Jungheinrich EFX 410 Operating Instructions Manual Download Page 331 | Manualshive

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3.3

Consumables

Code Order no.

Quantity

Name

Application

A

51 037 497

5 l

HLP D22 including
2 % share of additive
68 ID

– Hydraulic system

(Volume approx.
33 L)

51 037 494

1 L

51 085 361*

5 L

Plantohyd 22 S
(Bio-based hydraulic
oil)

B

51 076 550

20 L

Renolin CLP 100

– Transmission

(Volume approx.
2.9 L)

C

14 038 650

400 g

(cartridge)

Lithium KP2K-30
grease (DIN 51825)

– General
– Toothed racks
– Lift mast

29 201 430

1 kg

D

29 201 280

400 ml

Chain spray Tunfluid
LT 220

– Lift Chains

E

50 002 004

400 ml

Contact spray /
grease

– Running surfaces

F

51 085 365

500 ml

All-purpose cleaner

– Laser scanner of

personal protection
system (PPS)

51 085 537

1 unit

Cleaning cloth

*

Add a 2 % content of Additiv 68 ID to the hydraulic oil (order number: 50 307
735)

WARNING!

Industrial trucks are factory-equipped with hydraulic oil "HLP D22" or BIO hydraulic
oil "Plantohyd 22 S + 2% Additiv 68 ID".
You cannot change from BIO hydraulic oil "Plantohyd 22 S" to hydraulic oil "HLP
D22". The same applies to changing from hydraulic oil "HLP D22" to bio hydraulic oil
"Plantohyd 22 S".
Mixed operation with hydraulic oil "HLP D22" and BIO hydraulic oil "Plantohyd 22 S"
is not permitted.

329

04.19 en-GB

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Summary of Contents for EFX 410

Page 1: ...EFX 410 413 03 13 Operating instructions 51296679 04 19 en GB EFX 410 EFX 413 ...

Page 2: ...2 ...

Page 3: ...410 EFX 413 On behalf of Date EU DECLARATION OF CONFORMITY The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006 42 EG Machinery Directive and 2014 30 EU Electromagnetic Compatibility EMC The manufacturer is authorised to compile the technical documentation 3 04 19 en GB ...

Page 4: ...4 04 19 en GB ...

Page 5: ...ular features of the truck should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are indicated by the following graphics DANGER Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death WARNING Indicates an extremely hazardou...

Page 6: ...ght Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com 6 04 19 en GB ...

Page 7: ...equirements 42 5 Identification points and data plates 43 5 1 Indication Points 43 5 2 Data plate 45 5 3 Truck capacity plate 46 5 4 Attachment capacity plate 47 5 5 Jack contact points 47 6 Stability 48 C Transport and Commissioning 49 1 Transport 49 2 Lifting by crane 51 2 1 Lifting by crane with mast assembled 52 2 2 Lifting the basic truck by crane 54 2 3 Lifting the mast by crane 56 2 4 Lifti...

Page 8: ...122 3 4 Checking putting on and taking off the seat belt 127 4 Industrial Truck Operation 131 4 1 Safety regulations for truck operation 131 4 2 Preparing the truck for operation 138 4 3 Preparing the truck for operation with an additional access code o 139 4 4 Date and time setting 143 4 5 Checks and operations to be carried out when the truck is operational 145 4 6 Main Lift referencing 147 4 7 ...

Page 9: ...ct o 265 8 7 Horizontal positioning o 281 8 8 Weighing system o 296 8 9 Camera system o 298 8 10 Working platform o 300 8 11 ISM access module o 309 8 12 Rear view mirror o 310 8 13 Floor Spot o 311 F Industrial Truck Maintenance 317 1 Operational Safety and Environmental Protection 317 2 Maintenance Safety Regulations 319 2 1 Working on the electrical system 320 2 2 Consumables and used parts 320...

Page 10: ...mmissioning 353 5 3 Restoring the truck to service after decommissioning 354 6 Safety tests to be performed at intervals and after unusual incidents 355 7 Final de commissioning disposal 356 8 Human vibration measurement 356 G Maintenance Inspection and Changing of Maintenance Parts Requiring Replacement 357 1 Maintenance Contents EFX 410 413 358 1 1 Owner 358 1 2 Customer Service 362 10 04 19 en ...

Page 11: ...ungheinrich battery models If using another brand refer to the manufacturer s operating instructions 1 0506 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instructions ...

Page 12: ...0506 GB 2 0506 GB 2 ...

Page 13: ...page 199 The following operations are in accordance with regulations and are permitted Lifting lowering and transporting of loads When transporting a load outside the narrow aisle always keep it as low as possible allowing for ground clearance Negotiating narrow aisles The racking systems and the truck must be equipped to allow operation in narrow aisles The safety clearances required by the manuf...

Page 14: ... is forbidden to operate the truck in areas where there is a risk of explosion uIt is forbidden to operate the truck near the unprotected active components of electrical equipment Operation in industrial and commercial environments Operate the truck in enclosed indoor areas with a maximum air humidity of 95 non condensing Permissible temperature range of 5 C to 40 C Application only on level surfa...

Page 15: ...ype of guidance in the narrow aisle and the lift height h3 refer to the following table Truck guidance in the narrow aisle Lift height h3 Safety clearance Wire guided truck depending on the lift height h3 125 mm Rail guided truck to 4000 mm 90 mm to 6000 mm 100 mm from 6000 mm 125 mm Z The safety distance may however increase if special attachments are fitted WARNING An insufficient safety distanc...

Page 16: ...ded Furthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The operating company must ensure that all users have read and understood these operating instructions NOTICE Failure to comply with the operating instructions invalidates the warranty The same applies if improper work is carried out on the truck by the customer or thir...

Page 17: ...h the VDMA guideline Open bottom pallets or pallets with diagonal boards can be lifted outside the range of the load wheels Loads can be stacked unstacked and transported over long distances If the EFX is used for assembly work with an correspoding working platform the working platform must be supplied or approved in writing by the manufacturer 15 04 19 en GB ...

Page 18: ... truck to 4000 mm 90 mm to 6000 mm 100 mm from 6000 mm 125 mm Z The safety distance may however increase if special attachments are fitted WARNING An insufficient safety distance between the guided truck and the rack can result in accidents Failure to maintain the required and prescribed safety distance can result in collisions between the guided truck and the rack uThe maximum travel speeds are r...

Page 19: ... Travel direction definition The following determinations have been made for travel direction specification 1 4 2 3 Item Travel direction 1 Left 2 Drive direction 3 Load direction 4 Right 17 04 19 en GB ...

Page 20: ...t the load from lowering in the event of a hydraulic system failure Dead man s switch When the truck is ready for operation the following truck functions will be enabled or locked when the dead man s switch in the footwell is depressed Z Preparing the truck for operation see page 138 or see page 139 Press and hold down on the dead man s switch Drive functions are enabled Steering functions are ena...

Page 21: ... heavy duty and maintenance free threephase motor with no wear parts The motor is directly attached to the single wheel driving gear ensuring rapid and trouble free maintenance Brake system The operator can brake the truck gently and without causing wear by easing off the travel pedal or by pressing the brake pedal gently This feeds energy into the battery service brake The electromagnetic spring ...

Page 22: ...e is activated the steering is assumed by the truck controller when the guide wire is detected Manual steering is deactivated in this mode o Controls and displays Ergonomic controls ensure fatigue free operation for sensitive application of the travel and hydraulic operations Soft keys to control functions attachment traverse fork carriage rotate and menus Coloured driver s display unit displays a...

Page 23: ...tion damping lift cutout retardation and acceleration patterns cut outs etc rapidly and reliably To read off the error log to analyse fault causes To simulate and analyse program operations Simple function extension by releasing code numbers The controller is fitted with a CAN Bus and a constantly recording sensor system All operations can be set using parameters The controller provide smooth star...

Page 24: ...ect receipt of target position in narrow aisle by the truck computer Automatic vertical positioning Automatic horizontal positioning Automatic stacking Effective twin cycles Avoidance of wrong journeys through area detection Maximum flexibility in warehouse through adaptation to existing warehouse management systems and warehouse extension Transponder based truck controller system Permanent route ...

Page 25: ...s for stacking and retrieving With Rack Height Select the operator can select the required lift height via a keypad Lifting ends automatically when the required lift height has been reached Rack Height Select is designed for a range of warehouse areas with different rack heights 23 04 19 en GB ...

Page 26: ...ver s display 7 t Hydraulic functions control lever 8 t Key switch 9 t Emergency disconnect switch 10 t Operator position 11 t Overhead guard 12 o Strobe light or warning beacon 13 o Laser beam rack compartment display 14 o Working lights 15 t Lift mast 16 o Rear view mirror left and right hand 17 t Handles 18 t Load handler 19 t Fork carriage 20 t Dead man s switch 21 t Brake pedal 24 04 19 en GB...

Page 27: ... load handler 29 t Battery cover 30 t Load wheel 31 o Rail guidance roller mounting behind the load wheel on both sides 32 t Seat belt 33 t Battery connector under the battery cover 34 t Driver s seat 35 t Drive compartment cover 36 t Tilt safety device 37 o Rear personal protection system scanner 38 t Drive wheel 39 o Rear sensor for wire guidance system 40 o Rail guidance roller mounting next to...

Page 28: ...l specification is given according to the German guideline Type sheets for industrial trucks Technical modifications and additions reserved Values indicated with may vary depending on the configuration of the truck e g mast etc 26 04 19 en GB ...

Page 29: ...h4 s m h2 h3 h7 h6 h1 1 m2 l3 3 l8 y x z l1 Ast b3 r Q Ast b7 b1 b5 b12 l6 D l e l2 W a b2 b6 b14 b8 27 04 19 en GB ...

Page 30: ...hout load 0 44 0 44 m s Lower speed with load 0 44 0 44 m s Traverse speed without load 0 202 0 202 m s Traverse speed with load 0 202 0 202 m s Rotating without load 11 11 s 180 Rotating with load 11 11 s 180 Service Brake Inversion regenerative Parking brake Electric spring loaded brake magnetic brake Traction controller type AC traction controller Drive system Electric Steering Electric Safety ...

Page 31: ...4 2 Dimensions as per data plate h4 s m h2 h3 h7 h6 h1 1 m2 l3 3 l8 y x z l1 Ast b3 r Q Ast b7 b1 b5 b12 l6 D l e l2 W a b2 b6 b14 b8 29 04 19 en GB ...

Page 32: ...idth for pallets 1200 x 1200 3482 3482 mm Wa Turning radius 1847 1847 mm s Fork dimensions 40 40 mm e 100 100 mm l 1200 1200 mm Lowest position top of fork tine s 25 mm 65 65 mm Z The data listed in the table performance data dimensions and weights are based on a truck with the following masts The data performance data dimensions and weights for the particular truck supplied can be found on the da...

Page 33: ...h4 s m h2 h3 h7 h6 h1 1 m2 l3 3 l8 y x z l1 Ast b3 r Q Ast b7 b1 b5 b12 l6 D l e l2 W a b2 b6 b14 b8 31 04 19 en GB ...

Page 34: ... length 1200 1200 mm I8 Fork pivot point distance 843 843 mm m1 Ground clearance below mast with load 120 120 mm m2 Ground clearance centre of wheelbase 85 4 85 4 mm r Distance fork pivot point fork face 267 267 mm Net weight of the industrial truck without battery see page 45 Z The data listed in the table performance data dimensions and weights are based on a truck with the following masts The d...

Page 35: ...on of hydraulic lift function see page 171 WARNING Risk of collision caused by the lift mast due to the changed mast height h1 The dimension mast height lowered h1 increases as soon as the fork carriage is raised The operator must take this changed mast height into account when operating the truck e g when driving through doorways when the ceiling is low etc uWhen operating the truck ensure that t...

Page 36: ...completely lifts the fork carriage by chains The intermediate mast is then lifted by the two outer hydraulic cylinders At the same time the inner mast is raised by chains Z For a description of hydraulic lift function see page 171 WARNING Risk of collision caused by the load when the free lift is fully extended When the fork carriage is fully raised the height over the load can exceed the dimensio...

Page 37: ...ollowing table Depending on the battery type used counterweights 44 must be fitted in the battery compartment in order to guarantee the stability of the truck see page 73 Battery equipment may only be replaced with the agreement of the manufacturer Truck model Dimension Y Counterweights Basis truck weight including attachment and counterweights EFX 410 0 mm 0 kg 3145 kg 90 mm 152 kg 3297 kg 180 mm...

Page 38: ...nd on the data plate see page 45 A Net weight of the industrial truck without battery B Mast weight including fork carriage Formula for the EFX 410 B A 3145 kg Formula for the EFX 413 B A 3445 kg Example Required information see truck data plate Type of industrial truck EFX 413 Net weight of the industrial truck without battery 4350 kg Formula B A 3445 kg 4350 kg 3445 kg 905 kg Z The mast weight i...

Page 39: ...ry type used 5 PzS 625 6 PzS 750 Z The data listed in the table performance data dimensions and weights are based on a truck with the following masts The data performance data dimensions and weights for the particular truck supplied can be found on the data plate 1 EFX 410 with 400 telescopic mast ZT mast 2 EFX 413 with 400 telescopic mast ZT mast 3 with a strobe light this dimension increases to ...

Page 40: ...tomer service organisation authorised by the manufacturer EFX 410 Description EFX 410 Tyres Vulkollan Wheels front load wheel 295 mm x 144 mm Wheels rear drive wheel 343 mm x 110 mm Wheels number of front load wheel 2 Wheels number of rear drive wheel driven 1 EFX 413 Description EFX 413 Tyres Vulkollan Wheels front load wheel 295 mm x 144 mm Wheels rear drive wheel 343 mm x 110 mm Wheels number o...

Page 41: ...5 0 7 kW 0 7 kW 4 7 EN norms Noise emission level EFX 410 66 5 dB A EFX 413 66 5 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 39 04 19 en GB ...

Page 42: ...rations of the 2002 44 EC Vibrations operator directive The manufacturer offers a special service to measure these human vibrations see page 356 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 instruct...

Page 43: ...uck in areas where there is a risk of explosion uIt is forbidden to operate the truck near the unprotected active components of electrical equipment Ambient temperature operating at 5 C to 40 C Z Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations The industrial truck may only be operat...

Page 44: ...cturer certifies compliance with the requirements for the design and manufacture of electrical equipment according to EN 1175 Industrial Truck Safety Electrical Requirements provided the truck is used according to its purpose 42 04 19 en GB ...

Page 45: ...tes Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary 5 1 Indication Points 45 55 56 47 48 45 45 45 64 52 49 46 54 60 61 57 59 58 62 63 62 50 53 51 43 04 19 en GB ...

Page 46: ...Test plaque o 53 Information label Travel and brake pedals 54 Truck data plate 55 Warning label Tip over procedure 56 Warning label No passengers 57 Warning label Caution Low voltage electronic system 58 Information label Emergency lowering 59 Company and model information 60 Information label Add hydraulic oil t 61 Information label Add bio based hydraulic oil o 62 Jacking points on both sides of...

Page 47: ... number 72 Load centre mm 67 Rated capacity kg 73 Output 68 Battery voltage V 74 Min max battery weight kg 69 Net weight w o battery kg 75 Manufacturer 70 Option 76 Manufacturer s logo Z For queries regarding the truck or ordering spare parts always quote the truck serial number 66 5 2 1 Serial number position NOTICE The truck serial number 66 is indicated on the data plate 54 and is stamped on th...

