Jungheinrich ETX 513 Page 75 Operating Instructions Manual Download | Manualshive

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D Battery - Servicing, Recharging,

Replacement

1

Safety Regulations Governing the Handling of Lead-Acid

Batteries

Maintenance personnel

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

Fire protection

Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging there shall be no inflammable material or
lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand.

Battery maintenance

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

CAUTION!

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

Battery disposal

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

73

04.19 en-GB

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Summary of Contents for ETX 513

Page 1: ...ETX 513 ETX 515 03 11 Operating instructions 51190312 04 19 en GB ETX 513 ETX 515...

Page 2: ...2...

Page 3: ...13 ETX 515 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...

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

Page 5: ...lar 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 follo...

Page 6: ...ht 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...

Page 7: ...trical requirements 45 5 Identification points and data plates 46 5 1 Data plate 48 5 2 Truck capacity plate 49 5 3 Attachment capacity plate 50 5 4 Jack contact points 50 6 Stability 51 C Transport a...

Page 8: ...the Truck for Operation 124 3 1 Checks and operations to be performed before starting daily operation 124 3 2 Entry and exit 128 3 3 Setting up the operator position 128 4 Industrial Truck Operation 1...

Page 9: ...7 Rack Height Select o 262 8 8 Horizontal positioning o 276 8 9 Weighing system o 292 8 10 Camera system 294 8 11 Rear view mirror o 295 8 12 Working platform o 296 8 13 Floor Spot o 308 8 14 Fire ex...

Page 10: ...6 Safety tests to be performed at intervals and after unusual incidents 356 7 Final de commissioning disposal 357 8 Human vibration measurement 357 G Maintenance Inspection and Changing of Maintenance...

Page 11: ...ngheinrich 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 o...

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

Page 13: ...um load and load distance are indicated on the load chart and must not be exceeded The load must rest on the load handler or be lifted by an attachment approved by the manufacturer The load must rest...

Page 14: ...eatened by corrosion or excessive dust Furthermore the truck must not be operated in the vicinity of unprotected active components of electrical systems Operation in industrial and commercial environm...

Page 15: ...etween the swivel traverse frame and the rack as well as the stored goods the load handler and the rack as well as the stored goods the raised load and the rack as well as the stored goods Z The safet...

Page 16: ...rthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The proprietor must ensure that all users have read and understood these ope...

Page 17: ...d pick goods on level surfaces in accordance with 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 unstack...

Page 18: ...be increased 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 saf...

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

Page 20: ...p the load lowering speed in the event of a hydraulic system failure Deadman button After the truck is ready for operation see page 139 or see page 140 the deadman button in the footwell must be press...

Page 21: ...nd 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...

Page 22: ...idance mode 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 f...

Page 23: ...ion 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 func...

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 journey...

Page 25: ...ll as for stacking and retrieving With rack height select the drive can select the required lift height via a keypad Lifting automatically ends when the required lift height is reached Rack Height Sel...

Page 26: ...3 2 Assembly Overview 11 10 5 6 7 9 8 15 14 29 18 33 21 22 23 30 31 28 32 34 16 25 24 28 27 13 20 19 17 12 26 24 04 19 en GB...

Page 27: ...pedal 21 o Front sensor for wire guidance system not shown 22 o Front scanner for personal protection system not shown 23 t Fork tine 24 t Load wheel 25 o Rail guidance wheel attachment behind the loa...

Page 28: ...load free ranging 9 9 km h Travel speed without load RG 9 10 5 km h Travel speed with load RG 9 10 5 km h Travel speed without load WG 7 9 km h Travel speed without load WG 7 9 km h Lift speed withou...

Page 29: ...hout load WG 7 9 km h Travel speed without load WG 7 9 km h Lift speed without load 0 46 0 46 m s Lift speed with load 0 45 0 45 m s Lower speed without load 0 48 0 48 m s Lower speed with load 0 48 0...

Page 30: ...ions as per data plate 4 2 1 Dimensions of the ETX 513 ETX 515 with standard attachment W a b5 b3 b12 l1 l2 A st h 7 h 6 h 1 h 4 h 3 h 2 b 6 b 1 b 2 b 14 b 7 s m e D y x D z 1 m2 I6 I l8 l10 b8 r 28 0...

Page 31: ...7 Seat height approx 1360 approx 1360 mm Ast Working aisle width for pallets 1200 x 1000 1600 1600 mm Wa Turning radius 2135 2460 mm s Fork dimensions 40 50 mm e 120 120 mm l 1200 1200 mm Lowest posit...

Page 32: ...W a b5 b3 b12 l1 l2 A st h 7 h 6 h 1 h 4 h 3 h 2 b 6 b 1 b 2 b 14 b 7 s m e D y x D z 1 m2 I6 I l8 l10 b8 r 30 04 19 en GB...

Page 33: ...distance 903 760 mm I8 x Fork pivot point toothed rack distance 735 567 mm I10 Outrigger width 170 170 mm m1 Ground clearance below mast 80 80 mm m2 Ground clearance centre wheelbase 85 85 mm r Fork...

Page 34: ...4 2 2 Dimensions of ETX 513 T F ETX 513 T F with telescopic table z 32 04 19 en GB...

Page 35: ...approx 1360 mm Ast Working aisle width for pallets 1200 x 1000 1400 1450 mm Wa Turning radius 2135 2460 mm s Fork dimensions 60 60 mm e 180 180 mm l 1200 1200 mm Lowest position of flat telescopic for...

Page 36: ...z 34 04 19 en GB...

Page 37: ...m2 Ground clearance centre wheelbase 85 85 mm m3 Load handler ground clearance 25 25 mm Clear internal operator position height distance from operator position floor to bottom of overhead guard 1518 1...

Page 38: ...mast ZT Description ETX 513 ETX 515 h1 Mast height retracted 2570 5070 2670 5720 mm h3 Lift 3000 8000 3000 9000 mm h4 Mast height extended 4150 9150 4250 10250 mm h6 Overhead guard height 2461 2461 m...

Page 39: ...ETX 515 h1 Mast height retracted 2900 4700 3200 5800 mm h2 Free lift 1750 3550 1950 4550 mm h3 Lift 5500 10000 6000 13000 mm h4 Mast height extended 6650 11150 7250 14250 mm h6 Overhead guard height 2...

Page 40: ...ic truck mast weight including attachment 35 36 Basic truck weight excl battery Z The weight of the basic truck 36 is shown in the following table Truck Weight of basic truck ETX 513 2400 kg ETX 515 2...

Page 41: ...data plate see page 48 A Net weight of the industrial truck without battery B Mast weight including attachment Formula for the ETX 513 B A 2400 kg Formula for the ETX 515 B A 2500 kg Example Required...

Page 42: ...t load at front 38101 43502 Axle load without load at rear 27301 31802 Battery type used 3 PzS 465 5 PzS 775 Z The data listed in the table performance data dimensions and weights are based on a truck...

