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Foreword Foreword
Notes on the operating instructions Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously. numbered continuously.
The operator manual details different industrial truck models. When operating and The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your servicing the industrial truck, make sure that the particular section applies to your
truck model. truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the system. No guarantee of alter the design, equipment and technical features of the system. No guarantee of
particular features of the truck should therefore be assumed from the present particular features of the truck should therefore be assumed from the present
operating instructions. operating instructions.
Safety notices and text mark-ups Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following Safety instructions and important explanations are indicated by the following
graphics: graphics:
DANGER! DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death. result in severe irreparable injury and even death.
WARNING! WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death. may result in severe irreparable injury and even death.
CAUTION! CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury. slight to medium injury.
NOTE NOTE
Indicates a material hazard. Failure to comply with this instruction may result in Indicates a material hazard. Failure to comply with this instruction may result in
material damage. material damage.
Z Used before notices and explanations. Z Used before notices and explanations.
t Indicates standard equipment t Indicates standard equipment

o Indicates optional equipment o Indicates optional equipment
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Copyright Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG. Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft
Am Stadtrand 35 Am Stadtrand 35
22047 Hamburg - Germany 22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0 Tel: +49 (0) 40/6948-0

www.jungheinrich.com www.jungheinrich.com
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Contents Contents
A Correct Use and Application ................................................... 11 A Correct Use and Application ................................................... 11
1 General.................................................................................................... 11 1 General.................................................................................................... 11
2 Correct application................................................................................... 11 2 Correct application................................................................................... 11
3 Approved application conditions .............................................................. 11 3 Approved application conditions .............................................................. 11
4 Proprietor responsibilities ........................................................................ 12 4 Proprietor responsibilities ........................................................................ 12
5 Adding attachments and/or accessories.................................................. 12 5 Adding attachments and/or accessories.................................................. 12
B Truck Description .................................................................... 13 B Truck Description .................................................................... 13

1 Application ............................................................................................... 13 1 Application ............................................................................................... 13
2 Assemblies and Functional Description................................................... 14 2 Assemblies and Functional Description................................................... 14
2.1 Assembly Overview ................................................................................. 14 2.1 Assembly Overview ................................................................................. 14
2.2 Functional Description ............................................................................. 15 2.2 Functional Description ............................................................................. 15
3 Technical Specifications .......................................................................... 17 3 Technical Specifications .......................................................................... 17
3.1 Performance data .................................................................................... 17 3.1 Performance data .................................................................................... 17
3.2 Dimensions.............................................................................................. 18 3.2 Dimensions.............................................................................................. 18
3.3 Weights.................................................................................................... 23 3.3 Weights.................................................................................................... 23
3.4 Tyre type.................................................................................................. 23 3.4 Tyre type.................................................................................................. 23
3.5 EN norms................................................................................................. 24 3.5 EN norms................................................................................................. 24
3.6 Conditions of use..................................................................................... 24 3.6 Conditions of use..................................................................................... 24
3.7 Electrical requirements ............................................................................ 24 3.7 Electrical requirements ............................................................................ 24
3.8 Identification points and data plates ........................................................ 25 3.8 Identification points and data plates ........................................................ 25
C Transport and Commissioning ................................................ 29 C Transport and Commissioning ................................................ 29

1 Lifting by crane ........................................................................................ 29 1 Lifting by crane ........................................................................................ 29
2 Transport ................................................................................................. 30 2 Transport ................................................................................................. 30
3 Using the Truck for the First Time ........................................................... 31 3 Using the Truck for the First Time ........................................................... 31
D Battery - Servicing, Recharging, Replacement ....................... 33 D Battery - Servicing, Recharging, Replacement ....................... 33
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 33 1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 33
2 Battery types............................................................................................ 35 2 Battery types............................................................................................ 35
3 Exposing the battery................................................................................ 36 3 Exposing the battery................................................................................ 36
4 Charging the battery ................................................................................ 37 4 Charging the battery ................................................................................ 37
5 Battery removal and installation .............................................................. 38 5 Battery removal and installation .............................................................. 38
5.1 Removing the battery from the top .......................................................... 39 5.1 Removing the battery from the top .......................................................... 39
5.2 Removing the battery from the side......................................................... 40 5.2 Removing the battery from the side......................................................... 40
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E Operation ................................................................................ 41 E Operation ................................................................................ 41
1 Safety Regulations for the Operation of the Forklift Truck....................... 41 1 Safety Regulations for the Operation of the Forklift Truck....................... 41
2 Displays and Controls.............................................................................. 43 2 Displays and Controls.............................................................................. 43
2.1 Battery discharge indicator ...................................................................... 46 2.1 Battery discharge indicator ...................................................................... 46
3 Starting up the truck ................................................................................ 47 3 Starting up the truck ................................................................................ 47
3.1 Checks and operations to be performed before starting daily operation . 47 3.1 Checks and operations to be performed before starting daily operation . 47
3.2 Preparing the truck for operation ............................................................. 48 3.2 Preparing the truck for operation ............................................................. 48
3.3 Parking the truck securely ....................................................................... 49 3.3 Parking the truck securely ....................................................................... 49
3.4 Battery discharge monitor........................................................................ 49 3.4 Battery discharge monitor........................................................................ 49
4 Industrial Truck Operation ....................................................................... 50 4 Industrial Truck Operation ....................................................................... 50
4.1 Safety regulations for truck operation...................................................... 50 4.1 Safety regulations for truck operation...................................................... 50
4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 52 4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 52
4.3 Lifting, transporting and depositing loads ................................................ 58 4.3 Lifting, transporting and depositing loads ................................................ 58
5 Troubleshooting....................................................................................... 61 5 Troubleshooting....................................................................................... 61
5.1 Truck does not start................................................................................. 61 5.1 Truck does not start................................................................................. 61
5.2 Load cannot be lifted ............................................................................... 61 5.2 Load cannot be lifted ............................................................................... 61
6 Operating the truck without its own drive system .................................... 63 6 Operating the truck without its own drive system .................................... 63
7 Optional equipment ................................................................................. 65 7 Optional equipment ................................................................................. 65
7.1 CanCode keypad..................................................................................... 65 7.1 CanCode keypad..................................................................................... 65
7.2 Setting the truck parameters with CanCode............................................ 70 7.2 Setting the truck parameters with CanCode............................................ 70
7.3 Traction controller AS2412i parameters .................................................. 72 7.3 Traction controller AS2412i parameters .................................................. 72
7.4 AS2412iS combi controller parameters ................................................... 77 7.4 AS2412iS combi controller parameters ................................................... 77
7.5 CanDis display instrument....................................................................... 84 7.5 CanDis display instrument....................................................................... 84
7.6 ISM access module (o)........................................................................... 85 7.6 ISM access module (o)........................................................................... 85
7.7 Curve Control .......................................................................................... 85 7.7 Curve Control .......................................................................................... 85
F Industrial Truck Maintenance .................................................. 87 F Industrial Truck Maintenance .................................................. 87