Page 48: ...plied requires the manufacturer s approval 46 The capacity plate 46 gives the capacity Q kg of the truck for an upright mast The maximum capacity is shown as a table with a given load centre of gravity D mm and the required lift height h3 mm The capacity plate 46 of the truck indicates the truck s capacity with the forks as originally supplied Example of how to calculate the maximum capacity With ...

Page 49: ... each truck is specified by the manufacturer The capacity is shown in the same way as the truck s capacity and is to be determined in the same manner see page 46 Z For loads with a load centre distance greater than 600 mm the capacities are reduced depending on h3 Refer to the data on the capacity plate of the attachment 5 5 Jack contact points The Jack contact point decal 62 indicates where the t...

Page 50: ...een tested according to latest technological standards These take into account the dynamic and static tipover forces that can occur if used correctly Stability can also be affected by the following components Battery size and weight Wheels Lift mast Attachment Transported load size weight and centre of gravity Ground clearance e g modification of the tilt safety devices WARNING Loss of stability c...

Page 51: ...g on the height of the mast and the local conditions Vertically with the mast and load handler assembled for low heights Vertically with the mast and load handler disassembled for large truck heights All hydraulic lines between the basic truck and mast are disconnected for transportation 49 04 19 en GB ...

Page 52: ...er s customer service representatives who have been specially trained for these tasks uThe hydraulic and electrical lines may only be connected to the basic truck mast interface when the mast has been properly assembled uStart the truck only after the mast has been assembled correctly uIf several trucks have been delivered make sure that the serial numbers of the load handlers masts and basic truc...

Page 53: ...o fall when being lifted by crane Prevent the truck and mast from striking other objects when they are being raised and avoid any uncontrolled movement If necessary secure the truck and mast with guide ropes uThe truck and mast should only be loaded by people who are trained in handling lifting slings and lifting gear uWear personal protective equipment e g safety boots helmet hi vis jacket protec...

Page 54: ...ible protect the crane lifting gear with suitable supports such as foam uLifting slings should be fastened to the harness in such a way that they do not come into contact with any parts of the truck when it is being raised Safe lifting of the basic truck by crane with the mast assembled Requirements Park the truck securely see page 191 Remove the battery from the truck s battery compartment see pa...

Page 55: ...and the truck chassis uDo not attach the crane lifting gear to the lift mast Attach the crane lifting gear 77 to the attachment points 78 79 so that the truck cannot slip Attach the crane lifting gear 77 to both attachment points 78 on the overhead guard 11 Attach the crane lifting gear 77 to both attachment points 79 between the swivel traverse frame 25 and the truck chassis The truck can now be ...

Page 56: ...ny parts of the truck when it is being raised Safe lifting of the basic truck by crane without mast Requirements Position the support arm 18 in middle of the swivel traverse frame 25 and secure it with lashing straps to prevent accidental movement Park the truck securely see page 191 Remove the battery from the truck s battery compartment see page 82 Remove the mast The mast can only be removed by...

Page 57: ...tachment points 78 on the overhead guard 11 Attach the crane lifting gear 77 to both attachment points 79 between the swivel traverse frame 25 and the truck chassis The basic truck can now be lifted Raise and load the basic truck Lower the basic truck carefully onto a level surface Secure the basic truck with wedges to prevent it from rolling away Loading the basic truck by crane is now complete 5...

Page 58: ...rely see page 191 Remove the mast The mast can only be removed by the manufacturer s specialist customer service personnel who have been trained to do this In exceptional cases this task may be performed by a customer service organisation authorised by the manufacturer Tools and Material Required Crane lifting gear capacity see page 35 Two pallets with identical dimensions and composition Procedur...

Page 59: ...t 15 safely Place the mast 15 carefully on two identical pallets 83 Secure the lift mast 15 with the lashing straps 82 tightly on the pallets 83 Tighten the lashing straps 82 with their tensioners Loading the lift mast by crane is now complete 57 04 19 en GB ...

Page 60: ...dling lifting slings and lifting equipment uWear personal protective equipment e g safety boots helmet hi vis jacket protective gloves etc when loading by crane uDo not stand under swaying loads uDo not walk into or stand in a hazardous area uAlways use lifting gear with sufficient capacity for battery weight see battery data plate uAlways attach the crane lifting gear to the prescribed strap poin...

Page 61: ...taken into account when loading by crane can be taken from the battery data plate Lifting the battery with crane lifting gear Attach the lifting gear to the four eyes on the battery tray for weight refer to the battery rating plate The battery can now be raised and loaded with a crane Loading the battery onto a pallet Place the battery on a pallet Secure the battery to the pallet with two lashing ...

Page 62: ...ficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats 3 1 Mast transport retainer 83 83 19 85 86 87 88 89 90 80 81 80 15 80 82 80 82 Item Component 80 Support to protect the fastening belt from sharp edges WARNING Torn fastening belts can cause accidents Fastening belts can tear when routed over sharp edges uDo not route the fastening belts over sharp e...

Page 63: ... carefully on two identical pallets 83 Secure the lift mast 15 with the lashing straps 82 tightly on the pallets 83 Tighten the lashing straps 82 with their tensioners Stow any supplied parts forks guide rollers etc on a pallet 90 so that they cannot slip 90 Place a pallet 90 on the top section of the mast 15 Guide the lashing strap 89 through the pallet 90 and around the mast 15 and secure it NOT...

Page 64: ...us accidents uTo attach the truck to the lorry or trailer secure fastening belts on either side to at least two different fastening rings Securing the basic truck without lift mast for transport Requirements Position the support frame 18 in the middle of the swivel traverse frame 25 see page 177 Park the truck securely see page 191 Remove the mast The mast can only be removed by the manufacturer s...

Page 65: ...lts Secure the basic truck with two lashing straps 92 to the left hand and right hand attachment points 79 between the swivel traverse frame 25 and the truck chassis Thread the lashing straps 92 through the attachment points 79 between the swivel traverse frame 25 and the truck chassis Secure the lashing straps 92 to the lashing rings 85 Tighten the lashing straps 92 with their tensioners Secure t...

Page 66: ...port can result in accidents Improper securing of the truck during transport can result in serious accidents uTo attach the truck to the lorry or trailer secure fastening belts on either side to at least two different fastening rings Securing the basic truck with the mast assembled for transport Requirements Position the support arms 18 in the middle of the swivel traverse frame 25 see page 177 Pa...

Page 67: ...nd hydraulic lines from being damaged by the fastening belts Secure the truck with two lashing straps 92 to the left hand and right hand attachment points 79 between the swivel traverse frame 25 and the truck chassis Thread the lashing straps 92 through the attachment points 79 between the swivel traverse frame 25 and the truck chassis Secure the lashing straps 92 to the lashing rings 85 Tighten t...

Page 68: ...ufficient wire cross section to the battery tow cables can overheat setting the truck and battery on fire uThe truck must only be operated with battery current uCable connections to the battery tow leads must be less than 6 m long and have a minimum cross section of 50 mm Wheel flattening If the truck has been parked for a long period the wheel surfaces may tend to flatten This flattening has a ne...

Page 69: ...e attachment area while the attachment is traversing and swivelling uKeep all personnel out of the hazardous area during hydraulic operations uInstruct other people to move out of the hazardous area of the industrial truck uStop working with the truck if people do not leave the hazardous area 67 04 19 en GB ...

Page 70: ... a customer service organisation authorised by the manufacturer Procedure Check the equipment is complete Loosen the transport chains 96 Fit the battery if necessary see page 82 Charge the battery see page 82 Check the hydraulic oil level and refill if necessary see page 346 Close the load handler emergency lowering valve see page 211 Check that all safety mechanisms are present and test them e g ...

Page 71: ...after the serial number see page 43 WARNING Missing tilt safety devices can result in loss of stability The truck can tip over if it is operated either without or with incorrectly adjusted tilt safety devices uBefore starting check the truck to ensure the tilt safety devices are present uBefore starting check the truck to ensure the settings are correct NOTICE For a new drive wheel the distance fr...

Page 72: ...70 04 19 en GB ...

Page 73: ... be available CAUTION The use of unsuitable fire protection equipment can result in scalding Extinguishing fires with water can cause a reaction with the battery acid This can result in scalding from the acid uUse powder extinguishers uNever extinguish a burning battery with water Battery maintenance The battery cell covers must be kept dry and clean The terminals and cable shoes must be clean sec...

Page 74: ...ungheinrich for the truck can be hazardous The design weight and dimensions of the battery have a considerable effect on the operational safety of the truck in particular its stability and capacity The use of unsuitable batteries that have not been approved by Jungheinrich for the truck can lead to a deterioration of the braking system during energy recovery operations and also cause considerable ...

Page 75: ... insulated The EFX can be fitted with a variety of battery types All battery types comply with DIN 43531 A The following table shows which combinations are included as standard Truck type Battery type Voltage Capacity EFX 410 EFX 413 4 PzS 5001 48 V 500 Ah EFX 410 EFX 413 5 PzS 6251 48 V 625 Ah EFX 410 EFX 413 6 PzS 7501 48 V 750 Ah 1 Single part battery version Z The battery weights can be taken ...

Page 76: ...battery are identical with those of the previously used battery Failure to comply with the prescribed battery weight range can render the truck unstable uUse only batteries whose weight is within the minimum and maximum range stated on the truck s data plate uWhen replacing or installing the battery ensure that it is secured correctly in the truck s battery compartment uChanging the battery featur...

Page 77: ...H B L Truck type Length L Width W Height H EFX 410 1060 mm 640 mm 640 mm Maximum battery height 627 mm EFX 413 1060 mm 640 mm 640 mm Maximum battery height 627 mm 75 04 19 en GB ...

Page 78: ...ng place wedges underneath the wheels of the truck to prevent it from moving NOTICE The truck must not be parked on transport or escape routes in front of safety installations or in front of factory equipment that must be accessible at all times 9 8 97 98 29 Opening the battery panel Requirements Park the truck securely see page 191 Procedure Lower the load handler to the ground see page 171 Switc...

Page 79: ...panels and covers uDo not operate the truck unless the panels and covers are closed and properly locked CAUTION Trapping hazard There is a risk of trapping when you close the battery cover uMake sure there is nothing between the battery cover and the truck when you close the battery cover Closing the battery cover Requirements Park the truck securely see page 191 Battery cover open Procedure Close...

Page 80: ...uVentilate the room in which the truck is being charged uThe battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilation uDo not smoke and avoid naked flames when handling batteries uWherever an industrial truck is parked for charging there shall be no inflammable material or lubricants capable of creating sparks within 2 m around the tru...

Page 81: ...terial damage The charger must be adapted to the battery in terms of voltage and charge capacity Always follow the safety regulations of the battery and charger station manufacturers Switch on the charger Charge the battery 99 in accordance with the battery and charging station manufacturer s instructions The battery is charged 79 04 19 en GB ...

Page 82: ... battery on fire uBefore closing the battery cover make sure that the battery cables are not damaged uReport any defects immediately to your supervisor uMark defective truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fault 33 99 29 Preparing the battery for operation after charging Requirements The battery 99 is fully charged ...

Page 83: ... discharged battery has been completely re charged and the truck switched on it may take a few seconds before the truck is operational During this time the battery symbol in the driver s display flashes 81 04 19 en GB ...

Page 84: ...ain in the same position uPark the truck on a level surface to prevent the battery from sliding out uMake sure the crane lifting gear has sufficient capacity to replace the battery uUse only approved battery replacement devices battery roller stand replacement trolley etc uMake sure the battery is located securely in the truck s battery compartment CAUTION Battery installation and removal can caus...

Page 85: ...nt risk when battery is not installed The weight and dimensions of the battery have a considerable effect on the stability and capacity of the industrial truck In exceptional cases the truck may perform short shunting operations without the battery in the battery compartment e g battery replacement The following rules apply uOperate the truck with battery current only Rectified AC current damages ...

Page 86: ...rate the truck unless the panels and covers are closed and properly locked 100 42 102 101 33 99 29 Battery installation Requirements Park the truck securely see page 191 Expose the battery see page 76 Tools and Material Required Battery roller stand Procedure Position the battery roller stand with the battery 99 in front of the battery compartment in such a way that the battery 99 can be safely pu...

Page 87: ...lockwise see arrow direction B Fit the side panels 42 Insert the bottom section of the side panels 42 at an angle into the chassis see arrow direction A Pull up the side panels 42 and insert them in the chassis see arrow direction A Check all cables and connectors for visible signs of damage Connect the battery connector 33 to the truck Close the battery cover 29 see page 76 When the battery has b...

Page 88: ...have been applied If the battery retainers have not been inserted and latched correctly in the chassis the truck will not move The driver s display shows the Battery lock not applied symbol 103 Operating the truck without battery locks in place Requirements Prepare the truck for operation see page 138 or see page 139 Procedure Determine the travel direction Push the travel direction switch 105 rig...

Page 89: ...ttery retainer s is are inserted in the chassis The battery lock not applied symbol 103 fades out The truck can now travel again at the approved speed Z Hydraulic operations are not affected if the battery retainers are not in place 87 04 19 en GB ...

Page 90: ...88 04 19 en GB ...

Page 91: ...amiliar with the operating instructions Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator 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 informed immediately of any damage or faults to the truck or attachment Trucks which are unsaf...

Page 92: ...wering falling operating equipment uInstruct unauthorised persons to leave the hazardous area uIn case of danger to third parties give a warning signal in good time uIf unauthorised persons are still within the hazardous area stop the truck immediately WARNING Falling objects can cause accidents Falling objects can injure the operator while the truck is being operated uThe operator must remain wit...

Page 93: ...all times Replace if necessary WARNING Accident risk due to removing or disabling of safety devices Removal or disabling of safety devices such as the Emergency Disconnect switch deadman switch horn warning lights gates protective window covers etc may result in accidents and injuries uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the ...

Page 94: ...2 Displays and Controls 2 1 Controls and displays on the control panel 114 106 5 104 112 107 108 109 116 115 113 9 8 118 20 22 21 105 120 119 117 111 110 23 92 04 19 en GB ...

Page 95: ... not applied display is lit in the driver s display see page 97 Steering driver s display and horn are enabled Hydraulic functions fork carriage rotate attachment traverse are enabled Travel functions are inhibited When the deadman button is released the truck brakes regeneratively to a halt parking brake applied The industrial truck coasts to a stop according to the coasting brake parameter setti...

Page 96: ...ons shown in the driver s display shown as symbols are activated or confirmed with the button underneath the symbol The symbol has a dark background 105 Travel direction switch t Selects the travel direction of the truck Press travel direction switch to the right Travel in load direction to the left Travel in drive direction 106 Switch automatic guidance on off button t Activates wire guidance in ...

Page 97: ... and settings for standard functions e g setting the time and additional functions e g rack height select 110 Indicators t Note For manufacturer s service department only 111 Function keys F1 F6 t Rack Height Select zone change Warehouse navigation zone change 112 Numerical keypad t Controls and settings for standard functions e g setting the time and additional functions e g Rack Height Select ma...

Page 98: ...ion with the fork carriage traverse button 120 114 Options switches o Switch for optional functions 115 Grip t Handle with hydraulic functions control lever and horn button 116 Horn button t Activates the horn activates an audible warning 117 Armrest t 118 Control panel t Truck functions can be controlled with the control panel 119 Fork carriage rotate key t Changes the hydraulic functions control...

