 Serial number
24 Battery data plate 24 Battery data plate
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4.1 Data plate 4.1 Data plate

25 26 27 28 29 30 31 25 26 27 28 29 30 31

32 32

33 33

34 34

35 35

36 36

Item Description Item Description Item Description Item Description

25 Type 31 Year of manufacture 25 Type 31 Year of manufacture
26 Serial number 32 Load centre (mm) 26 Serial number 32 Load centre (mm)
27 Rated capacity (kg) 33 Output 27 Rated capacity (kg) 33 Output
28 Battery voltage (V) 34 Min./max. battery weight (kg) 28 Battery voltage (V) 34 Min./max. battery weight (kg)
29 Net weight w.o. battery (kg) 35 Manufacturer 29 Net weight w.o. battery (kg) 35 Manufacturer
30 Option 36 Manufacturer’s logo 30 Option 36 Manufacturer’s logo

Z For queries regarding the truck or ordering spare parts always quote the truck serial Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (26). number (26).

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24 24
 4.2 Truck load chart 4.2 Truck load chart

X.XXXX.XX.XX X.XXXX.XX.XX
20 20
3600 1105 3600 1105

600 600

The load chart (20) indicates the maximum capacity Q (in kg) for a given load centre The load chart (20) indicates the maximum capacity Q (in kg) for a given load centre
C (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load. C (in mm) and corresponding lift height H (in mm) for the truck with a horizontal load.

Example of calculating the maximum capacity: Example of calculating the maximum capacity:
With a load centre of gravity distance C of 600 mm and a maximum lift height H of With a load centre of gravity distance C of 600 mm and a maximum lift height H of
3600 mm. the max. capacity Q is 1105 kg. 3600 mm. the max. capacity Q is 1105 kg.

The arrow shape markings ("37" and "37") on the inner The arrow shape markings ("37" and "37") on the inner
mast and bottom cross member indicate to the driver 37 37 mast and bottom cross member indicate to the driver 37 37
when he has exceeded the height limits specified by the when he has exceeded the height limits specified by the
capacity plate (21). capacity plate (21).
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25 25
4.3 Capacity, wheel arm lift 4.3 Capacity, wheel arm lift
For trucks with wheel arm lift the additional plate (20) indicates the permissible spread For trucks with wheel arm lift the additional plate (20) indicates the permissible spread
for wheel arm lift and Main Lift. for wheel arm lift and Main Lift.

4.4 Plate, order, inventory and service nos. 4.4 Plate, order, inventory and service nos.

38 38

39 39

40 40

Item Name Item Name

38 Order no. 38 Order no.
39 Inventory no. 39 Inventory no.
40 Full service no. 40 Full service no.

Z The capacity plate with the full service number is only issued when a service Z The capacity plate with the full service number is only issued when a service
agreement has been reached. agreement has been reached.

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26 26
 C Transport and Commissioning C Transport and Commissioning
1 Lifting by crane 1 Lifting by crane

WARNING! WARNING!

Improper lifting by crane can result in accidents
The use of unsuitable lifting gear can cause the truck to crash when being lifted by
crane.
Prevent the truck from striking other objects when it is being raised, and avoid any
involuntary movements. If necessary secure the truck with guide ropes.
XThe truck should only be handled by people who are trained in using lifting slings
and tools.
XWear safety shoes when lifting the truck by crane.
XDo not stand under a swaying load.
XDo not walk into or stand in a hazardous area.
XAlways use lifting gear with sufficient capacity (for truck weight see truck data
plate).
XAlways attach the crane slings to the prescribed strap points and prevent them from
slipping.
XUse the lifting gear only in the prescribed load direction.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.
Improper lifting by crane can result in accidents
The use of unsuitable lifting gear can cause the truck to crash when being lifted by
crane.
Prevent the truck from striking other objects when it is being raised, and avoid any
involuntary movements. If necessary secure the truck with guide ropes.
XThe truck should only be handled by people who are trained in using lifting slings
and tools.
XWear safety shoes when lifting the truck by crane.
XDo not stand under a swaying load.
XDo not walk into or stand in a hazardous area.
XAlways use lifting gear with sufficient capacity (for truck weight see truck data
plate).
XAlways attach the crane slings to the prescribed strap points and prevent them from
slipping.
XUse the lifting gear only in the prescribed load direction.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting.

17 17
Lifting the truck by crane Lifting the truck by crane

Requirements Requirements
– Park the industrial truck securely, – Park the industrial truck securely,
(see "Parking the truck securely" on (see "Parking the truck securely" on
page 55). page 55).

Tools and Material Required Tools and Material Required

– Lifting gear – Lifting gear
– Crane lifting gear – Crane lifting gear

Procedure Procedure
• Secure the crane lifting gear to the 17 • Secure the crane lifting gear to the 17
attachment points (17). attachment points (17).
The industrial truck can now be lifted by The industrial truck can now be lifted by
crane. crane.
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2 Transport 2 Transport

WARNING! WARNING!

Accidental movement during transport Accidental movement during transport

Improper fastening of the truck and mast during transport can result in serious
accidents.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case
correct measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe lorry / trailer must have fastening rings.
XUse wedges to prevent the truck from moving.
XUse only tension belts or tie-down straps or with sufficient strength.
Improper fastening of the truck and mast during transport can result in serious
accidents.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case
correct measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe lorry / trailer must have fastening rings.
XUse wedges to prevent the truck from moving.
XUse only tension belts or tie-down straps or with sufficient strength.

Securing the truck for transport Securing the truck for transport

Tools and Material Required Tools and Material Required

– Tension belts/tie down straps – Tension belts/tie down straps
Procedure Procedure
• Move the truck onto the transporting • Move the truck onto the transporting
truck. truck.
• Park the truck securely, (see • Park the truck securely, (see
"Parking the truck securely" on "Parking the truck securely" on
page 55). page 55).
• Strap the belts (41) around the truck • Strap the belts (41) around the truck
and tension them sufficiently. and tension them sufficiently.
The truck can now be transported. The truck can now be transported.
41 41

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28 28
 3 Using the Truck for the First Time 3 Using the Truck for the First Time

CAUTION! CAUTION!

Operate the truck with battery current only. Rectified AC current will damage the Operate the truck with battery current only. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less electronic components. Cable connections to the battery (tow leads) must be less
than 6 m long and have a minimum cross-section of 50 . than 6 m long and have a minimum cross-section of 50 .

Procedure
• Check the equipment is complete.
• If necessary install the battery, (see "Battery removal and installation" on page 42)
Z If necessary, adjust the combination instrument to match the battery type.
• Charge the battery, (see "Charging the battery" on page 35).
Z For trucks with an optionally fitted charger set the charger characteristic curve
(charging curve).
The truck can now be started, (see "Starting up the truck" on page 52)
03.11 EN
Procedure
• Check the equipment is complete.
• If necessary install the battery, (see "Battery removal and installation" on page 42)
Z If necessary, adjust the combination instrument to match the battery type.
• Charge the battery, (see "Charging the battery" on page 35).
Z For trucks with an optionally fitted charger set the charger characteristic curve
(charging curve).
The truck can now be started, (see "Starting up the truck" on page 52)

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29 29
30
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30

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 D Battery - Servicing, Recharging,
Replacement
1 Safety Regulations Governing the Handling of Lead-Acid
Batteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This
operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work.
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging there shall be no inflammable material or
lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand.
D Battery - Servicing, Recharging,
Replacement
1 Safety Regulations Governing the Handling of Lead-Acid
Batteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This
operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work.
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging there shall be no inflammable material or
lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand.

Battery maintenance Battery maintenance

The battery cell covers must be kept dry and clean. The terminals and cable shoes The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease. must be clean, secure and have a light coating of dielectric grease.

CAUTION! CAUTION!

Before closing the battery panel make sure that the battery cable cannot be Before closing the battery panel make sure that the battery cable cannot be
damaged. There is a risk of short circuits with damaged cables. damaged. There is a risk of short circuits with damaged cables.

Battery disposal Battery disposal

Batteries may only be disposed of in accordance with national environmental Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions protection regulations or disposal laws. The manufacturer’s disposal instructions
must be followed. must be followed.
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31 31
 WARNING! WARNING!

Batteries can be hazardous Batteries can be hazardous

Batteries contain an acid solution which is poisonous and corrosive. Above all avoid
any contact with battery acid.
XDispose of used battery acid in accordance with regulations.
XAlways wear protective clothing and goggles when working with batteries.
XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XCall for a doctor immediately in the event of physical damage (e.g. skin or eye
contact with battery acid).
XNeutralise any spilled battery acid immediately with plenty of water.
XOnly batteries with a sealed battery container may be used.
XFollow national guidelines and legislation.
Batteries contain an acid solution which is poisonous and corrosive. Above all avoid
any contact with battery acid.
XDispose of used battery acid in accordance with regulations.
XAlways wear protective clothing and goggles when working with batteries.
XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XCall for a doctor immediately in the event of physical damage (e.g. skin or eye
contact with battery acid).
XNeutralise any spilled battery acid immediately with plenty of water.
XOnly batteries with a sealed battery container may be used.
XFollow national guidelines and legislation.

WARNING!
Using unsuitable batteries can cause accidents
The weight and dimensions of the battery have a considerable effect on the
operational safety and capacity of the industrial truck. Changing the battery features
requires the manufacturer’s approval, as compensating weights are required if
smaller batteries are fitted. When replacing/installing the battery make sure the
battery is securely located in the battery compartment of the truck.
WARNING!
Using unsuitable batteries can cause accidents
The weight and dimensions of the battery have a considerable effect on the
operational safety and capacity of the industrial truck. Changing the battery features
requires the manufacturer’s approval, as compensating weights are required if
smaller batteries are fitted. When replacing/installing the battery make sure the
battery is securely located in the battery compartment of the truck.

Park the truck securely before carrying out any work on the batteries ((see "Parking Park the truck securely before carrying out any work on the batteries ((see "Parking
the truck securely" on page 55)). the truck securely" on page 55)).

2 Battery types 2 Battery types

Depending on the model, the truck will be supplied with different battery types. The Depending on the model, the truck will be supplied with different battery types. The
following table shows which combinations are included as standard: following table shows which combinations are included as standard:

Battery type Capacity Battery type Capacity

24 volt battery 3 PzS 240 Ah 24 volt battery 3 PzS 240 Ah
24 volt battery 3 PzS 270 Ah 24 volt battery 3 PzS 270 Ah
24 volt battery 3 PzS 375 Ah 24 volt battery 3 PzS 375 Ah
24 volt battery 3 PzV 210 Ah 24 volt battery 3 PzV 210 Ah
24 volt battery 3 PzV 300 Ah 24 volt battery 3 PzV 300 Ah

The battery weights can be taken from the battery data plate. Batteries with non The battery weights can be taken from the battery data plate. Batteries with non
insulated terminals must be covered with a non slip insulating mat. insulated terminals must be covered with a non slip insulating mat.
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32 32
 3 Exposing the battery 3 Exposing the battery

CAUTION! CAUTION!

Trapping hazard Trapping hazard

XMake sure there is nothing between the battery cover and the truck when you fit the XMake sure there is nothing between the battery cover and the truck when you fit the
battery cover. battery cover.

WARNING! WARNING!
An unsecured truck can cause accidents An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load handler is dangerous and is Parking the truck on an incline or with a raised load handler is dangerous and is
strictly prohibited. strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges. secured with wedges.
XAlways fully lower the mast and forks. XAlways fully lower the mast and forks.
XSelect a place to park where no other people are at risk of injury from lowering XSelect a place to park where no other people are at risk of injury from lowering
forks. forks.

1 1

41 41

8 8
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33 33
 Requirements Requirements
– Park the truck on a level surface. – Park the truck on a level surface.
– Park the truck securely, (see "Parking the truck securely" on page 55). – Park the truck securely, (see "Parking the truck securely" on page 55).
Procedure Procedure
• Depress the Emergency Disconnect (8). • Depress the Emergency Disconnect (8).
• Open the battery panel (41). • Open the battery panel (41).

CAUTION! CAUTION!
A closing battery panel can pose a trapping hazard A closing battery panel can pose a trapping hazard
X Make sure the battery panel engages in the restraint when opened. X Make sure the battery panel engages in the restraint when opened.

The battery is exposed. The battery is exposed.

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34 34
 4 Charging the battery 4 Charging the battery

WARNING! WARNING!

The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge
capacity.
XBefore charging, check all cables and plug connections for visible signs of damage.
XVentilate the room in which the truck is being charged.
XThe battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.
XDo not smoke and avoid naked flames when handling batteries.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station
manufacturers.
The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge
capacity.
XBefore charging, check all cables and plug connections for visible signs of damage.
XVentilate the room in which the truck is being charged.
XThe battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation.
XDo not smoke and avoid naked flames when handling batteries.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station
manufacturers.

Charging the battery Charging the battery

Requirements Requirements
– Park the truck on a level surface. – Park the truck on a level surface.
– Expose the battery, (see "Exposing the battery" on page 33). – Expose the battery, (see "Exposing the battery" on page 33).
– Disconnect the battery – Disconnect the battery

Procedure Procedure
• Remove the battery connector (43) from the plug connection on the truck (42). • Remove the battery connector (43) from the plug connection on the truck (42).
• Remove any insulating mats from the battery. • Remove any insulating mats from the battery.
• Connect the charger lead of the battery charger station to the battery connector • Connect the charger lead of the battery charger station to the battery connector
(43). (43).
• Switch on the charger. Charging begins automatically. • Switch on the charger. Charging begins automatically.
The battery is now charged. The battery is now charged.
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35 35
 42 42

43 43

Completing the battery charge, restoring the truck to operation Completing the battery charge, restoring the truck to operation

NOTE NOTE

If charging has been interrupted, the full battery capacity will not be available. If charging has been interrupted, the full battery capacity will not be available.

Requirements Requirements
– Battery charging is complete. – Battery charging is complete.

Procedure Procedure
• Switch off the charger. • Switch off the charger.
• Disconnect the battery from the charger. • Disconnect the battery from the charger.
• Connect the battery to the truck. • Connect the battery to the truck.
• Close the battery panel securely. • Close the battery panel securely.
The truck is now ready for operation. The truck is now ready for operation.
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36 36
 4.1 Charging the battery with an on-board charger 4.1 Charging the battery with an on-board charger

DANGER! DANGER!
Risk of electric shock and burning Risk of electric shock and burning
Damaged and unsuitable wires can cause electric shocks and can overheat, resulting Damaged and unsuitable wires can cause electric shocks and can overheat, resulting
in fires. in fires.
XOnly use mains cables with a maximum length of 30 m. XOnly use mains cables with a maximum length of 30 m.
Local regulations must be observed. Local regulations must be observed.
XFully unreel the cable reel when using it. XFully unreel the cable reel when using it.
XAlways use original manufacturer’s mains cables. XAlways use original manufacturer’s mains cables.
XInsulation safety, acid and caustic ratings must comply with the manufacturer's XInsulation safety, acid and caustic ratings must comply with the manufacturer's
mains cable. mains cable.