Page 43: ...ed by a customer service organisation authorised by the manufacturer ETX 513 Description ETX 513 Tyres Vulkollan Wheels front load wheel 295 mm x 144 mm Wheels rear drive wheel 400 mm x 160 mm Wheels...

Page 44: ...easuring chain for at 21 C at 0 02 m s Further deviations may occur in particular through the positioning of the sensor and different driver weights Z The vibration acceleration acting on the body in...

Page 45: ...be damaged by non ionised radiation Electrical equipment on the truck emitting non ionised radiation e g wireless data transmission can affect operators medical equipment pacemakers hearing aids etc...

Page 46: ...o be constantly used in conditions of extreme temperature or air humidity fluctuations The truck is not authorised for use in cold stores The truck must only be used in an closed indoor environment Th...

Page 47: ...turer 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...

Page 48: ...and data plates Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary 37 41 37 37 40 38 39 44 46 45 40 50 49 47 48 51 52 53 52...

Page 49: ...azards in narrow aisle warning notice 43 Test plaque o 44 Read operating instructions notice 45 Capacity decal 46 Truck data plate 47 Add hydraulic oil decal t 48 Add bio hydraulic oil decal o 49 Caut...

Page 50: ...kg 62 Output 57 Battery voltage V 63 Min max battery weight kg 58 Net weight w o battery kg 64 Manufacturer 59 Option 65 Manufacturer s logo Z For queries regarding the truck or ordering spare parts...

Page 51: ...y plate 45 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 pl...

Page 52: ...hment as the specific capacity for each truck is indicated by the manufacturer It is shown in the same way as the truck s capacity and can be determined accordingly Z For loads with a centre of gravit...

Page 53: ...en 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 fac...

Page 54: ...52 04 19 en GB...

Page 55: ...or Assembly and Commissioning WARNING Incorrect assembly can result in accidents The assembly of the truck at the application site commissioning and driver training must only be performed by the manuf...

Page 56: ...are trained in handling lifting slings and tools uWear personal protective equipment e g safety boots helmet hi vis jacket protective gloves etc when loading by crane uDo not stand under a swaying loa...

Page 57: ...n lifting by crane refer to the truck data plate see page 48 WARNING Crane lifting gear can tear resulting in accidents Crane lifting gear can tear when routed over sharp edges causing the load to cra...

Page 58: ...etc when loading by crane uDo not stand under a swaying load uDo not walk into or stand in a hazardous area uAlways use lifting gear with sufficient capacity for truck weight see truck data plate uAl...

Page 59: ...ne lifting gear can tear resulting in accidents Crane lifting gear can tear when routed over sharp edges causing the load to crash uProtect the crane lifting gear with a suitable support 69 uDo not ro...

Page 60: ...n handling lifting slings and tools uWear personal protective equipment e g safety boots helmet hi vis jacket protective gloves etc when loading by crane uDo not stand under a swaying load uDo not wal...

Page 61: ...uding cab and load handler to be taken into account see page 38 Fit the transport retainer 71 WARNING Crane lifting gear can tear resulting in accidents Crane lifting gear can tear when routed over sh...

Page 62: ...e crane slings only to the prescribed strap points and prevent them from slipping uUse the lifting gear only in the prescribed load direction uCrane slings should be fastened in such a way that they d...

Page 63: ...ry 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 lo...

Page 64: ...uck from moving uUse only fastening belts with sufficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats 77 78 24 79 80 31 81 82 69 73 74 75 69 76 Securing...

Page 65: ...he tie down straps tensioning belts over sharp edges If this is not possible protect the tie down straps tensioning belts with a suitable material e g foam uProtect the tie down straps tensioning belt...

Page 66: ...g uUse only fastening belts with sufficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats 85 85 84 77 86 11 82 87 84 71 83 69 Securing the mast for transpo...

Page 67: ...outed over the lift chains with a suitable material e g foam Secure the mast 11 to the pallets 85 with tie down straps 84 Stow any supplied parts fork tines guide wheels etc on a pallet 88 so that the...

Page 68: ...ges to prevent the truck from moving uUse only fastening belts with sufficient strength uUse non slip materials to securing the load aids pallet wedges e g non slip mats 76 70 73 69 89 83 77 78 24 69...

Page 69: ...n straps tensioning belts can tear when routed over sharp edges uProtect the tie down straps tensioning belts with a suitable support 69 uDo not route the tie down straps tensioning belts over sharp e...

Page 70: ...ssembled uThe truck can then be started uIf several trucks have been delivered make sure that always the serial numbers of the load handlers masts and basic trucks match each other CAUTION Only operat...

Page 71: ...ation authorised by the manufacturer WARNING Trapping hazard in the swivel and traverse area of the attachment There is a trapping hazard in the attachment area while the attachment is traversing and...

Page 72: ...ainers ETX 515 only Z The transport retainers release the load wheel brakes when they are de energised Disassemble the load wheel guards by removing the three Allen screws from the load wheels Remove...

Page 73: ...oil level and top up if necessary see page 346 Check that all safety mechanisms are present and test them e g tilt safety devices etc Start up the industrial truck as indicated see page 124 and see p...

Page 74: ...assis When a tilt safety device 28 is used under the right side panel 16 an X is engraved in the chassis 34 after the serial number see page 46 CAUTION Before commissioning check industrial trucks to...

Page 75: ...be no inflammable material or lubricants capable of creating sparks within 2 m around the truck The room must be ventilated Fire protection equipment must be on hand Battery maintenance The battery c...

Page 76: ...with battery acid uNeutralise any spilled battery acid immediately with plenty of water uOnly batteries with a sealed battery container may be used uFollow national guidelines and legislation WARNING...

Page 77: ...ion Z The battery weights can be taken from the battery data plate WARNING Loss of stability can cause accidents The weight and dimensions of the battery have a considerable effect on the operational...

Page 78: ...ry compartment H B L H B L Truck model Length L Width W Height H ETX 513 ETX 513 T F 1072 mm 583 mm 923 5 mm Maximum battery height 880 mm ETX 515 ETX 515 T F 1072 mm 870 mm 923 5 mm Maximum battery h...

Page 79: ...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 r...

Page 80: ...s strictly prohibited uAlways park the truck on a level surface In special cases the truck may need to be secured with wedges uAlways fully lower the mast and forks uSelect a place to park where no ot...

Page 81: ...cedure Turn the industrial truck off with the key switch 8 and remove the key Press the Emergency Disconnect switch 9 down Unlatch the battery cover 15 To do this loosen the hook 97 on the mast 11 Clo...

Page 82: ...ces 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 i...

Page 83: ...e exposed to provide sufficient ventilation Do not place any metal objects on the battery Before charging check all cables and plug connections for visible signs of damage NOTICE Risk of fire and mate...