Page 99: ... Display Function 121 Parking brake applied warning lamp t Truck is ready for operation Indicates the truck is stationary Parking brake drive wheel brake is applied 122 Service hours t Displays the number of service hours since the truck was started for the first time 123 Time t Shows the time 97 04 19 en GB ...

Page 100: ... with aisle detection o Symbol lights up as soon as the truck is automatically guided and has received an aisle signal Truck guided without aisle detection Symbol lights up as soon as the truck is automatically guided and has not received an aisle signal Continue driving industrial truck along the narrow aisle As soon as the industrial truck receives an aisle signal the Truck guided without aisle ...

Page 101: ...row aisle As soon as the industrial truck receives an aisle signal the Truck guided without aisle detection symbol is replaced by the Truck guided with aisle detection symbol Truck not guided Symbol is lit as soon as the industrial truck has been turned off and on again with the key switch on the guide wire Continue driving industrial truck along the narrow aisle Truck not guided symbol is replace...

Page 102: ... lowering of the main lift 127 Battery discharge indicator t Shows the battery charge status bar display 75 o Displays the battery charge status residual capacity as a percentage 128 Menu structure level t The current level of the menu structure displayed in the driver s display has a dark background 129 Change hydraulic oil o Indicates that the permissible water content level in the hydraulic oil...

Page 103: ...tem in the narrow aisle see page 245 Indicates missing activation frequency for the stationary personal safety system The truck brakes to a halt Perform cycle test display o Indicates that the cycle test of the personal protection system must be performed every 24 hours see page 243 The truck brakes During this time the travel speed is restricted to creep speed 2 5 km h 131 kg Weighing function o ...

Page 104: ...gency disconnect switch pressed 135 Displays possible travel speeds t Rabbit Max travel speed t Turtle Inching speed 136 Service mode active warning lamp t Shows event and or information messages on the driver s display The truck brakes The travel speed is restricted to creep speed 2 5 km h Wire guidance fault warning lamp o A wire guidance sensor on the truck has left the prescribed range of the ...

Page 105: ...265 or see page 281 t Denotes standard equipment o Denotes optional equipment WG Wire guidance RG Rail guidance 2 3 Hourmeter Z Prepare the truck for operation see page 138 or see page 139 Service hours are counted while the truck is operational and the deadman button is pressed 103 04 19 en GB ...

Page 106: ...at least every 2 months Z Charge the battery see page 78 Requirements Connect the battery to the truck Close the battery cover Enter the operator position see page 121 Procedure Turn the EMERGENCY DISCONNECT switch 9 to unlock it Switch on the truck to do this Insert the key in the key switch 8 and turn it as far right as it will go Hold the card or transponder in front of the ISM access module 23...

Page 107: ...he greater the battery s residual capacity Flashing Battery charge recommended Depending on the battery type the battery discharge indicator symbol flashes when there are one or two remaining bars Battery charge required charge is below residual capacity level The battery discharge indicator symbols does not show any bars The load handler can no longer be lifted The lift function is disabled by th...

Page 108: ...fully discharge Full discharge shortens the useful life of the battery uCharge the battery at least every 2 months Z Charge the battery see page 78 Requirements Connect the battery to the truck Close the battery cover Enter the operator position see page 121 Procedure Turn the EMERGENCY DISCONNECT switch 9 to unlock it Switch on the truck to do this Insert the key in the key switch 8 and turn it a...

Page 109: ...harge recommended 20 0 Battery charge required charge is below residual capacity level The load handler can no longer be lifted The lift function is disabled by the controller Z Raising is only enabled when the battery connected is at least 40 charged Battery discharge monitor for gel batteries Battery symbol Percentage Meaning Permanently lit 100 41 Battery is charged The higher the percentage th...

Page 110: ...k rotation to the left symbol t Indicates that it is possible to synchronously rotate the fork carriage to the left and traverse the attachment to the right manually Manual synchronised fork rotation to the left key t Activates manual synchronised rotation of the fork carriage to the left and traverse of the attachment to the right The attachment traverse movement is controlled with the hydraulic ...

Page 111: ...5 Symbol Manual synchronised rotation until forks are in the centre position o Indicates that it is possible to synchronously rotate the fork carriage through 90 and traverse the load handler to the centre position manually Key Manual synchronised rotation until forks are in the centre position o Activates manual synchronised rotation of the fork carriage through 90 and traverse of the attachment ...

Page 112: ...rical fork positioning menu change functions Asymmetrical fork positioning menu change key o Changes menu Pressing the asymmetrical fork positioning menu change key changes the menu currently shown in the driver s display changes to the asymmetrical fork positioning menu Left hand fork positioning symbol o Indicates that the left hand fork can be positioned Left hand fork positioning button o Acti...

Page 113: ...protection system in the narrow aisle see page 244 The truck brakes During this time the travel speed is restricted to creep speed 2 5 km h Acknowledge cycle test symbol o Indicates that the cycle test of the personal protection system must be performed every 24 hours see page 243 The truck brakes During this time the travel speed is restricted to creep speed 2 5 km h Acknowledge cycle test button...

Page 114: ... stacking depth symbol o Indicates that the 2nd stacking depth function is possible 2nd stacking depth button o Activates the 2nd stacking depth of the telescopic forks This hydraulic function is controlled with the hydraulic functions control lever see page 256 112 04 19 en GB ...

Page 115: ...tton o Overrides lowering cut out see page 219 This hydraulic function is controlled with hydraulic functions control lever Travel cut out symbol o Appears as soon as automatic height dependent travel cut out is activated see page 215 Travel cut out override button o Overrides the automatic height dependent travel cut out see page 215 Travel is controlled with the accelerator pedal End of aisle sa...

Page 116: ...g the quit sub menu key the menu currently shown in the driver s display changes to the truck functions menu Battery latch not applied symbol t Appears when the truck has been switched on but the battery latch has not been applied Travel without battery latch key t Overrides the battery latch not applied display see page 86 The truck can only travel at creep speed 0 8 km h 114 04 19 en GB ...

Page 117: ...an menu Overhead guard working lights symbol o Indicates that the overhead guard working lights can be switched on off Overhead guard working lights key o Switches the overhead guard working lights on and off Operator position lighting symbol o Indicates that the operator position lighting can be switched on off Operator position lighting key o Switches the operator position lighting on and off Ov...

Page 118: ... camera on and off 0 Weighing system display zero setting symbol o Indicates that the weight measurement display can be set tared to ZERO see page 296 Weighing system display zero setting key o Sets the weight measurement to ZERO WG Wire guidance t Indicates standard equipment RG Rail Guidance o Indicates optional equipment 116 04 19 en GB ...

Page 119: ...a despite the warning prevent the truck from being used by unauthorised people 3 1 Checks and operations to be performed before starting daily operation WARNING Damage and other truck or attachment optional equipment defects can result in accidents If damage or other truck or attachment optional equipment defects are discovered during the following checks the truck must be taken out of service unt...

Page 120: ...cessary see page 123 Check seat belt and belt lock function properly and check for damage see page 127 Check travel control labels are legible and complete Check hydraulic control labels are legible and complete Check control panel for damage Check control panel setting and adjust if necessary see page 125 and see page 126 Test the gas struts on the battery cover and check for damage Make sure til...

Page 121: ... replaced before the truck is started uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault uSpilled fluids must be removed immediately with an appropriate bonding agent The bonding agent consumable mixture must be disposed of in accordance with regulations Check that the l...

Page 122: ...mage Check the battery connectors are secure Check battery lock battery attachment is present and working Make sure battery is securely fixed in the battery compartment Check battery cover and side panels are secure and look for damage 3 1 4 Wheel visual inspection Procedure Check drive wheel and load wheels for wear and damage For rail guidance systems check guide wheels run smoothly and check fo...

Page 123: ...lowered Procedure Z Enter or leave the truck only from the left hand side facing the truck To enter and exit hold onto the handle 139 and use the steps 140 Enter or leave the truck CAUTION No more than one person may operate the truck at a time 121 04 19 en GB ...

Page 124: ...seat and control panel must be locked in place when the truck is in operation uDo not adjust the driver s seat and control panel during operation Procedure Before operating adjust the driver s seat and control panel so that all the controls are within reach and can be applied without having to strain Adjust the visibility aid equipment mirrors camera systems etc so that the working environment can...

Page 125: ...e starting up the truck uHold the weight setting lever only by the recess do not reach through underneath the lever Adjusting the driver s weight NOTICE To achieve optimal seat cushioning the driver s seat must be set to the driver s weight Set the driver s weight when the seat is unoccupied Seat cushioning setting range 50 kg 130 kg Procedure Pull the weight adjustment lever 143 in the direction ...

Page 126: ...el resulting in accidents uThe driver s seat must be locked in position uDo not adjust the driver s seat while travelling Procedure Sit on the driver s seat Pull up the driver s seat locking lever 144 in the direction of the arrow Push the driver s seat forwards or backwards to the desired position Engage the driver s seat locking lever 144 in position The seat position is now correctly set Adjust...

Page 127: ...n place when the truck is in operation uDo not adjust the control panel during operation Procedure Hold onto the control panel 118 Turn the height adjusting lever 146 anti clockwise Set the control panel 118 to the required position Pull the control panel up see arrow direction A Push the control panel down see arrow direction B Turn the control panel adjusting lever 146 clockwise and secure the c...

Page 128: ...n the truck is in operation uDo not adjust the control panel during operation Procedure Hold onto the control panel 118 Pull the longitudinal adjusting lever 147 up Set the control panel 118 to the required position Push the control panel to the right see arrow direction A Pull the control panel to the left see arrow direction B Release the longitudinal adjusting lever 147 and lock the control pan...

Page 129: ...replaced after an accident uOnly original spare parts must be used for retrofits or repairs uReport any defects immediately to your supervisor uRemove the truck from service until a functional seat belt has been fitted NOTICE The driver must check the operation and condition of the seat belt each day before using the industrial truck Z Protect the seat belt from contamination e g cover it when the...

Page 130: ...nd check for damage loose seams fraying and nicks Test the belt buckle and make sure the belt returns correctly into the retractor Check the automatic locking system Procedure Park the truck on a level surface Jerk the seat belt out suddenly Z The locking system should prevent the belt from coming out The seat belt has now been checked 128 04 19 en GB ...

Page 131: ...so that your back is resting against the backrest Pull the seat belt smoothly out of the reel Place the seat belt tightly against your body over your thigh Take care not to twist it Engage the locking tongue 149 in the lock 148 The seat belt is now in place Take off the seat belt Procedure Hold onto the lock tongue 149 with one hand Press the red button on the lock 148 Manually guide the lock tong...

Page 132: ... should not jump out of the truck and must keep his whole body inside the operator position The operator uMust not leave the driver s seat under any circumstance uMust not jump off the truck uMust hold onto the operator position with both hands uMust brace himself with both feet uMust lean against the direction of fall uMust not undo the seat belt 130 04 19 en GB ...

Page 133: ...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 NOTICE Loads must not be deposited on travel or escape routes in ...

Page 134: ...n for travel steering and braking under the prevailing ambient conditions The details on the truck data plate assume a level and dry travel surface Other ground surfaces may have a negative affect on the stability of the truck They will result in a modification of the rated performance e g speed reduction etc of the truck 132 04 19 en GB ...

Page 135: ...uck CAUTION There must be no ramps or inclines in areas where forklift trucks are used NOTICE Static charge can cause material damage to truck components When the truck is operated on a surface with a shunt resistance in excess of 106 Ω static charge can result in damage to electric components controller control panel uOperate the truck only on surfaces with a shunt resistance of less than 106 Ω u...

Page 136: ...talkie without a handsfree device while operating the truck WARNING What to do if the industrial truck tips over If the truck is in danger of tipping over the operator should not jump out of the truck and must keep his whole body inside the operator position The operator uMust not leave the driver s seat under any circumstance uMust not jump off the truck uMust hold onto the operator position with...

Page 137: ...ase proceed only at walking pace and pay particular attention Stop the truck immediately if visual contact is lost between the lookout and the operator Use the mirror only to observe the traffic behind you Should you need visibility aids mirrors monitors etc to ensure adequate visibility practice working with them beforehand Negotiating slopes and inclines WARNING Do not negotiate slopes or inclin...

Page 138: ...tact with the walls of the lift shaft Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to rest and must leave the lift before the truck Work platforms WARNING The use of working platforms is governed by national law In some states the use of working platforms is prohibited on industrial trucks Observe the applicable law Working platforms can only...

Page 139: ...out A change in the load centre due to sudden lifting and drive movements the load falling down as a result Adverse effect on the stability of the industrial truck due to slipping or unstable loads uFollow the instructions in the section Transporting a load see page 202 WARNING Suspended and swaying loads can cause accidents and tipovers during transport Transporting suspended and swaying loads ca...

Page 140: ...ERGENCY DISCONNECT switch 9 to unlock it Z Press the Emergency Disconnect 9 immediately if the truck starts to move or lift as soon as it is switched on Brief steering movements caused by steering referencing are permissible Switch on the truck to do this Insert the key in the key switch 8 and turn it as far right as it will go Hold the card or transponder in front of the ISM access module 23 and ...

Page 141: ...ition to the access code the key switch ISM access module o is still used to switch on the truck Z In conjunction with the user specific setting option pre defined travel programs and hydraulic programs as well as various rights can be assigned to the different access codes see page 257 Possible authorisation levels User access code without change rights to user specific settings User access code ...

Page 142: ...rocedure Turn the EMERGENCY DISCONNECT switch 9 to unlock it Z Press the Emergency Disconnect 9 immediately if the truck starts to move or lift as soon as it is switched on Brief steering movements caused by steering referencing are permissible Switch on the truck to do this Insert the key in the key switch 8 and turn it as far right as it will go Hold the card or transponder in front of the ISM a...

Page 143: ...key 150 one digit back Press the CE key 154 to cancel entering the 5 digit access code Press OK 153 and confirm the access code entry Z If no travel steer or hydraulic operations are performed within a factory set interval the driver s display 107 will prompt you again to enter the 5 digit access code with the numerical keypad 112 In addition all truck functions are inhibited When you have entered...

Page 144: ...r symbol 155 appears in the driver s display Z Truck operations are inhibited in this menu Press the 104 key under the Log off user symbol 155 The user is logged off All truck functions are inhibited In the driver s display 107 you will be prompted to enter your 5 digit access code with the numerical keypad 112 104 108 155 107 112 104 108 112 142 04 19 en GB ...

Page 145: ...ate Time Standard setting dd mm yyyy hh mm ss US setting mm dd yyyy hh mm ss am pm Selecting the Set Date Time menu Requirements Prepare the truck for operation see page 138 or see page 139 Procedure Press the Quit sub menu button 108 The driver s display shows the current date and time Z Truck operations are inhibited in this menu 108 143 04 19 en GB ...

Page 146: ...an also be entered directly with the number field on the numerical keypad 112 Use the cursor keys 150 152 to select the next or previous field Cursor key 150 previous field Cursor key 152 one field forward Z The selected field appears with a dark background Press OK on the numerical keypad 112 to save the date and time settings 112 156 152 157 150 151 108 Leaving the menu Procedure Press 104 under...

Page 147: ...age or other defects are discovered on the truck or attachment special equipment the truck must be taken out of service until it has been repaired uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault 115 139 Requirements Prepare the truck for operation see page 138 or see ...