1 Operational Safety and Environmental Protection................................... 87 1 Operational Safety and Environmental Protection................................... 87
2 Maintenance Safety Regulations............................................................. 87 2 Maintenance Safety Regulations............................................................. 87
3 Servicing and Inspection ......................................................................... 92 3 Servicing and Inspection ......................................................................... 92
4 Maintenance checklist ERE 225 fixed platform ....................................... 93 4 Maintenance checklist ERE 225 fixed platform ....................................... 93
4.1 Proprietor................................................................................................. 93 4.1 Proprietor................................................................................................. 93
4.2 Customer Service .................................................................................... 94 4.2 Customer Service .................................................................................... 94
5 Maintenance checklist ERE 225 folding platform .................................... 98 5 Maintenance checklist ERE 225 folding platform .................................... 98
5.1 Proprietor................................................................................................. 98 5.1 Proprietor................................................................................................. 98
5.2 Customer Service .................................................................................... 99 5.2 Customer Service .................................................................................... 99
6 Lubricants and Lubrication Schedule ...................................................... 103 6 Lubricants and Lubrication Schedule ...................................................... 103
6.1 Handling consumables safely .................................................................. 103 6.1 Handling consumables safely .................................................................. 103
6.2 Lubrication Schedule ............................................................................... 105 6.2 Lubrication Schedule ............................................................................... 105
6.3 Consumables........................................................................................... 106 6.3 Consumables........................................................................................... 106
7 Maintenance and repairs ......................................................................... 107 7 Maintenance and repairs ......................................................................... 107
7.1 Preparing the truck for maintenance and repairs .................................... 107 7.1 Preparing the truck for maintenance and repairs .................................... 107
7.2 Replacing the drive wheel ....................................................................... 108 7.2 Replacing the drive wheel ....................................................................... 108
7.3 Checking the hydraulic oil level ............................................................... 108 7.3 Checking the hydraulic oil level ............................................................... 108
7.4 Removing the front panel ........................................................................ 108 7.4 Removing the front panel ........................................................................ 108
7.5 Checking electrical fuses......................................................................... 110 7.5 Checking electrical fuses......................................................................... 110
7.6 Restoring the truck to service after maintenance and repairs ................. 112 7.6 Restoring the truck to service after maintenance and repairs ................. 112
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8 Safety tests to be performed at intervals and after unusual incidents ..... 113 8 Safety tests to be performed at intervals and after unusual incidents ..... 113
9 Decommissioning the industrial truck ...................................................... 114 9 Decommissioning the industrial truck ...................................................... 114
8 8
9.1 Before taking the truck out of service ...................................................... 114 9.1 Before taking the truck out of service ...................................................... 114
9.2 Action to be taken during decommissioning ............................................ 115 9.2 Action to be taken during decommissioning ............................................ 115
9.3 Restoring the truck to service after decommissioning ............................. 116 9.3 Restoring the truck to service after decommissioning ............................. 116
10 Final de-commissioning, disposal............................................................ 116 10 Final de-commissioning, disposal............................................................ 116
11 Human vibration measurement ............................................................... 117 11 Human vibration measurement ............................................................... 117
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10
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Appendix Appendix
JH Traction Battery Operating Instructions JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB
0506.GB
1 1
2
0506.GB
0506.GB
A Correct Use and Application A Correct Use and Application
1 General 1 General
The industrial truck described in the present operating instructions is designed for The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units. lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions. It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property. personnel, the industrial truck or property.
2 Correct application 2 Correct application
NOTE NOTE
The maximum load and load distance are indicated on the load chart and must not be The maximum load and load distance are indicated on the load chart and must not be
exceeded. exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the The load must rest on the load handler or be lifted by an attachment approved by the
manufacturer. manufacturer.
The load must rest on the back of the fork carriage and centrally between the forks. The load must rest on the back of the fork carriage and centrally between the forks.
– Lifting and lowering of loads. – Lifting and lowering of loads.