Page 84: ...highly explosive and must not be ignited uSwitch the charging station and truck off first before connecting disconnecting the charging cable of the battery charging station to from the battery connect...

Page 85: ...uDo not return the industrial truck to service until you have identified and rectified the fault Attach the battery connector 14 to the industrial truck CAUTION Open covers can cause injury and accid...

Page 86: ...he 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...

Page 87: ...i clockwise see arrow direction B Lift up the battery retainer 100 see arrow direction C Lift up the battery retainer 101 see arrow direction D Position the battery roller stand in front of the batter...

Page 88: ...sition the battery roller stand with the battery 98 in front of the battery compartment in such a way that the battery 98 can be safely pushed into the truck s battery compartment Z The battery retain...

Page 89: ...the chassis see arrow direction A Check all cables and plug connections for visible signs of damage CAUTION There is a risk of short circuits with damaged cables uReport any defects immediately to you...

Page 90: ...ed Fork lift truck with a minimum fork length of 880 mm and a capacity in excess of 1 5 t Attention Note the maximum capacity with respect to the load centre distance Procedure Remove the battery conn...

Page 91: ...ing the batteries during removal assembly Set the mast of the truck upright thereby bringing the load handler into a horizontal position Insert the forks of the truck into the fork shoes 102 of the ba...

Page 92: ...the battery cover 14 98 102 16 101 15 101 102 Battery installation Requirements Park the truck on a level surface Expose the battery see page 78 Tools and Material Required Fork lift truck with a mini...

Page 93: ...101 can swap positions This means that they can both be fitted in either the left or right side of the truck s chassis Insert the battery retainers 101 on either side into the truck chassis see arrow...

Page 94: ...ave 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 Operati...

Page 95: ...tery 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 bat...

Page 96: ...94 04 19 en GB...

Page 97: ...perating instructions The driver shall be afforded all due rights Unauthorised use of truck The driver is responsible for the truck during the time it is in use The driver must prevent unauthorised pe...

Page 98: ...mmediately Safety devices and warning labels Safety devices warning signs see page 46 and warning instructions in the present operating instructions must be strictly observed Z Warnings and notices su...

Page 99: ...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 18 20 19 105 120 119 117 111 110 26 97 04 19 en GB...

Page 100: ...114 106 5 104 112 107 108 109 116 115 113 9 8 118 18 20 19 105 120 119 117 111 110 26 98 04 19 en GB...

Page 101: ...ot applied display is lit in the driver s display see page 103 Steering driver s display and horn are enabled Hydraulic functions fork carriage rotate attachment traverse are enabled Travel functions...

Page 102: ...ns 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 dir...

Page 103: ...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...

Page 104: ...14 Option button o Button 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...

Page 105: ...ready for operation Indicates the truck is stationary Parking brake drive wheel brake is applied R Drive wheel brake referencing indicator t Indicates the truck has come to a halt and the drive wheel...

Page 106: ...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 auto...

Page 107: ...ow 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...

Page 108: ...wer referencing t Requests Main Lift to lower 127 Battery Discharge Indicator t Shows the battery charge status bar display 75 o Displays the battery charge status residual capacity as a percentage 12...

Page 109: ...the narrow aisle see page 241 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 239 The...

Page 110: ...Truck is ready for operation Emergency Disconnect switch pressed 135 Displays possible travel speeds t Rabbit Max travel speed t Turtle Inching speed 136 Service mode active indicator t Shows event a...

Page 111: ...62 or see page 276 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 139 or see page 140 Service hour...

Page 112: ...at least every 2 months Z Charge the battery see page 80 Requirements Connect the battery to the truck Close the battery cover Enter the operator position see page 128 Procedure Turn the EMERGENCY DI...

Page 113: ...harge indicator shows the 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...

Page 114: ...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 80 Requirements Connect the battery to the truck Close...

Page 115: ...residual capacity Flashing 30 21 Battery charge recommended 20 0 Battery charge required charge is below residual capacity level Main Lift and Auxiliary Lift raising is inhibited Z Raising is only ena...

Page 116: ...e right Fork manual synchronised left rotate button t Activates manual fork carriage synchronised left rotate and load handler right traverse The attachment traverse movement is controlled with the hy...

Page 117: ...ork carriage 90 and traverse the load handler to the centre Fork manual synchronised rotate to centre position button o Activates manual fork carriage synchronised 90 rotate and load handler centre tr...

Page 118: ...lescopic forks can be operated Telescopic forks button o Activates the telescopic forks This hydraulic function is controlled with the hydraulic functions control lever Telescopic forks synchronised m...

Page 119: ...ates asynchronous movement of the bottom telescopic forks This hydraulic function is controlled with the hydraulic functions control lever see page 249 2nd stacking depth display o Indicates that the...

Page 120: ...y o Indicates that the left fork can be adjusted Left fork positioning button o Activates left fork positioning This hydraulic function is controlled with the hydraulic functions control lever Right f...

Page 121: ...ctivates fork tilt This hydraulic function is controlled with the hydraulic functions control lever Special attachment display o Indicates that a special attachment can be operated Special attachment...

Page 122: ...241 Travel is controlled with the travel control knob Warning field infringement display o Indicates that there are people obstacles in the warning field of the personal protection system in the narro...

Page 123: ...ton o Overrides the lower limit This hydraulic function is controlled with the hydraulic functions control lever Travel cutout display o Appears as soon as automatic height dependent travel cutout is...

Page 124: ...ton the menu currently shown in the driver s display changes to the Truck functions menu Battery latch not applied display t Appears when the truck has been switched on but the battery latch has not b...

Page 125: ...strobe on and off Spotlight positioning display o Indicates that the spotlight can be switched on off Spotlight positioning button o Switches the spotlight on and off Reverse lights display o Indicat...

Page 126: ...vented from being used by unauthorised people if people do not leave the hazardous area despite the warning 3 1 Checks and operations to be performed before starting daily operation WARNING Damage and...

Page 127: ...the operator mat and step boards are non slip and damage free Check the tilt safety devices are present o see page 72 Check the load handler forks etc for visible signs of damage such as cracks bent o...

Page 128: ...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 rec...

Page 129: ...age 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 pan...

Page 130: ...ore than one person may operate the truck at a time 3 3 Setting up the operator position CAUTION An unsecured driver s seat and control panel can result in falls and injury An unsecured driver s seat...

Page 131: ...r 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 envi...

Page 132: ...starting to use the truck uHold the weight setting lever 142 only by the recess do not reach through underneath the lever Adjusting the driver s weight NOTICE To achieve optimal seat cushioning the d...

Page 133: ...ry An unsecured driver s seat can slide out of its guide during travel resulting in accidents uThe driver s seat must be locked in position uDo not adjust the driver s seat while travelling Procedure...

Page 134: ...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 144 anti clockwise Set the control pan...