Page 148: ...uts o see page 217 Test the travel functions see page 153 and see page 159 Test the end of aisle safety device and aisle detection functions o see page 221 Test the travel cut outs o see page 215 Check the lighting working lights strobe light etc o Test the personal protection system o see page 237 Check the front screens laser scanner of the personal protection system for dirt o and clean as requ...

Page 149: ... the truck for operation see page 138 or see page 139 Procedure Press the dead man s switch 20 Carry out a raise main lift reference run Raise the main lift until the symbol 159 is no longer displayed Turn the hydraulic functions control lever 113 clockwise Carry out a lower main lift reference run Lower the main lift completely until the symbol 160 is no longer displayed Turn the hydraulic functi...

Page 150: ... g when confronted with an obstacle uWhen the lift cutout has been de activated the truck must be operated with extra care in order to detect obstacles when the mast is extended uStop lifting before you reach the obstacle Procedure Pressing the lift cut out override button 104 below the lift cut out symbol 161 disables the lift cut out The hydraulic functions are controlled with the hydraulic func...

Page 151: ...ocedure Do not press the deadman button 20 Press and hold down on the Attachment traverse button 120 Traverse the attachment through the centre of the swivel traverse frame Turn the Hydraulic functions control lever 113 clockwise Attachment right traverse Turn the Hydraulic functions control lever 113 anti clockwise Attachment left traverse Traverse attachment back to home position see page 192 Tr...

Page 152: ...k carriage right rotation Turn the Hydraulic functions control lever 113 anti clockwise Fork carriage left rotation Rotate fork carriage back to home position see page 192 Rotate referencing is successful if the Rotate reference run symbol 163 goes out after referencing If the Rotate reference run symbol 163 does not go out after referencing contact the manufacturer s service department and take t...

Page 153: ...cies CAUTION Faulty or non accessible Emergency Disconnect switches can cause accidents A faulty or non accessible Emergency Disconnect switch can cause accidents In dangerous situations the operator cannot bring the truck to a halt in time by applying the Emergency Disconnect switch uThe operation of the Emergency Disconnect switch must not be affected by any objects placed in its way uReport any...

Page 154: ...t switch Procedure Turn the EMERGENCY DISCONNECT switch 9 to unlock it Trucks with ISM access module o Hold the card or transponder in front of the ISM access module and depending on the setting press the green button on the ISM access module All electrical functions are enabled and the truck is operational again assuming the truck was operational before the Emergency Disconnect was pressed 152 04...

Page 155: ...uEnsure that there is nobody in the hazardous area when carrying out travel and hydraulic operations uInstruct other people to move out of the hazardous area of the truck uStop working with the truck if people do not leave the hazardous area WARNING Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is operated with open panels and covers uDo ...

Page 156: ... Turn the hydraulic functions control lever 113 clockwise Determine the travel direction Pushing the travel direction switch 105 to the right travel in load direction 164 Pushing the travel direction switch 105 to the left travel in drive direction 165 Press the accelerator pedal 22 Z The travel speed is infinitely controlled by the accelerator pedal 22 The further the accelerator pedal 22 is pres...

Page 157: ...oes not take his foot of the accelerator pedal in time Changing direction during travel causes the truck to decelerate sharply uWhen the truck starts to move in the opposite direction only depress the accelerator pedal lightly or not at all uDo not make any abrupt steering movements uLook in the direction of travel uHave an adequate overview of the route to be travelled 155 04 19 en GB ...

Page 158: ...avel set the travel direction switch 105 to the opposite direction The truck brakes regeneratively via the traction controller until it starts to move in the opposite direction The travel direction change reduces the truck s energy consumption Energy is recovered which is controlled by the traction current controller When the truck starts to move in the opposite direction only depress the accelera...

Page 159: ...king distance increases when the ground is wet or dirty uThe operator must be aware of floor conditions and take them into account when braking uBrake with care to prevent the load from slipping The truck can brake in three different ways Braking with the coasting brake t Braking with the brake pedal t Braking with the dead man s switch o Z Braking with the coasting brake or the brake pedal is ref...

Page 160: ...eration The truck decelerates depending on the position of the brake pedal 21 20 22 21 Braking with the deadman button o Procedure During travel take your foot off the deadman button 20 Z This method of braking only acts as a parking brake and not as a service brake The truck brakes to a halt 158 04 19 en GB ...

Page 161: ...this purpose uBefore entering a narrow aisle the operator must look for people or other trucks in the aisle Never enter an aisle where there are people or other trucks If there are people or trucks in the aisle stop the truck immediately WARNING Objects protruding out of the racks can be hazardous The operator of the truck in a narrow aisle can be injured by objects protruding from the racks e g p...

Page 162: ... aisle Lift height h3 Safety clearance Wire guided truck depending on the lift height h3 125 mm Rail guided truck to 4000 mm 90 mm to 6000 mm 100 mm from 6000 mm 125 mm Z The safety distance may however increase if special attachments are fitted Travelling in narrow aisles with rail guided trucks Requirements Narrow aisles must be equipped with guide rails 166 Prepare the truck for operation see p...

Page 163: ...l only in narrow aisles with undamaged secure guide rails Press the deadman button Approach the aisle at reduced speed so that the truck 167 is aligned with the narrow aisle and is within the demarcations Note the markings attached along the route e g aisle centre line Drive the truck slowly into the narrow aisle 167 Ensure that the guide wheels of the truck 167 enter the narrow aisle guide rails ...

Page 164: ...ravel speed is governed by the accelerator pedal 22 Z The travel speed is infinitely controlled by the accelerator pedal 22 The further the accelerator pedal 22 is pressed the greater the travel speed For details of the brake functions see page 157 For details of hydraulic operation see page 171 and see page 175 The truck has now entered the narrow aisle and is automatically guided 168 105 22 106 ...

Page 165: ...Switch automatic guidance on off button 106 Z The Truck guided display 168 changes to the steer angle indicator 124 The truck is now free to move again The steer angle indicator 124 shows the current position of the drive wheel Z Always travel outside of narrow aisles with the load lowered The truck has left the narrow aisle Use the steering wheel 5 to adjust the angle of the drive wheel again 124...

Page 166: ... ineffective misused adjusted or removed uReport any defects to your supervisor immediately uMark defective truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fault uTag out faulty racking systems and block them for entry uReturn the truck to service only when you have identified and rectified the fault uNote DIN 15185 Part 2 uN...

Page 167: ...learances between the truck and rack Refer to the following table for the safety clearances required by the manufacturer depending on the type of guidance system and the lift height h3 Truck guidance in the narrow aisle Lift height h3 Safety clearance Wire guided truck depending on the lift height h3 125 mm Rail guided truck to 4000 mm 90 mm to 6000 mm 100 mm from 6000 mm 125 mm Z The safety dista...

Page 168: ...Negotiating narrow aisles with wire guided trucks Requirements Narrow aisles must be equipped with a guide wire Prepare the truck for operation see page 138 or see page 139 166 04 19 en GB ...

Page 169: ...u are close to the guide wire 169 switch wire guidance on with the switch automatic guidance on off key 106 The acquisition signal sounds Move the truck 167 slowly in the direction of the guide wire 169 Z On reaching the guide wire 169 the truck is guided automatically Guide wire acquisition ensues automatically at reduced speed Manual steering is deactivated The steering angle indicator 124 chang...

Page 170: ...ravel speed is governed by the accelerator pedal 22 Z The travel speed is infinitely controlled by the accelerator pedal 22 The further the accelerator pedal 22 is pressed the greater the travel speed For details of the brake functions see page 157 For details of hydraulic operation see page 171 and see page 175 The truck has now entered the narrow aisle and is automatically guided 168 105 22 106 ...

Page 171: ...Switch automatic guidance on off button 106 Z The Truck guided display 168 changes to the steer angle indicator 124 The truck is now free to move again The steer angle indicator 124 shows the current position of the drive wheel Z Always travel outside of narrow aisles with the load lowered The truck has left the narrow aisle Use the steering wheel 5 to adjust the angle of the drive wheel again 124...

Page 172: ...y To lower the load handler Turn the hydraulic functions control lever 113 anticlockwise To raise the load handler Turn the hydraulic functions control lever 113 clockwise To travel in load direction Pushing the travel direction switch 105 to the right travel in load direction Press the accelerator pedal 22 The travel speed is governed by the accelerator pedal 22 To travel in drive direction Pushi...

Page 173: ...truck Stop working with the truck if people do not leave the hazardous area uIf people do not leave the hazardous area despite the warning prevent the truck from being used by unauthorised people uOnly carry loads that have been secured and positioned in accordance with regulations Use suitable precautions to prevent parts of the load from tipping or falling down uDamaged loads must not be transpo...

Page 174: ... there no leakage in the hydraulic system raise the Main Lift slightly and then lower it again slowly uReport any defects immediately to your supervisor uMark defective truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fault uSpilled leaking hydraulic oil must be removed immediately with an appropriate bonding agent uThe bondin...

Page 175: ...aulic hoses may become damaged uWhen lowering the load handler ensure that the lift chains are not resting on anything and are slack uRaise the load handler carefully until the lift chains are tensioned and not resting on anything uWhen raising the load handler ensure that the hydraulic hoses are located in their guides uIn the event of a block raise the load handler carefully until the lift chain...

Page 176: ...rol lever 113 clockwise To lower the load handler Turn the hydraulic functions control lever 113 anticlockwise The load handler is being raised lowered 113 20 Z The lift and lowering speeds are proportional to how far the hydraulic functions control lever 113 is moved The maximum lift speed is reached when the attachment is in the home position see page 192 174 04 19 en GB ...

Page 177: ...nt in the danger zone when carrying out swivel traverse synchronised rotate or lifting or lowering movements with the load handler Stop working with the truck if people do not leave the hazardous area uIf people do not leave the hazardous area despite the warning prevent the truck from being used by unauthorised people uOnly carry loads that have been secured and positioned in accordance with regu...

Page 178: ...external signs of damage or defects Faulty attachments can cause the load to fall uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault 176 04 19 en GB ...

Page 179: ...Turn the Hydraulic functions control lever 113 clockwise Traverse attachment to the left Turn the Hydraulic functions control lever 113 anti clockwise Z The traverse speed is in proportion to how far the Hydraulics function control lever 113 is rotated The attachment moves to the right or left Z If the attachment is not in the home position you can only travel lift or lower at a reduced speed see ...

Page 180: ...urn the Hydraulic functions control lever 113 clockwise Rotate fork carriage left Turn the Hydraulic functions control lever 113 anti clockwise Z The rotary speed is in proportion to how far the Hydraulics function control lever 113 is rotated The fork carriage is rotated to the right or left 113 20 120 119 Z If the attachment is not in the home position you can only travel lift or lower at a redu...

Page 181: ... see page 192 A load greater than 500 kg is on the load handler Load handler is raised above 2 m Procedure Symbol rotation cut out 171 is shown in the driver s display The following hydraulic functions are enabled and can be performed Lifting and lowering the load handler see page 171 Attachment traverse see page 177 The following hydraulic function is disabled and cannot be carried out Fork carri...

Page 182: ...171 and lift cut out 161 The following hydraulic functions are enabled and can be performed Lowering the load handler see page 171 Attachment traverse see page 177 The following hydraulic functions are disabled and cannot be carried out Fork carriage rotation Lifting the load handler see page 171 Z The fork carriage rotation hydraulic function is released again when the load handler has been lower...

Page 183: ... present in the danger zone when carrying out swivel traverse synchronised rotate or lifting or lowering movements with the load handler Stop working with the truck if people do not leave the hazardous area uIf people do not leave the hazardous area despite the warning prevent the truck from being used by unauthorised people uOnly carry loads that have been secured and positioned in accordance wit...

Page 184: ...external signs of damage or defects Faulty attachments can cause the load to fall uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault 182 04 19 en GB ...

Page 185: ... by releasing the 104 key or the hydraulic functions control lever 113 The attachment must then be moved manually to the home position Synchronised fork carriage rotation to the right and load handler traverse to the left Press and hold down the key 104 under the synchronised fork rotation to the right symbol 175 Turn the hydraulic functions control lever 113 anticlockwise until the home position ...

Page 186: ...Z If the attachment is not in the home position you can only travel lift or lower at a reduced speed see page 192 184 04 19 en GB ...

Page 187: ...traverse rotate operation can be cancelled by releasing the key 104 The attachment must then be moved manually to the home position Synchronised fork carriage rotation to the right and attachment traverse to the left Press and hold down the key 104 under the synchronised fork rotation to the right symbol 175 until the home position has been reached Synchronised fork carriage rotation to the left a...

Page 188: ...Z If the attachment is not in the home position you can only travel lift or lower at a reduced speed see page 192 186 04 19 en GB ...

Page 189: ...h 20 Press the key 104 under the synchronised rotation menu change symbol 173 The display changes from the menu item synchronised rotation menu change 173 to synchronised rotation until forks are in centre position 176 Z The rotation speed is preset The traverse speed is proportional to how far the hydraulics function control lever 113 is moved Synchronised rotation until forks in centre position ...

Page 190: ...gh 90 to the left and load handler traverse to the centre position Press and hold down the key 104 under the synchronised rotation until forks are in centre position symbol 176 until the fork carriage stops rotating Turn the hydraulic functions control lever 113 clockwise until the attachment comes to a stop in the middle of the swivel traverse frame The attachment is middle of the swivel traverse...

Page 191: ...otation until forks are in centre position 176 Z The rotary and traverse speeds are preset Synchronised rotation until forks in centre position can be cancelled by releasing the 104 key The attachment must then be moved manually to the home position Synchronised fork carriage rotation through 90 and load handler traverse to the centre position Press and hold down key 104 under the synchronised rot...

Page 192: ...Z If the attachment is not in the home position you can only travel lift or lower at a reduced speed see page 192 190 04 19 en GB ...

Page 193: ...ruck may need to be secured with wedges uFully lower the load handler uSelect a place to park where no other people are at risk of injury from the lowered load handler uIf the brakes are not working place wedges underneath the wheels of the truck to prevent it from moving NOTICE The truck must not be parked on transport or escape routes in front of safety installations or in front of factory equip...

Page 194: ... be switched off after the red button of the ISM access module has been pressed twice The truck controller prevents the truck from being switched off see page 211 uTo consciously switch off the truck press the red button again and hold it down for at least 2 seconds Press the emergency disconnect switch 9 The truck is now securely switched off 4 16 1 Traversing and rotating the attachment in the h...

Page 195: ... leave the hazardous area uOnly carry loads that have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping or falling down uDo not transport loads other than on the authorised load handler uDamaged loads must not be transported uIf the stacked load obscures forward visibility then you must reverse the truck uDo not exceed the maximum loads specif...

Page 196: ...the extension safety mechanisms 178 The truck must not be operated without an extension safety mechanism 178 uCheck the extension safety mechanisms 178 are present uEnsure the extension safety mechanisms 178 are secure Adjusting the forks Requirements Park the truck securely see page 191 Procedure Lift up the locking lever 177 Push the forks 28 into the correct position on the fork carriage 19 Swi...

Page 197: ...e CAUTION Injury risk when replacing forks The forks can slide off the fork carriage when being replaced As a result you could injure your legs uWear personal protective equipment e g safety boots etc when replacing the forks uAlways push the forks away from your body never towards it uSecure heavy forks with lifting slings and a crane before pushing them down from the fork carriage uAfter replaci...