NOTE NOTE

Improper use of the on-board charger can cause material damage.
The on-board charger consisting of a battery charger and battery controller must not
be opened. For faults, contact the manufacturer’s service department.
XThe charger must only be used for batteries supplied by Jungheinrich or other
approved batteries provided it has been adapted by the manufacturer's service
department.
XBatteries must never be swapped from truck to truck.
XDo not connect the battery to two chargers simultaneously.
Improper use of the on-board charger can cause material damage.
The on-board charger consisting of a battery charger and battery controller must not
be opened. For faults, contact the manufacturer’s service department.
XThe charger must only be used for batteries supplied by Jungheinrich or other
approved batteries provided it has been adapted by the manufacturer's service
department.
XBatteries must never be swapped from truck to truck.
XDo not connect the battery to two chargers simultaneously.

Z The factory setting for trucks without a battery is the 0 position. A battery discharge Z The factory setting for trucks without a battery is the 0 position. A battery discharge
indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached indicator, a charge/discharge indicator, a CanDis or a bipolar LED can be attached
to the connector (45). to the connector (45).

44 45 44 45

Setting the charging characteristics Setting the charging characteristics

CAUTION! CAUTION!
03.11 EN

03.11 EN

XRemove the mains connector before setting the respective charging curve. XRemove the mains connector before setting the respective charging curve.

37 37
 Set the charging characteristic Set the charging characteristic

Requirements Requirements
– Battery connected. – Battery connected.

Procedure Procedure
• Turn the setting switch (44) on the charger right to adapt the charging curve to the • Turn the setting switch (44) on the charger right to adapt the charging curve to the
battery being used. battery being used.
• The validity of the new setting is acknowledged by the flashing of the green LED • The validity of the new setting is acknowledged by the flashing of the green LED
and the setting takes immediate effect. and the setting takes immediate effect.
The charging characteristic is now set. The charging characteristic is now set.

Switch setting / charging curve assignment Switch setting / charging curve assignment
Switch position (44) Selected charging curves (characteristics) Switch position (44) Selected charging curves (characteristics)
0 Truck without battery 0 Truck without battery
Wet cell battery: PzS with 100 - 300 Ah Wet cell battery: PzS with 100 - 300 Ah
1 1
Wet cell battery: PzM with 100 - 180 Ah Wet cell battery: PzM with 100 - 180 Ah
2 Maintenance-free: PzV with 100 - 149 Ah 2 Maintenance-free: PzV with 100 - 149 Ah
3 Maintenance-free: PzV with 150 - 199 Ah 3 Maintenance-free: PzV with 150 - 199 Ah
4 Maintenance-free: PzV with 200 - 300 Ah 4 Maintenance-free: PzV with 200 - 300 Ah
Wet cell battery: PzS with pulse characteristic 200 - Wet cell battery: PzS with pulse characteristic 200 -
400 Ah 400 Ah
5 5
Wet cell battery: PzM with pulse characteristic 180 - Wet cell battery: PzM with pulse characteristic 180 -
400 Ah 400 Ah
6 Jungheinrich 100 - 300 Ah 6 Jungheinrich 100 - 300 Ah

NOTE NOTE

XAll other switch positions (44) block the charger, and the battery is not charged.
XFor PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond
180 Ah set characteristic 5.
XWith PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be
used. Characteristic 5 achieves a faster charge.
XWhen the battery is connected this allows you to adjust via the charger: If the switch
position is valid the green LED flashes according to the position set; if the switch
position is invalid the red LED flashes.
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XAll other switch positions (44) block the charger, and the battery is not charged.
XFor PzM batteries with a capacity of less than 180 Ah set characteristic 1, beyond
180 Ah set characteristic 5.
XWith PzS 200-300 Ah wet cell batteries both characteristic curves 1 and 5 can be
used. Characteristic 5 achieves a faster charge.
XWhen the battery is connected this allows you to adjust via the charger: If the switch
position is valid the green LED flashes according to the position set; if the switch
position is invalid the red LED flashes.

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 Starting to charge with the onboard charger Starting to charge with the onboard charger
Mains connection Mains connection

Mains voltage: 230 V / 110 V (+10/-15%) Mains voltage: 230 V / 110 V (+10/-15%)
Mains frequency: 50 Hz / 60 Hz Mains frequency: 50 Hz / 60 Hz
The mains cable of the charger (46) is contained in the front panel or the battery The mains cable of the charger (46) is contained in the front panel or the battery
compartment. compartment.

Charge the battery Charge the battery

Requirements Requirements
– Park the truck securely, (see "Parking the truck – Park the truck securely, (see "Parking the truck
securely" on page 55). 46 securely" on page 55). 46
– Expose the battery, (see "Exposing the battery" on – Expose the battery, (see "Exposing the battery" on
page 33). page 33).
– Correct charging program set on charger. – Correct charging program set on charger.

Procedure Procedure
• Remove any insulating mats from the battery. • Remove any insulating mats from the battery.
• The battery connector must remain plugged. • The battery connector must remain plugged.
• Attach the mains connector (46) to a mains socket. • Attach the mains connector (46) to a mains socket.
• Pull Emergency Disconnect switch up. • Pull Emergency Disconnect switch up.
The flashing LED indicates the charge status or a fault (for flashing codes see “LED The flashing LED indicates the charge status or a fault (for flashing codes see “LED
Display” table). Display” table).
The battery is now charged. The battery is now charged.
Z When the mains connector (46) is connected to the mains, all the truck’s electrical Z When the mains connector (46) is connected to the mains, all the truck’s electrical
functions are disconnected (electric immobilizer). The truck cannot be operated. functions are disconnected (electric immobilizer). The truck cannot be operated.
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 Completing the battery charge, restoring the truck to operation Completing the battery charge, restoring the truck to operation

NOTE NOTE
If charging has been interrupted, the full battery capacity will not be available If charging has been interrupted, the full battery capacity will not be available

Requirements Requirements
– Battery charging is complete. – Battery charging is complete.
Procedure Procedure
• Remove the mains connector (46) from the socket and store it in the battery • Remove the mains connector (46) from the socket and store it in the battery
compartment with the cable. compartment with the cable.
• If applicable, place the existing insulating mats back over the battery. • If applicable, place the existing insulating mats back over the battery.
• Close the battery cover securely. • Close the battery cover securely.
The truck is now ready for operation. The truck is now ready for operation.

Charging times Charging times

The duration of charge depends on the battery capacity. The duration of charge depends on the battery capacity.

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

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40 40
 LED display (47) LED display (47)

47 47
Green LED (charge status) Green LED (charge status)
Lit Charging complete, battery full. Lit Charging complete, battery full.
(Charge interval, float or (Charge interval, float or
compensation charge). compensation charge).
Flashes slowly Charging. Flashes slowly Charging.
Rapid flash Display at beginning of charge or Rapid flash Display at beginning of charge or
after setting a new characteristic after setting a new characteristic
curve. Number of flash pulses curve. Number of flash pulses
corresponds to the characteristic corresponds to the characteristic
curve set. curve set.

Red LED (fault) Red LED (fault)

Lit Overtemperature. Charging is Lit Overtemperature. Charging is
interrupted. interrupted.
Flashes slowly Safety charging time exceeded. Flashes slowly Safety charging time exceeded.
Charging is cancelled. Charging is cancelled.
Mains must be disconnected for Mains must be disconnected for
charging to restart. charging to restart.
Rapid flash Invalid characteristic curve Rapid flash Invalid characteristic curve
setting. setting.
Compensation charge Compensation charge

The compensation charge starts automatically when charging is complete. The compensation charge starts automatically when charging is complete.
Partial charging Partial charging

The charger is designed to automatically adapt to partially charged batteries. This The charger is designed to automatically adapt to partially charged batteries. This
keeps battery wear to a minimum. keeps battery wear to a minimum.
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5 Battery removal and installation 5 Battery removal and installation

WARNING! WARNING!

Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the
battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" section in this chapter.
XWear safety shoes when removing and installing the battery.
XUse only batteries with insulated cells and terminal connectors. If necessary cover
them with a rubber mat.
XPark the truck on a level surface.
XMake sure the crane lifting gear has sufficient capacity to replace the battery.
XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the
battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" section in this chapter.
XWear safety shoes when removing and installing the battery.
XUse only batteries with insulated cells and terminal connectors. If necessary cover
them with a rubber mat.
XPark the truck on a level surface.
XMake sure the crane lifting gear has sufficient capacity to replace the battery.
XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.

CAUTION! CAUTION!
Trapping hazard Trapping hazard
There is a risk of trapping when you close the battery cover. There is a risk of trapping when you close the battery cover.
XMake sure there is nothing between the battery cover and the truck when you close XMake sure there is nothing between the battery cover and the truck when you close
the battery cover. the battery cover.

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42 42
 5.1 Changing the battery from the top, trucks without wheel arm lift 5.1 Changing the battery from the top, trucks without wheel arm lift
Removing the battery Removing the battery
Requirements Requirements
– Park the truck securely, (see "Parking the truck securely" on page 55). – Park the truck securely, (see "Parking the truck securely" on page 55).
– Expose the battery, (see "Exposing the battery" on page 33). – Expose the battery, (see "Exposing the battery" on page 33).
Procedure Procedure
• Disconnect the battery connector from the truck connector. • Disconnect the battery connector from the truck connector.
Z Place the battery cable on the tray so that it cannot be severed when the battery is Z Place the battery cable on the tray so that it cannot be severed when the battery is
pulled out. pulled out.
• Strap the crane lifting gear to the eyes (48). • Strap the crane lifting gear to the eyes (48).
Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must
never fall into the battery cells. never fall into the battery cells.
• Pull the battery up out of the container. • Pull the battery up out of the container.

Z Installation is the reverse order. When reinstalling the battery, note the proper Z Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. Place the installation position and make sure the battery is connected correctly. Place the
battery cable on the tray so that it cannot be severed when the battery is inserted. battery cable on the tray so that it cannot be severed when the battery is inserted.

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

48 48
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43 43
5.2 Changing the battery from the top, trucks with wheel arm lift 5.2 Changing the battery from the top, trucks with wheel arm lift
Removing the battery Removing the battery
Requirements Requirements
– Park the truck securely, (see "Parking the truck securely" on page 55). – Park the truck securely, (see "Parking the truck securely" on page 55).
– Expose the battery, (see "Exposing the battery" on page 33). – Expose the battery, (see "Exposing the battery" on page 33).
Procedure Procedure
• Disconnect the battery connector from the truck connector. • Disconnect the battery connector from the truck connector.
Z Place the battery cable on the tray so that it cannot be severed when the battery is Z Place the battery cable on the tray so that it cannot be severed when the battery is
pulled out. pulled out.
• Strap the crane lifting gear to the eyes (48). • Strap the crane lifting gear to the eyes (48).
Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must
never fall into the battery cells. never fall into the battery cells.
• Pull the battery up out of the container. • Pull the battery up out of the container.

Z Installation is the reverse order. When reinstalling the battery, note the proper Z Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. Place the installation position and make sure the battery is connected correctly. Place the
battery cable on the tray so that it cannot be severed when the battery is inserted. battery cable on the tray so that it cannot be severed when the battery is inserted.

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

48 48

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44 44
 5.3 Removing the battery from the side 5.3 Removing the battery from the side
Z Lateral battery removal is an option only. Z Lateral battery removal is an option only.

CAUTION! CAUTION!

Trapping hazard Trapping hazard

Trapping hazard when removing and installing the battery. Trapping hazard when removing and installing the battery.
XWhen removing and installing the battery do not put your hands between the XWhen removing and installing the battery do not put your hands between the
battery and the chassis. battery and the chassis.

Battery removal Battery removal

Requirements
– Park the truck securely, (see "Parking
the truck securely" on page 55).
– Expose the battery, (see "Exposing
the battery" on page 33).
Requirements
– Park the truck securely, (see "Parking
the truck securely" on page 55).
49 – Expose the battery, (see "Exposing 49
the battery" on page 33).

Procedure 50 Procedure 50
• Turn the battery lock up (52) as far as • Turn the battery lock up (52) as far as
the stop. the stop.
• Move the lever (43) to force the 51 • Move the lever (43) to force the 51
battery slightly beyond the perimeter battery slightly beyond the perimeter
of the truck. of the truck.
• Position the battery trolley by the 52 • Position the battery trolley by the 52
truck. truck.
• Pull the battery (50) slightly towards • Pull the battery (50) slightly towards
you. you.
• Carefully pull the battery from off the truck onto the trolley. • Carefully pull the battery from off the truck onto the trolley.
The battery is now removed. The battery is now removed.

Battery installation Battery installation

Requirements Requirements
– Park the truck securely, (see "Parking the truck securely" on page 55). – Park the truck securely, (see "Parking the truck securely" on page 55).

Procedure Procedure
Z Installation is the reverse order. When reinstalling the battery, note the proper Z Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. installation position and make sure the battery is connected correctly.
• Push the battery into its receptacle. • Push the battery into its receptacle.
• Push the battery lock (52) towards the battery tray as far as the stop. • Push the battery lock (52) towards the battery tray as far as the stop.
• Attach the battery connector (43) to the truck connector. • Attach the battery connector (43) to the truck connector.
The battery is now assembled. The battery is now assembled.
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45 45
46
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46

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 E Operation
1 Safety Regulations for the Operation of the
Forklift Truck
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities
The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. The driver
shall be afforded all due rights. Safety shoes must be worn for pedestrian operated
trucks.
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver must
prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
Repairs
The driver must not carry out any repairs or alterations to the truck without the
necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches.
Hazardous area
WARNING!
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering
operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck
immediately.
Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" on
page 23)) and warning instructions in the present operating instructions must be
03.11 EN
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strictly observed.
47
E Operation
1 Safety Regulations for the Operation of the
Forklift Truck
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities
The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. The driver
shall be afforded all due rights. Safety shoes must be worn for pedestrian operated
trucks.
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver must
prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
Repairs
The driver must not carry out any repairs or alterations to the truck without the
necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches.
Hazardous area
WARNING!
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering
operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck
immediately.
Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" on
page 23)) and warning instructions in the present operating instructions must be
strictly observed.
47
2 Displays and Controls 2 Displays and Controls