Page 135: ...ce when 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 145 up Set the control panel 118 to...

Page 136: ...issible 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 front of safety mechanisms or op...

Page 137: ...st always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times Abrupt stopping except in emergencies rapid U turns...

Page 138: ...on 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...

Page 139: ...ct with the walls of the lift shaft People travelling in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must exit the lift before the truck Work platf...

Page 140: ...out WARNING Accident risk when transporting liquid loads The following risks may be present when transporting liquid loads Liquids sloshing out A change in the load centre due to sudden lifting and d...

Page 141: ...RGENCY 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 refe...

Page 142: ...ion see page 124 Connect the battery to the truck Insert and lock the battery latch Insert and lock the side panels correctly Close the battery cover see page 78 Enter the operator position see page 1...

Page 143: ...ey 146 one digit back Press the CE key 150 to cancel entering the 5 digit access code Press OK 149 and confirm the access code entry Z If no travel steer or hydraulic operations are performed within a...

Page 144: ...lic system is defective or faulty If damage 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 d...

Page 145: ...nd see page 172 Test the lift cutouts o see page 207 Test the travel functions see page 152 and see page 156 Test the end of aisle safety device and aisle detection functions o see page 211 Test the t...

Page 146: ...e the truck for operation see page 139 or see page 140 Procedure Press the deadman button 18 Carry out a Raise main lift reference run Raise the Main Lift until the 151 symbol is no longer illuminated...

Page 147: ...which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle Procedure Pressing the lift cutout override button 104 underneath to the li...

Page 148: ...cedure Do not press the deadman button 18 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...

Page 149: ...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 182 Rotate referencing is success...

Page 150: ...te 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 139 or see page 140 Procedure P...

Page 151: ...n also be entered directly with the number field on the numerical keypad 112 Use the cursor keys 146 148 to select the next or previous field Cursor key 146 previous field Cursor key 148 one field for...

Page 152: ...4 7 Emergency Disconnect 9 150 04 19 en GB...

Page 153: ...the Emergency Disconnect 9 as a service brake Press the Emergency Disconnect 9 All electrical functions are deactivated The truck brakes to a halt Releasing the Emergency Disconnect Procedure Turn th...

Page 154: ...ation see page 139 or see page 140 Procedure Press and hold down on the deadman button 18 Fully lower the Main Lift Turn the Hydraulic functions control lever 113 anti clockwise Carry out a test run o...

Page 155: ...travel speed is infinitely controlled by the accelerator pedal 20 The further the accelerator pedal 20 is pressed the greater the travel speed Use the steering wheel 5 to steer the truck in the requir...

Page 156: ...side narrow aisles The truck is automatically guided and steering wheel 5 operation is deactivated 4 10 Brakes WARNING Accident risk while braking The truck s brake pattern depends largely on the grou...

Page 157: ...brake pedal 19 Braking with the reversing brake t Procedure During travel set the travel direction switch 105 to the opposite direction The truck brakes regeneratively via the traction controller unt...

Page 158: ...e must not be rendered ineffective misused adjusted or removed uReport any defects to your supervisor immediately uTag out and decommission a faulty lift truck uOnly return the truck to service when y...

Page 159: ...e g pallets load units etc A collision between the truck and the protruding objects could also cause material damage to the truck and the rack construction uCheck the length and height of the narrow...

Page 160: ...only in narrow aisles with undamaged secure guide rails Press the deadman button Approach the aisle at reduced speed so that the truck 162 is aligned with the narrow aisle and is within the demarcati...

Page 161: ...avel speed is governed by the accelerator pedal 20 Z The travel speed is infinitely controlled by the accelerator pedal 20 The further the accelerator pedal 20 is pressed the greater the travel speed...

Page 162: ...Switch automatic guidance on off button 106 Z The Truck guided display 163 changes to the steer angle indicator 124 The truck is now free to move again The steer angle indicator 124 shows the current...

Page 163: ...endered ineffective misused adjusted or removed uReport any defects to your supervisor immediately uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identif...

Page 164: ...driver of the truck in a narrow aisle can be injured by objects protruding from the racks e g pallets load units etc A collision between the truck and the protruding objects could also cause material...

Page 165: ...e has been deactivated note the position of the drive wheel as manual steering is now activated again uRe activate the wire guidance and re align the truck During alignment the rear section of the tru...

Page 166: ...itch automatic guidance on off button 106 The wire acquisition signal sounds Move the truck 162 slowly in the direction of the guide wire 164 Z The truck is automatically guided when it reaches the gu...

Page 167: ...avel speed is governed by the accelerator pedal 20 Z The travel speed is infinitely controlled by the accelerator pedal 20 The further the accelerator pedal 20 is pressed the greater the travel speed...

Page 168: ...Switch automatic guidance on off button 106 Z The Truck guided display 163 changes to the steer angle indicator 124 The truck is now free to move again The steer angle indicator 124 shows the current...

Page 169: ...dal 20 simultaneously Main Lift lower Turn the Hydraulic functions control lever 113 anti clockwise Main lift raise Turn the Hydraulic functions control lever 113 clockwise Travel in load direction Pu...

Page 170: ...uck 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...

Page 171: ...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 uD...

Page 172: ...ulic 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 tensione...

Page 173: ...re in proportion to how far the Hydraulic functions control lever 113 is moved The maximum lift speed is achieved when the attachment is in the home position or the telescopic table is in the centre p...

Page 174: ...ing out swivel traverse synchronised rotate or lift lower movements with the load handler Stop working with the truck if people do not leave the hazardous area uThe truck must be prevented from being...

Page 175: ...xternal 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...

Page 176: ...urn 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 t...

Page 177: ...rn 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 Hydrau...

Page 178: ...ions control lever 113 The attachment must then be moved manually to the home position Synchonised fork carriage right rotation and load handler left traverse Press and hold down on the 104 button und...

Page 179: ...e cancelled by releasing the 104 button The attachment must then be moved manually to the home position Synchonised fork carriage right rotation and load handler left traverse Press and hold down on t...

Page 180: ...on 18 Press 104 under the synchronised rotate menu change symbol 166 The display changes from the menu item Synchronised rotation menu change 166 to Synchronised rotation until forks in centre positio...

Page 181: ...matic synchronised rotation until forks are in centre position the fork carriage is rotated 90 from the home position and the attachment is positioned in the centre of the traverse pivot frame Require...

Page 182: ...or with a raised load load handler is dangerous and is strictly prohibited uAlways park the truck on a level surface In special cases the truck may need to be secured with wedges uAlways fully lower t...

Page 183: ...wn Set the attachment to the home position t see page 182 Traverse the telescopic table to the centre position o see page 183 Switch off the truck to do this Turn the key in the key switch 8 left as f...

Page 184: ...on see page 139 or see page 140 Procedure Do not press the deadman button 18 Traverse the attachment to the right or left limit position of the sideshift frame 113 see page 174 Rotate the forks 23 par...