Page 198: ...vy forks with lifting slings and a crane before pushing them down from the fork carriage uKeep all parts of your body away from the forks and fork carriage WARNING Using two different forks can cause accidents Installing fork tines that are not identical in design will affect the stability of the industrial truck uUse only the same type of fork that has been approved by the manufacturer uAlways re...

Page 199: ...d and forks not touching the ground Procedure Disassemble the extension safety mechanism 178 Lift up the locking lever 177 Carefully push the fork tines 28 off the fork carriage 19 The fork tines 28 are now dismantled from the fork carriage 19 and can be replaced 177 28 19 178 197 04 19 en GB ...

Page 200: ...177 down and move the fork tines 28 until the locking pin engages in a slot WARNING Unsecured forks can cause accidents The forks must be prevented from falling with the extension safety mechanisms 178 The truck must not be operated without an extension safety mechanism 178 uCheck the extension safety mechanisms 178 are present uEnsure the extension safety mechanisms 178 are secure Assemble the ex...

Page 201: ... not transport loads other than on the authorised load handler uDamaged loads must not be transported uIf the stacked load obscures forward visibility then you must reverse the truck uDo not exceed the maximum loads specified on the capacity plate uCheck the fork spread before lifting the load and adjust if necessary uInsert the forks as far as possible underneath the load WARNING Persons standing...

Page 202: ...o that the load can be lifted Do not press the dead man s switch Slowly insert the load handler into the pallet until the fork face touches the load or the pallet Z The load unit must not extend by more than 50 mm beyond the fork tines Press the dead man s switch Raise the load handler slightly until the load rests freely on the forks Do not press the dead man s switch Slowly retract the load hand...

Page 203: ...ight angles 90 to the truck see page 178 Press the deadman button Lower raise the load handler so that the load can be lifted Slowly insert the forks into the pallet until the fork shank touches the load or the pallet Z The load unit must not extend by more than 50 mm beyond the fork tines Raise the load handler slightly until it rests freely on the forks Make sure you can see behind you and that ...

Page 204: ...ler until the load rests freely on the forks Z Always transport a load outside the narrow aisle as low as possible allowing for ground clearance Accelerate gradually Travel at a constant speed Adapt your travel speed to the conditions of the route and the load you are transporting Be prepared to brake at all times Brake gently in normal circumstances Only stop suddenly in dangerous situations Redu...

Page 205: ...come damaged uWhen lowering the load handler ensure that the lift chains are not resting on anything and are slack uRaise the load handler carefully until the lift chains are tensioned and not resting on anything uWhen raising the load handler ensure that the hydraulic hoses are located in their guides uIn the event of a block raise the load handler carefully until the lift chains are retensioned ...

Page 206: ...he load into its storage location Press the dead man s switch Carefully lower the load handler so that the forks are clear of the load Z Avoid setting down the load abruptly to avoid damaging the load load handler and the rack Do not press the dead man s switch Slowly retract the load handler to the home position see page 192 Press the dead man s switch Fully lower the load handler The load has be...

Page 207: ...ecome damaged uWhen lowering the load handler ensure that the lift chains are not resting on anything and are slack uRaise the load handler carefully until the lift chains are tensioned and not resting on anything uWhen raising the load handler ensure that the hydraulic hoses are located in their guides uIn the event of a block raise the load handler carefully until the lift chains are retensioned...

Page 208: ...n without striking any objects Carefully bring the load to its storage location Carefully lower the load handler so that the forks are clear of the load Z Avoid depositing the load suddenly to avoid damaging the load load handler and the rack Make sure you can see behind you and that you have sufficient space to move Carefully remove the load handler from the load Do not press the deadman switch S...

Page 209: ...rror code contact the manufacturer s service department Troubleshooting must only be performed by the manufacturer s customer service department The manufacturer has a service department specially trained for these tasks 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 applic...

Page 210: ...eplace if necessary see page 336 Travel cut out activated Press the key under the travel cut out override symbol see page 215 Travel cut out activated via end of aisle safety device Set the accelerator pedal to neutral and apply it again Load cannot be lifted Truck not operational Carry out all remedial measures listed under Truck does not start Battery charge too low Lift cut out Check battery ch...

Page 211: ...al measures listed under Truck does not start Automatic guidance switched on Press the switch automatic guidance on off key and switch off travelling in narrow aisle 1901 Accelerator pedal pressed during power up test Do not press the accelerator pedal switch truck on and off again 2902 Hydraulic functions control lever applied during power up test Do not apply the hydraulic functions control leve...

Page 212: ... rotation switch the truck off and on again 4918 Dead man s switch pressed during power up test Do not press the dead man s switch switch truck off and on again 9901 The personal protection system cycle test must be performed Carry out the personal protection system cycle test see page 243 9963 Front screen of personal protection system PPS laser scanner is dirty Clean the front screen of personal...

Page 213: ...ed button on the ISM access module Press the red button on the ISM access module again and hold it down for at least 2 seconds The truck is switched off 6 3 Load handler emergency lowering WARNING Risk of accidents material damage through automatic lowering of load handler If the load handler is in the rack emergency lowering is not to be carried out Due to leakage losses in the hydraulic system t...

Page 214: ...a of the truck during emergency lowering uDo not stand underneath a raised load handler uIf the load handler is lowered with the emergency lowering device below it the operator must be in a safe area to avoid any danger uDo not activate emergency lowering of the load handler when the load handler is in the rack uReport any defects immediately to your supervisor uMark defective truck and take out o...

Page 215: ...in the key switch as far to the left as it will go 8 Press the red button of the ISM access module o twice in a row Press the emergency disconnect switch 9 Open the drive compartment cover 35 see page 334 Turn the lowering valve 181 with the Allen key 180 a maximum of two revolutions anticlockwise The load handler is lowered Z The lowering speed increases the further the lowering valve 181 is open...

Page 216: ...The load handler is lowered WARNING Only return the truck to service when you have identified and rectified the fault 214 04 19 en GB ...

Page 217: ...o initiate braking if necessary uWhen the travel cutout has been de activated the truck must be operated with extra care in order to avoid colliding with obstacles uStop travelling before you reach the obstacle Z The travel cut out override symbol 182 lights up in the driver s display when the travel function has been disabled after lifting beyond a certain lift height or range If however the the ...

Page 218: ... in load direction Pushing the travel direction switch 105 to the left travel in drive direction Press the accelerator pedal 22 The truck can now travel at creep speed 182 104 22 20 105 NOTICE Pressing the 104 button under the corresponding override symbol releases different travel and hydraulic speeds as well as travel and hydraulic directions The override functions can be adjusted by the manufac...

Page 219: ...support the operator which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle uWhen the lift cutout has been de activated the truck must be operated with extra care in order to detect obstacles when the mast is extended uStop lifting before you reach the obstacle Z Lift cutout only becomes effective after referencing has been carr...

Page 220: ...Lift is raised Lift cutout is deactivated Z Lift cutout is re activated every time the mast falls below the lift limit height 161 104 20 113 NOTICE Pressing the 104 button under the corresponding override symbol releases different travel and hydraulic speeds as well as travel and hydraulic directions The override functions can be adjusted by the manufacturer s customer service department 218 04 19...

Page 221: ... the operator which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle uWhen the lower cutout has been de activated the truck must be operated with extra care in order to detect obstacles when lowering the load handler uStop lowering the load handler before you reach the obstacle Z Lower cutout only becomes effective after referen...

Page 222: ...Lift is lowered The lower cutout is deactivated Z Lift cutout is re activated every time the mast rises above the lower limit height 183 104 20 113 NOTICE Pressing the 104 button under the corresponding override symbol releases different travel and hydraulic speeds as well as travel and hydraulic directions The override functions can be adjusted by the manufacturer s customer service department 22...

Page 223: ...gnets in the direction of the end of the aisle it comes to a halt WARNING The stopping distance depends on the travel speed To continue travelling Briefly release the deadman button and accelerator pedal and then apply it again The truck can be driven out of the narrow aisle at max 2 5 km h WARNING Accident risk due to truck without braking system End of aisle safety braking is an additional funct...

Page 224: ...t of the narrow aisle at this speed WARNING The stopping distance depends on the travel speed WARNING Accident risk due to truck without braking system End of aisle safety braking is an additional function designed to support the operator but which does not release him from his responsibilities such as to monitor braking at the aisle end and if necessary to apply the brakes 222 04 19 en GB ...

Page 225: ...y Stop If during operation one of the monitors for steering control steering system wire guidance the safety cutout for the traction electronic system or the power electronic system applies the truck safety devices will cause the truck to stop To enable the truck to travel again after an Emergency Stop carry out the following Procedure Z The driver s display flashes the Wire guidance fault symbol ...

Page 226: ...sed 6 9 Recovering the truck from a narrow aisle Moving the truck without a battery WARNING Disabling the brakes can be dangerous Recovering the truck from a narrow aisle or moving the truck without a battery must only be performed by specialist repair personnel uThe specialist must be trained in operating the truck with the brakes disabled uWhen the brakes are de activated the truck must be parke...

Page 227: ...er fully lowered see page 171 or see page 211 Attachment in home position see page 192 Tools and Material Required Two set screws hex socket with hex nuts supplied with the truck Allen key key width 4 Open ended spanner opening 8 Procedure Switch off the truck to do this Turn the key in the key switch 8 to the left as far as the stop and remove the key Press the red button of the ISM access module...

Page 228: ...en them with the two hex nuts Z The two set screws 184 are used to tension unlock the compression springs which activate the parking brake so that the truck does not brake when de energised Fit the drive compartment cover 35 see page 334 Remove the wedges The drive wheel brake is now released and the truck can be moved The truck can now be towed or pushed 226 04 19 en GB ...

Page 229: ...d handler uIf the brakes are not working place wedges underneath the wheels of the truck to prevent it from moving NOTICE The truck must not be parked on transport or escape routes in front of safety installations or in front of factory equipment that must be accessible at all times WARNING Collision hazard when operating the truck Collisions with personnel and equipment can result if the truck is...

Page 230: ...et screws 184 from the drive wheel brake 187 Fit the set screws 184 with the two hex nuts to the bracket 185 above the drive wheel brake 187 Fit the drive compartment cover 35 see page 334 When using the truck again check the braking deceleration The drive wheel brake can now be applied without current The industrial truck can no longer be pushed WARNING Only return the truck to service when you h...

Page 231: ...truck if the steering system is damaged The truck can only be steered without its own drive system when it is stationary uDo not adjust the truck s steering angle during a recovery operation uWhen setting an angle of more than 4 degrees it is advisable to relieve the wheel by raising jacking up the truck 8 9 35 188 38 189 229 04 19 en GB ...

Page 232: ...Press the emergency disconnect switch 9 Disconnect the battery Disassemble the drive compartment cover 35 see page 334 Using the open ended spanner set the wheel 38 in the required direction by turning the hex bolt 188 on the steering potentiometer 189 Z When setting an angle of more than 4 degrees it is advisable to relieve the drive wheel 38 by safely raising or jacking up the truck see page 332...

Page 233: ...out its own braking system uAlways tow the truck at walking pace uDo not park the truck with the parking brake released WARNING Accidental truck movement When the brakes are de activated the truck must be parked on a level surface since the brakes are no longer effective uDo not release the brake on slopes or inclines uDo not park the truck with the brake released uApply the brake again when you r...

Page 234: ...ed and rectified the fault WARNING An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited uPark the truck on a level surface In special cases the truck may need to be secured with wedges uFully lower the load handler uSelect a place to park where no other people are at risk of injury from the lowered load handler...

Page 235: ... Switch off the truck to do this Turn the key in the key switch 8 to the left as far as the stop and remove the key Press the red button of the ISM access module o twice in a row Press the emergency disconnect switch 9 Disconnect the battery NOTICE Risk of damage from the tow rope During recovery route the tow rope to the front in such a way as to avoid damaging hydraulic hoses electric cables and...

Page 236: ...ring angle has to be changed during a recovery operation brake until the truck comes to a halt CAUTION A non steered truck can cause injury The truck can only be steered without its own drive system when it is stationary see page 229 After recovery secure the truck to prevent it from moving see page 225 WARNING Only return the truck to service when you have identified and rectified the fault 234 0...

Page 237: ...do this Turn the key in the key switch 8 to the left as far as the stop and remove the key Press the red button of the ISM access module o twice in a row Press the emergency disconnect switch 9 Disconnect the battery Route the tow rope 190 through the lifting eyes 78 on the overhead guard 11 see illustration WARNING Risk of injury during recovery operations Do not stand between the tow truck and t...

Page 238: ...ION A non steered truck can cause injury The truck can only be steered without its own drive system when it is stationary see page 229 After recovery secure the truck to prevent it from moving see page 225 WARNING Only return the truck to service when you have identified and rectified the fault 236 04 19 en GB ...

Page 239: ...am are required eye protection The laser scanner meets the requirements of standards CDRH 21 CFR 1030 10 and DIN EN 60825 2001 WARNING Caution exposure to hazardous radiation can result if the operating or adjusting devices used or procedures carried out differ from those stated in the above standards and directives National international regulations apply to the assembly and use of the safety las...

Page 240: ...ner covered load handler lowered Crawl speed released when approaching the last pallet location at a closed narrow aisle end Automatic reduction of maximum speed to 2 5 km h before exiting the aisle Additional stop at aisle end optionally temporary confirmed or absolute Short range apron field protection directly in front of and behind the truck depending on travel direction Lower cutout for prote...

Page 241: ...3 Environmental awareness The safety laser scanner is designed to keep environmental damage to a minimum It uses minimal energy and resources Always act with regard to the environment at your place of work Please note the following disposal information Disposal Always dispose of unusable or irreparable safety laser scanners in accordance with national waste disposal regulations Remove the plastic ...

Page 242: ...ttracted to the front screen Moreover there is also the risk of scratching the front screen In addition damp clean the connecting lug at the bottom of the front screen Wipe the screen dry with a clean soft woollen cloth a microfibre cloth or a new soft paper towel CAUTION Cleaning can damage the front screen Do not use dirty or large fibre cleaning cloths as these can scratch the front screen A sc...

Page 243: ...gement object in protection field The truck stops Off Warning field clear no object in warning field The truck can move at the maximum speed setting Lit Warning field infringement object in warning field The truck decelerates to 2 5 km h and will only travel at this speed Off Front screen clean The truck can move at the maximum speed setting Lit Front screen contaminated Operation inhibited Clean ...

Page 244: ...turer s customer service department The manufacturer has a customer service department specially trained for these tasks In order for customer services to respond quickly and specifically to the fault the following information is essential Truck serial number Error number from the seven segment display if available Description of the error Current location of truck 242 04 19 en GB ...

Page 245: ... you to perform the cycle test During this time the travel speed is restricted to slow travel 2 5 km h uThe speed restriction is only removed when the cycle test has been performed Cycle test Procedure Switch off the truck Switch on the truck Z When the truck is switched on the display unit shows the Acknowledge cycle test symbols 130 191 Press 104 under the Acknowledge cycle test symbol 191 The t...

Page 246: ...ruck for operation see page 138 or see page 139 Drive the truck into the narrow aisle and establish automatic guidance see page 159 192 104 22 20 Obstacles and or persons in the PPS warning field The driver s display shows the Warning field infringement symbol 192 The travel speed is restricted to 2 5 km h The obstacle or person are no longer in the warning field The truck can travel again at the ...

Page 247: ... see page 139 Drive the truck into the narrow aisle and establish automatic guidance see page 159 Procedure WARNING Risk of accidents and injury from the truck Travel cutout override is an additional function to ensure the position of the truck can be adjusted despite a protection field infringement However it does not release the operator from his responsibility to bring the truck to a halt in go...