53 53 53 53
54 54
55 56 57 58 55 56 57 58
2 2

4 4
5 5
6 6
7 59 7 59

8 8

60 60
9 9

14 14
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48 48
 Ite Control / ERC ERC ERC Function Ite Control / ERC ERC ERC Function
m Display 212 214 / Z12 / m Display 212 214 / Z12 /
216 Z14 / 216 Z14 /
Z16 Z16
53 Warning signal t t t – “Warning” button 53 Warning signal t t t – “Warning” button
(horn) button (horn) button
54 Collision safety t t t Pedestrian mode: 54 Collision safety t t t Pedestrian mode:
switch switch
Safety function Safety function
– When applied the truck travels for – When applied the truck travels for
approx. 3 seconds in the forks approx. 3 seconds in the forks
direction. The parking brake then direction. The parking brake then
applies. The truck remains switched applies. The truck remains switched
off until the travel switch is set to off until the travel switch is set to
neutral. neutral.
Rider mode: Rider mode:
– No function. (Optionally available – No function. (Optionally available
from the factory.) from the factory.)
55 "Wheel arm - - t – Lowers the wheel arms at a constant 55 "Wheel arm - - t – Lowers the wheel arms at a constant
lower" button speed. lower" button speed.
56 "Wheel arm - - t – Raises the wheel arms at a constant 56 "Wheel arm - - t – Raises the wheel arms at a constant
raise" button speed. raise" button speed.
57 “Lift” button t t t – Raises the lift mechanism. 57 “Lift” button t t t – Raises the lift mechanism.
58 “Lower” button t t t – Lowers the lift mechanism. 58 “Lower” button t t t – Lowers the lift mechanism.
2 Travel switch t t t – Controls the direction of travel as well 2 Travel switch t t t – Controls the direction of travel as well
as the travel speed. as the travel speed.
4 Tiller t t t – Set to brake zone (B) ((see 4 Tiller t t t – Set to brake zone (B) ((see
"Emergency Disconnect, Travel, "Emergency Disconnect, Travel,
Steering, Braking" on page 59)): Steering, Braking" on page 59)):
The truck brakes mechanically. The truck brakes mechanically.
– Set to travel zone (F) ((see – Set to travel zone (F) ((see
"Emergency Disconnect, Travel, "Emergency Disconnect, Travel,
Steering, Braking" on page 59)): Steering, Braking" on page 59)):
The mechanical brake is released The mechanical brake is released
and the truck is ready for operation. and the truck is ready for operation.
5 Key switch and t t t – Activates the industrial truck by 5 Key switch and t t t – Activates the industrial truck by
key switching on the control voltage. key switching on the control voltage.
– Removing the key prevents the truck – Removing the key prevents the truck
from being switched on by from being switched on by
unauthorized personnel. unauthorized personnel.
6 CanDis o o o Display instrument for 6 CanDis o o o Display instrument for
– Battery charge status – Battery charge status
– Service hours – Service hours
– Warning messages – Warning messages
– Parameter settings – Parameter settings
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49 49
 Ite Control / ERC ERC ERC Function Ite Control / ERC ERC ERC Function
m Display 212 214 / Z12 / m Display 212 214 / Z12 /
216 Z14 / 216 Z14 /
Z16 Z16
7 CanCode o o o Replaces the key switch 7 CanCode o o o Replaces the key switch
– The truck is activated when you enter – The truck is activated when you enter
the appropriate code. the appropriate code.
– Travel program selection. – Travel program selection.
– Code setting – Code setting
– Parameter setting. – Parameter setting.
9 Folding side - t t*) When the side restraints are not 9 Folding side - t t*) When the side restraints are not
restraint unfolded and the operator platform is restraint unfolded and the operator platform is
laden and unfolded: laden and unfolded:
– travel inhibited. – travel inhibited.
14 Folding operator t t t Pedestrian mode 14 Folding operator t t t Pedestrian mode
platform platform
– Operator platform folded up: – Operator platform folded up:
Pedestrian speed restricted to max. Pedestrian speed restricted to max.
6.0 km/h. 6.0 km/h.
Rider mode, operator platform acts as a Rider mode, operator platform acts as a
deadman: deadman:

– Operator platform down and vacated: – Operator platform down and vacated:
travel inhibited. travel inhibited.
– Operator platform down and laden by – Operator platform down and laden by
weight of operator (both restraints weight of operator (both restraints
must be folded fully out or in): must be folded fully out or in):
travel enabled. travel enabled.
59 Clip pad t t t – Paper storage. 59 Clip pad t t t – Paper storage.
8 Emergency t Disconnects the battery supply 8 Emergency t Disconnects the battery supply
Disconnect – All electric functions are deactivated Disconnect – All electric functions are deactivated
and the truck decelerates and the truck decelerates
60 On-board o o o – Charges the battery 60 On-board o o o – Charges the battery
charger charger
t = Standard equipment o = Optional equipment 03.11 EN
t = Standard equipment o = Optional equipment

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50 50
 2.1 Battery discharge indicator 2.1 Battery discharge indicator

When the truck has been released via the key When the truck has been released via the key
switch, code lock or ISM, the battery charge status 61 switch, code lock or ISM, the battery charge status 61
is displayed. The LED (61) colours represent the is displayed. The LED (61) colours represent the
following conditions: following conditions:

LED colour Residual capacity LED colour Residual capacity

Green 40 - 100 % Green 40 - 100 %
Orange 30 - 40 % Orange 30 - 40 %
Flashing Flashing
20 - 30 % 20 - 30 %
green/orange 1Hz green/orange 1Hz
Red 0 - 20 % Red 0 - 20 %

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

If the LED flashes red and the truck is not ready for operation, inform the If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a truck controller code. The manufacturer's service department. Red flashing is a truck controller code. The
flashing sequence indicates the type of fault. flashing sequence indicates the type of fault.
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51 51
3 Starting up the truck 3 Starting up the truck
3.1 Checks and operations to be performed before starting daily 3.1 Checks and operations to be performed before starting daily
operation operation

WARNING! WARNING!

Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.

Pre-start inspections Pre-start inspections

Procedure Procedure
• Check the whole of the outside of the truck for signs of damage and leaks. • Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately. Damaged hoses must be replaced immediately.
• Check the battery attachment and wire connections for damage and make sure • Check the battery attachment and wire connections for damage and make sure
they are secure. they are secure.
• Check the battery connectors are secure. • Check the battery connectors are secure.
• Check the load handler for visible signs of damage such as cracks, bent or severely • Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks. worn forks.
• Check the drive wheel and load wheels for damage. • Check the drive wheel and load wheels for damage.
• Check that the markings and labels are present, clean and legible, (see • Check that the markings and labels are present, clean and legible, (see
"Identification points and data plates" on page 23). "Identification points and data plates" on page 23).
• Test the Emergency Disconnect switch. • Test the Emergency Disconnect switch.
• Check the control handle (damper) is restored to its normal position. • Check the control handle (damper) is restored to its normal position.
• Check the controls are automatically restored to zero after being applied. • Check the controls are automatically restored to zero after being applied.
• Test the warning signal. • Test the warning signal.
• Test the brakes. • Test the brakes.
• Test the collision safety switch. • Test the collision safety switch.
• Check the steering play. • Check the steering play.
• Safety cutout height switch (mast), check cable connections and magnet • Safety cutout height switch (mast), check cable connections and magnet
attachment. attachment.
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52 52
 3.2 Preparing the truck for operation 3.2 Preparing the truck for operation
Switching on the truck Switching on the truck
Requirements Requirements
– For checks and operations to be performed before starting daily operation, (see – For checks and operations to be performed before starting daily operation, (see
"Checks and operations to be performed before starting daily operation" on "Checks and operations to be performed before starting daily operation" on
page 52). page 52).

Procedure Procedure
• Step onto the operator platform (14). • Step onto the operator platform (14).
• Pull out the Emergency Disconnect switch (8). • Pull out the Emergency Disconnect switch (8).
• Switch on the truck, to do this: • Switch on the truck, to do this:
• Insert the key in the key switch (5) and turn it to the right as far as it will go • Insert the key in the key switch (5) and turn it to the right as far as it will go
(position “I”) or for CANCODE (7,o) enter the activation code, (see "CanCode (position “I”) or for CANCODE (7,o) enter the activation code, (see "CanCode
keypad" on page 72). keypad" on page 72).
• Test the warning signal button (53). • Test the warning signal button (53).
• Test the travel switch (2). • Test the travel switch (2).
• Test the steering. • Test the steering.
• Test lifting operations. • Test lifting operations.
The truck is operational. The truck is operational.

WARNING! WARNING!

Do not press the travel switch or the "pedestrian" button (o) when entering and Do not press the travel switch or the "pedestrian" button (o) when entering and
exiting the truck. exiting the truck.

Z The CanDis display instrument (6(o)) indicates the available battery capacity. Z The CanDis display instrument (6(o)) indicates the available battery capacity.
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53 53
 2 2

53 53
7 7
6 6
5 5

8 8

14 14

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54 54
 3.3 Parking the truck securely 3.3 Parking the truck securely

WARNING! WARNING!
An unsecured truck can cause accidents An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load / load Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited. handler is dangerous and is strictly prohibited.
XAlways park the truck on a level surface. In special cases the truck may need to be XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges. secured with wedges.
XAlways fully lower the mast and forks. XAlways fully lower the mast and forks.
XSelect a place to park where no other people are at risk of injury from lowering XSelect a place to park where no other people are at risk of injury from lowering
forks. forks.

Parking the truck securely Parking the truck securely

Procedure Procedure
• Fully lower the load handler. • Fully lower the load handler.
• Set the drive wheel to “Straight ahead”. • Set the drive wheel to “Straight ahead”.
Z Set the control handle to the "forward position". Z Set the control handle to the "forward position".
• Switch off the truck (5) and remove the key. • Switch off the truck (5) and remove the key.
• For CanCode (7) press the O key. • For CanCode (7) press the O key.
• Press the Emergency Disconnect (8). • Press the Emergency Disconnect (8).
• Fold in the side arms (9). • Fold in the side arms (9).
The truck is parked. The truck is parked.

5 5

8 8
9 9

14 14

3.4 Battery discharge monitor 3.4 Battery discharge monitor

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Z The standard setting for the battery discharge indicator / discharge monitor is Z The standard setting for the battery discharge indicator / discharge monitor is
based on standard batteries. When using maintenance-free or special batteries the based on standard batteries. When using maintenance-free or special batteries the

55 55
 display and cutout points of the battery discharge monitor must be set by display and cutout points of the battery discharge monitor must be set by
authorised specialist personnel. If this adjustment is not made the battery may authorised specialist personnel. If this adjustment is not made the battery may
become damaged through excessive depletion. become damaged through excessive depletion.

If the residual capacity falls below the required level, lifting is inhibited. An alternating If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (61) appears. Lifting is only released when the battery connected is at least display (61) appears. Lifting is only released when the battery connected is at least
70% charged. 70% charged.

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03.11 EN
56 56
 4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in
control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
Travel visibility
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye
contact.
Negotiating slopes and inclines
Negotiating slopes or inclines is only permitted if they are specifically designed as
travel routes, are clean and have a non-slip surface and providing they can be safely
travelled along in accordance with the truck's technical specifications. The truck must
always be driven with the load unit facing uphill. The industrial truck must not be
turned, operated at an angle or parked on inclines or slopes. Inclines must only be
negotiated at slow speed, with the driver ready to brake at any moment.
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57
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in
control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
Travel visibility
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye
contact.
Negotiating slopes and inclines
Negotiating slopes or inclines is only permitted if they are specifically designed as
travel routes, are clean and have a non-slip surface and providing they can be safely
travelled along in accordance with the truck's technical specifications. The truck must
always be driven with the load unit facing uphill. The industrial truck must not be
turned, operated at an angle or parked on inclines or slopes. Inclines must only be
negotiated at slow speed, with the driver ready to brake at any moment.
57
 Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down.
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58
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down.
03.11 EN
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 4.2 Emergency Disconnect, Travel, Steering, Braking 4.2 Emergency Disconnect, Travel, Steering, Braking

4.2.1 Emergency Disconnect 4.2.1 Emergency Disconnect

Applying the Emergency Disconnect Applying the Emergency Disconnect
Procedure Procedure

CAUTION! CAUTION!
Accident risk Accident risk
The operation of the Emergency Disconnect switch must not be affected by any The operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way. objects placed in its way.

Z Do not use the Emergency Disconnect (8) as a service brake. Z Do not use the Emergency Disconnect (8) as a service brake.
• Press the Emergency Disconnect (8). • Press the Emergency Disconnect (8).
All electrical functions are deactivated. The truck brakes to a halt. All electrical functions are deactivated. The truck brakes to a halt.

Release the Emergency Disconnect Release the Emergency Disconnect

Procedure Procedure
• Pull the Emergency Disconnect (8) to unlock it. • Pull the Emergency Disconnect (8) to unlock it.
All electrical functions are enabled and the truck is operational again (assuming the All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed). truck was not operational before the Emergency Disconnect was pressed).
For CanCode and ISM the truck remains switched off. For CanCode and ISM the truck remains switched off.

B B

4 4

8 8
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59 59
4.2.2 Travel 4.2.2 Travel

CAUTION! CAUTION!

XDo not drive the truck unless the panels are closed and properly locked. XDo not drive the truck unless the panels are closed and properly locked.
XWhen travelling through swing doors etc. make sure that the doors do not activate XWhen travelling through swing doors etc. make sure that the doors do not activate
the collision safety button. the collision safety button.

WARNING! WARNING!
Trapping hazard Trapping hazard
Be extremely careful when driving and steering, especially if parts of your body Be extremely careful when driving and steering, especially if parts of your body
extend outside the border of the truck. extend outside the border of the truck.
XDo not reach between the standing platform and the truck frame when you fold up XDo not reach between the standing platform and the truck frame when you fold up
the platform. the platform.
XIn pedestrian mode make sure you have sufficient distance from the industrial XIn pedestrian mode make sure you have sufficient distance from the industrial
truck. truck.

Industrial trucks with a folding standing platform and moving tiller Industrial trucks with a folding standing platform and moving tiller
We distinguish between two travel modes: We distinguish between two travel modes:

– Travel in pedestrian mode – Travel in pedestrian mode

– Travel in rider mode – Travel in rider mode
Travelling in pedestrian mode Travelling in pedestrian mode

Requirements Requirements
– Start up the truck, (see "Starting up the truck" on page 52) – Start up the truck, (see "Starting up the truck" on page 52)
Procedure Procedure
• Move both folding side arms (9) in. • Move both folding side arms (9) in.
Z Both side arms must always be folded in or out; otherwise all functions are Z Both side arms must always be folded in or out; otherwise all functions are
deactivated (E-1926). deactivated (E-1926).
• Fold up the operator platform (14). • Fold up the operator platform (14).
• Set the tiller (4) to the travel zone (F). • Set the tiller (4) to the travel zone (F).
• Set the travel switch (2) to the desired travel direction: forward (V) or reverse (R). • Set the travel switch (2) to the desired travel direction: forward (V) or reverse (R).
Z When the travel switch is release it automatically returns to its original position. Z When the travel switch is release it automatically returns to its original position.
• Control the travel speed with the travel switch (2). • Control the travel speed with the travel switch (2).
The brakes are released and the truck moves in the selected direction. The brakes are released and the truck moves in the selected direction.

Z In pedestrian mode the truck can now operate again at normal speed. Z In pedestrian mode the truck can now operate again at normal speed.

Travelling in rider mode Travelling in rider mode

Requirements Requirements
– Start up the truck, (see "Starting up the truck" on page 52) – Start up the truck, (see "Starting up the truck" on page 52)
Procedure Procedure
• Move the folding side arms (9) out. • Move the folding side arms (9) out.
03.11 EN

03.11 EN
• Fold down the operator platform (14). • Fold down the operator platform (14).
• Set the tiller (4) to the travel zone (F). • Set the tiller (4) to the travel zone (F).

60 60
 • Set the travel switch (2) to the desired travel direction: forward (V) or reverse (R). • Set the travel switch (2) to the desired travel direction: forward (V) or reverse (R).
Z When the travel switch is release it automatically returns to its original position. Z When the travel switch is release it automatically returns to its original position.
• Control the travel speed with the travel switch (2). • Control the travel speed with the travel switch (2).
The brakes are released and the truck moves in the selected direction. The brakes are released and the truck moves in the selected direction.