– Transporting lowered loads. – Transporting lowered loads.
– Do not carry or lift passengers. – Do not carry or lift passengers.
– Do push or pull load units. – Do push or pull load units.
3 Approved application conditions 3 Approved application conditions

– Operation in industrial and commercial environments. – Operation in industrial and commercial environments.
– Permissible temperature range -10°C to 40°C. – Permissible temperature range -10°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity. – Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor. – Operation only on routes that are visible and approved by the proprietor.
– Inclines of max. 8 % may be negotiated with load, and 16 % without load. – Inclines of max. 8 % may be negotiated with load, and 16 % without load.
– Do not travel across or at an angle on inclines. Travel with the load facing uphill. – Do not travel across or at an angle on inclines. Travel with the load facing uphill.
– Operation in partially public traffic. – Operation in partially public traffic.
Z Special equipment and authorisation are required if the truck is to be used in Z Special equipment and authorisation are required if the truck is to be used in
extreme conditions. extreme conditions.
The truck is not authorised for use in areas at risk of explosion. The truck is not authorised for use in areas at risk of explosion.
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4 Proprietor responsibilities 4 Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as For the purposes of the present operating instructions the “proprietor” is defined as
any natural or legal person who either uses the industrial truck himself, or on whose any natural or legal person who either uses the industrial truck himself, or on whose
behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered
the person who, in accordance with existing contractual agreements between the the person who, in accordance with existing contractual agreements between the
owner and user of the industrial truck, is charged with operational duties. owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose for The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions. ensure that all users have read and understood these operating instructions.
NOTE NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer. parties without the permission of the manufacturer.
5 Adding attachments and/or accessories 5 Adding attachments and/or accessories

Adding accessories Adding accessories
The mounting or installation of additional equipment which affects or enhances the The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer. performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained. Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval. Local authority approval does not however constitute the manufacturer’s approval.
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B Truck Description B Truck Description
1 Application 1 Application
The forklift truck is a tiller-operated electric pallet truck with either a fixed or a folding The forklift truck is a tiller-operated electric pallet truck with either a fixed or a folding
operator platform. It is designed for transporting goods on level surfaces. Open operator platform. It is designed for transporting goods on level surfaces. Open
bottom pallets or pallets with transverse boards (provided that the boards are outside bottom pallets or pallets with transverse boards (provided that the boards are outside
the perimeter of the load wheels) can be lifted. the perimeter of the load wheels) can be lifted.
The rated capacity of the truck is shown on the data plate or capacity plate Qmax. The rated capacity of the truck is shown on the data plate or capacity plate Qmax.
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2 Assemblies and Functional Description 2 Assemblies and Functional Description
2.1 Assembly Overview 2.1 Assembly Overview
1 2 3,4,5 1 2 3,4,5
6 6
7 7
8 8
9 9
10 10
12 11 12 11
13 13
Item Component Item Component Item Component Item Component

1 t Travel switch 7 t Folding side restraint 1 t Travel switch 7 t Folding side restraint
2 t Tiller 8 o Folding operator platform 2 t Tiller 8 o Folding operator platform
3 t Charge indicator 9 o Tiller height adjuster 3 t Charge indicator 9 o Tiller height adjuster
4 o CanCode 10 t Fixed operator platform 4 o CanCode 10 t Fixed operator platform
o CanDis 11 t Caster wheel o CanDis 11 t Caster wheel
o ISM 12 o Skirt o ISM 12 o Skirt
5 t Key switch 13 t Drive wheel 5 t Key switch 13 t Drive wheel

Emergency Disconnect (main Emergency Disconnect (main
6 t 6 t
switch) switch)
t = Standard version o = Option t = Standard version o = Option

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2.2 Functional Description 2.2 Functional Description
Safety Mechanisms Safety Mechanisms
– An enclosed, smooth truck geometry with rounded edges ensures safe handling of – An enclosed, smooth truck geometry with rounded edges ensures safe handling of
the truck. the truck.
– The wheels are surrounded by a solid skirt. – The wheels are surrounded by a solid skirt.
– Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions – Pressing the Emergency Disconnect switch rapidly cuts out all electrical functions
in hazardous situations. in hazardous situations.
Hydraulic system Hydraulic system
– Lifting and lowering are activated via the lift and lower buttons. – Lifting and lowering are activated via the lift and lower buttons.
– When lifting is activated, the pump unit starts to operate, supplying hydraulic oil – When lifting is activated, the pump unit starts to operate, supplying hydraulic oil
from the oil reservoir to the lift cylinder. from the oil reservoir to the lift cylinder.
Emergency Stop safety feature Emergency Stop safety feature
– The emergency stop is activated by the traction controller. – The emergency stop is activated by the traction controller.
– The steering controller sends a system status signal which is monitored by the – The steering controller sends a system status signal which is monitored by the
traction controller. If the signal fails to appear or a fault is identified the truck traction controller. If the signal fails to appear or a fault is identified the truck
automatically brakes to a halt. Control displays on the driver’s display indicate the automatically brakes to a halt. Control displays on the driver’s display indicate the
emergency stop. emergency stop.
– Each time the truck is switched on the system performed an automatic diagnosis. – Each time the truck is switched on the system performed an automatic diagnosis.
Operator position Operator position
– All travel and lift operations can be performed sensitively without having to reach. – All travel and lift operations can be performed sensitively without having to reach.
– Tiller for secure control of the industrial truck. – Tiller for secure control of the industrial truck.
– The truck can either be equipped with a fixed or folding operator platform and – The truck can either be equipped with a fixed or folding operator platform and
moving side arms. moving side arms.
Operator platform Operator platform
– Travel functions are only released when the driver stands on the operator platform. – Travel functions are only released when the driver stands on the operator platform.
Drive system Drive system
– A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox. – A fixed AC threephase motor actuates the drive wheel via a bevel spur gearbox.
– The electronic traction controller ensures smooth drive motor speed control and – The electronic traction controller ensures smooth drive motor speed control and
hence smooth travel, powerful acceleration and electrically controlled braking with hence smooth travel, powerful acceleration and electrically controlled braking with
energy regeneration. energy regeneration.
– The driver can choose from 3 travel programs, depending on the load and the – The driver can choose from 3 travel programs, depending on the load and the
environment. from maximum performance to energy saving. environment. from maximum performance to energy saving.
Steering Steering
– The driver steers with a tiller. – The driver steers with a tiller.
– The steering motion is transmitted directly from the steering controller via a steer – The steering motion is transmitted directly from the steering controller via a steer
motor directly to the ring gear of the pivoted drive system. motor directly to the ring gear of the pivoted drive system.
– The progressive electric steering allows for a 90° turn of the drive wheel when the – The progressive electric steering allows for a 90° turn of the drive wheel when the
tiller is turned only 70°. tiller is turned only 70°.
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Electric Steering Electric Steering
– The electric steering system is self-monitoring. – The electric steering system is self-monitoring.
The steering controller permanently monitors the entire steering system. If an error The steering controller permanently monitors the entire steering system. If an error
is detected the traction controller interrupts travel, brakes regeneratively and the is detected the traction controller interrupts travel, brakes regeneratively and the
magnetic brake is applied. magnetic brake is applied.
Electrical System Electrical System
– 24 volt system. – 24 volt system.