Page 248: ...without restriction over a certain distance or for a certain time in the set direction The maximum travel speed is restricted to 2 5 km h The setting for continued travel after encountering obstacles and or persons located in the PSS protection field is made by the manufacturer s customer service department 246 04 19 en GB ...

Page 249: ...ft the forks to the right Turn the hydraulic functions control lever 113 clockwise To shift the forks to the left Turn the hydraulic functions control lever 113 anticlockwise Attachment is in the right hand home position i e the fork carriage is at the right end of the swivel traverse frame and the forks are facing left To shift the forks in the load direction Turn the hydraulic functions control ...

Page 250: ...248 04 19 en GB ...

Page 251: ... on the button 104 under the Fork adjustment symbol 195 To reduce the fork spread Turn the Hydraulic functions control lever 113 clockwise To increase the fork spread Turn the Hydraulic functions control lever 113 anti clockwise Z The traverse speed of the fork spread is in proportion to the movement of the Hydraulic functions control lever 113 The fork spread is reduced or increased 113 20 104 19...

Page 252: ...and sideshifter do not enter into the contour of the truck The fork positioner can move the forks beyond the swivel traverse frame and thus damage the truck uTo avoid injury to personnel and damage to the truck and load trained operators must handle the attachment with particular care uStop hydraulic movements of the sideshifter with integrated fork positioner before the truck contour has been rea...

Page 253: ...ead Turn the Hydraulic functions control lever 113 clockwise To increase the fork spread Turn the Hydraulic functions control lever 113 anti clockwise Z The traverse speed of the fork spread is in proportion to the movement of the Hydraulic functions control lever 113 The fork spread is reduced or increased 113 20 104 195 Procedure Do not press the dead man s switch 20 Press and hold down the key ...

Page 254: ...nticlockwise Attachment is in the left hand home position i e the fork carriage is at the left end of the swivel traverse frame and the forks are facing right To shift the forks in the drive direction Turn the hydraulic functions control lever 113 clockwise To shift the forks in the load direction Turn the hydraulic functions control lever 113 anticlockwise Z The traverse speed of the forks is pro...

Page 255: ...ise damage to the eyes or retina can be caused if it comes into direct eye contact uDo not look into the laser beam 13 11 The laser beam rack compartment display indicates the correct position of the truck with respect to the rack compartment It is a spot light 13 which can be attached to one or both sides of the overhead guard 11 The truck is correctly positioned with respect to the rack compartm...

Page 256: ...tachment can be hazardous Check the attachment daily for external signs of damage or defects Faulty attachments can cause the load to fall uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault Z Maintenance intervals are specified in the section Maintenance Inspection and C...

Page 257: ...control lever 113 anticlockwise To extend to the right Turn the hydraulic functions control lever 113 clockwise To retract the telescopic forks To retract to the right Turn the hydraulic functions control lever 113 clockwise To retract to the left Turn the hydraulic functions control lever 113 anticlockwise Z The extending and retracting speed of the telescoping forks is proportional to the moveme...

Page 258: ...matically see page 177 The second stacking depth has been reached Retract the attachment to the left or right it stops automatically see page 177 The first stacking depth has been reached Press the key 104 under the symbol 2nd stacking depth 198 symbol changes to the normal display mode inactive mode Traverse attachment to the right or left to the home position see page 177 Right or left home posi...

Page 259: ...an be displayed User specific settings can be changed Master access code with change rights to user specific settings for the selected user access code User specific settings for the selected user access code can be displayed User specific settings for the selected user access code can be changed The master can determine for new or inexperienced users user access code without rights the maximum se...

Page 260: ...n lift lifting speed V Main lift lowering speed V Sideshift speed V 8 4 3 Changing the user specific settings Select the Operator specific settings menu Requirements Prepare the truck for operation see page 138 or see page 139 Procedure Press the Quit sub menu button 108 The Warnings sub menu item 172 appears in the driver s display Z Truck operations are inhibited in this menu Press the button 10...

Page 261: ...The Operator specific settings menu now opens 259 04 19 en GB ...

Page 262: ...settings menu Press 104 under the Other functions symbol 201 The driver s display shows other functions for the user specific settings see page 258 Press 104 under the Previous functions symbol 200 The driver s display shows the previous functions for the user specific settings see page 258 112 156 152 157 150 151 108 104 201 200 260 04 19 en GB ...

Page 263: ...ions from 1 weak to 8 strong This allows individual settings to be made within a pre defined area in the program Cursor key 150 weaken the setting Cursor key 152 strengthen the setting Press OK on the numerical keypad 112 to save the settings Press the Quit sub menu key 108 The driver s display shows the current date and time 112 156 152 157 150 151 108 202 104 261 04 19 en GB ...

Page 264: ...functions menu 104 158 CAUTION Altering settings for the travel and hydraulic functions can result in accidents Increasing the settings for travel and hydraulic functions can result in accidents uCarry out a test run in a secure environment uThis requires greater attention on the part of the operator 262 04 19 en GB ...

Page 265: ...ck Press the CE key 154 to cancel entering the 5 digit access code Press OK 153 and confirm the access code entry Under the master access code entered you will be prompted to enter the user access code Enter the user access code Press the Select key 151 in the cursor field Enter your 5 digit access code with the numerical keypad 112 The cursor keys 150 152 can be used to enter each digit of the 5 ...

Page 266: ... fire to spread and hence injure the operator uThe proprietor is responsible for choosing suitable extinguishing agents and fire extinguishers uThe fire extinguisher must comply with national regulations Z The fire extinguisher 205 is mounted on the left hand column of the overhead guard 205 204 203 Procedure Open the latch 204 Pull the fire extinguisher 205 out of its bracket 203 see arrow direct...

Page 267: ...wing symbols are shown in the driver s display Symbol Function Attachment Attachment in home position without load Attachment in home position with load Lifting or lowering an attachment without load Lifting or lowering an attachment with load Traversing an attachment to the left or right without load Traversing an attachment to the left or right with load Zone selection Area selection Z A load se...

Page 268: ...for operation see page 138 or see page 139 Drive the truck into the narrow aisle and establish automatic guidance see page 159 Procedure Press the Select button 151 in the cursor field Using the numerical keypad 112 enter the area If an incorrect entry is made it can be deleted by pressing the CE button on the numerical keypad 112 Press OK on the numerical keypad 112 to save the area entry The ent...

Page 269: ... and the second a unit For a 3 digit entry the first number entered is a multiple of one hundred the second a multiple of ten and the third a unit If an incorrect entry is made it can be deleted by pressing the CE key on the numerical keypad 112 Press OK on the numerical keypad 112 to save the area entry The entered rack number 207 is now shown above the fork in the driver s display An arrow 207 i...

Page 270: ...edure Using the numerical keypad 112 enter the area 206 see page 266 Using the numerical keypad 112 enter the rack number 207 see page 267 Z Depending on the current lift height an arrow is shown on the driver s display next to the rack number that has been entered This arrow indicates whether the Main Lift needs to be raised or lowered to reach the warehouse location 112 156 152 157 150 151 113 2...

Page 271: ... the positioning process this is displayed for approx 1 second and stored in an intermediate log On reaching the current warehouse location the rack number is automatically transferred from the intermediate log and can be approached as detailed above The rack number entered has now been reached 112 156 152 157 150 151 113 22 20 207 206 Z The warehouse location approach can be cancelled by pressing...

Page 272: ... do this To approach the required height manually t The Hydraulic functions control lever 113 must be pressed and held down until the required height has been reached automatic stop Z The lift and lower speeds are in proportion to the movement of the Hydraulic functions control lever 113 Z The warehouse location approach can be cancelled by pressing the CE button on the numerical keypad or by pres...

Page 273: ...ed The rest of the hydraulic operation is performed automatically Z The lift and lower speeds are in proportion to the movement of the Hydraulic functions control lever 113 Z The warehouse location approach can be cancelled by pressing the CE button on the numerical keypad or by pressing the EMERGENCY DISCONNECT switch 112 113 120 20 119 271 04 19 en GB ...

Page 274: ...e desired direction The desired height is then automatically approached Z The lift and lowering speeds are fixed and cannot be influenced Z The warehouse location approach can be cancelled by pressing the CE button on the numerical keypad or by pressing the EMERGENCY DISCONNECT switch 112 113 120 20 119 272 04 19 en GB ...

Page 275: ...65 Press the accelerator pedal 22 The nominal height is then approached automatically in the optimum manner depending on how far away the warehouse location is Z The lifting and lowering speeds are fixed and cannot be influenced The travel speed can be controlled with the accelerator pedal Z The warehouse location approach can be cancelled by pressing the CE button on the numerical keypad or by pr...

Page 276: ...owing stacking options are available for stacking operations Z The following types of stacking operation are set up by the manufacturer s specialist customer service personnel who have been trained to do this Stacking procedure not active Press the deadman button 20 When the selected height is reached the Rack Height Select order disappears from the driver s display Do not press the deadman button...

Page 277: ...rminal is only issued when the attachment has left and then returned to the home position During the positioning procedure another compartment can be entered This entry is shown for approx 1 sec in the driver s display and stored in the cache After stacking the shelf is automatically taken from the intermediate log Z The stacking operation can be cancelled by pressing the CE button on the numerica...

Page 278: ...an follow if the Hydraulic functions control lever 113 is in neutral Z The hydraulic speeds are in proportion to the movement of the Hydraulic functions control lever 113 During the positioning procedure another compartment can be entered This entry is shown for approx 1 sec in the driver s display and stored in the cache After stacking the shelf is automatically taken from the intermediate log Z ...

Page 279: ...s control lever 113 clockwise and hold it down until the operation is complete Z The hydraulic speeds are fixed and cannot be influenced The hydraulic functions stop when the hydraulic functions control lever 113 is released The stacking operation continues when the hydraulic functions control lever 113 is actuated again During the positioning procedure another compartment can be entered This entr...

Page 280: ...hydraulic functions stop when the hydraulic functions control lever 113 is released The stacking operation continues when the hydraulic functions control lever 113 is actuated again Pressing one of the attachment traverse 120 or fork carriage rotate 119 keys cancels the automatic stacking operation The driver is notified of this via an audible signal After the cancellation the operator must comple...

Page 281: ... lever 113 anticlockwise Rest time active When stacking after the attachment has been extended there is an pause to reduce mast vibration Press the dead man s switch 20 Hydraulic functions control lever 113 turn clockwise Lift retrieve turn anticlockwise Lower stack Do not press the dead man s switch 20 Traverse attachment to the right to the home position Press and hold down on attachment travers...

Page 282: ...tacking operation can be cancelled by pressing the CE button on the numerical keypad 112 or by pressing the emergency disconnect switch No order processed message is sent to the truck terminal 280 04 19 en GB ...

Page 283: ...the manufacturer s customer service department To achieve constant stacking depths widths over the entire lift height ten height dependent traverse adjustment values can be programmed as an option The setting is made by the manufacturer s customer service department When entering the narrow aisle the narrow aisle and the position of the load handler are checked Options Manual entry of destination ...

Page 284: ...ertical position of the warehouse location entered is the height of the forks This ensures that the required pallet is stacked or retrieved The horizontal position of the warehouse location entered is the centre of the load handler This ensures that the required pallet is stacked or retrieved 282 04 19 en GB ...

Page 285: ... 219 220 224 223 225 226 222 221 212 213 214 215 Item Symbol Function Description 208 Truck detected in narrow aisle transponder 209 The travel in drive direction symbol indicates that a horizontal adjustment in the drive direction is required to reach the destination 210 The travel in load direction symbol indicates that a horizontal adjustment is required in load direction to reach the destinati...

Page 286: ...lift heights Single digit entry only 218 Rack row display The entry can be one two or three digit 219 Location marker display Horizontal position in narrow aisle The entry can be one two or three digit 220 Rack height Rack display Lift height vertical position in narrow aisle The entry can be one two or three digit 221 Warning symbol see page 285 222 Question mark symbol see page 285 223 Lightning...

Page 287: ...ontrol lever Select the correct direction for the stacking operation with the hydraulic functions control lever The forks warning symbol flashes as long as the wrong direction is selected 212 213 Forks attachment are not in the correct position for the stacking operation requested error in stacking operation Rotate and traverse the forks and attachment in the directed displayed The forks warning s...

Page 288: ...rmed until the attachment is in the home position The warning symbol lights up 221 Incorrect checksum on data entry The order cannot be carried out Re enter the data or amend the order The warning symbol flashes until the order is deleted Orders cannot be entered as there is already an order in the memory The order entry is blocked Carry out the existing order Faulty data transmission The order is...

Page 289: ...oad on the load handler Symbols in storage mode with attachment Symbol Function Attachment in home position without load with load Without load lower lift to reach the warehouse location With load lower lift to reach the warehouse location Without load traverse the attachment to the left right With load traverse the attachment to the left right Rest time without with load 132 287 04 19 en GB ...

Page 290: ...ehouse management system transmits the required destination to the truck terminal by radio Warehouse destination manual entry default setting Z The position of the symbols can be adapted to customer requirements The setting is made by the manufacturer s customer service department In this case the positions rack row location marker compartment height and zone must be entered so as to match the sym...

Page 291: ... The entry in the location marker field 219 can have one two or three digits Press the cursor key 152 The background of the rack height field 220 goes dark Enter the required rack height with the numerical keypad 112 The entry in the rack height field 220 can have one two or three digits Press the cursor key 152 The background of the zone selection area selection field 217 goes dark Enter the requ...

Page 292: ...tored in the truck s memory In this case the order in memory symbol 216 is shown in the driver s display When the current order has been processed it is deleted from the driver s display and any order stored in the memory is displayed An order shown on the driver s display can be deleted by pressing the CE button twice on the numerical keypad 112 216 112 20 22 113 290 04 19 en GB ...

Page 293: ... maximum of two orders can be stored in the truck s memory The destination scanned in first is shown on the driver s display as the current order The second destination scanned in is stored in the truck s memory In this case the order in memory symbol 216 is shown in the driver s display When the current order has been processed it is deleted from the driver s display and any order stored in the m...

Page 294: ... with the truck terminal is now complete The destination can now be approached When the current order has been processed it is deleted from the driver s display Feedback is sent from the industrial truck to the truck terminal Subsequently another destination sent to the truck terminal from the warehouse management system via radio data transmission can be received and appears in the driver s displ...

Page 295: ...mbol 209 is displayed Pushing the travel direction switch 105 to the left travel in drive direction Slowly apply the accelerator pedal 22 Travel in the load direction if the travel in load direction symbol 210 is displayed Pushing the travel direction switch 105 to the right travel in load direction Slowly apply the accelerator pedal 22 Z The travel speed is infinitely controlled by the accelerato...

Page 296: ...3 anti clockwise Z Continue to apply the Hydraulic functions control lever 113 until you reach the required height The vertical position of the warehouse location has now been reached The operator can start to stack and retrieve goods 227 228 112 20 22 113 Z The entered warehouse location can also be approached through diagonal travel simultaneous travel and lifting lowering of the Main Lift For d...

Page 297: ...when the travel in load direction symbol 210 is displayed Slowly apply the accelerator pedal 22 Z The travel speed is infinitely controlled by the accelerator pedal 22 The further the accelerator pedal 22 is pressed the greater the travel speed The industrial truck begins automatic horizontal and vertical destination approach Z Truck movement can be interrupted by releasing the accelerator pedal 2...