Page 185: ...Requirements Prepare the truck for operation see page 139 or see page 140 Procedure Do not press the deadman button 18 Traverse the telescopic table to the centre position 113 The driver s display sho...

Page 186: ...o not leave the hazardous area uOnly carry loads that have been correctly secured and positioned Use suitable protection measure to prevent parts of the load from tipping or falling down uDamaged load...

Page 187: ...e extension safety mechanisms 172 The truck must not be operated without an extension safety mechanism 172 uCheck the extension safety mechanisms 172 are present uEnsure the extension safety mechanism...

Page 188: ...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...

Page 189: ...y 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 a...

Page 190: ...nd forks not touching the ground Procedure Disassemble the extension safety mechanism 172 Lift up the locking lever 170 Carefully push the fork tines 23 off the fork carriage 171 The fork tines 23 are...

Page 191: ...70 down and move the fork tines 23 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 172...

Page 192: ...e transported uIf the stacked load obscures forward visibility then you must reverse the truck uMake sure you have enough visibility when reversing uNever exceed the maximum loads specified in the cap...

Page 193: ...ad handler so that the load can be lifted Do not press the deadman button 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...

Page 194: ...gles 90 to the truck see page 175 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...

Page 195: ...ions Procedure Z Always transport loads with both forks When transporting heavy loads always ensure that both forks carry the same weight Press the deadman button Raise the load slightly Z Always tran...

Page 196: ...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 resti...

Page 197: ...y set the load into its storage location Press the deadman button Carefully lower the load handler so that the forks are clear of the load Z Avoid depositing the load suddenly to avoid damaging the lo...

Page 198: ...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 resti...

Page 199: ...thout 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 damag...

Page 200: ...system is displayed with a corresponding error code contact the manufacturer s service department Additional troubleshooting must only be performed by the manufacturer s specialist service engineers...

Page 201: ...e 205 Travel cutout 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...

Page 202: ...age 213 4916 During the power up test a Functions button under the driver s display and or a key on the numerical keypad has been pressed Do not press the Functions button switch truck off and on agai...

Page 203: ...NG Risk of accidents material damage through automatic lowering of load handler If the load handler is in the rack emergency lowering cannot be performed Due to leakage from the hydraulic system there...

Page 204: ...ing uNever stand underneath a raised load handler uIf the load handler is lowered with the emergency lowering device below it the driver must be in a safe area to avoid any danger uDo not perform emer...

Page 205: ...to do this Turn the key in the key switch as far to the left as it will go 8 Press the red button on the ISM access module o Press the Emergency Disconnect 9 Open the drive compartment cover 95 see pa...

Page 206: ...The load handler is lowered WARNING Only return the truck to service when you have identified and rectified the fault 204 04 19 en GB...

Page 207: ...ver the position of the truck needs to be adjusted with respect to the rack in order to stack or retrieve a load proceed as follows WARNING The truck can cause accidents Travel cutout is an additional...

Page 208: ...direction Push the travel direction switch 105 left Travel in drive direction Press the deadman button 18 Apply the accelerator pedal 20 The truck can now travel at slow speed 175 104 20 18 105 NOTICE...

Page 209: ...liary function designed to support the operator which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle Z Lift cutout only becomes...

Page 210: ...ift is raised Lift cutout is deactivated Z Lift cutout is re activated every time the mast falls below the lift limit height 153 104 18 113 NOTICE Pressing the 104 button under the corresponding overr...

Page 211: ...auxiliary function designed to support the operator which however does not release him from his responsibility to stop hydraulic operations e g when confronted with an obstacle Z Lower cutout only be...

Page 212: ...ift is lowered The lower cutout is deactivated Z Lift cutout is re activated every time the mast rises above the lower limit height 176 104 18 113 NOTICE Pressing the 104 button under the correspondin...

Page 213: ...nets 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 ped...

Page 214: ...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 func...

Page 215: ...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...

Page 216: ...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...

Page 217: ...s Fully lower the mast see page 168 or see page 201 Traverse the attachment to the home position t see page 182 Traverse the telescopic table to the centre position o see page 183 Disconnect the batte...

Page 218: ...setscrews 177 are used to tension unlock the compression springs which activate the parking brake so that the truck does not brake when de energised Release the load wheel brake ETX 515 only see page...

Page 219: ...ruck on a level surface In special cases the truck may need to be secured with wedges uAlways fully lower the mast and forks uSelect a place to park where no other people are at risk of injury from lo...

Page 220: ...y the load wheel brake ETX 515 only see page 219 CAUTION Open covers can cause injury and accidents uThe covers battery cover side panels drive compartment cover etc must be closed during operation Cl...

Page 221: ...81 182 Releasing the load wheel brake Requirements Fully lower the mast see page 168 or see page 201 Traverse the attachment to the home position t see page 182 Traverse the telescopic table to the ce...

Page 222: ...o undo the load wheel brake from the drive compartment Z The setscrews are used to tension unlock the compression springs which activate the load wheel brakes so that the truck does not brake when de...

Page 223: ...are at risk of injury from lowering forks WARNING If the brakes are not working place wedges underneath the wheels of the truck to prevent it from moving 95 8 9 183 24 181 181 182 Activating the load...

Page 224: ...ompartment cover etc must be closed during operation Close the drive compartment cover 95 see page 330 Fit the panels 183 of the load wheels 24 on both sides Place the panels 183 onto the load wheels...

Page 225: ...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 se...

Page 226: ...eft as far as the stop and remove the key Press the red button on the ISM access module o Press the Emergency Disconnect 9 Open the drive compartment cover 95 see page 330 Set the drive wheel 31 to th...

Page 227: ...ing angle has to be changed during a recovery operation this can only be performed when the truck is stationary see page 223 uOnly return the truck to service when you have identified and rectified th...

Page 228: ...nd the recovered truck during a recovery operation Recover the truck carefully and slowly If the steering angle has to be changed during a recovery operation brake until the truck comes to a halt CAUT...

Page 229: ...n on the ISM access module o Press the Emergency Disconnect 9 NOTICE Risk of damage from the tow rope During recovery route the tow ropes to the front in such a way as to avoid damaging the hydraulic...

Page 230: ...eered without its own drive system when it is stationary see page 223 After recovery secure the truck to prevent it from moving see page 215 and see page 219 WARNING If the brakes are not working plac...

Page 231: ...the red button on the ISM access module o Press the Emergency Disconnect 9 NOTICE Risk of damage from the tow rope During recovery route the tow ropes to the front in such a way as to avoid damaging t...

Page 232: ...eered without its own drive system when it is stationary see page 223 After recovery secure the truck to prevent it from moving see page 215 and see page 219 WARNING If the brakes are not working plac...