– Standard electronic traction, lift and steering control are standard. – Standard electronic traction, lift and steering control are standard.
Controls and Displays Controls and Displays
– Ergonomic controls ensure fatigue-free operation for sensitive application of the – Ergonomic controls ensure fatigue-free operation for sensitive application of the
travel operations. travel operations.
– The battery discharge indicator shows the available battery capacity. – The battery discharge indicator shows the available battery capacity.
– The optional CanDis displays show the key driver information and travel program, – The optional CanDis displays show the key driver information and travel program,
service hours, battery capacity and event messages. service hours, battery capacity and event messages.
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3 Technical Specifications 3 Technical Specifications
Z Technical specification details in accordance with VDI 2198. Technical Z Technical specification details in accordance with VDI 2198. Technical
modifications and additions reserved. modifications and additions reserved.
3.1 Performance data 3.1 Performance data
ERE 225 ERE 225

Q Rated capacity 2500 kg Q Rated capacity 2500 kg
c Load centre distance with standard fork length 600 mm c Load centre distance with standard fork length 600 mm
Travel speed w / w.o. rated load 9.5 / 12.5 km/h Travel speed w / w.o. rated load 9.5 / 12.5 km/h
Lift speed with / without rated load 0.05 / 0.06 m/s Lift speed with / without rated load 0.05 / 0.06 m/s
Lowering speed with / without load 0.055 / 0.04 m/s Lowering speed with / without load 0.055 / 0.04 m/s
Max. gradeability (5 min) w / w.o. load 8.0 / 16.0 % Max. gradeability (5 min) w / w.o. load 8.0 / 16.0 %
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3.2 Dimensions 3.2 Dimensions
ERE 225 ERE 225

h13 Lowered fork height 85 mm h13 Lowered fork height 85 mm
h14 Truck with fixed operator platform min mm h14 Truck with fixed operator platform min mm
1254 / 1314 1254 / 1314
/ max / max
Truck with folding operator platform mm Truck with folding operator platform mm
1158 / 1414 1158 / 1414
min / max min / max
h3 Rated lift 122 mm h3 Rated lift 122 mm
l2 For truck with fixed operatorplatform1) 1243 mm l2 For truck with fixed operatorplatform1) 1243 mm
For truck with fixed operator platform1) 834 mm For truck with fixed operator platform1) 834 mm
b1 Truck width 770 mm b1 Truck width 770 mm

y Wheelbase 2) 1482 mm y Wheelbase 2) 1482 mm
m2 Ground clearance centre wheelbase 30 mm m2 Ground clearance centre wheelbase 30 mm
b5 Outside straddle 510/540/670 mm b5 Outside straddle 510/540/670 mm
e Fork width 172 mm e Fork width 172 mm
s Fork thickness 55 mm s Fork thickness 55 mm
a Safety distance 200 mm a Safety distance 200 mm
Net weight: See truck data plate Net weight: See truck data plate
1) Depending on the truck design and the load frame, see table for 1) Depending on the truck design and the load frame, see table for
respective specifications respective specifications
2) Dimensions with top battery removal 2) Dimensions with top battery removal
Dimensions with side battery removal: +72.5 mm Dimensions with side battery removal: +72.5 mm
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3.2.1 Specification sheet for industrial truck with fixed standing platform 3.2.1 Specification sheet for industrial truck with fixed standing platform
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ERE 225 working aisle widths ERE 225 working aisle widths
Headlength I2 = 1,243 mm (fixed operator platform) Headlength I2 = 1,243 mm (fixed operator platform)
(all dimensions in mm) (all dimensions in mm)
l l12) y 1)2) x 1) l6 Wa1) 2) Ast2) l l12) y 1)2) x 1) l6 Wa1) 2) Ast2)

1000 2243 1331 761 1000 2004 2443 1000 2243 1331 761 1000 2004 2443
1150 2393 1481 911 1200 2154 2643 1150 2393 1481 911 1200 2154 2643
1200 2443 1531 961 1200 2204 2643 1200 2443 1531 961 1200 2204 2643
1400 2643 1731 1161 1400 2404 2843 1400 2643 1731 1161 1400 2404 2843
1600 2843 1931 1361 1600 2604 3043 1600 2843 1931 1361 1600 2604 3043
1750 2993 1707 1137 1800 2380 3243 1750 2993 1707 1137 1800 2380 3243
1800 3043 1757 1187 1800 2430 3243 1800 3043 1757 1187 1800 2430 3243
1950 3193 1907 1337 2000 2580 3443 1950 3193 1907 1337 2000 2580 3443
2150 3393 2107 1537 2150 2780 3593 2150 3393 2107 1537 2150 2780 3593
2150 3393 1867 1297 2150 2540 3593 2150 3393 1867 1297 2150 2540 3593
2400 3643 2731 2161 2400 3404 3843 2400 3643 2731 2161 2400 3404 3843
2400 3643 2357 1787 2400 3030 3843 2400 3643 2357 1787 2400 3030 3843
2400 3643 2117 1547 2400 2790 3843 2400 3643 2117 1547 2400 2790 3843
l1 = l2 + l l1 = l2 + l
Ast = Wa + l6 - x + a (pallet length, a = 200 mm) Ast = Wa + l6 - x + a (pallet length, a = 200 mm)
1) 1)
Load section raised; if load section lowered: +53 mm Load section raised; if load section lowered: +53 mm
2) 2)
Dimensions with top battery removal Dimensions with top battery removal
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3.2.2 Dimensions sheet for industrial truck with folding standing platform 3.2.2 Dimensions sheet for industrial truck with folding standing platform
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ERE 225 working aisle widths ERE 225 working aisle widths
Headlength I2 = 834 mm 2) (folding operator platform) Headlength I2 = 834 mm 2) (folding operator platform)
(all dimensions in mm) (all dimensions in mm)
l l12) y 1)2) x 1) l6 Wa1)2)3) Ast2)3) l l12) y 1)2) x 1) l6 Wa1)2)3) Ast2)3)