Page 298: ...y with the Main Lift the weight is shown on the driver s display in kg 131 see page 171 NOTICE The weighing system is not a substitute for a calibrated weigher 8 8 1 Tare function o Z The weighing system can optionally be equipped with tare function The tare function sets the weigher display to zero 131 296 04 19 en GB ...

Page 299: ...allowed when in this menu The driver s display shows the weighing system display zero setting symbol 230 Press the 104 key under the weighing system display zero setting symbol 230 The weight measurement in the driver s display is zero 131 Press key 104 under the truck functions symbol 158 Z The driver s display changes to the truck functions menu Fully lower the load handler Turn the hydraulic fu...

Page 300: ...ign the camera so that the hidden work area can be seen Z When using the camera to reverse the monitor automatically switches on when you set the travel direction switch to travel in drive direction NOTICE Risk of material damage when working with visual aids Should you need visual aids monitors etc to ensure adequate visibility practice working with them beforehand 298 04 19 en GB ...

Page 301: ...settings Press the button 231 to open the menu Z Pressing the button several times changes the menu item contrast brightness colour saturation language video light reflection or quits the menu Adjusting the menu items Press the button 233 to go one step forward Press the button 232 to go one step back Z Clean a dirty screen or vent slots with a soft cloth or brush 299 04 19 en GB ...

Page 302: ...platforms can be hazardous Do not use work platforms that have not been approved for this truck Unsuitable work platforms can slide off the load handler and fall when the truck is being operated uUse only work platforms that have been approved by the manufacturer uThe work platform must be connected both mechanically and electrically to the truck at all times during operation Z When operating the ...

Page 303: ...ey to open the door in emergencies 237 Handles two handed operation 238 Connecting cable between work platform and truck 239 Door 240 Operator platform 241 Fork shoes 242 Work platform for the standard attachment 243 Work platform lock 244 Stop on the attachment of the truck 301 04 19 en GB ...

Page 304: ...ck by the manufacturer Procedure Check the work platform for damage before use Check the lock 243 on the work platform is present and check for damage Close the gate 239 Z The work platform must be lifted in such a way that at all times during travel lifting or lowering eye contact is maintained between the driver and the person in the work platform Before lifting the work platform make sure there...

Page 305: ...rk platform raised securely symbol appears in the driver s display The raised and locked work platform is monitored by non contact sensors Slowly retract the forks and work platform back to the home position Attach the connecting cable 238 of the work platform to the truck Z When the truck and work platform have been connected electrically the truck can only travel and or carry out hydraulic opera...

Page 306: ... out and decommission a faulty lift truck uOnly return the work platform to service when you have identified and rectified the fault WARNING Work platforms can be hazardous When operating the work platform the person in the platform is at risk from falling uClose the work platform gate during operation uGrab the work platform handles two hand compulsion with both hands while the truck is travellin...

Page 307: ...rm to fall and injure people inside the work platform Objects falling out of the work platform can injure the operator of the truck or damage the truck uBefore operating the work platform make sure there are no objects protruding out of it uBefore operating the work platform make sure that any objects inside are secured correctly NOTICE The maximum load for the work platform umust not be exceeded ...

Page 308: ...the work platform Close the work platform gate 239 Z While the truck is in operation the work platform attachment and the closed gate 239 are permanently monitored Opening the gate 239 will cause travel and or hydraulic operations to stop Person has stepped onto the work platform Raise lower and or transport a person in the work platform Grab the work platform handles 237 two hand compulsion with ...

Page 309: ...le in a raised position uThe operator must never leave the truck while the work platform is in operation Destination reached The person in the work platform can commence operation Leaving the work platform Lower the work platform to the ground Press the Gate opener switch on the work platform Open the work platform gate 239 Leave the work platform Close the work platform gate 239 Person has left t...

Page 310: ...of the ground Disconnect the work platform electrically from the truck Remove the connecting cable 238 and hang it in the work platform Fully extend the attachment and work platform Lower the forks until they are no longer in contact with the work platform The mechanical lock 243 of the work platform is disconnected from the stop on the load handler 244 Retract the forks to their home position The...

Page 311: ...8 11 ISM access module o Z If the truck is equipped with an ISM access module refer to the ISM Access Module operator manual 309 04 19 en GB ...

Page 312: ...w aisle Lift height h3 Safety clearance Wire guided truck depending on the lift height h3 125 mm Rail guided truck to 4000 mm 90 mm to 6000 mm 100 mm from 6000 mm 125 mm NOTICE Risk of collision if the rear view mirror is incorrectly adjusted Incorrectly adjusted rear view mirrors can collide with the racking or the goods when operating in the narrow aisle uAdjust rear view mirrors so that the cle...

Page 313: ...e are forewarned of the approaching truck This avoids accidents when exiting the narrow aisle at interchanges and other warehouse areas with restricted visibility CAUTION Risk of accident due to restricted view Looking directly at the LED light can dazzle and temporarily impair eyesight uDo not look directly at the LED light uPractise travelling and working with the floor spot carefully uDo not ch...

Page 314: ...he warning notice Caution Potentially dangerous optical radiation is present and legible and replace if necessary uDo not look directly into the light beam of the Floor Spot uWhen performing maintenance and repairs take the Floor Spot out of service e g by disconnecting the battery and secure it against unintentional recommissioning Z The warning notice 245 is attached to the overhead guard or mas...

Page 315: ...8 13 2 List of assemblies for Floor Spot 246 247 Item Description 246 o Floor Spot in the load direction 247 o Floor Spot in the drive direction 313 04 19 en GB ...

Page 316: ...ng stationary Floor Spot 246 and Floor Spot 247 are switched off Truck travels in drive or load direction Truck travel function Function of the Floor Spot Truck travels in drive direction Floor Spot 247 is switched on Floor Spot 246 is switched off Truck travels in load direction Floor Spot 246 is switched on Floor Spot 247 is switched off 314 04 19 en GB ...

Page 317: ...or Spot 247 is switched on Floor Spot 246 is switched off Truck travels in load direction Floor Spot 246 is switched on Floor Spot 247 is switched off Travel within narrow aisle narrow aisle with end of aisle safety device Truck travel function Function of the Floor Spot Guided truck travels between end of aisle safety device areas in drive direction Floor Spot 246 and Floor Spot 247 are switched ...

Page 318: ... passes over the end of aisle safety device in the drive direction Floor Spot 247 is switched on Floor Spot 246 is switched off Guided truck passes over the end of aisle safety device in the load direction Floor Spot 246 is switched on Floor Spot 247 is switched off Narrow aisle exit guided travel outside of the narrow aisle Truck travel function Function of the Floor Spot Guided truck exits the n...

Page 319: ... safety mechanisms is prohibited Exception Owners should only make changes or have changes made to powered industrial trucks if the truck manufacturer is no longer operating in the field and there is no successor to the business owners must however Ensure that the changes to be made are planned tested and performed by a specialist engineer in industrial trucks taking safety into account keep perma...

Page 320: ...urer 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 by similar components from other trucks of the same series Z On completion of inspection and service work carry out the operations listed in the Recommissioning the truck after cleaning or maintena...

Page 321: ...ups Operating company The maintenance personal of the operating company has the technical expertise and experience to perform the activities in the maintenance check list for the operating company The maintenance and repair work to be performed by the operating company are also written down see page 330 Customer Services Customer Services are specially trained in the use of the truck and are able ...

Page 322: ...ical system uBefore working on the electrical system take all precautionary measures to avoid electric shocks uPark the truck securely see page 191 uDisconnect the battery uRemove any rings metal wrist bands etc 2 2 Consumables and used parts CAUTION Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental...

Page 323: ...ts Otherwise the manufacturer s specification will not be adhered to Wheel flattening If the truck has been parked for a long period the wheel surfaces may tend to flatten This flattening has a negative effect on the safety and stability of the truck Once the truck has covered a certain distance the flattening will disappear 2 4 Attachment Repairs and Inspection WARNING A faulty attachment can be ...

Page 324: ...ft chains Replace a chain immediately if it shows external signs of damage Damage will result in permanent breakage and hence tearing of the lift chain uReport any defects immediately to your supervisor uTag out and decommission a faulty lift truck uLift chains must only be replaced by the manufacturer s customer service department which has been specially trained uOnly return the truck to service...

Page 325: ...two chains uWhen replacing chains the connecting bolts between the chain anchor and the chain must be replaced uAlways use new original parts uLift chains must only be replaced by the manufacturer s customer service department which has been specially trained Z The manufacturer has a service department specially trained for these tasks 323 04 19 en GB ...

Page 326: ...ture must be disposed of in accordance with regulations WARNING Faulty hydraulic hoses can result in injury and infection Pressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulic hoses Brittle hydraulic hoses can burst during operation People standing near the truck can be injured by the hydraulic oil uCall for a doctor immediately in the event of an injury uDo not ...

Page 327: ...replace if necessary uIf the operating conditions become more arduous the inspection intervals must be reduced accordingly uIn normal operating conditions a precautionary replacement of the hydraulic hoses is recommended after 6 years The owner must carry out a risk assessment to ensure safe prolonged use The resulting protection measures must be observed and the inspection interval reduced accord...

Page 328: ...d containers uAlways fill consumables in clean containers uDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the operating instructions CAUTION Spilled consumables can cause slipping and endanger the environment Risk of slipping from spilled consumables The risk is greater when combined with water uDo not spill consumables uSpilled co...

Page 329: ...t smoke when handling oil uAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has come into contact with your skin rinse your skin with water uIf oil has come into contact with your eyes rinse them with water and seek medical assistance immediately uReplace oil soaked clothing...

Page 330: ...Schedule E C E C D C C B A F F E E C E C C C C C C C g Contact surfaces c Hydraulic oil drain plug s Grease nipple b Transmission oil filler neck Hydraulic oil filler neck a Transmission oil drain plug 328 04 19 en GB ...

Page 331: ... 002 004 400 ml Contact spray grease Running surfaces F 51 085 365 500 ml All purpose cleaner Laser scanner of personal protection system PPS 51 085 537 1 unit Cleaning cloth Add a 2 content of Additiv 68 ID to the hydraulic oil order number 50 307 735 WARNING Industrial trucks are factory equipped with hydraulic oil HLP D22 or BIO hydraulic oil Plantohyd 22 S 2 Additiv 68 ID You cannot change fro...

Page 332: ...4 Maintenance and repairs 4 1 Preparing the truck for maintenance and repairs 8 9 33 330 04 19 en GB ...

Page 333: ...ad handler Park the truck securely see page 191 Switch off the truck to do this Turn the key in the key switch 8 to the left as far as the stop and remove the key Press the red button of the ISM access module o twice in a row Press the emergency disconnect switch 9 Disconnect the battery connector 33 to prevent the truck from being switched on accidentally 331 04 19 en GB ...

Page 334: ...ng gear at the points specially provided for this purpose uNote the weight of the truck on the data plate uAlways use a jack with a minimum capacity of 5000 kg kg uRaise the unladen truck on a level surface uWhen raising the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks 332 04 19 en GB ...

Page 335: ... repairs see page 330 Tools and Material Required Jack Hard wooden blocks Procedure Place the jack against the contact point Z Jack contact point see page 43 Raise the truck Support the truck with hard wooden blocks Remove the jack The truck is now securely raised and jacked up 333 04 19 en GB ...

Page 336: ... the truck for maintenance and repairs see page 330 Tools and Material Required Slot screwdriver to loosen the screws 248 Procedure Remove the two slotted head screws 248 using the slot screwdriver Tilt the cover 35 back and lift it away The drive compartment cover has been removed 248 35 334 04 19 en GB ...

Page 337: ...over uMake sure there is nothing between the cover and the truck when fitting the cover Close the drive compartment cover Tools and Material Required Slot screwdriver to tighten the screws 248 Procedure Insert the cover 35 at an angle into the chassis and tilt it forward Attach the cover 35 to the truck with the slotted screws 248 Tighten the slotted screws 248 using the slot screwdriver The drive...

Page 338: ...ical system take all precautionary measures to avoid electric shocks uPark the truck securely see page 191 uDisconnect the battery uRemove any rings metal wrist bands etc CAUTION The use of incorrect fuses can cause fire and damage components The use of incorrect fuses can damage the electrical system and result in fire The safety and functionality of the truck cannot be ensured uUse only fuses wi...

Page 339: ...troller 256 Pull the fuses 249 255 and their brackets out of the controller 256 Check the fuses 249 255 in accordance with the following table and replace as required Insert the fuses 249 255 and their brackets into the controller 256 Using the slotted screwdriver turn each fuse 249 255 clockwise into the controller 256 Assemble the drive compartment cover see page 334 337 04 19 en GB ...

Page 340: ...code scanner radio terminal etc 10 A 251 F1 2 Control panel and horn control fuse 10 A 252 5F1 Overhead guard control fuse e g working lights operator s compartment lighting etc 10 A 253 F2 1 Internal DC DC converter control fuse 10 A 254 7F3 DC DC converter control fuse 10 A 255 1F3 Three phase controller U8 control fuse 10 A 256 Three phase controller U8 257 Controller display 338 04 19 en GB ...

Page 341: ... Load circuit Controller active Display status when truck is switched on When the truck is switched on the displays indicated grey are lit green If one of the displays A1 A3 A4 A5 B2 B3 B4 is not lit replace the corresponding fuse The other displays reflect truck specific operating conditions The controller on displays A9 B6 B9 flash when the truck is ready for operation 1 2 3 4 5 6 7 8 9 A B 1 2 ...

Page 342: ...aning e g by short circuiting CAUTION Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity uCover all electronic system assemblies controllers sensors motors etc before cleaning the truck with a pressure washer uDo not hold the jet of the pressure washer by the marked points to avoid damaging them see page 43 uDo not clean the ...

Page 343: ...ed solvents and water Use a sponge or cloth to clean In particular clean the following areas Windows All walk on areas Oil filler ports and their surroundings Grease nipples before lubrication Dry the truck after cleaning e g with compressed air or a dry cloth Carry out all the tasks in the section Recommissioning the truck after cleaning or maintenance work see page 350 The truck is now clean 341...

Page 344: ...electrical system assemblies Requirements Prepare the truck for maintenance and repairs see page 330 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure Expose the electrical system see page 334 Clean the electrical system assemblies with weak suction or compressed air use a compressor with a water trap and not a conductive anti static brush Fit th...

Page 345: ...ofibre cloth or a new soft paper towel NOTICE Cleaning can damage the front screen Do not use dirty or large fibre cleaning cloths as these can scratch the front screen A scratched front screen will lead to faults so that the sensor will have to be replaced After cleaning hold a light or torch against the front screen Check for any contamination or scratches on the front screen and clean again if ...

Page 346: ...doctor uWear personal protective equipment e g safety boots hi vis jacket goggles work gloves etc when working with solvents Z The intervals stated in the service checklist apply to normal duty use More demanding conditions dust temperature require more regular lubrication of the lift chains The prescribed chain spray must be used in accordance with the instructions Applying grease externally will...

Page 347: ...strial truck uNever reach or climb into moving truck parts uNever stand underneath a raised load handler Position the work platform lifting platform or safety ladder directly next to the industrial truck From your position on the work platform lifting platform or safety ladder Lubricate lift chains Clean the running faces in the mast sections and apply grease Z Lubrication diagram see page 328 Lub...