Page 233: ...ergency Disconnect 9 Open the drive compartment cover see page 330 NOTICE Risk of damage from the tow rope Do not route the tow rope 187 over the tailgate 188 as the tailgate 188 is not designed for r...

Page 234: ...eered without its own drive system when it is stationary see page 223 After recovery secure the truck to prevent it from moving see page 215 and see page 219 WARNING If the brakes are not working plac...

Page 235: ...m 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 operatin...

Page 236: ...er 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 Ad...

Page 237: ...h lower cutout on detection of persons 7 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 r...

Page 238: ...hing 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 micro fibre cloth or a new soft paper towel CAUTIO...

Page 239: ...ement 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 fie...

Page 240: ...pecialist service engineers 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 info...

Page 241: ...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...

Page 242: ...uck for operation see page 139 or see page 140 Drive the truck into the narrow aisle and establish automatic guidance see page 156 190 104 20 18 Obstacles and or persons in the PPS warning field The d...

Page 243: ...stacle or person are no longer in the protection field Requirements Prepare the truck for operation see page 139 or see page 140 Drive the truck into the narrow aisle and establish automatic guidance...

Page 244: ...ion field infringement However it does not release the operator from his responsibility to bring the truck to a halt in good time before it reaches any obstacles and or persons The personal protection...

Page 245: ...retina if it comes into direct eye contact uDo not look into the laser beam 192 192 The laser beam rack compartment display indicates the correct position of the truck with respect to the rack compart...

Page 246: ...working with the truck if people do not leave the hazardous area uThe truck must be prevented from being used by unauthorised people if people do not leave the hazardous area despite the warning uOnl...

Page 247: ...ut traverse or lift lower movements with the load handler Stop working with the truck if people do not leave the hazardous area uThe truck must be prevented from being used by unauthorised people if p...

Page 248: ...rn the truck to service when you have identified and rectified the fault Z Maintenance intervals are specified in the section Maintenance Inspection and Changing of Maintenance Parts Requiring Replace...

Page 249: ...pic forks of the telescopic table 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 i...

Page 250: ...aterial damage to the telescopic forks The telescopic forks must not be used to push or press loads Requirements Prepare the truck for operation see page 139 or see page 140 Procedure Do not press the...

Page 251: ...elescopic table when choosing the telescopic forks An individual telescopic fork tine must not be chosen when the load on the two telescopic forks is overlapping i e when laden with a wire box uAlways...

Page 252: ...escopic table to the right Turn the Hydraulic functions control lever 113 clockwise To traverse the selected telescopic fork of the telescopic table to the left Turn the Hydraulic functions control le...

Page 253: ...Changing of Maintenance Parts Requiring Replacement see page 359 8 3 1 Fork sideshift o Requirements Prepare the truck for operation see page 139 or see page 140 Procedure Do not press the deadman bu...

Page 254: ...on the button 104 under the Fork adjustment symbol 198 To reduce the fork spread Turn the Hydraulic functions control lever 113 clockwise To increase the fork spread Turn the Hydraulic functions contr...

Page 255: ...for operation see page 139 or see page 140 Procedure Press 104 under the Fork adjustment sideshift menu change symbol 199 The display changes from the menu item Fork adjustment sideshift menu change 1...

Page 256: ...nder the Fork adjustment symbol 198 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 c...

Page 257: ...chment 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 uOnl...

Page 258: ...load greater than the weights specified on the capacity plate for completely extended telescopic forks is lifted extension of telescopic forks is disabled The Telescopic fork sideshift 201 symbol ligh...

Page 259: ...n the weights specified on the capacity plate for completely extended telescopic forks is lifted extension of telescopic forks is disabled Retract the attachment left or right until the automatic stop...

Page 260: ...Warnings sub menu item 203 appears in the driver s display Z Truck operations are inhibited in this menu Press the button 104 under the Warnings sub menu symbol 203 The Operator specific settings men...

Page 261: ...he Select button 147 in the cursor field The Travel acceleration symbol appears in the driver s display see table below The operator can toggle between functions using the cursor keys 146 148 Cursor k...

Page 262: ...in lift lower speed V Sideshift speed V Steering wheel transmission v CAUTION Altering travel parameters can cause accidents Increasing the settings for acceleration steering travel lifting and loweri...

Page 263: ...n a pre defined area in the program Cursor key 156 strengthen the setting Cursor key 157 weaken the setting Press OK on the numerical keypad 112to save the settings 112 156 148 157 146 147 108 Leaving...

Page 264: ...ttachment in home position without load Attachment in centre position without load Attachment in home position with load Attachment in centre position with load Lowering and lifting an attachment with...

Page 265: ...or operation see page 139 or see page 140 Drive the truck into the narrow aisle and establish automatic guidance see page 156 Procedure Press the Select button 147 in the cursor field Using the numeri...

Page 266: ...the first number entered is used as a multiple of ten the second as a unit position If an incorrect entry is made it can be deleted by pressing the CE button on the numerical keypad 112 Press OK on th...

Page 267: ...dure Using the numerical keypad 112 enter the area 205 see page 263 Using the numerical keypad 112 enter the rack number 206 see page 264 Z Depending on the current lift height an arrow is shown on th...

Page 268: ...ions control lever 113 anti clockwise Z If another rack is selected during the positioning process this is displayed for approx 1 second and stored in an intermediate log On reaching the current wareh...

Page 269: ...cancelled by pressing the CE button on the numerical keypad or by pressing the EMERGENCY DISCONNECT switch To approach the Pre limit required height manually o The Hydraulic functions control lever 1...

Page 270: ...ENCY DISCONNECT switch To approach the required height automatically o Select the travel direction with the direction switch Depress accelerator The nominal height is then approached automatically in...

Page 271: ...load handler see page 168 Retract the load handler see page 174 The following stacking options are available for stacking operations Stacking procedure not active Press the deadman button 18 When the...

Page 272: ...rminal is only issued when the attachment has abandoned and then returned to the home position During the positioning procedure another compartment can be entered This entry is shown for approx 1 sec...

Page 273: ...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 anothe...

Page 274: ...er 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 Hydraulics function control lever 113...

Page 275: ...ons stop when the Hydraulics function control lever 113 is released The stacking operation continues when the Hydraulic functions control lever 113 is applied again Pressing one of the Attachment trav...

Page 276: ...The following symbols appear in the driver s display for left stacking operations 112 113 120 18 119 274 04 19 en GB...

Page 277: ...press the deadman button Hydraulic functions control lever 113 Clockwise turn Lift retrieve Anti clockwise turn Lower stack Do not press the deadman button Traverse attachment right to the home posit...

Page 278: ...grammable warehouse conditions The setting is made by the manufacturer s customer service department To achieve constant insertion widths over the entire lift height ten height dependent traverse adju...

Page 279: ...rtical 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...

Page 280: ...218 219 223 222 224 225 221 220 211 212 213 214 Item Symbol Function Description 207 Truck in narrow aisle transponder recognised 208 The travel in drive direction symbol indicates that a horizontal...