Z Preventing the truck from “rolling downhill”: Z Preventing the truck from “rolling downhill”:
If the truck rolls backwards on an incline the controller detects the situation and the If the truck rolls backwards on an incline the controller detects the situation and the
travel switch brake applies automatically after a short jerk. travel switch brake applies automatically after a short jerk.
Higher rider mode speed Higher rider mode speed

Requirements Requirements
– Start up the truck, (see "Starting up the truck" on page 52) – Start up the truck, (see "Starting up the truck" on page 52)

Procedure Procedure
• Fold down the operator platform (14). • Fold down the operator platform (14).
• Move the folding side restraints (9) out. • Move the folding side restraints (9) out.
• Set the tiller (4) to the travel zone (F). • Set the tiller (4) to the travel zone (F).
• Set the travel switch (2) to the desired travel direction: forward (V) or reverse (R). • Set the travel switch (2) to the desired travel direction: forward (V) or reverse (R).
Z When the travel switch is released it automatically returns to its original position. Z When the travel switch is released it automatically returns to its original position.
• Control the travel speed with the travel switch (2). • Control the travel speed with the travel switch (2).
The brakes are released and the truck moves in the selected direction. The brakes are released and the truck moves in the selected direction.

Z Preventing the truck from “rolling downhill”: Z Preventing the truck from “rolling downhill”:

If the truck rolls backwards on an incline the controller detects the situation and the If the truck rolls backwards on an incline the controller detects the situation and the
travel switch brake applies automatically after a short jerk. travel switch brake applies automatically after a short jerk.

NOTE NOTE

XTravelling is inhibited when the operator platform is unladen and the side arms are XTravelling is inhibited when the operator platform is unladen and the side arms are
not folded out. not folded out.
XIf the standing platform is occupied and the gates are not folded out, the industrial XIf the standing platform is occupied and the gates are not folded out, the industrial
truck can only be operated at reduced speed. truck can only be operated at reduced speed.
XIf the operator platform is occupied and only one gate is folded out, travelling is XIf the operator platform is occupied and only one gate is folded out, travelling is
inhibited. inhibited.
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61 61
 B B
R R
V2 V2
F F
4 4

B B

R R
8 8

9 9

V V
14 14

4.2.3 Steering 4.2.3 Steering

CAUTION! CAUTION!
In narrow bends the driver extends beyond the outer edge of the industrial truck. In narrow bends the driver extends beyond the outer edge of the industrial truck.

Procedure Procedure
• Move the tiller (4) to the left or right. • Move the tiller (4) to the left or right.
The truck is steered in the required direction. The truck is steered in the required direction.

4.2.4 Brakes 4.2.4 Brakes

The brake pattern of the truck depends largely on the travel route conditions. The The brake pattern of the truck depends largely on the travel route conditions. The
driver must take this into account when travelling. driver must take this into account when travelling.

The truck can brake in different ways: The truck can brake in different ways:

– By inversion braking (controller) – By inversion braking (controller)

– By regenerative braking (coasting) – By regenerative braking (coasting)
– With the tiller in zone "B" – With the tiller in zone "B"

CAUTION! CAUTION!

XOnly with Emergency Disconnect (magnetic brake) in emergencies XOnly with Emergency Disconnect (magnetic brake) in emergencies

Braking with the Emergency Disconnect switch Braking with the Emergency Disconnect switch
Procedure Procedure
03.11 EN

03.11 EN
• Press the Emergency Disconnect switch (8) down. • Press the Emergency Disconnect switch (8) down.

62 62
 The circuit is disconnected, all electrical functions are cut out and the industrial truck The circuit is disconnected, all electrical functions are cut out and the industrial truck
brakes automatically (magnetic brake). brakes automatically (magnetic brake).
Z The truck can only start again when the Emergency Disconnect switch (8) has been Z The truck can only start again when the Emergency Disconnect switch (8) has been
unlocked again by pulling it up. unlocked again by pulling it up.

Inversion braking Inversion braking

Procedure Procedure
• During travel, set the travel switch (2) to the opposite direction. • During travel, set the travel switch (2) to the opposite direction.
The truck brakes are regenerative until it starts to move in the opposite direction. The truck brakes are regenerative until it starts to move in the opposite direction.

Z The brake force can be set by the manufacturer’s service department. Z The brake force can be set by the manufacturer’s service department.

Regenerative braking Regenerative braking

Procedure Procedure
• If the travel switch is set to 0, the truck automatically uses regenerative brakes . • If the travel switch is set to 0, the truck automatically uses regenerative brakes .
The truck comes to a halt regeneratively via the coasting brake. The brake then The truck comes to a halt regeneratively via the coasting brake. The brake then
applies. applies.

Z With regenerative braking energy is recuperated to the battery, ensuring a longer Z With regenerative braking energy is recuperated to the battery, ensuring a longer
service time. service time.

Braking with the tiller in the "B" zone Braking with the tiller in the "B" zone

Procedure
• Move the tiller up or down to one of the brake zones (B).
Z Initially the truck brakes regeneratively. The mechanical brake is only applied when
this brake fails to achieve the necessary braking force.
The truck will decelerate at the maximum rate and the brake will apply.
03.11 EN
Procedure
• Move the tiller up or down to one of the brake zones (B).
Z Initially the truck brakes regeneratively. The mechanical brake is only applied when
this brake fails to achieve the necessary braking force.
The truck will decelerate at the maximum rate and the brake will apply.

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4.3 Lifting, transporting and depositing loads 4.3 Lifting, transporting and depositing loads

WARNING!
Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
XDamaged loads must not be transported.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XInsert the forks as far as possible underneath the load.
WARNING!
Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
XDamaged loads must not be transported.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XInsert the forks as far as possible underneath the load.

NOTE NOTE

The operator platform (14) must be occupied by the operator for lifting/lowering to be The operator platform (14) must be occupied by the operator for lifting/lowering to be
enabled. enabled.

NOTE NOTE
On the duplex (ZZ) and triplex (DZ) masts, travel is automatically reduced from a On the duplex (ZZ) and triplex (DZ) masts, travel is automatically reduced from a
truck-specific lift height. It increases again when the load is lowered. truck-specific lift height. It increases again when the load is lowered.

NOTE NOTE

Adapt a slower speed when stacking and retrieving. Adapt a slower speed when stacking and retrieving.

4.3.1 Lifting and lowering 4.3.1 Lifting and lowering

Lift a load unit Lift a load unit

Requirements Requirements
– Load unit correctly palletised. – Load unit correctly palletised.
– Load unit weight matches the truck's – Load unit weight matches the truck's
capacity. capacity.
– Forks evenly loaded for heavy loads. – Forks evenly loaded for heavy loads.

Procedure Procedure
• Drive the truck carefully up to the pallet. • Drive the truck carefully up to the pallet.
• Slowly insert the forks into the pallet until • Slowly insert the forks into the pallet until
57 58 57 58
the fork shank touches the pallet. the fork shank touches the pallet.
Z Z
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03.11 EN
The load unit must not extend by more than 50 mm beyond the fork tips. The load unit must not extend by more than 50 mm beyond the fork tips.
• Press the “Raise load handler” button (57) until you reach the desired lift height. • Press the “Raise load handler” button (57) until you reach the desired lift height.

64 64
 The load unit is raised. The load unit is raised.

Z The lift/lower speed can be infinitely controlled via the movement of the button Z The lift/lower speed can be infinitely controlled via the movement of the button
(approx. 8 mm). (approx. 8 mm).
Short stroke = slow lift / lower Short stroke = slow lift / lower
Long stroke = fast lift / lower Long stroke = fast lift / lower

CAUTION! CAUTION!
XRelease the button as soon as you reach the load handler limit position. XRelease the button as soon as you reach the load handler limit position.

Depositing load units Depositing load units

Requirements Requirements
– Storage location suitable for storing the load. – Storage location suitable for storing the load.

Procedure Procedure
• Set the mast vertical. • Set the mast vertical.
• Drive carefully up to the storage location. • Drive carefully up to the storage location.
• Press the "Lower load handler" button (58) until the forks are clear of the load. • Press the "Lower load handler" button (58) until the forks are clear of the load.
Z Avoid depositing the load to prevent damage to the load and the load handler. Z Avoid depositing the load to prevent damage to the load and the load handler.
• Lower the load handler. • Lower the load handler.
• Carefully remove the forks from the pallet. • Carefully remove the forks from the pallet.
The load unit is lowered. The load unit is lowered.

Lifting the wheel arms Lifting the wheel arms

Procedure Procedure
• Press the “Wheel arm lift” button (56) . • Press the “Wheel arm lift” button (56) .
The wheel arms raise. The wheel arms raise.

55 56 55 56

Lowering the wheel arms Lowering the wheel arms

Procedure Procedure
• Press the “wheel arm lower” button (55) . • Press the “wheel arm lower” button (55) .
The wheel arms lower. The wheel arms lower.

NOTE NOTE
03.11 EN

03.11 EN

Avoid dropping the load abruptly, in order to protect the load and the rack surface. Avoid dropping the load abruptly, in order to protect the load and the rack surface.

65 65
 Transporting load units Transporting load units

Requirements Requirements
– Load unit positioned correctly on the forks. – Load unit positioned correctly on the forks.
– Load handler lowered for transport (max. 500 mm above the ground). – Load handler lowered for transport (max. 500 mm above the ground).
– Mast tilted back fully. – Mast tilted back fully.
Procedure Procedure
• Accelerate and decelerate gradually. • Accelerate and decelerate gradually.
• Adapt your travel speed to the conditions of the route and the load you are • Adapt your travel speed to the conditions of the route and the load you are
transporting. transporting.
• Watch out for other traffic at crossings and passageways. • Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots. • Always travel with a lookout at blind spots.
• On slopes and inclines always carry the load facing uphill, never approach at an • On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn. angle or turn.

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66 66
 4.4 Switch Matrix / Safety Switch Height 4.4 Switch Matrix / Safety Switch Height
ERC without side restraint mechanism ERC without side restraint mechanism

Operator Lift height Speed km/h Collision safety Lifting Operator Lift height Speed km/h Collision safety Lifting
platform with load switch active Active platform with load switch active Active
Folded up <Sh*) 4,2 Yes Yes Folded up <Sh*) 4,2 Yes Yes
) )
Folded up >Sh* 2,5 Yes Yes Folded up >Sh* 2,5 Yes Yes
Folded out <Sh*) 6,0 No Yes Folded out <Sh*) 6,0 No Yes
Folded out >Sh*) 2,5 No Yes Folded out >Sh*) 2,5 No Yes

ERC with side restraint mechanism ERC with side restraint mechanism

Operator Side Lift Speed km/h Collision Lifting active Operator Side Lift Speed km/h Collision Lifting active
platform restraint height with load safety switch platform restraint height with load safety switch
active active
Folded up Folded in <Sh*) 4,2 Yes Yes Folded up Folded in <Sh*) 4,2 Yes Yes
Folded up Folded in >Sh*) 2,5 Yes Yes Folded up Folded in >Sh*) 2,5 Yes Yes
Folded up Folded out Any 0 No No Folded up Folded out Any 0 No No
Folded out Folded in <Sh*) 6,0 No Yes Folded out Folded in <Sh*) 6,0 No Yes
Folded out Folded in >Sh*) 2,5 No Yes Folded out Folded in >Sh*) 2,5 No Yes
Folded out Folded out <Sh*) See options table below Folded out Folded out <Sh*) See options table below
Folded out Folded out >Sh*) 0 No No Folded out Folded out >Sh*) 0 No No
) Sh ) Sh
* = Safety switch height approx. 1800 mm (depending on mast version) * = Safety switch height approx. 1800 mm (depending on mast version)

**) optionally,travel (4.3 km/h) and lifting above 1800 mm with side restraints folded **) optionally,travel (4.3 km/h) and lifting above 1800 mm with side restraints folded
out is available in conjunction with a load backrest. out is available in conjunction with a load backrest.
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5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the
table.
Z If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially
trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Error number on the display unit (if applicable)
- Error description
- Current location of truck
5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the
table.
Z If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially
trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the
following information is essential:
- Truck serial number
- Error number on the display unit (if applicable)
- Error description
- Current location of truck

5.1 Truck does not start 5.1 Truck does not start

Possible Cause Action Possible Cause Action

Battery connector not plugged in
Emergency Disconnect pressed.
Key switch set to O.
Battery charge too low
Faulty fuse
Check the battery connector and plug it in Battery connector not plugged in Check the battery connector and plug it in
if necessary. if necessary.
Unlock the Emergency Disconnect Emergency Disconnect pressed. Unlock the Emergency Disconnect
Set the key switch to “I” Key switch set to O. Set the key switch to “I”
Check the battery charge and charge Battery charge too low Check the battery charge and charge
battery if necessary. battery if necessary.
Check fuses Faulty fuse Check fuses

5.2 Load cannot be lifted 5.2 Load cannot be lifted

Possible Cause Action Possible Cause Action

Truck not operational Carry out all measures listed under “Truck Truck not operational Carry out all measures listed under “Truck
does not start” does not start”
Hydraulic oil level too low Check the hydraulic oil level Hydraulic oil level too low Check the hydraulic oil level
Battery discharge monitor has switched Charge the battery Battery discharge monitor has switched Charge the battery
off off
Faulty fuse Check fuses Faulty fuse Check fuses
Excessive load Note maximum capacity, see data plate Excessive load Note maximum capacity, see data plate
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 6 Operating the truck without its own drive system 6 Operating the truck without its own drive system

WARNING! WARNING!

Uncontrolled truck movement Uncontrolled truck movement

When the brakes are de-activated the truck must be parked on a level surface, since When the brakes are de-activated the truck must be parked on a level surface, since
the brakes are no longer effective. the brakes are no longer effective.
XDo not release the brake on slopes or inclines. XDo not release the brake on slopes or inclines.
XApply the brake again when you reach your destination. XApply the brake again when you reach your destination.
XDo not park the truck with the brake released. XDo not park the truck with the brake released.

Releasing the brake Releasing the brake

Tools and Material Required Tools and Material Required

– Two M5x45 screws – Two M5x45 screws
– Spanner wrench – Spanner wrench
Procedure Procedure
• Turn of the key switch, CanCode (o). • Turn of the key switch, CanCode (o).
• Switch off the Emergency Disconnect button. • Switch off the Emergency Disconnect button.
• Disconnect the battery. • Disconnect the battery.
• Prevent the truck from rolling away. • Prevent the truck from rolling away.
• Lift up the front cover (78) and put it to one side, (see "Removing the front panel" • Lift up the front cover (78) and put it to one side, (see "Removing the front panel"
on page 96). on page 96).
• Tighten the two M5x45 screws (62). • Tighten the two M5x45 screws (62).
The brake is now released and the truck can be moved. The brake is now released and the truck can be moved.