Page 348: ...isposed of in accordance with regulations uObserve national regulations when handling hydraulic oil uWear safety gloves when handling hydraulic oil uPrevent hydraulic oil from coming into contact with hot motor parts uDo not smoke when handling hydraulic oil uAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately uSeek fresh air after breathin...

Page 349: ... spilled hydraulic immediately with an appropriate bonding agent uThe bonding agent consumable mixture must be disposed of in accordance with regulations CAUTION Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations To change the oil contact the manufacturer s customer service dep...

Page 350: ...e hydraulic reservoir can result in accidents and damage the environment The hydraulic oil should not be above the MAX marking on the dipstick as any oil leakage can damage the environment and cause truck malfunctions The escaping hydraulic oil could run under the drive wheel for example and increase the truck s stopping distance as well as affect its handling uAdd hydraulic oil only up to the MAX...

Page 351: ... on the hydraulic reservoir Add hydraulic oil In this case you may only use hydraulic oil HLP D22 with a 2 share of Additiv 68 ID to fill the hydraulic reservoir WARNING You cannot change from BIO hydraulic oil Plantohyd 22 S to hydraulic oil HLP D22 The same applies to changing from hydraulic oil HLP D22 to bio hydraulic oil Plantohyd 22 S Mixed operation with hydraulic oil HLP D22 and BIO hydrau...

Page 352: ...eparing the truck for operation see page 117 Prepare the truck for operation see page 138 or see page 139 WARNING After cleaning or maintenance work test all the safety mechanisms to ensure they are working correctly Test the safety mechanisms see page 145 WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times uReport any defects immediately t...

Page 353: ...decommissioning as described hereafter 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 Z Jack up the truck see page 332 If the truck is to be out of service for more than 6 months agree further measures with the manufacturer s customer service department 351 04 1...

Page 354: ...vel and replenish if necessary see page 346 Apply a thin layer of oil or grease to any non painted mechanical components Lubricate the truck according to the lubrication schedule see page 328 Charge the battery see page 78 Disconnect the battery clean it and grease the terminals Z In addition follow the battery manufacturer s instructions 352 04 19 en GB ...

Page 355: ...l discharge can damage the battery Self discharge can cause the battery to fully discharge Full discharge shortens the useful life of the battery uCharge the battery at least every 2 months Z Charge the battery see page 78 353 04 19 en GB ...

Page 356: ...uld have formed Replace hydraulic oil Condensation water could have formed Z The manufacturer s customer service department is specially trained to carry out these operations Start up the truck see page 117 WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times uReport any defects immediately to your supervisor uTag out and decommission the fa...

Page 357: ...d inspector The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose A complete test must be carried out on the technical condition of the truck with regard to safety The truck must also be examined thoroughly for damage The operating company is responsible for ensuring that faults are rectified immediately 355 04 19 en GB ...

Page 358: ...trained personnel in accordance with the procedures as specified by the manufacturer 8 Human vibration measurement Z Vibrations that affect the operator over the course of the day are known as human vibrations Excessive human vibrations will cause the operator long term health problems The European 2002 44 EC Vibration operator directive has therefore been established to protect operators To help ...

Page 359: ...ruck have a considerable impact on component wear The following service inspection and replacement intervals are based on single shift operation under normal operating conditions The intervals must be reduced accordingly if more stringent requirements are placed on the equipment e g use in conditions of extreme dust temperature fluctuations or multiple shifts uTo prevent damage due to wear the man...

Page 360: ...s but at least once a week 1 1 1 Maintenance contents 1 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains Clean the running faces in the mast sections and apply grease Correct the hydraulic oil level Clean and lubricate the gear racks 358 04 19 en GB ...

Page 361: ...gnition Load sensing Hydraulic operations Clean the sensors Swivel traverse frame Hydraulic operations Clean and lubricate the attachment End of aisle safety device visual Electrical system Clean the optical sensors Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised ...

Page 362: ...ry connector and for damage Travel Wheels for wear and damage Chassis structure Industrial truck for damage and leaks Labels are legible complete and plausible The secure seating of the driver s seat and the function of the adjustment mechanism Doors and or covers for damage The function of the battery panel gas strut and for damage Protective mechanism against trapping and shearing is present sec...

Page 363: ... Support columns Tilt safety devices Chassis structure Supports tilt safety devices are present and for damage Optional equipment Chassis structure The function of optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc and for damage Strobe light beacon Electrical system Strobe light warning beacon for function and damage Lead acid battery internati...

Page 364: ... and or relays Carry out a chassis insulation resistance test Power supply Adjust the battery latch Travel Clean the vent slots of the combined control unit Clean the sensors Correct the oil level or grease filling of the transmission Chassis structure Clean the air vents of the drive compartment covers Hydraulic operations Clean the sensors Test the sensors Adjust the slide pieces Adjust the load...

Page 365: ...ting and lowering speeds if necessary traversing rotating speeds for the correct value Agreed services Carry out a test run with the rated load or a customer specific load Clean the motor housing of the travel and lift motor Demonstration after maintenance Lubricate truck according to the lubrication diagram Steering Lubricate steering gear teeth or steering chain System components Test lift tract...

Page 366: ...ser scanner Test the warning and protective field areas of the Personal Protection System Rail guidance Travel Measure the distance between the guide rollers and the guide rails over the entire length of the rails Fork adjuster Hydraulic operations Adjust the attachment Clean and grease attachment bearings guides and stops The axial play of the front and rear rollers End of aisle safety device mag...

Page 367: ...detection function of the rack height select automatic stacking Data radio System components Clean the scanner and terminal Video system System components Clean the camera Clean the display Support columns Tilt safety devices Chassis structure Measure the height related and capacity related settings Swivel traverse frame Hydraulic operations Adjust eccentric bolts on the swivel traverse fork Adjus...

Page 368: ...nents Test the functions of the external Personal Protection System e g to ensure it is cut off by the activation frequency Lead acid battery international Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using demineralised water Lead acid battery Power supply Clean and grease the battery terminals Cl...

Page 369: ...e Power supply The function of the battery latch and battery attachment and for damage The function and secure seating of the battery connector and for damage Travel The function of the deadman switch and for damage The function and secure seating of the sensors and for damage Drivetrain bearings for wear and damage The drive support plate is secure and for damage Transmission for noise and leaks ...

Page 370: ...or wear and damage The secure seating of the cylinders and piston rods and for leaks and damage Lateral play of the mast sections and fork carriage Slides and stops for wear and damage Load chain mounting elements and chain pins for wear and damage Mast rollers and their running surfaces for wear and damage The function of the hydraulic system The secure seating of the hoses pipes and connections ...

Page 371: ...guidance Travel The fastening of the rail guidance The rail guidance and their bearings for wear and damage Battery refill system Power supply The function of the battery refill system and for leaks Fork adjuster Hydraulic operations Attachment bearings guides and stops for wear and damage Proper securing of the attachment to the truck and the load bearing components for secure fit and damage Slid...

Page 372: ...ecorder Electrical system The shock sensor data recorder is secure and for damage Data radio System components The function and secure seating of the scanner and terminal and for damage Fuse ratings The secure seating of the cables and for damage Video system System components The secure seating of the cables and for damage The function and secure seating of the camera and for damage The function ...

Page 373: ...the attachment and for damage Cylinder seals for leaks and damage The pistons and piston rods for wear and damage Electrical optional equipment Electrical system The function of the optional electrical equipment and for damage Optional equipment Chassis structure The function of optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc and for damage D...

Page 374: ...eating of the battery battery cables and cell connectors and for damage The presence of safety labels are present and for damage Lead acid battery Power supply The secure seating of the battery battery cables and cell connectors and for damage 372 04 19 en GB ...

Page 375: ...parts at the specified intervals 1 2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic oil additive 2000 12 Hydraulic system breather filter 2000 12 Hydraulic oil filter 2000 12 Hydraulic oil filter seal kit 2000 12 Transmission oil 2000 12 373 04 19 en GB ...

Page 376: ......

Page 377: ...ects of the equipment No guarantee of particular features of the traction battery should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are indicated by the following graphics DANGER Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury...

Page 378: ...6 EN 4 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com ...

Page 379: ...ted cells 17 5 1 Description 17 5 2 Operation 18 5 3 Servicing PzV and PzV BS lead acid batteries with sealed armour plated cells 21 6 Aquamatik water replenishment system 22 6 1 Water replenishment system design 22 6 2 Functional Description 23 6 3 Adding water 23 6 4 Water pressure 23 6 5 Filling time 24 6 6 Water quality 24 6 7 Battery tubing 24 6 8 Operating temperature 24 6 9 Cleaning measure...

Page 380: ...02 16 EN 6 ...

Page 381: ...ng with the battery or using electrolyte additives will invalidate the warranty Observe the instructions for maintaining the safety rating during operation for batteries in accordance with Ex I and Ex II see relevant certification 2 Data plate 1 3 7 9 11 5 2 4 8 6 13 12 14 10 1 Model battery name 2 Production week production year 3 Serial number 4 Supplier number 5 Rated voltage 6 Capacity 7 Numbe...

Page 382: ...02 16 EN 8 14 Safety instructions and warning information ...

Page 383: ...ing Keep away from naked flames and strong heat sources Always wear protective clothing e g safety goggles and safety gloves when working on cells and batteries Always wash your hands after completing the work Use only insulated tools Do not mechanically machine the battery strike crush compress notch dent or modify it in any way Hazardous electric voltage The metal parts of the battery cells are ...

Page 384: ...ncrease the electrolyte density The corresponding adjustment factor is 0 0007 kg l per K e g electrolyte density 1 28 kg l at 45 C corresponds to a density of 1 29 kg l at 30 C The electrolyte must comply with the purity regulations of DIN 43530 Part 2 Name Explanation PzS Lead acid battery with Standard armour plated cells and liquid electrolyte Battery cell width 198 mm PzB Lead acid battery wit...

Page 385: ...ge current C5 5h 5 Nominal electrolyte density1 1 Reached within the first 10 cycles 1 29 kg l 6 Nominal temperature2 2 Higher temperatures shorten the useful life lower temperatures reduce the available capacity 30 C 7 System rated electrolyte level up to Max electrolyte level marking Limit temperature3 3 Not permissible as operating temperature 55 C ...

Page 386: ...tive to negative and check that contacts on the battery terminal conducting system are secure Check the M10 terminal screws of the conductors and connectors are secure and if necessary torque to 23 1 Nm Charge the battery see page 13 Check the electrolyte level of each battery cell after charging and top up if necessary Open the plug 15 Z The electrolyte level should not be less than the Min elect...

Page 387: ...ted to the battery in terms of voltage charge capacity and battery technology Before charging check all cables and plug connections for visible signs of damage Ventilate the room in which the truck is being charged Battery cell surfaces must remain exposed during charging in order to ensure sufficient ventilation see truck operating instructions chapter D Charging the Battery Do not smoke and avoi...

Page 388: ... charger ensuring the terminals are connect positive to positive and negative to negative Switch on the charger The battery is charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compensation charging is used to ensure the useful life and maintain capacity after full discharge and repeated insu...

Page 389: ... suitable for the production of electrolyte 4 3 2 Daily Charge the battery after each discharge After charging check the electrolyte level of each battery cell and replenish as required Open the plug 15 If necessary add electrolyte with pure water up to the Max electrolyte level marking 17 Close the plug 15 Z The electrolyte level should not be less than the Min electrolyte marking 16 and must not...

Page 390: ... electrolyte density and the electrolyte temperature in all the cells Compare the results with the previous ones Z If you find significant differences compared with the previous measurements or differences between the cells contact the manufacturer s customer service department 4 3 5 Annually Measure the insulation resistance of the truck in accordance with EN 1175 1 Measure the insulation resista...

Page 391: ...electrolyte is sulphuric acid which is fixed in gel The density of the electrolyte cannot be measured 5 1 1 Battery nominal data Name Explanation PzV Lead acid battery with Standard closed armour plated cells and electrolyte in gel compound Battery cell width 198 mm PzV BS Lead acid battery with British Standard closed armour plated cells and electrolyte in gel compound Battery cell width 158 mm 1...

Page 392: ...rging can cause explosions The battery gives off a mixture of oxygen and hydrogen electrolytic gas during charging Gassing is a chemical process This gas mixture is highly explosive and must not be ignited Always disconnect the charger and truck before connecting or disconnecting the charger and battery The charger must be adapted to the battery in terms of voltage charge capacity and battery tech...

Page 393: ...ttery cell Always charge the battery with DC current All DIN 41773 charging procedures are permitted in the format approved by the manufacturer Always connect the battery to a charger that is appropriate to the size and type of the battery If necessary have the charger checked by the manufacturer s customer service department for suitability Do not exceed the limit curents in accordance with DIN E...

Page 394: ...d with 0 004 V C per C The battery is charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compensation charging is used to ensure the useful life and maintain capacity after full discharge and repeated insufficient charging Z Compensation charging should be carried out weekly Trickle charging B...

Page 395: ...ous ones Z Carry out the measurements after full charging and subsequent resting for at least 5 hours Z If you find significant differences compared with the previous measurements or differences between the cells contact the manufacturer s customer service department 5 3 4 Annually Measure the insulation resistance of the truck in accordance with EN 1175 1 Measure the insulation resistance of the ...

Page 396: ...ik water replenishment system 6 1 Water replenishment system design 18 Water container 19 Tap connection with ball cock 20 Flow indicator 21 Shut off cock 22 Locking coupling 23 Battery lock connector 18 19 20 21 22 23 3 m ...

Page 397: ... securely The plug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port 6 3 Adding water Water should be added to the batteries just before the battery is fully charged This ensures that the amount of water added is mixed with the electrolyte 6 4 Water pressure The water replenishment system must be operated with a water ...

Page 398: ...tubing of the individual plugs is in accordance with the existing electric circuit No changes should be made 6 8 Operating temperature Batteries with automatic water replenishment systems should only be stored in rooms with temperatures 0 C as otherwise the systems could freeze 6 9 Cleaning measures The plug systems must only be cleaned with purified water in accordance with DIN 43530 4 No parts o...

Page 399: ...t be checked and replaced if necessary Battery connection A hose is attached to the pump module which together with the charge leads is routed from the charger to the charging connector The air is passed on to the battery via the electrolyte circulation coupling ducts in the connector When routing make sure the hose is not bent Pressure monitoring module The electrolyte circulation pump is activat...

Page 400: ...ted to severe temperature fluctuations the electrolyte may flow back into the hose system Attach a separate coupling system to the air inlet line such as locking coupling to the battery side and through coupling to the air supply side Schematic illustration Electrolyte circulation on the battery and air supply via the charger ...

Page 401: ...close to a drainage system for processing the electrolytic rinsing water All health and safety as well as water and waste disposal regulations are observed when disposing of used electrolyte or rinsing water Protective goggles and clothing are worn Cell plugs are not removed or opened Clean the plastic components of the battery in particular the cell containers only with water or water based cloth...

Page 402: ...at the temperature does not exceed 60 C at a distance of 30cm behind the outlet nozzle Observe the maximum operating pressure of 50 bar Observe a minimum distance of 30 cm from the top of the battery The battery should be sprayed over its entire surface to avoid localised overheating Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the maximum battery surface tempera...

Page 403: ...f cells for PzV batteries If the battery is to be taken out of service for a long period 3 months it should as far as possible be charged to 50 of its charge level and stored in a dry room protected from frost 10 Troubleshooting If any faults are found on the battery or charger contact the manufacturer s customer service department immediately Z The operations required must be carried out by the m...

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