1000 1834 1331 761 1000 1595 2034 1000 1834 1331 761 1000 1595 2034
1150 1984 1481 911 1200 1745 2234 1150 1984 1481 911 1200 1745 2234
1200 2034 1531 961 1200 1795 2234 1200 2034 1531 961 1200 1795 2234
1400 2234 1731 1161 1400 1995 2434 1400 2234 1731 1161 1400 1995 2434
1600 2434 1931 1361 1600 2195 2634 1600 2434 1931 1361 1600 2195 2634
1750 2584 1707 1137 1800 1971 2834 1750 2584 1707 1137 1800 1971 2834
1800 2634 1757 1187 1800 2021 2834 1800 2634 1757 1187 1800 2021 2834
1950 2784 1907 1337 2000 2171 2034 1950 2784 1907 1337 2000 2171 2034
2150 2984 2107 1537 2150 2371 3184 2150 2984 2107 1537 2150 2371 3184
2150 2984 1867 1297 2150 2131 3184 2150 2984 1867 1297 2150 2131 3184
2400 2334 2731 2161 2400 2995 3434 2400 2334 2731 2161 2400 2995 3434
2400 3234 2357 1787 2400 2621 3434 2400 3234 2357 1787 2400 2621 3434
2400 3234 2117 1547 2400 2381 3434 2400 3234 2117 1547 2400 2381 3434
l1 = l2 + l l1 = l2 + l
Ast = Wa + l6 - x + a (pallet length, a = 200 mm) Ast = Wa + l6 - x + a (pallet length, a = 200 mm)
1) 1)
Load section raised; if load section lowered: +53 mm Load section raised; if load section lowered: +53 mm
2) 2)
Dimensions with top battery removal Dimensions with top battery removal
3) Dimensions for rider mode: +384 mm 3) Dimensions for rider mode: +384 mm
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3.3 Weights 3.3 Weights
ERE 225 ERE 225 ERE 225 ERE 225

(fixed operator (folding operator (fixed operator (folding operator
platform) platform) platform) platform)
Net weight excl. battery 562 503 kg Net weight excl. battery 562 503 kg
Axle load, w. load Axle load, w. load
2150 / 1200 2104 / 1187 kg 2150 / 1200 2104 / 1187 kg
front/rear + battery front/rear + battery
Axle load, w.o. load Axle load, w.o. load
160 / 690 159 / 632 kg 160 / 690 159 / 632 kg
front/rear + battery front/rear + battery
Battery weight (see "Battery types" on page 35) kg Battery weight (see "Battery types" on page 35) kg
3.4 Tyre type 3.4 Tyre type
ERE 220 (fixed ERE 225 (folding ERE 220 (fixed ERE 225 (folding
standing platform) standing platform) standing platform) standing platform)
Tyre size, drive 230 / 77 230 / 77 Tyre size, drive 230 / 77 230 / 77
Tyre size, load section 85 / 110 85 / 110 Tyre size, load section 85 / 110 85 / 110
Castor wheel (twin wheel) 140 X 57 140 X 57 Castor wheel (twin wheel) 140 X 57 140 X 57
Wheels, number front/rear Wheels, number front/rear
1x +2 /2 1x +2 /2 1x +2 /2 1x +2 /2
(x = driven) (x = driven)
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3.5 EN norms 3.5 EN norms
Noise emission level Noise emission level
– ERE 225: 66 dB(A) – ERE 225: 66 dB(A)
in accordance with EN 12053 as harmonised with ISO 4871. in accordance with EN 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and 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 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. level is measured at the level of the driver's ear.
Vibration Vibration
– ERE 225: 0,81 m/s² – ERE 225: 0,81 m/s²

in accordance with EN 13059 in accordance with EN 13059
Z The vibration acceleration acting on the body in the operating position is, in Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over bumps at acceleration in the vertical direction. It is calculated when travelling over bumps at
constant speed. These recordings were taken on a single occasion and must not constant speed. These recordings were taken on a single occasion and must not
be confused with the human vibrations of the "2002/44/EC/Vibrations" operator be confused with the human vibrations of the "2002/44/EC/Vibrations" operator
directive. The manufacturer offers a special service to measure these human directive. The manufacturer offers a special service to measure these human
vibrations, (see "Human vibration measurement" on page 117). vibrations, (see "Human vibration measurement" on page 117).
Electromagnetic compatibility (EMC) Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic 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 emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein. with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer. made without the written agreement of the manufacturer.
3.6 Conditions of use 3.6 Conditions of use

Ambient temperature Ambient temperature
– operating at -10°C to 40°C – operating at -10°C to 40°C