Applying the brake Applying the brake

Procedure Procedure
• Unscrew the two M5x45 screws again. • Unscrew the two M5x45 screws again.
• Refit the front panel. • Refit the front panel.
Braking is now restored again. Braking is now restored again.
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70
62

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70
62

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 7 Load handler emergency lowering
Load handler emergency lowering
Requirements
– Load handler is not in the rack.
Tools and Material Required
– Allen key 5 mm (ERC 212 / Z12)
– Fork wrench SW 6 (ERC 214 / Z14, ERC 216
/ Z16)
Procedure
• Set key switch (5) to “0”.
• Depress the Emergency Disconnect (8),
(see "Emergency Disconnect" on page 59).
• Lift off the front panel, (see "Removing the
front panel" on page 96)
• Undo the screw on the valve block (64).
The load handler is lowered.
Z After carrying out the emergency lowering,
turn in the screw on the valve block (64) as
far as the stop.
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7 Load handler emergency lowering
Load handler emergency lowering
Requirements
– Load handler is not in the rack.
Tools and Material Required
– Allen key 5 mm (ERC 212 / Z12)
– Fork wrench SW 6 (ERC 214 / Z14, ERC 216
/ Z16)
64 Procedure 64
• Set key switch (5) to “0”.
• Depress the Emergency Disconnect (8),
64 (see "Emergency Disconnect" on page 59). 64
• Lift off the front panel, (see "Removing the
front panel" on page 96)
• Undo the screw on the valve block (64).
The load handler is lowered.
Z After carrying out the emergency lowering,
turn in the screw on the valve block (64) as
far as the stop.
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8 Optional equipment 8 Optional equipment
8.1 CanCode keypad 8.1 CanCode keypad
CanCode keypad CanCode keypad
The keypad consists of 10 digit keys, a Set key and a o The keypad consists of 10 digit keys, a Set key and a o
key. key.
1 2 3 1 2 3
The O key indicates the follow operating statuses via a The O key indicates the follow operating statuses via a
red / green LED: 4 5 6 red / green LED: 4 5 6
– Code lock function (starting up the truck). – Code lock function (starting up the truck).
7 8 9 7 8 9
– Adjusting the travel program depending on the setting – Adjusting the travel program depending on the setting
and truck. Set 0 and truck. Set 0
– Setting and changing parameters. – Setting and changing parameters.

8.1.1 Code lock 8.1.1 Code lock

When the correct code is entered, the truck is ready for use. You can allocate an When the correct code is entered, the truck is ready for use. You can allocate an
individual code to each truck, operator or group of operators. When the truck is individual code to each truck, operator or group of operators. When the truck is
supplied from the factory, the code is indicated on a sticker. Change the master and supplied from the factory, the code is indicated on a sticker. Change the master and
operator codes when you use the truck for the first time. operator codes when you use the truck for the first time.

Z Set different codes for rider and pedestrian trucks. Z Set different codes for rider and pedestrian trucks.

65 66 67 65 66 67
Starting the Truck Starting the Truck

Procedure Procedure
• Switching on the Emergency • Switching on the Emergency
Disconnect. 1 2 3 Disconnect. 1 2 3
LED (70) lights up red. LED (70) lights up red.
4 5 6 4 5 6
• Enter the code. • Enter the code.
7 8 9 7 8 9
When you enter the correct operator When you enter the correct operator
code the LED (70) turns green. If the Set 0 68 code the LED (70) turns green. If the Set 0 68
LED (70) flashes red this means the 69 LED (70) flashes red this means the 69
wrong code has been entered. Try wrong code has been entered. Try
again. again.
70 70
The truck is switched on The truck is switched on

Z The Set key (69) has no function in operating mode. Z The Set key (69) has no function in operating mode.

Switching the truck off Switching the truck off

Procedure Procedure
• Press the O key. • Press the O key.
The truck is switched off. The truck is switched off.

Z The truck can switch off automatically after a set time. To do this the relevant code Z The truck can switch off automatically after a set time. To do this the relevant code
lock parameters must be entered, (see "Parameter Settings" on page 73). lock parameters must be entered, (see "Parameter Settings" on page 73).
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 8.1.2 Parameters 8.1.2 Parameters
The keypad enables parameters to be adjusted in programming mode. The keypad enables parameters to be adjusted in programming mode.
Parameter Groups Parameter Groups
The parameter number is composed of three digits. The first digit refers to the The parameter number is composed of three digits. The first digit refers to the
parameter group as shown in Table 1. The second and third digits are numbered in parameter group as shown in Table 1. The second and third digits are numbered in
sequence from 00 to 99. sequence from 00 to 99.

No. Parameter Groups No. Parameter Groups

0XX Code lock settings (codes, travel program release, automatic cut-out, etc.) 0XX Code lock settings (codes, travel program release, automatic cut-out, etc.)

8.1.3 Parameter Settings 8.1.3 Parameter Settings

To change the truck settings you must enter the master code. To change the truck settings you must enter the master code.
Z The master code factory setting is 7-2-9-5. Change the master code the first time Z The master code factory setting is 7-2-9-5. Change the master code the first time
you use the truck. you use the truck.

Z Set different codes for rider and pedestrian trucks. Z Set different codes for rider and pedestrian trucks.

Changing the truck settings Changing the truck settings

Procedure Procedure
• Press the O key (68). • Press the O key (68).
• Enter the master code. • Enter the master code.
• Enter the three-digit parameter number. • Enter the three-digit parameter number.
• Confirm with the SET key (69). • Confirm with the SET key (69).
• Enter the setting as per parameter list. • Enter the setting as per parameter list.
Z If the entry is incorrect, the LED (70) of the O key (68) turns red. Z If the entry is incorrect, the LED (70) of the O key (68) turns red.
• Enter the parameter number again. • Enter the parameter number again.
• Enter the setting again or change it. • Enter the setting again or change it.
• Confirm with the SET key (69). • Confirm with the SET key (69).
• Repeat the procedure for other parameters. • Repeat the procedure for other parameters.
• Then press the O key (68). • Then press the O key (68).
The settings are now saved. The settings are now saved.
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 Parameter list Parameter list

No. Function Setting range Standard Procedure No. Function Setting range Standard Procedure
setting setting
000 Change master code: 0000 - 9999 7295 – (LED 65 flashes) 000 Change master code: 0000 - 9999 7295 – (LED 65 flashes)
The length (4-6 digits) of or Enter current The length (4-6 digits) of or Enter current
the master code also 00000 - 99999 code the master code also 00000 - 99999 code
determines the length of or – Confirm determines the length of or – Confirm
the operator code (4-6 000000 - 999999 (Set 69) the operator code (4-6 000000 - 999999 (Set 69)
digits). Provided the – (LED 66 flashes) digits). Provided the – (LED 66 flashes)
operator codes are Enter new code operator codes are Enter new code
programmed, only new programmed, only new
– Confirm – Confirm
codes of the same codes of the same
(Set 69) (Set 69)
length can be entered. If length can be entered. If
you wish to change the – (LED 67 flashes) you wish to change the – (LED 67 flashes)
code length, you must Repeat new code code length, you must Repeat new code
first delete all the – Confirm first delete all the – Confirm
operator codes. (Set 69) operator codes. (Set 69)
001 Add code (max. 250) 0000 - 9999 2580 – (LED 66 flashes) 001 Add code (max. 250) 0000 - 9999 2580 – (LED 66 flashes)
or Enter a code or Enter a code
00000 - 99999 – Confirm 00000 - 99999 – Confirm
or (Set 69) or (Set 69)
000000 - 999999 – (LED 67 flashes) 000000 - 999999 – (LED 67 flashes)
Confirm code re- Confirm code re-
entry entry
– Confirm – Confirm
(Set 69) (Set 69)
002 Delete code 0000 - 9999 – (LED 65 flashes) 002 Delete code 0000 - 9999 – (LED 65 flashes)
or Enter current code or Enter current code
00000 - 99999 – Confirm 00000 - 99999 – Confirm
or (Set 69) or (Set 69)
000000 - 999999 – (LED 66 flashes) 000000 - 999999 – (LED 66 flashes)
Enter new code Enter new code
– Confirm – Confirm
(Set 69) (Set 69)
– (LED 67 flashes) – (LED 67 flashes)
Confirm code re- Confirm code re-
entry entry
– Confirm – Confirm
(Set 69) (Set 69)
003 Delete code 0000 - 9999 – (LED 66 flashes) 003 Delete code 0000 - 9999 – (LED 66 flashes)
or Enter new code or Enter new code
00000 - 99999 – Confirm 00000 - 99999 – Confirm
or (Set 69) or (Set 69)
000000 - 999999 – (LED 67 flashes) 000000 - 999999 – (LED 67 flashes)
repeat code entry repeat code entry
– Confirm – Confirm
(Set 69) (Set 69)
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LEDs 65-67 are located in keypads 1-3. LEDs 65-67 are located in keypads 1-3.

74 74
 No. Function Setting range Standard Procedure No. Function Setting range Standard Procedure
setting setting
004 Delete code log (deletes 3265 – 3265 = delete 004 Delete code log (deletes 3265 – 3265 = delete
all codes) – other inputs = do all codes) – other inputs = do
not delete not delete
010 Automatic timeout 00-31 00 – 00 = No timeout 010 Automatic timeout 00-31 00 – 00 = No timeout
– 01 - 30 = Timeout – 01 - 30 = Timeout
in minutes in minutes
– 31 = Timeout after – 31 = Timeout after
10 seconds 10 seconds
LEDs 65-67 are located in keypads 1-3. LEDs 65-67 are located in keypads 1-3.
Assigning the starting travel program (depending on the truck) Assigning the starting travel program (depending on the truck)
The travel programs are connected to the code. The travel programs can be The travel programs are connected to the code. The travel programs can be
individually released or blocked for each code. A starting travel program can be individually released or blocked for each code. A starting travel program can be
assigned to each code. assigned to each code.

When a user code has been set up, all travel programs are globally released and the When a user code has been set up, all travel programs are globally released and the
valid starting travel program is 2. valid starting travel program is 2.
The user code configuration can then be altered via program number 024. The user code configuration can then be altered via program number 024.

No. Function Setting range Standard Procedure No. Function Setting range Standard Procedure
setting setting
024 Code configuration 1112 024 Code configuration 1112

1. digit: travel program 1 release (0 = blocked, or 1 = released)
2. digit: travel program 2 release (0 = blocked, or 1 = released)
3. digit: travel program 3 release (0 = blocked, or 1 = released)
4. digit: Start travel program (0, 1, 2 or 3)
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1. digit: travel program 1 release (0 = blocked, or 1 = released)
2. digit: travel program 2 release (0 = blocked, or 1 = released)
3. digit: travel program 3 release (0 = blocked, or 1 = released)
4. digit: Start travel program (0, 1, 2 or 3)

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 Setting the travel program configuration to a code Setting the travel program configuration to a code

Procedure Procedure
• Press the O key (68). • Press the O key (68).
• Enter the master code. • Enter the master code.
• Enter the three-digit parameter number 024. • Enter the three-digit parameter number 024.
• Confirm with the SET key (69). • Confirm with the SET key (69).
• Enter the code to be changed and confirm with SET. • Enter the code to be changed and confirm with SET.
• Enter the configuration (4 digit) and confirm with SET. • Enter the configuration (4 digit) and confirm with SET.
• Enter the configuration (4 digit) again and confirm with SET. • Enter the configuration (4 digit) again and confirm with SET.
• Repeat the procedure for other codes. • Repeat the procedure for other codes.
• Then press the O key. • Then press the O key.
The travel programs are assigned to the codes The travel programs are assigned to the codes

Keypad error messages Keypad error messages

LED (70) flashes red to indicate the following errors: LED (70) flashes red to indicate the following errors:
– New master code is already in use. – New master code is already in use.
– New code is already the master code – New code is already the master code
– Code to be changed does not exist – Code to be changed does not exist
– Attempt to change the code to one that already exists. – Attempt to change the code to one that already exists.
– Attempt to delete a code that does not exist – Attempt to delete a code that does not exist
– Code memory full. – Code memory full.

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 8.1.4 Setting the truck parameters with CanCode 8.1.4 Setting the truck parameters with CanCode

CAUTION! CAUTION!

Faulty entry Faulty entry

Without CanDis only CanCode internal parameters can be changed. Traction Without CanDis only CanCode internal parameters can be changed. Traction
controller parameters can only be changed with CanDis, without CanDis the settings controller parameters can only be changed with CanDis, without CanDis the settings
must be performed by the manufacturer's service department. must be performed by the manufacturer's service department.

CAUTION! CAUTION!

Altering travel parameters can cause accidents Altering travel parameters can cause accidents
Increasing the settings for acceleration, steering, travel, lifting and lowering can result Increasing the settings for acceleration, steering, travel, lifting and lowering can result
in accidents. in accidents.
XCarry out a test run in a secure environment. XCarry out a test run in a secure environment.
XThis requires greater attention on the part of the operator. XThis requires greater attention on the part of the operator.

Parameter setting example: Parameter setting example:

The following example shows the parameter setting for the acceleration of travel The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 0256). program 1 (parameter 0256).
Acceleration example Acceleration example

Procedure
• Enter four-digit parameter number "0256" and confirm with the SET key (69).
• Enter sub-index (enter "2") and confirm with the SET key (69).
Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-3).
• Enter the parameter according to the parameter list and confirm with the Set key
(69).
Z The LED (70) of the O key (68) switches briefly to steady light and start flashing
again after approx. 2 seconds.
Z If the entry is incorrect, the LED (70) of the O key (68) turns red. Enter the
parameter number again to repeat the setting.
Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-5).
The travel parameter is now set.
Procedure
• Enter four-digit parameter number "0256" and confirm with the SET key (69).
• Enter sub-index (enter "2") and confirm with the SET key (69).
Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-3).
• Enter the parameter according to the parameter list and confirm with the Set key
(69).
Z The LED (70) of the O key (68) switches briefly to steady light and start flashing
again after approx. 2 seconds.
Z If the entry is incorrect, the LED (70) of the O key (68) turns red. Enter the
parameter number again to repeat the setting.
Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-5).
The travel parameter is now set.

Repeat the procedure to enter further parameters as soon as the LED (70) of the O Repeat the procedure to enter further parameters as soon as the LED (70) of the O
key (68) flashes. key (68) flashes.
Z Travel is disabled while the parameters are being entered. Z Travel is disabled while the parameters are being entered.
Checking the settings in programming mode Checking the settings in programming mode

Procedure Procedure
• Select the travel program to be worked on after changing the parameter value, and • Select the travel program to be worked on after changing the parameter value, and
confirm with the Set key (69). confirm with the Set key (69).
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The truck is now in travel mode and can be checked. The truck is now in travel mode and can be checked.

77 77
 Z To continue setting, confirm with the Set key (69) again. Z To continue setting, confirm with the Set key (69) again.

Saving travel parameters Saving travel parameters

Requirements Requirements
– Enter all parameters. – Enter all parameters.
Procedure Procedure
• Run "SaveParameters" by pressing 1-2-3-Set. • Run "SaveParameters" by pressing 1-2-3-Set.
• Confirm with the O key (68). • Confirm with the O key (68).