Page 281: ...ed 217 Rack row display only single digit entry allowed 218 Position mark display horizontal position in narrow aisle single double or three digit entries allowed 219 Rack height Rack display lift hei...

Page 282: ...iage left warning symbols flash until the correct position is reached 212 213 217 Incorrect rack row entered with order Check entry The question mark and rack row symbols flash alternately 221 218 Inc...

Page 283: ...Carry out the existing order Faulty data transmission The order is not accepted The error number is issued Data transmission not repeated despite error recognition NAK The order is not accepted The er...

Page 284: ...a load on the forks 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 l...

Page 285: ...to reach the warehouse location With load lower lift to reach the warehouse location Without load traverse the telescopic forks to the left right With load traverse the telescopic forks to the left ri...

Page 286: ...input via radio The destination is transmitted to the truck via radio Warehouse destination manual entry default setting Z The position of the symbols can be adapted to customer requirements The setti...

Page 287: ...12 The entry in the location marker field 218 can be one two or three digits Press the cursor key 148 The background of the Rack height field 219 goes dark Enter the required rack height with the nume...

Page 288: ...ored in the truck s memory In this case the order in memory symbol 215 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...

Page 289: ...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 truc...

Page 290: ...put via the radio 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...

Page 291: ...in the drive direction when the Travel in drive direction symbol 208 is displayed Push the travel direction switch 105 left Travel in drive direction Slowly apply the accelerator pedal 20 Travel in th...

Page 292: ...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...

Page 293: ...vel direction switch 105 right Travel in load direction Slowly apply the accelerator pedal 20 The industrial truck begins automatic horizontal and vertical destination approach Z Truck movement can be...

Page 294: ...ptionally with a weighing system When the load has been raised slightly with the Main Lift the weight is shown on the driver s display in kg 131 see page 168 NOTICE The weighing system is not a substi...

Page 295: ...Hydraulic function control lever 113 for approx 10 cm Press the Quit sub menu button 108 Z Truck movement is inhibited in this truck menu The driver s display shows the Weigher display zero setting s...

Page 296: ...irection 230 231 232 234 233 Using the camera system Press the button 234 on the monitor to switch the camera system on or off Press the button 233 to lighten or darken the screen day night settings P...

Page 297: ...r her individual needs CAUTION Incorrect adjustment of the rear view mirror can cause accidents An incorrectly adjusted rear view mirror can collide with the rack or goods when operating in narrow ais...

Page 298: ...travelling or lifting lowering Z Operate the work platform only at reduced travel hydraulic speeds WARNING The use of working platforms is governed by national law In some states the use of working p...

Page 299: ...en the gate in emergencies 237 Grab handles two hand compulsion 238 Connecting cable between work platform and truck 239 Gate 240 Operator platform 241 Fork shoes 242 Work platform for the standard at...

Page 300: ...k by the owner Procedure Check the work platform for damage before using it Check the lock 243 on the work platform is present and check for damage Close the gate 239 Z The work platform must be lifte...

Page 301: ...Work 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 hom...

Page 302: ...mage before using it 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...

Page 303: ...stop on the load handler 244 The work platform is prevented from falling The Work platform raised securely symbol appears in the driver s display The raised and locked work platform is monitored by n...

Page 304: ...ely to your supervisor uTag 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...

Page 305: ...m 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 the...

Page 306: ...ork platform gate 239 Step on 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 Openin...

Page 307: ...ile in a raised position uThe driver must never leave the truck while the work platform is in operation Destination reached The person in the work platform can start to work Leaving the work platform...

Page 308: ...is clear of the ground Disconnect the work platform electrically from the truck Remove the connecting cable 238 and suspend it in the work platform Fully extend the attachment and work platform Lower...

Page 309: ...clear of the ground Disconnect the work platform electrically from the truck Remove the connecting cable 238 and suspend it in the work platform Remove the physical lock 243 of the work platform from...

Page 310: ...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 restri...

Page 311: ...e 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 maintenanc...

Page 312: ...8 13 2 List of assemblies for Floor Spot 247 248 Item Description 247 o Floor Spot in the load direction 248 o Floor Spot in the drive direction 310 04 19 en GB...

Page 313: ...lling stationary Floor Spot 247 and Floor Spot 248 are switched off Truck travels in drive or load direction Truck travel function Function of the Floor Spot Truck travels in drive direction Floor Spo...

Page 314: ...r Spot 248 is switched on Floor Spot 247 is switched off Truck travels in load direction Floor Spot 247 is switched on Floor Spot 248 is switched off Travel within narrow aisle narrow aisle with end o...

Page 315: ...passes over the end of aisle safety device in the drive direction Floor Spot 248 is switched on Floor Spot 247 is switched off Guided truck passes over the end of aisle safety device in the load direc...

Page 316: ...The use of inappropriate extinguishing agents can cause fire to spread and hence injure the operator uThe proprietor is responsible for choosing suitable extinguishing agents and fire extinguishers uT...

Page 317: ...perating speeds of the truck must not be increased under any circumstances Exception Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer...

Page 318: ...ufacturer 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 r...

Page 319: ...the following target groups 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...

Page 320: ...uck only on a level surface and prevent it from moving accidentally uOnly use a jack with sufficient capacity When jacking up the truck take appropriate measures to prevent it from slipping or tipping...

Page 321: ...er uDo not clean the electrical system with water uClean the electrical system with weak suction or compressed air use a compressor with a water trap and not a conductive anti static brush CAUTION Ris...

Page 322: ...Electric currents can cause accidents Make sure the electrical system is voltage free before starting work on it The capacitors built into the controller must be completely discharged The capacitors...

Page 323: ...environmental protection regulations To change the oil contact the manufacturer s customer service department who have been specially trained for this task uNote the safety regulations when handling...

Page 324: ...ight at the same time Z When replacing wheels fitted at the factory only use the manufacturer s original spare parts Otherwise the truck s rated performance cannot be ensured Attachment Repairs and In...

Page 325: ...rescribed 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 instr...

Page 326: ...ntact and digestion If you swallow oil do not induce vomiting but call for a doctor immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has come into contact with your skin rin...

Page 327: ...Lubrication Schedule Z Details of the correct lubricant to be used are given in the lubricant chart see page 327 Outer mast Grease nipple Centre mast Load handler Inner mast Load handler 325 04 19 en...

Page 328: ...F F C E E A C D D E C B 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 326 04 19 en GB...

Page 329: ...s 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...

Page 330: ...Preparing the truck for maintenance and repairs 9 8 18 20 19 15 14 16 All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs The following preparation...

Page 331: ...tched on accidentally When working under a raised lift truck secure it to prevent it from lowering tipping or sliding away WARNING Risk of accidents when working under the load handler driver s cab an...