Z Special equipment and authorisation are required if the truck is to be constantly Z Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations. used in conditions of extreme temperature or air humidity fluctuations.
Z Special equipment and authorisation are required if the truck is to be used in Z Special equipment and authorisation are required if the truck is to be used in
extreme conditions (e.g. cold stores). extreme conditions (e.g. cold stores).
The truck is not authorised for use in areas at risk of explosion. The truck is not authorised for use in areas at risk of explosion.
3.7 Electrical requirements 3.7 Electrical requirements

The manufacturer certifies compliance with the requirements for the design and The manufacturer certifies compliance with the requirements for the design and
manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -
Electrical Requirements", provided the truck is used according to its purpose. Electrical Requirements", provided the truck is used according to its purpose.
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3.8 Identification points and data plates 3.8 Identification points and data plates
14 14
15 15
Qmax XXX kg Qmax XXX kg

16 16
17 17
18 18
19 19
20 20
Item Component Item Component

14 Serial number 14 Serial number
15 Strap points for crane lifting 15 Strap points for crane lifting
16 Capacity Qmax 16 Capacity Qmax
17 Battery data plate 17 Battery data plate
18 Model name 18 Model name
19 Test plaque 19 Test plaque
20 Data plate 20 Data plate
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Qmax XXX kg Qmax XXX kg
16 14 16 14
15 15
19 19
17 17
20 20
Item Component Item Component

15 Strap points for crane lifting 15 Strap points for crane lifting
16 Capacity Qmax 16 Capacity Qmax
17 Battery data plate 17 Battery data plate
19 Test plaque 19 Test plaque
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3.8.1 Data plate 3.8.1 Data plate
21 22 23 24 25 26 27 21 22 23 24 25 26 27
28 28
29 29
30 30
31 31
32 32
Item Description Item Description Item Description Item Description

21 Type 27 Year of manufacture 21 Type 27 Year of manufacture
22 Serial number 28 Load centre (mm) 22 Serial number 28 Load centre (mm)
23 Rated capacity (kg) 29 Output 23 Rated capacity (kg) 29 Output
24 Battery voltage (V) 30 Min./max. battery weight (kg) 24 Battery voltage (V) 30 Min./max. battery weight (kg)
25 Net weight w.o. battery (kg) 31 Manufacturer 25 Net weight w.o. battery (kg) 31 Manufacturer
26 Option 32 Manufacturer’s logo 26 Option 32 Manufacturer’s logo
Z For queries regarding the truck or ordering spare parts always quote the truck serial Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (22). number (22).
3.8.2 Truck load chart 3.8.2 Truck load chart
Qmax XXX kg 16
Qmax XXX kg 16
The load chart (16) gives the capacity (Q) of the truck in kg assuming the load on the The load chart (16) gives the capacity (Q) of the truck in kg assuming the load on the
load handler is evenly distributed. load handler is evenly distributed.
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28
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C Transport and Commissioning C Transport and Commissioning
1 Lifting by crane 1 Lifting by crane
WARNING! WARNING!
Improper lifting by crane can result in accidents Improper lifting by crane can result in accidents
The use of unsuitable lifting gear can cause the truck to crash when being lifted by The use of unsuitable lifting gear can cause the truck to crash when being lifted by
crane. crane.
Prevent the truck from striking other objects when it is being raised, and avoid any Prevent the truck from striking other objects when it is being raised, and avoid any
involuntary movements. If necessary secure the truck with guide ropes. involuntary movements. If necessary secure the truck with guide ropes.
The truck should only be handled by people who are trained in using lifting slings The truck should only be handled by people who are trained in using lifting slings
and tools. and tools.
Wear safety shoes when lifting the truck by crane. Wear safety shoes when lifting the truck by crane.
Do not stand under a swaying load. Do not stand under a swaying load.
Do not walk into or stand in a hazardous area. Do not walk into or stand in a hazardous area.
Always use lifting gear with sufficient capacity (for truck weight see truck data Always use lifting gear with sufficient capacity (for truck weight see truck data
plate). plate).
Always attach the crane slings to the prescribed strap points and prevent them from Always attach the crane slings to the prescribed strap points and prevent them from
slipping. slipping.
Use the lifting gear only in the prescribed load direction. Use the lifting gear only in the prescribed load direction.
Crane slings should be fastened in such a way that they do not come into contact Crane slings should be fastened in such a way that they do not come into contact
with any attachments when lifting. with any attachments when lifting.
Lifting the truck by crane Lifting the truck by crane

15 15 15 15 15 15
Requirements Requirements
– Park the truck securely, (see – Park the truck securely, (see
"Parking the truck securely" on "Parking the truck securely" on
page 49). page 49).
Tools and Material Required Tools and Material Required

– Lifting gear – Lifting gear
– Crane lifting gear – Crane lifting gear
Procedure Procedure
• Secure the lifting slings to the strap • Secure the lifting slings to the strap
points (15). points (15).
The truck can now be lifted by crane. The truck can now be lifted by crane.
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2 Transport 2 Transport
WARNING! WARNING!
Accidental movement during transport Accidental movement during transport

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

– Tension belts/tie down straps – Tension belts/tie down straps
Procedure Procedure
• Move the truck onto the transporting • Move the truck onto the transporting
truck. truck.
• Park the truck securely, (see 34 • Park the truck securely, (see 34
page 49). page 49).
• Strap the belts (34) around the truck • Strap the belts (34) around the truck
and tension them sufficiently. and tension them sufficiently.
The truck can now be transported. The truck can now be transported.
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3 Using the Truck for the First Time 3 Using the Truck for the First Time
CAUTION! CAUTION!
Only operate the truck with battery current. Rectified AC current will damage the Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less electronic components. Cable connections to the battery (tow leads) must be less
than 6 m long and have a minimum cross-section of 50 mm². than 6 m long and have a minimum cross-section of 50 mm².
Procedure Procedure
• Check the equipment is complete. • Check the equipment is complete.
• If necessary install the battery, (see "Battery removal and installation" on page 38) • If necessary install the battery, (see "Battery removal and installation" on page 38)
• Charge the battery, (see "Charging the battery" on page 37). • Charge the battery, (see "Charging the battery" on page 37).
The truck can now be started, (see "Starting up the truck" on page 47) The truck can now be started, (see "Starting up the truck" on page 47)
NOTE NOTE
Cold store trucks Cold store trucks