8.2 Parameter 8.2 Parameter

Travel program 1 Travel program 1

No. Function Setting Standard Comments No. Function Setting Standard Comments
range setting range setting
101 Acceleration 0-9 6 101 Acceleration 0-9 6
102 Coasting brake with release 0-9 6 102 Coasting brake with release 0-9 6
104 Max. speed in drive direction 0-9 6 104 Max. speed in drive direction 0-9 6
105 Pedestrian travel switch 105 Pedestrian travel switch
0-9 6 0-9 6
speed in drive direction speed in drive direction
108 Max. speed in forks direction 0-9 108 Max. speed in forks direction 0-9
6 6
109 Pedestrian travel switch 0-9 109 Pedestrian travel switch 0-9
6 6
speed in forks direction speed in forks direction

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 Battery parameters Battery parameters

No. Function Setting Standard Comments No. Function Setting Standard Comments
range setting range setting
411 Battery type 0-2 0 0 = Normal (wet) 411 Battery type 0-2 0 0 = Normal (wet)
(normal / high (normal / high
performance / dry) 1 = High performance performance / dry) 1 = High performance
(wet) (wet)

2 = Dry (maintenance- 2 = Dry (maintenance-

free) free)

CAUTION! CAUTION!

Battery type parameters Battery type parameters

The battery and charger used must match the battery parameters The battery and charger used must match the battery parameters
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8.3 CANDIS display instrument 8.3 CANDIS display instrument
The instrument indicates: The instrument indicates:

Battery charge display (on board charger Battery charge display (on board charger
71 71
only) only)
Capacity display bars 71 72 Capacity display bars 71 72
72 72
Battery residual charge status Battery residual charge status
73 74 73 74
Warning - pre-warning symbol, Warning - pre-warning symbol,
73 73
Battery charge recommended 75 76 Battery charge recommended 75 76
Stop symbol; lift cutout, Stop symbol; lift cutout,
74 74
Battery charge required Battery charge required
T symbol appears during operation when T symbol appears during operation when
75 the discharge indicator is set to 75 the discharge indicator is set to
maintenance-free battery maintenance-free battery
6 digit LCD display; 6 digit LCD display;
76 hourmeter, input display; 76 hourmeter, input display;
error display error display
In addition, service messages for the electronic components and parameter changes In addition, service messages for the electronic components and parameter changes
are displayed. are displayed.
Discharge status display Discharge status display
Setting limits for the additional “Warning” (73) and “Stop” (74) displays will depend on Setting limits for the additional “Warning” (73) and “Stop” (74) displays will depend on
the battery type. the battery type.

The available capacity is shown via 8 LED bars. The available capacity is shown via 8 LED bars.

The current battery capacity is shown by the illuminated LED bars. 8 bars correspond The current battery capacity is shown by the illuminated LED bars. 8 bars correspond
to full battery capacity, 1 bar corresponds to the minimum available capacity. to full battery capacity, 1 bar corresponds to the minimum available capacity.
If only one LED bar is lit, the battery capacity is almost depleted and the “Warning” If only one LED bar is lit, the battery capacity is almost depleted and the “Warning”
indicator (73) is lit. The battery must be charged immediately. indicator (73) is lit. The battery must be charged immediately.

If no more LED bars are illuminated, the “Stop” indicator (74) lights up. Lifting is now If no more LED bars are illuminated, the “Stop” indicator (74) lights up. Lifting is now
inhibited. The battery must be charged. inhibited. The battery must be charged.

8.3.1 Discharge monitor function 8.3.1 Discharge monitor function

When the discharge monitor function is enabled, lifting is cut out when reaching the When the discharge monitor function is enabled, lifting is cut out when reaching the
discharge limit is reached (the Stop LED goes on). Travel and lowering are still discharge limit is reached (the Stop LED goes on). Travel and lowering are still
possible. possible.
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 8.3.2 Service hour display 8.3.2 Service hour display
Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are
logged. This is a backlit display. logged. This is a backlit display.
Z For maintenance-free batteries a “T” symbol is shown in the hourmeter Z For maintenance-free batteries a “T” symbol is shown in the hourmeter
display (75). display (75).

8.3.3 Error messages 8.3.3 Error messages

The service hour display is also used for indicating errors. The display starts with a
"C" for component and a three digit component number. The error display starts with
an ”E” for Error and a three digit error number.
If several errors occur simultaneously they are displayed one after the other. The
errors are displayed until they are rectified. Error messages overwrite the service
hour display. Most errors cause the Emergency Stop to be triggered. The error
display remains until the control circuit is switched off (key switch).
The service hour display is also used for indicating errors. The display starts with a
"C" for component and a three digit component number. The error display starts with
an ”E” for Error and a three digit error number.
If several errors occur simultaneously they are displayed one after the other. The
errors are displayed until they are rectified. Error messages overwrite the service
hour display. Most errors cause the Emergency Stop to be triggered. The error
display remains until the control circuit is switched off (key switch).

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

8.3.4 Power up test 8.3.4 Power up test

On power up the display shows: On power up the display shows:
– The software version of the display instrument (briefly), – The software version of the display instrument (briefly),
– The service hours, – The service hours,
– The battery charge status. – The battery charge status.
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82
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 F Industrial Truck Maintenance
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.
WARNING!
Risk of accidents and damage to components
All modifications to the forklift truck assemblies, in particular the safety mechanisms,
are prohibited. The operating speeds of the truck must not be increased under any
circumstances.
NOTE
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series.
2 Maintenance Safety Regulations
Maintenance personnel
The truck should only be serviced and repaired by the manufacturer's specialist
customer service personnel who have been trained to do this. We therefore
recommend that you enter into a maintenance contract with the manufacturer’s local
sales office.
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F Industrial Truck Maintenance
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.
WARNING!
Risk of accidents and damage to components
All modifications to the forklift truck assemblies, in particular the safety mechanisms,
are prohibited. The operating speeds of the truck must not be increased under any
circumstances.
NOTE
Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts.
For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series.
2 Maintenance Safety Regulations
Maintenance personnel
The truck should only be serviced and repaired by the manufacturer's specialist
customer service personnel who have been trained to do this. We therefore
recommend that you enter into a maintenance contract with the manufacturer’s local
sales office.
83
 Lifting and jacking up
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Transport and Commissioning" on
page 27).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
Cleaning
CAUTION!
Fire hazard
Do not use flammable liquids to clean the industrial truck.
XAlways disconnect the battery before starting cleaning work.
XCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
CAUTION!
Risk of electrical system damage
The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
CAUTION!
Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” ((see "Restoring the truck to service after
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maintenance and repairs" on page 101)).
84
Lifting and jacking up
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XAlways use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Transport and Commissioning" on
page 27).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
Cleaning
CAUTION!
Fire hazard
Do not use flammable liquids to clean the industrial truck.
XAlways disconnect the battery before starting cleaning work.
XCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting).
CAUTION!
Risk of electrical system damage
The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water.
XDo not clean the electrical system with water.
XClean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush.
CAUTION!
Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck after
cleaning or maintenance work” ((see "Restoring the truck to service after
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maintenance and repairs" on page 101)).
84
 Electrical system Electrical system

WARNING! WARNING!
Accident risk Accident risk
XOnly suitably trained electricians may operate on the truck's electrical system. XOnly suitably trained electricians may operate on the truck's electrical system.
XBefore working on the electrical system, take all precautionary measures to avoid XBefore working on the electrical system, take all precautionary measures to avoid
electric shocks. electric shocks.
XAlways disconnect the battery before starting cleaning operations. XAlways disconnect the battery before starting cleaning operations.

WARNING! WARNING!

Electric currents can cause accidents Electric currents can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before Make sure the electrical system is voltage-free before starting work on it. Before
starting maintenance on the electrical system: starting maintenance on the electrical system:
XPark the truck securely ((see "Parking the truck securely" on page 55)). XPark the truck securely ((see "Parking the truck securely" on page 55)).
XPress the Emergency Disconnect. XPress the Emergency Disconnect.
X Disconnect the battery. X Disconnect the battery.
XRemove any rings or metal bracelets etc. before working on electrical components. XRemove any rings or metal bracelets etc. before working on electrical components.

Consumables and used parts Consumables and used parts

CAUTION! CAUTION!

Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.

Welding Welding
Remove electrical and electronic components from the truck before performing Remove electrical and electronic components from the truck before performing
welding operations, to avoid damage. welding operations, to avoid damage.

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

WARNING! WARNING!

The use of wheels that do not match the manufacturer's specifications can
result in accidents.
The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
XWhen replacing wheels make sure the truck is not skewed.
XAlways replace wheels in pairs, i.e. left and right at the same time.
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The use of wheels that do not match the manufacturer's specifications can
result in accidents.
The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance.
XWhen replacing wheels make sure the truck is not skewed.
XAlways replace wheels in pairs, i.e. left and right at the same time.

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85 85
 Z When replacing wheels fitted at the factory, only use the manufacturer’s original
spare parts. Otherwise the truck's rated performance cannot be ensured.
Hydraulic hoses
WARNING!
Brittle hydraulic hose lines can cause accidents
The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations.
XComply with the safety regulations for hydraulic hose lines in accordance with BGR
237.
WARNING!
Hydraulic line leaks can cause accidents
Hydraulic oil can escape from leaky and faulty hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Hairline cracks in the hydraulic lines can cause injury and infection
Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury.
XCall for a doctor immediately if you are injured.
XDo not touch pressurised hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
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86
Z When replacing wheels fitted at the factory, only use the manufacturer’s original
spare parts. Otherwise the truck's rated performance cannot be ensured.
Hydraulic hoses
WARNING!
Brittle hydraulic hose lines can cause accidents
The hoses must be replaced every six years. The manufacturer's customer service
department is specially trained to carry out these operations.
XComply with the safety regulations for hydraulic hose lines in accordance with BGR
237.
WARNING!
Hydraulic line leaks can cause accidents
Hydraulic oil can escape from leaky and faulty hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
WARNING!
Hairline cracks in the hydraulic lines can cause injury and infection
Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks
in the hydraulic lines, causing severe injury.
XCall for a doctor immediately if you are injured.
XDo not touch pressurised hydraulic lines.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
XSpilled fluids must be removed immediately with an appropriate bonding agent. The
bonding agent / consumable mixture must be disposed of in accordance with
regulations.
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 3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
WARNING!
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage
due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance
k =
interval)
Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary.
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87
3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
WARNING!
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage
due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly
A = Every 500 service hours
B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually
t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance
k =
interval)
Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary.
87
4 Maintenance checklist 4 Maintenance checklist

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Brakes Brakes
1.1 Test brakes. t 1.1 Test brakes. t
1.2 Check magnetic brake air gap. t 1.2 Check magnetic brake air gap. t

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Electrical System Electrical System
Test warning and safety devices in accordance with operating Test warning and safety devices in accordance with operating
2.1 t 2.1 t
instructions. instructions.
2.2 Test the cables and motor attachments. k t 2.2 Test the cables and motor attachments. k t
2.3 Test displays and controls. t 2.3 Test displays and controls. t
2.4 Test Emergency Disconnect switch. t 2.4 Test Emergency Disconnect switch. t
2.5 Check fuse ratings. t 2.5 Check fuse ratings. t
2.6 Carry out a frame leakage test. t 2.6 Carry out a frame leakage test. t
Check the carbon brushes, replace if necessary. Note: When Check the carbon brushes, replace if necessary. Note: When
2.7 t 2.7 t
replacing the carbon brushes apply compressed air to the motor. replacing the carbon brushes apply compressed air to the motor.
Check electric wiring for damage [insulation damage, connections]. Check electric wiring for damage [insulation damage, connections].
2.8 t 2.8 t
Make sure wire connections are secure. Make sure wire connections are secure.

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Power Supply Power Supply
Check battery cable connections are secure, grease terminals if Check battery cable connections are secure, grease terminals if
3.1 t 3.1 t
necessary. necessary.
3.2 Check battery and battery components. t 3.2 Check battery and battery components. t
3.3 Check acid density and battery voltage. t 3.3 Check acid density and battery voltage. t
Check battery connector for damage, test it and make sure it is Check battery connector for damage, test it and make sure it is
3.4 t 3.4 t
secure. secure.

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Travel Travel
4.1 Checking bedding and attachment of the drive system. t 4.1 Checking bedding and attachment of the drive system. t
4.2 Check transmission for noise and leakage. t 4.2 Check transmission for noise and leakage. t
4.3 Note: Replace the transmission oil after 10000 service hours. 4.3 Note: Replace the transmission oil after 10000 service hours.
4.4 Check wheel suspension and attachment. t 4.4 Check wheel suspension and attachment. t
4.5 Check wheels for wear and damage. t 4.5 Check wheels for wear and damage. t
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 Maintenance intervals Maintenance intervals
Standard = t W A B C Standard = t W A B C
Chassis and Superstructure Chassis and Superstructure
5.1 Check doors and/or covers. t 5.1 Check doors and/or covers. t
5.2 Check labels are legible and complete. t 5.2 Check labels are legible and complete. t
5.3 Check the chassis and screw connections for damage. t 5.3 Check the chassis and screw connections for damage. t
5.4 Check operator position mounting bolts. t 5.4 Check operator position mounting bolts. t
5.5 Test the operator platform and check for damage. t 5.5 Test the operator platform and check for damage. t
5.6 Check mast attachment / mounting. t 5.6 Check mast attachment / mounting. t

5.7 Check operator mat and steps are non-slip and damage-free. t 5.7 Check operator mat and steps are non-slip and damage-free. t
5.8 Check the mast guard for damage t 5.8 Check the mast guard for damage t
5.9 Check the mast guard for damage t 5.9 Check the mast guard for damage t
5.10 Test battery panel damper operation t 5.10 Test battery panel damper operation t

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Hydraulic Operation Hydraulic Operation
Test "hydraulic" controls and make sure the labels are present, Test "hydraulic" controls and make sure the labels are present,
6.1 t 6.1 t
legible and complete. legible and complete.
6.2 Test the lift sensor system in the mast and check for damage. t 6.2 Test the lift sensor system in the mast and check for damage. t
Check cylinders and piston rods for damage and leaks, and make Check cylinders and piston rods for damage and leaks, and make
6.3 t 6.3 t
sure they are secure. sure they are secure.
Check settings and wear levels of slide pieces and stops and adjust Check settings and wear levels of slide pieces and stops and adjust
6.4 t 6.4 t
the slide pieces if necessary. the slide pieces if necessary.
6.5 Check the load chain setting and tension if necessary. t 6.5 Check the load chain setting and tension if necessary. t
Check lateral clearance of the mast connections and the fork Check lateral clearance of the mast connections and the fork
6.6 t 6.6 t
carriage. carriage.
Visually inspect the mast rollers and check contact surface wear Visually inspect the mast rollers and check contact surface wear
6.7 t 6.7 t
level. level.
6.8 Test hydraulic system. t 6.8 Test hydraulic system. t
6.9 Replace hydraulic oil filter, ventilation/discharge filter. k t 6.9 Replace hydraulic oil filter, ventilation/discharge filter. k t
Check that hydraulic ports, hose and pipe lines are secure, check for Check that hydraulic ports, hose and pipe lines are secure, check for
6.10 t 6.10 t
leaks and damage. leaks and damage.
6.11 Test emergency lowering system. t 6.11 Test emergency lowering system. t
6.12 Check hydraulic oil level and top up if necessary. t 6.12 Check hydraulic oil level and top up if necessary. t
6.13 Test relief valve and adjust if necessary. t 6.13 Test relief valve and adjust if necessary. t
6.14 Replace hydraulic oil. k t 6.14 Replace hydraulic oil. k t
6.15 Check forks or load handler for wear and damage. t 6.15 Check forks or load handler for wear and damage. t
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89 89
 Maintenance intervals Maintenance intervals
Standard = t W A B C Standard = t W A B C
Agreed performance levels Agreed performance levels
1 Carry out a test run with rated load. t 1 Carry out a test run with rated load. t
2 Demonstration after servicing. k t 2 Demonstration after servicing. k t
3 Lubricate truck according to the lubrication schedule. k t 3 Lubricate truck according to the lubrication schedule. k t

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C
Steering Steering
1 Check tiller recuperating function. k t 1 Check tiller recuperating function. k t
2 Test electric steering and its components. t 2 Test electric steering and its components. t

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90 90
 5 Lubricants and Lubrication Schedule 5 Lubricants and Lubrication Schedule
5.1 Handling consumables safely 5.1 Handling consumables safely
Handling consumables Handling consumables
Consumables must always be handled correctly. Follow the manufacturer’s Consumables must always be handled correctly. Follow the manufacturer’s
instructions. instructions.