Page 332: ...er Requirements Prepare the truck for maintenance and repairs see page 328 Tools and Material Required Allen key key width 5 to undo the screws 94 Procedure Remove both screws 94 using the Allen key k...

Page 333: ...ver and the truck when you close the cover Carefully close the drive compartment cover 95 CAUTION Open covers can cause injury and accidents uThe covers battery cover side panels drive compartment cov...

Page 334: ...ruck securely see page 180 uPress the Emergency Disconnect uDisconnect the battery uRemove any rings or metal bracelets etc before working on electrical components CAUTION The use of incorrect fuses c...

Page 335: ...ntroller 259 Pull the fuses 252 258 and their brackets out of the controller 259 Check the fuses 252 258 in accordance with the following table and replace as required Insert the fuses 252 258 and the...

Page 336: ...dio terminal etc 10 A 254 F1 2 Control panel and horn control fuse 10 A 255 5F1 Overhead guard control fuse e g work lights operator position lighting fan etc 10 A 256 F2 1 Internal DC DC converter co...

Page 337: ...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 r...

Page 338: ...68 Tools and Material Required Allen key key width 22 to undo or tighten the screw 264 of the fastening bolt 263 Procedure Raise the load handler until the inner mast 261 is above the bracket 262 see...

Page 339: ...the lowering valve see page 201 Turn the lowering valve clockwise as far as it will go Close the drive compartment cover see page 330 The load handler is now protected against accidental lowering Mai...

Page 340: ...ed load handler driver s cab Raise the load handler until the inner mast 261 is no longer resting on the bracket 262 see page 168 Z If the Lift cutout symbol 153 appears as the load handler is being r...

Page 341: ...nothing between the battery cover and the truck when you close the battery cover Close the battery cover see page 78 Turn the EMERGENCY DISCONNECT switch 9 to unlock it Switch on the truck to do this...

Page 342: ...for a 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...

Page 343: ...ial truck uNever reach or climb into moving truck parts uNever stand underneath a raised load handler Position the working platform lifting stage or safety ladder directly next to the industrial truck...

Page 344: ...t 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 superviso...

Page 345: ...wo 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 cu...

Page 346: ...ure 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...

Page 347: ...eplace 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 h...

Page 348: ...t be disposed 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 contac...

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 envi...

Page 350: ...267 WARNING Overfilling the 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 escaping oil can damage...

Page 351: ...ing notice on the hydraulic reservoir Add hydraulic oil In this case you may only use hydraulic oil HLP D22 including 2 share of Additiv 68 ID to fill the hydraulic reservoir WARNING You cannot change...

Page 352: ...access module and depending on the setting press the green button on the ISM access module o WARNING After cleaning or maintenance work test all the safety mechanisms to ensure they are working corre...

Page 353: ...rt 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 Test the service and park...

Page 354: ...lows uJack up the truck only on a level surface and prevent it from moving accidentally uOnly use a jack with sufficient capacity When jacking up the truck take appropriate measures to prevent it from...

Page 355: ...you have identified and rectified the fault Test the brakes Check the hydraulic oil level and replenish if necessary see page 346 Apply a thin layer of oil or grease to any non painted mechanical com...

Page 356: ...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 th...

Page 357: ...and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault Start up the truck see page 124 Z If there are switching problems in the electri...

Page 358: ...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 t...

Page 359: ...rained 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 vi...

Page 360: ...358 04 19 en GB...

Page 361: ...uck 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...

Page 362: ...ce 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 a...

Page 363: ...aisle recognition Load sensing Hydraulic operations Clean the sensors Telescopic table Hydraulic operations Clean and lubricate the attachment Swivel traverse frame Hydraulic operations Clean and lub...

Page 364: ...ery components for damage The function and secure seating of the battery connector and for damage Travel Wheels for wear and damage Chassis structure Industrial truck for damage and leaks Labels are l...

Page 365: ...tructure Supports tilt safety devices are present and for damage Restraint system Chassis structure The function of the driver s seat restraint system and for damage Optional equipment Chassis structu...

Page 366: ...acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead acid battery Power supply Battery cable connections are secure 364 04 19 en...

Page 367: ...Electrical system Note All safety components encoder laser scanner Flexisoft safety PLC and relays must be replaced after 240 months Test the contactors and or relays Carry out a chassis insulation re...

Page 368: ...ecessary 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 Demo...

Page 369: ...nents Test the Personal Protection System Clean the front screens of the PPS laser scanner Test the warning and protective field areas of the Personal Protection System Rail guidance Electrical system...

Page 370: ...and or light switch for aisle recognition Load sensing Hydraulic operations Clean the sensors Test the sensors 2nd stacking depth System components Test function and settings W S lowering cut off Trav...

Page 371: ...upport 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 f...

Page 372: ...ion 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 ba...

Page 373: ...the combined control unit and for damage Electrostatic discharge strap or chain is present and for damage Power supply The function of the battery latch and battery attachment and for damage The funct...

Page 374: ...leaks and damage Lateral play of the mast sections and fork carriage The presence of the stops and for wear and damage Load chain mounting elements and chain pins for wear and damage Mast rollers and...

Page 375: ...uidance 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 Fo...

Page 376: ...of the attachment to the truck and the load bearing components for secure fit and damage Aisle recognition System components The function of the aisle recognition magnetic switch and or light button a...

Page 377: ...le Electrical system Access module is secure and functions correctly and for damage Telescopic table Hydraulic operations Attachment bearings guides and stops for wear and damage Proper securing of th...

Page 378: ...Electrical optional equipment Electrical system The function of the optional electrical equipment and for damage Restraint system Chassis structure The function of the driver s seat restraint system a...

Page 379: ...and for damage The mains plug and mains cable for damage The current collectors and bus bar feed for damage The secure seating of the cables and electrical connections and for damage Lead acid batter...

Page 380: ...arts 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...

Page 381: ...cts 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 instruction...

Page 382: ...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 jungheinric...

Page 383: ...ed 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 sy...

Page 384: ...02 16 EN 6...

Page 385: ...g 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...

Page 386: ...02 16 EN 8 14 Safety instructions and warning information...

Page 387: ...ng 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...

Page 388: ...crease 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 com...

Page 389: ...e 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 availab...

Page 390: ...ive 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 N...

Page 391: ...ed 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...

Page 392: ...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 densi...

Page 393: ...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 1...

Page 394: ...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 differ...

Page 395: ...lectrolyte 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 plate...

Page 396: ...ging 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 ign...

Page 397: ...tery 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 appropria...

Page 398: ...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 Compen...

Page 399: ...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 betwe...

Page 400: ...k 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...

Page 401: ...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 batter...

Page 402: ...ubing 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 b...

Page 403: ...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 pass...

Page 404: ...ed 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 throug...

Page 405: ...lose 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...

Page 406: ...t 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 T...

Page 407: ...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 fr...

Page 408: ......

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