Trucks designed for use in cold stores have a cold store hydraulic oil and a Trucks designed for use in cold stores have a cold store hydraulic oil and a
protective frame instead of a mast guard on the mast. protective frame instead of a mast guard on the mast.
If a truck with cold store oil is used outside the cold store, the lowering speeds may If a truck with cold store oil is used outside the cold store, the lowering speeds may
increase. increase.
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32
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D Battery - Servicing, Recharging, D Battery - Servicing, Recharging,
Replacement Replacement
1 Safety Regulations Governing the Handling of Lead-Acid 1 Safety Regulations Governing the Handling of Lead-Acid
Batteries Batteries
Maintenance personnel Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This Batteries may only be charged, serviced or replaced by trained personnel. This
operator manual and the manufacturer’s instructions concerning batteries and operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work. charging stations must be observed when carrying out the work.
Fire protection Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever an 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 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 lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand. ventilated. Fire protection equipment must be on hand.
Battery maintenance Battery maintenance
The battery cell covers must be kept dry and clean. The terminals and cable shoes The battery cell covers must be kept dry and clean. The terminals and cable shoes
must be clean, secure and have a light coating of dielectric grease. must be clean, secure and have a light coating of dielectric grease.
CAUTION! CAUTION!
Before closing the battery panel make sure that the battery cable cannot be Before closing the battery panel make sure that the battery cable cannot be
damaged. There is a risk of short circuits with damaged cables. damaged. There is a risk of short circuits with damaged cables.
Battery disposal Battery disposal
Batteries may only be disposed of in accordance with national environmental Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions protection regulations or disposal laws. The manufacturer’s disposal instructions
must be followed. must be followed.
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WARNING! WARNING!
Batteries can be hazardous Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Avoid contact Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times. with battery acid at all times.
Dispose of used battery acid in accordance with regulations. Dispose of used battery acid in accordance with regulations.
Always wear protective clothing and goggles when working with batteries. Always wear protective clothing and goggles when working with batteries.
Do not let battery acid come into contact with skin, clothing or eyes. If necessary, Do not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water. rinse with plenty of clean water.
In the event of physical damage (e.g. skin or eye contact with battery acid) call for In the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately. a doctor immediately.
Spilled battery acid should be neutralised immediately with plenty of water. Spilled battery acid should be neutralised immediately with plenty of water.
Only batteries with a sealed battery container may be used. Only batteries with a sealed battery container may be used.
Follow national guidelines and legislation. Follow national guidelines and legislation.
WARNING! WARNING!
Unsuitable batteries that have not been approved by Jungheinrich for the truck Unsuitable batteries that have not been approved by Jungheinrich for the truck
can be hazardous can be hazardous
The design, weight and dimensions of the battery have a considerable effect on the 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 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 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 lead to a deterioration of the braking system during energy recovery operations and
also cause considerable damage to the electrical control system. The use of batteries also cause considerable damage to the electrical control system. The use of batteries
that have not been approved by Jungheinrich can therefore affect the health and that have not been approved by Jungheinrich can therefore affect the health and
safety of personnel. safety of personnel.
Only manufacturer-approved batteries may be used on the truck. Only manufacturer-approved batteries may be used on the truck.
Replacement of the battery equipment requires the manufacturer's agreement. Replacement of the battery equipment requires the manufacturer's agreement.
When replacing/installing the battery make sure the battery is securely located in When replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck. the battery compartment of the truck.
Do not use batteries that have not been approved by the manufacturer. Do not use batteries that have not been approved by the manufacturer.
Park the truck securely before carrying out any work on the batteries ((see "Parking Park the truck securely before carrying out any work on the batteries ((see "Parking
the truck securely" on page 49)). the truck securely" on page 49)).
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2 Battery types 2 Battery types
Depending on the model, the truck will be supplied with different battery types. The Depending on the model, the truck will be supplied with different battery types. The
following table shows which combinations are included as standard: following table shows which combinations are included as standard:
Tray type Battery type Capacity Weight Tray type Battery type Capacity Weight
ERE L tray 24 volt battery ERE L tray 24 volt battery
3 EPzS 375 Ah 302 kg 3 EPzS 375 Ah 302 kg
624x284x627 mm (Lxwxh) 624x284x627 mm (Lxwxh)
24 volt battery 3 EPzV 300 Ah 302 kg 24 volt battery 3 EPzV 300 Ah 302 kg
624x284x627 mm (Lxwxh) maintenance-free 624x284x627 mm (Lxwxh) maintenance-free
24 volt battery 3 PzW 330 Ah - 288 kg 24 volt battery 3 PzW 330 Ah - 288 kg
624X284X627 mm maintenance-free 624X284X627 mm maintenance-free
(LXWXH) 200 (LXWXH) 200
ERE L tray 24 volt battery 3 EPzS 450 Ah ERE L tray 24 volt battery 3 EPzS 450 Ah
302 kg 302 kg
Side battery 624x284x627 mm (Lxwxh) HX Side battery 624x284x627 mm (Lxwxh) HX
removal 24 volt battery 3 EPzV 300 Ah 302 kg removal 24 volt battery 3 EPzV 300 Ah 302 kg
624x284x627 mm (Lxwxh) maintenance-free 624x284x627 mm (Lxwxh) maintenance-free
24 volt battery 3 PzW 330 Ah - 288 kg 24 volt battery 3 PzW 330 Ah - 288 kg
624X284X627 mm maintenance-free 624X284X627 mm maintenance-free
(LXWXH) 200 (LXWXH) 200
ERE L tray, high 24 V - Battery 3 EPzS 465 Ah 370 kg ERE L tray, high 24 V - Battery 3 EPzS 465 Ah 370 kg
Side battery 798X212X627 mm Side battery 798X212X627 mm
removal (LXWXH) removal (LXWXH)
The battery weights can be taken from the battery data plate. Batteries with non The battery weights can be taken from the battery data plate. Batteries with non
insulated terminals must be covered with a non slip insulating mat. insulated terminals must be covered with a non slip insulating mat.
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3 Exposing the battery 3 Exposing the battery
CAUTION! CAUTION!
Trapping hazard Trapping hazard