WARNING!
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.
WARNING!
Improper handling is hazardous to health, life and the environment
Consumables can be flammable.
XKeep consumables away from hot components and naked flames.
XAlways keep consumables in prescribed containers.
XAlways fill consumables in clean containers.
XDo not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions.

CAUTION! CAUTION!

Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.
Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water.
XDo not spill fluids.
XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations.

WARNING! WARNING!

Oils (chain spray / hydraulic oil) are flammable and poisonous. Oils (chain spray / hydraulic oil) are flammable and poisonous.
XDispose of used oils in accordance with regulations. Store used oil safely until it can XDispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations. be disposed of in accordance with regulations.
XDo not spill oil. XDo not spill oil.
XSpilled fluids must be removed immediately with an appropriate bonding agent. XSpilled fluids must be removed immediately with an appropriate bonding agent.
XThe bonding agent / consumable mixture must be disposed of in accordance with XThe bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
XObserve national regulations when handling oils. XObserve national regulations when handling oils.
XWear safety gloves when handling oils. XWear safety gloves when handling oils.
XPrevent oil from coming into contact with hot motor parts. XPrevent oil from coming into contact with hot motor parts.
XDo not smoke when handling oil. XDo not smoke when handling oil.
XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a XAvoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately. doctor immediately.
XSeek fresh air after breathing in oil fumes or vapours. XSeek fresh air after breathing in oil fumes or vapours.
XIf oil has come into contact with your skin, rinse your skin with water. XIf oil has come into contact with your skin, rinse your skin with water.
XIf oil has come into contact with your eyes, rinse them with water and call for a XIf oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately. doctor immediately.
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XReplace oil-soaked clothing and shoes immediately. XReplace oil-soaked clothing and shoes immediately.

91 91
 Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
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92
Consumables and used parts
CAUTION!
Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task.
XNote the safety regulations when handling these materials.
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92
 5.2 Lubrication Schedule 5.2 Lubrication Schedule

g E g E

G G

G s E G s E
2) 2)
ERC/Z ERC/Z
g s E g s E

1) 1)
A A+C A A+C

B B
b 1,25 - 1,3 l b 1,25 - 1,3 l

a a

g Contact surfaces Cold Store Application g Contact surfaces Cold Store Application
s Grease nipple b Transmission oil filler neck s Grease nipple b Transmission oil filler neck
a Transmission oil drain plug a Transmission oil drain plug a Transmission oil drain plug a Transmission oil drain plug

Hydraulic oil filler neck Hydraulic oil filler neck

1 Compound ratio for cold store usage 1:1 1 Compound ratio for cold store usage 1:1
2 Gear oil values are guidelines only. The spur wheel should be dipped approx. 2mm 2 Gear oil values are guidelines only. The spur wheel should be dipped approx. 2mm
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in the oil. in the oil.

93 93
5.3 Consumables 5.3 Consumables

Code Order no. Package Name Used for Code Order no. Package Name Used for
quantity quantity
A 51132827 5.0 l Jungheinrich Hydraulic System A 51132827 5.0 l Jungheinrich Hydraulic System
51132826 1.0 l Hydraulic oil* 51132826 1.0 l Hydraulic oil*

B 50380904 5.0 l Titan Gear Transmission B 50380904 5.0 l Titan Gear Transmission
HSY 75W-90 HSY 75W-90
C 29200810 5.0 l H-LP 10, Hydraulic System C 29200810 5.0 l H-LP 10, Hydraulic System
DIN 51524 DIN 51524
E 29202050 1.0 kg Polylub GA 352P Lubrication E 29202050 1.0 kg Polylub GA 352P Lubrication
G 29201280 0.4 l Chain spray Chains G 29201280 0.4 l Chain spray Chains
Grease guidelines Grease guidelines

Code Saponification Dew point Worked NLG1 class Application Code Saponification Dew point Worked NLG1 class Application
°C penetration temperature °C penetration temperature
at 25 °C °C at 25 °C °C
E Lithium >220 280 - 310 2 -35/+120 E Lithium >220 280 - 310 2 -35/+120
*The trucks are factory-equipped with a special hydraulic oil (the Jungheinrich *The trucks are factory-equipped with a special hydraulic oil (the Jungheinrich
hydraulic oil with a blue colouration) and the cold store hydraulic oil (red hydraulic oil with a blue colouration) and the cold store hydraulic oil (red
colouration). The Jungheinrich hydraulic oil can only be obtained from the colouration). The Jungheinrich hydraulic oil can only be obtained from the
Jungheinrich service department. The use of named alternative hydraulic oils is not Jungheinrich service department. The use of named alternative hydraulic oils is not
prohibited but may lead to a decline in functionality. The Jungheinrich hydraulic oil prohibited but may lead to a decline in functionality. The Jungheinrich hydraulic oil
may be mixed with one of the named alternative hydraulic oils. may be mixed with one of the named alternative hydraulic oils.

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94 94
 6 Maintenance and repairs 6 Maintenance and repairs
6.1 Preparing the truck for maintenance and repairs 6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made: maintenance and repairs. The following preparations must be made:
Requirements Requirements
– Park the truck securely, (see "Parking the truck securely" on page 55). – Park the truck securely, (see "Parking the truck securely" on page 55).
Procedure Procedure
• Remove the battery connector (43) to prevent the truck from being switched on • Remove the battery connector (43) to prevent the truck from being switched on
accidentally. accidentally.
• When working under a raised lift truck, secure it to prevent it from lowering, tipping • When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away. or sliding away.

WARNING! WARNING!

Risk of accidents when working under the load handler, driver's cab and lift
truck
XWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.
XWhen raising the truck, follow the instructions, (see "Transport and
Commissioning" on page 27). When working on the parking brake, prevent the
truck from accidentally rolling away (e.g. with wedges).
03.11 EN
Risk of accidents when working under the load handler, driver's cab and lift
truck
XWhen working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away.
XWhen raising the truck, follow the instructions, (see "Transport and
Commissioning" on page 27). When working on the parking brake, prevent the
truck from accidentally rolling away (e.g. with wedges).

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95 95
6.2 Removing the front panel 6.2 Removing the front panel
Disassemble the front panel (trucks with folding operator platform) Disassemble the front panel (trucks with folding operator platform)
Requirements Requirements
– Folding operator platform (14) folded down. – Folding operator platform (14) folded down.
– Side arms (9) folded out. – Side arms (9) folded out.
Tools and Material Required Tools and Material Required
– Allen key (width 8) – Allen key (width 8)

Procedure Procedure
• Undo the screws on the front panel (77) with an Allen key (key width 8). • Undo the screws on the front panel (77) with an Allen key (key width 8).
• Lift the front panel (78), remove it from the truck and place it securely next to the • Lift the front panel (78), remove it from the truck and place it securely next to the
truck. truck.
The front panel is now disassembled. The front panel is now disassembled.

77 77

9 9

78 78

14 14

Remove the front panel (industrial truck with fixed standing platform) Remove the front panel (industrial truck with fixed standing platform)

Tools and Material Required Tools and Material Required

– Allen key (width 8) – Allen key (width 8)

Procedure Procedure
• Undo the screws on the front panel (77) with an Allen key (key width 8). • Undo the screws on the front panel (77) with an Allen key (key width 8).
• Lift the front panel (78), remove it from the truck and place it securely next to the • Lift the front panel (78), remove it from the truck and place it securely next to the
truck. truck.
The front panel is now disassembled. The front panel is now disassembled.

Z Assembly is the reverse order. Z Assembly is the reverse order.

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96 96
 6.3 Checking the hydraulic oil level 6.3 Checking the hydraulic oil level
Check oil level Check oil level
Requirements Requirements
– Lower the load handler. – Lower the load handler.
– Prepare the truck for maintenance and repairs, (see "Preparing the truck for – Prepare the truck for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 95). maintenance and repairs" on page 95).
– Remove the front panel, (see "Removing the front panel" on page 96). – Remove the front panel, (see "Removing the front panel" on page 96).
Procedure Procedure
• Check the oil level in the hydraulic reservoir. • Check the oil level in the hydraulic reservoir.
• If necessary add transmission oil of the correct grade, (see "Consumables" on • If necessary add transmission oil of the correct grade, (see "Consumables" on
page 94), (see also table). page 94), (see also table).
The oil level is now checked. The oil level is now checked.

Z There are markings (101) on the hydraulic reservoir. The oil level must be checked Z There are markings (101) on the hydraulic reservoir. The oil level must be checked
when the lift mechanism is lowered. when the lift mechanism is lowered.

Marking Litres Lift heights (h3) Marking Litres Lift heights (h3)
ZT ZZ DZ ZT ZZ DZ

3 approx. 8.3 -- >4100 >5300 3 approx. 8.3 -- >4100 >5300

2 approx. 7.5 >3100 >2800 -- 2 approx. 7.5 >3100 >2800 --
1 approx. 6.5 <3100 <2800 -- 1 approx. 6.5 <3100 <2800 --
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97 97
6.4 Check the gear oil level 6.4 Check the gear oil level
Check oil level Check oil level
Requirements Requirements
– Prepare the truck for maintenance and repairs, (see "Preparing the truck for – Prepare the truck for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 95). maintenance and repairs" on page 95).

Procedure Procedure
• Loosen the screws of the front panel (77). • Loosen the screws of the front panel (77).
• Remove the front panel (78) and place it in a safe location. • Remove the front panel (78) and place it in a safe location.
• Check the transmission oil level. • Check the transmission oil level.
• If necessary add transmission oil of the correct grade, (see "Consumables" on • If necessary add transmission oil of the correct grade, (see "Consumables" on
page 94). page 94).
Z The transmission oil level should reach the filler neck. Z The transmission oil level should reach the filler neck.
The oil level is now checked. The oil level is now checked.

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98 98
 6.5 Tightening the wheel nuts 6.5 Tightening the wheel nuts
Z The wheel nuts on the drive wheel must be retightened in accordance with the Z The wheel nuts on the drive wheel must be retightened in accordance with the
maintenance intervals indicated in the maintenance checklist, (see "Servicing and maintenance intervals indicated in the maintenance checklist, (see "Servicing and
Inspection" on page 87) Inspection" on page 87)
Tightening the wheel nuts Tightening the wheel nuts
Requirements Requirements
– To prepare the truck for maintenance and repairs, (see "Preparing the truck for – To prepare the truck for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 95) maintenance and repairs" on page 95)

Tools and Material Required Tools and Material Required

– Torque wrench – Torque wrench

Procedure Procedure
• Position the drive wheel (79) so that the wheel nuts (80) can be pulled through the • Position the drive wheel (79) so that the wheel nuts (80) can be pulled through the
hole (81). hole (81).
• Tighten all the wheel nuts (80) in the skirt with the socket wrench through the hole • Tighten all the wheel nuts (80) in the skirt with the socket wrench through the hole
(81). (81).
To do this, torque the wheel nuts in the prescribed order To do this, torque the wheel nuts in the prescribed order
• initially to 10 Nm • initially to 10 Nm
• then to 150 Nm. • then to 150 Nm.
The wheel nuts are now tightened. The wheel nuts are now tightened.

79 79

80 80

4 4
2 2

1 1
81 5 81 5
3 3
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99 99
6.6 Checking electrical fuses 6.6 Checking electrical fuses
Checking fuses Checking fuses
Requirements Requirements
– Truck prepared for maintenance and repairs, (see "Preparing the truck for – Truck prepared for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 95). maintenance and repairs" on page 95).
– Front panel removed, (see "Removing the front panel" on page 96). – Front panel removed, (see "Removing the front panel" on page 96).

Procedure Procedure
• Check the fuse ratings against the table and replace if necessary. • Check the fuse ratings against the table and replace if necessary.
The fuses are now checked. The fuses are now checked.

82 82
83 83

84 84

85 86 85 86

Item Name To protect Rating Item Name To protect Rating

(A) (A)
82 6F1 Battery discharge indicator / battery hour meter 10 82 6F1 Battery discharge indicator / battery hour meter 10
83 F1 Overall control circuit fuse 10 83 F1 Overall control circuit fuse 10
84 1F10 Drive motor (parallel to 1F1) 40 84 1F10 Drive motor (parallel to 1F1) 40
85 2F1 Pump motor 150 85 2F1 Pump motor 150
86 1F1 Drive motor (parallel to 1F10) 150 86 1F1 Drive motor (parallel to 1F10) 150
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100 100
 6.7 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 93).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Charging the battery" on page 35).
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 52).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
03.11 EN
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101
6.7 Restoring the truck to service after maintenance and repairs
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 93).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Charging the battery" on page 35).
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 52).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
101
7 Safety tests to be performed at intervals and after unusual
incidents
Z Perform a safety check in accordance with national regulations. Jungheinrich
recommends the truck be checked to FEM guideline 4.004. The Jungheinrich
safety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
03.11 EN
102
7 Safety tests to be performed at intervals and after unusual
incidents
Z Perform a safety check in accordance with national regulations. Jungheinrich
recommends the truck be checked to FEM guideline 4.004. The Jungheinrich
safety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
03.11 EN
102
 8 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial
reasons, it must be stored in a frost-free and dry room. All necessary measures
must be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XOnly use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose. (see "Identification points and data plates" on
page 23).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
8.1 Prior to decommissioning
Procedure
• Thoroughly clean the truck.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Test the brakes.
• Check the hydraulic oil level and replenish if necessary, (see "Consumables" on
page 94).
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 93).
• Charge the battery, (see "Charging the battery" on page 35).
03.11 EN
03.11 EN
• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer's instructions.
103
8 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial
reasons, it must be stored in a frost-free and dry room. All necessary measures
must be taken before, during and after decommissioning as described hereafter.
WARNING!
Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows:
XJack up the truck only on a level surface and prevent it from moving accidentally.
XOnly use a jack with sufficient capacity. When jacking up the truck, take appropriate
measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).
XIn order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose. (see "Identification points and data plates" on
page 23).
XWhen jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clear
of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department.
8.1 Prior to decommissioning
Procedure
• Thoroughly clean the truck.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Test the brakes.
• Check the hydraulic oil level and replenish if necessary, (see "Consumables" on
page 94).
• Apply a thin layer of oil or grease to any non-painted mechanical components.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 93).
• Charge the battery, (see "Charging the battery" on page 35).
• Disconnect the battery, clean it and grease the terminals.
Z In addition, follow the battery manufacturer's instructions.
103
 • Spay all exposed electrical contacts with a suitable contact spray. • Spay all exposed electrical contacts with a suitable contact spray.

8.2 Action to be taken during decommissioning 8.2 Action to be taken during decommissioning

NOTE NOTE

Full discharge can damage the battery Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery. useful life of the battery.
XCharge the battery at least every 2 months. XCharge the battery at least every 2 months.

Z Charge the battery (see "Charging the battery" on page 35). Z Charge the battery (see "Charging the battery" on page 35).

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104 104
 8.3 Restoring the truck to service after decommissioning
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 93).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Charging the battery" on page 35).
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 52).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
9 Final de-commissioning, disposal
Z Final de-commissioning or disposal of the truck in 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.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety
instructions as specified in the service documentation.
03.11 EN
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105
8.3 Restoring the truck to service after decommissioning
Procedure
• Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 93).
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, (see "Charging the battery" on page 35).
• Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out
these operations.
WARNING!
Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
• Start up the truck, (see "Starting up the truck" on page 52).
Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly.
9 Final de-commissioning, disposal
Z Final de-commissioning or disposal of the truck in 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.
The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety
instructions as specified in the service documentation.
105
10 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations.
10 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations.

03.11 EN

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 Instructions for use Instructions for use
Jungheinrich traction battery Jungheinrich traction battery
Table of contents Table of contents
1 Jungheinrich traction battery 1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB ..........................................2-6 with positive tubular plates type EPzS and EPzB ..........................................2-6

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

Instruction for use Instruction for use

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

2 Jungheinrich traction battery 2 Jungheinrich traction battery

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

Type plate Jungheinrich traction battery............................................17 Type plate Jungheinrich traction battery............................................17
0506.GB

0506.GB

1 1
1 Jungheinrich traction battery 1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB with positive tubular plates type EPzS and EPzB

Rating Data Rating Data

1. Nominal capacity C5: See type plate 1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells 2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h 3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte* 4. Nominal S.G. of electrolyte*
Type EPzS: 1,29 kg/l Type EPzS: 1,29 kg/l
Type EPzB: 1,29 kg/l Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C 5. Rated temperature: 30° C
6. Nominal electrolyte level: up to electrolyte level mark „max.“ 6. Nominal electrolyte level: up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles. * Will be reached within the first 10 cycles.

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

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

•No smoking! •No smoking!

•Do not expose batteries to naked flames, glowing embers or sparks, as it may •Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode! cause the battery to explode!

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

•Risk of explosion and fire, avoid short circuits! •Risk of explosion and fire, avoid short circuits!

•Electrolyte is highly corrosive! •Electrolyte is highly corrosive!

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

•Dangerous electrical voltage! •Dangerous electrical voltage!

•Caution! Metal parts of the battery are always live. Do not place tools or other me- •Caution! Metal parts of the battery are always live. Do not place tools or other me-
tal objects on the battery! tal objects on the battery!
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0506.GB
2 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:
steel
M 10 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 ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open 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 di-
scharge. 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 excee-
ded. 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
0506.GB
0506.GB
provision must be made for venting of the charging gases.
3 3
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:
steel
M 10 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 ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open 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 di-
scharge. 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 excee-
ded. 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.
 Battery container lids and the covers of battery compartments must be opened or re-
moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect. (positive to positive, negative to negative). Now switch on the charger. 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 batte-
ries 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 po-
tentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flamma-
bility due to adequate ventilation. The containers for batteries with plate 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 follo-
wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-
pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-
peratures shorten the life of the battery, lower temperatures reduce the capacity avai-
lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-
perature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher tempe-
ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte 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.
0506.GB
4 4
Battery container lids and the covers of battery compartments must be opened or re-
moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect. (positive to positive, negative to negative). Now switch on the charger. 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 batte-
ries 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 po-
tentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flamma-
bility due to adequate ventilation. The containers for batteries with plate 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 follo-
wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-
pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-
peratures shorten the life of the battery, lower temperatures reduce the capacity avai-
lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-
perature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher tempe-
ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte 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.
0506.GB
 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 bat-
tery 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 re-
corded.
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. Clea-
ning 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 man-
ner. 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.
0506.GB
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5 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 bat-
tery 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 re-
corded.
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. Clea-
ning 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 man-
ner. 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. Storage 5. Storage

If batteries are taken out of service for a lengthy period they should be stored in the 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 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: for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3 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 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. time should be taken into account when considering the life of the battery.

6. Malfunctions 6. Malfunctions

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

A service contract with us will make it easier to detect and correct faults in good time. A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer! Back to the manufacturer!

Batteries with this sign must be recycled. Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must be Batteries which are not returned for the recycling process must be
disposed of as hazardous waste! disposed of as hazardous waste!

We reserve the right make technical modification. We reserve the right make technical modification.

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6 6
 7. Type plate, Jungheinrich traction battery 7. Type plate, Jungheinrich traction battery

1 2 1 2

2/3 Typ
Type
Baujahr
Year of manufacture 6 2/3 Typ
Type
Baujahr
Year of manufacture 6
4 Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
4
5 4 Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
4
5
10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

5
11 10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

5
11
12
7
Zellenzahl
Number of Cells
Batteriegewicht min/max
Battery mass min/max
8
13 12
7
Zellenzahl
Number of Cells
Batteriegewicht min/max
Battery mass min/max
8
13

9 9

7 Jungheinrich AG, D-22047 Hamburg, Germany Jungheinrich AG, D-22047 Hamburg, Germany
Hersteller
Manufacturer 7 Hersteller
Manufacturer

Pb Pb 1 Pb Pb 1
8 8
9 9
14 14

Item Designation Item Designation Item Designation Item Designation

1 Logo 8 Recycling symbol 1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material 2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage 3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity 4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells 5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight 6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings 7 Battery manufacturer's logo 14 Safety instructions and warnings

* CE mark is only for batteries with a nominal voltage greater than 75 volt. * CE mark is only for batteries with a nominal voltage greater than 75 volt.
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 Aquamatic/BFS III water refilling system for Jungheinrich traction battery with Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions Aquamatic plug arrangement for the Operating Instructions

Cell series* Aquamatic plug type (length) Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (yellow) BFS (black) EPzS EPzB Frötek (yellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm 2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm
2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm 2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm – 2/ 84 – 12/ 504 50,5 mm 51,0 mm
– 2/110 – 12/ 660 50,5 mm 51,0 mm – 2/110 – 12/ 660 50,5 mm 51,0 mm
– 2/130 – 12/ 780 50,5 mm 51,0 mm – 2/130 – 12/ 780 50,5 mm 51,0 mm
– 2/150 – 12/ 900 50,5 mm 51,0 mm – 2/150 – 12/ 900 50,5 mm 51,0 mm
– 2/172 – 12/1032 50,5 mm 51,0 mm – 2/172 – 12/1032 50,5 mm 51,0 mm
– 2/200 – 12/1200 56,0 mm 56,0 mm – 2/200 – 12/1200 56,0 mm 56,0 mm
– 2/216 – 12/1296 56,0 mm 56,0 mm – 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm 2/180 – 10/900 – 61,0 mm 61,0 mm
2/210 – 10/1050 – 61,0 mm 61,0 mm 2/210 – 10/1050 – 61,0 mm 61,0 mm
2/230 – 10/1150 – 61,0 mm 61,0 mm 2/230 – 10/1150 – 61,0 mm 61,0 mm
2/250 – 10/1250 – 61,0 mm 61,0 mm 2/250 – 10/1250 – 61,0 mm 61,0 mm
2/280 – 10/1400 – 72,0 mm 66,0 mm 2/280 – 10/1400 – 72,0 mm 66,0 mm
2/310 – 10/1550 – 72,0 mm 66,0 mm 2/310 – 10/1550 – 72,0 mm 66,0 mm

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column * The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600. EPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g. These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120. 2 EPzS 120.
length

length
stroke

stroke
length

length
stroke

stroke
Aquamatic plug with Aquamatic plug BFS III with Aquamatic plug with Aquamatic plug BFS III with
diagnostics hole diagnostics hole diagnostics hole diagnostics hole

Non-adherence to the operating instructions, repairs carried out with non-original Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty. (alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the in- When using batteries which comply with I and II, it is important to follow the in-
structions on maintaining the respective protection class during operation (see asso- structions on maintaining the respective protection class during operation (see asso-
ciated certification). ciated certification).
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 Diagrammatic view Diagrammatic view

Equipment for the Equipment for the

water refilling system water refilling system

1. Water tank 1. Water tank

2. Level switch 2. Level switch
3. Discharge point with ball 3. Discharge point with ball
valve valve
4. Discharge point with sole- 4. Discharge point with sole-

at least 3 m

at least 3 m
noid valve noid valve
5. Charger 5. Charger
6. Sealing coupler 6. Sealing coupler
7. Closing nipple 7. Closing nipple
8. Ion exchange cartridge with 8. Ion exchange cartridge with
conductance meter and conductance meter and
solenoid valve solenoid valve
9. Connection for untreated 9. Connection for untreated
water water
10. Charging lead 10. Charging lead

1. Design 1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically adjus-
ting the nominal electrolyte level. Venting holes are provided for letting off the 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 den-
sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-
matic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
The Aquamatic/BFS battery water refilling systems are used for automatically adjus-
ting the nominal electrolyte level. Venting holes are provided for letting off the 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 den-
sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-
matic/BFS filling systems. The water can be refilled by means of a central 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 con-
nections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
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 con-
nections 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 sys-
tem, 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.
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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 sys-
tem, 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.

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9 9
 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 fil-
ling.
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 wa-
ter feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to 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.
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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 fil-
ling.
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 wa-
ter feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to 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.
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 8. Battery hose connections 8. Battery hose connections

Hose connections for the individual plugs are laid along the existing electric circuit. Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made. No changes may be made.

9. Operating temperature 9. Operating temperature

The temperature limit for battery operation is set at 55° C. Exceeding this 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 tempe- damages the batteries. The battery filling systems may be operated within a tempe-
rature range of > 0° C to a maximum of 55° C. rature range of > 0° C to a maximum of 55° C.

CAUTION: CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms 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 with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze). freeze).
9.1 Diagnostics hole 9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling sys- To be able to measure the acid density and temperature easily, the water refilling sys-
tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs). 7.5 mm-diameter (BFS plugs).

9.2 Float 9.2 Float

Different floats are used depending on the cell design and type. Different floats are used depending on the cell design and type.

9.3 Cleaning 9.3 Cleaning

The plug systems may only be cleaned with water. No parts of the plugs may come 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. in contact with soap or fabrics which contain solvents.

10. Accessories 10. Accessories

10.1 Flow indicator 10.1 Flow indicator

To monitor the filling process, a flow indicator can be inserted into the water feed pipe 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 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 water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542). the filling process. (ident no.: 50219542).

10.2 Plug lifter 10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug sys- Only the appertaining special-purpose tool may be used to disassemble the plug sys-
tems (plug lifter). The greatest of care must be employed when prising out the plug to tems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems. prevent any damage to the plug systems.
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 10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres-
sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-
ry's main supply pipe for supplying battery water. This filter element has a 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 cen-
tral 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.
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12
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres-
sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-
ry's main supply pipe for supplying battery water. This filter element has a 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 cen-
tral 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.
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 2 Jungheinrich traction batterie 2 Jungheinrich traction batterie

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

Rating Data Rating Data

1. Nominal capacity C5: See type plate 1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells 2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h 3. Discharge current: C5/5h
4. Rated temperature: 30° C 4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe- EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe-
re a water refilling isn’t permitted during the whole battery life. Instead of a vent plug re 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. there are valves used, who will be destroyed when they are opened.

When operating valve-regulated lead-acid batteries the same safety requirements as 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 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 of electrolytic gas and in case of the cell container is damaged, from the corrosive
electrolyte. electrolyte.

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

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

• No smoking! • No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may • Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode! cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of • Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately! accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water. • Clothing contaminated by acid should be washed in water.

• Risk of explosion and fire, avoid short circuits! • Risk of explosion and fire, avoid short circuits!

• Electrolyte is highly corrosive! • 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.
• 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! • Dangerous electrical voltage!

• Caution! Metal parts of the battery are always live. Do not place tools or other • Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery! metal objects on the battery!
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 Ignoring the operation instructions, repair with non-original parts and non authorised
interventions 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
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the 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:
steel
M 10 23 ± 1 Nm
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left dischar-
ged.
This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifica-
tions. 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 re-
0506.GB
moved.
14
Ignoring the operation instructions, repair with non-original parts and non authorised
interventions 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
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the 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:
steel
M 10 23 ± 1 Nm
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 60%
of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only
the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left dischar-
ged.
This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN
41773 and DIN 41774 must only be applied in the manufacturer approved modifica-
tions. 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 re-
0506.GB
moved.
14
 With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect (positive to positive, negative to negative). Now switch on the charger. 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 tem-
peratures 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.
2.3 Equalising charge
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 char-
gers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher tempera-
tures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating tempera-
ture.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
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15
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect (positive to positive, negative to negative). Now switch on the charger. 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 tem-
peratures 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.
2.3 Equalising charge
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 char-
gers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher tempera-
tures shorten the life of the battery, lower temperatures reduce the available capacity.
45° C is the upper temperature limit and is not acceptable as an operating tempera-
ture.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be
measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
15
 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
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 43539-1.
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. Clea-
ning 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 man-
ner.
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 batte-
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3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured 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
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 43539-1.
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. Clea-
ning 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 man-
ner.
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 batte-
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ry.
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 6. Malfunctions 6. Malfunctions

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

A service contract with us will make it easier to detect and correct faults in good time. A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer! Back to the manufacturer!

Batteries with this sign must be recycled. Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be Batteries which are not returned for the recycling process must be
disposed of as hazardous waste! disposed of as hazardous waste!

We reserve the right make technical modification. We reserve the right make technical modification.

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

1 2 1 2

2/3 Typ
Type
Baujahr
Year of manufacture 6 2/3 Typ
Type
Baujahr
Year of manufacture 6
4 Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
4
5 4 Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
4
5
10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

5
11 10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

5
11
12
7
Zellenzahl
Number of Cells
Batteriegewicht min/max
Battery mass min/max
8
13 12
7
Zellenzahl
Number of Cells
Batteriegewicht min/max
Battery mass min/max
8
13

9 9

7 Jungheinrich AG, D-22047 Hamburg, Germany Jungheinrich AG, D-22047 Hamburg, Germany
Hersteller
Manufacturer 7 Hersteller
Manufacturer

Pb Pb 1 Pb Pb 1
8 8
9 9
14 14

Item Designation Item Designation Item Designation Item Designation

1 Logo 8 Recycling symbol 1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material 2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage 3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity 4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells 5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight 6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings 7 Battery manufacturer's logo 14 Safety instructions and warnings

* CE mark is only for batteries with a nominal voltage greater than 75 volt. * CE mark is only for batteries with a nominal voltage greater than 75 volt.
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18
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