Make sure there is nothing between the battery cover and the truck when you fit the Make sure there is nothing between the battery cover and the truck when you fit the
battery cover. battery cover.
WARNING! WARNING!
An unsecured truck can cause accidents An unsecured truck can cause accidents
Parking the truck on an incline or with a raised load handler is dangerous and is Parking the truck on an incline or with a raised load handler is dangerous and is
strictly prohibited. strictly prohibited.
Always park the truck on a level surface. In special cases the truck may need to be Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges. secured with wedges.
Always fully lower the mast and forks. Always fully lower the mast and forks.
Select a place to park where no other people are at risk of injury from lowering Select a place to park where no other people are at risk of injury from lowering
forks. forks.
35 35
– Park the truck on a level surface. 36 – Park the truck on a level surface. 36
– Park the truck securely, (see – Park the truck securely, (see
page 49). 6 page 49). 6
Procedure Procedure
• Depress the Emergency • Depress the Emergency
Disconnect (6). Disconnect (6).
• Pull up the battery panel (35) using • Pull up the battery panel (35) using
the recess and lift it back (36). the recess and lift it back (36).
The battery connector and battery The battery connector and battery
retainer can be accessed retainer can be accessed
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4 Charging the battery 4 Charging the battery
WARNING! WARNING!
The gases produced during charging can cause explosions The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited. must not be ignited.
Switch the charging station and truck off first before connecting/disconnecting the Switch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector. charging cable of the battery charging station to/from the battery connector.
The charger must be adapted to the battery in terms of voltage and charge The charger must be adapted to the battery in terms of voltage and charge
capacity. capacity.
Before charging, check all cables and plug connections for visible signs of damage. Before charging, check all cables and plug connections for visible signs of damage.
Ventilate the room in which the truck is being charged. Ventilate the room in which the truck is being charged.
The battery cover must be open and the battery cell surfaces must be exposed The battery cover must be open and the battery cell surfaces must be exposed
during charging to ensure adequate ventilation. during charging to ensure adequate ventilation.
Do not smoke and avoid naked flames when handling batteries. Do not smoke and avoid naked flames when handling batteries.
Wherever an industrial truck is parked for charging there shall be no inflammable 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. material or lubricants capable of creating sparks within 2 m around the truck.
Fire protection equipment must be on hand. Fire protection equipment must be on hand.
Do not lay any metallic objects on battery. Do not lay any metallic objects on battery.
It is essential to follow the safety regulations of the battery and charger station It is essential to follow the safety regulations of the battery and charger station
manufacturers. manufacturers.
Charge the battery Charge the battery
– Expose the battery, (see "Exposing the – Expose the battery, (see "Exposing the
battery" on page 36). battery" on page 36).
Procedure Procedure
• Disconnect the battery connector (37) 37 • Disconnect the battery connector (37) 37
from the truck connector. from the truck connector.
38 38
• Connect the battery connector (37) to • Connect the battery connector (37) to
the charging cable (38) of the stationary the charging cable (38) of the stationary
charger. charger.
• Start charging in accordance with the • Start charging in accordance with the
charger operating instructions. charger operating instructions.
The battery is now charged. The battery is now charged.
Completing the battery charge, restoring the truck to operation Completing the battery charge, restoring the truck to operation
NOTE NOTE
If charging has been interrupted, the full battery capacity will not be available If charging has been interrupted, the full battery capacity will not be available
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– Battery charging is complete. – Battery charging is complete.
37 37
Procedure Procedure
• Complete charging in accordance with the charger operating instructions. • Complete charging in accordance with the charger operating instructions.
• Disconnect the battery from the charger. • Disconnect the battery from the charger.
• Connect the battery to the truck. • Connect the battery to the truck.
The truck is operational again The truck is operational again
5 Battery removal and installation 5 Battery removal and installation
WARNING! WARNING!
Accident risk during battery removal and installation Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the Due to the battery weight and acid there is a risk of trapping or scalding when the
battery is removed and installed. battery is removed and installed.
Note the "Safety regulations for handling acid batteries" section in this chapter. Note the "Safety regulations for handling acid batteries" section in this chapter.
Wear safety shoes when removing and installing the battery. Wear safety shoes when removing and installing the battery.
Use only batteries with insulated cells and terminal connectors. Use only batteries with insulated cells and terminal connectors.
Park the truck on a level surface to prevent the battery from sliding out. Park the truck on a level surface to prevent the battery from sliding out.
Make sure the crane slings have sufficient capacity to replace the battery. Make sure the crane slings have sufficient capacity to replace the battery.
Use only approved battery replacement devices (battery roller stand, replacement Use only approved battery replacement devices (battery roller stand, replacement
trolley etc.). trolley etc.).
Make sure the battery is securely located in the truck's battery compartment. Make sure the battery is securely located in the truck's battery compartment.
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5.1 Removing the battery from the top 5.1 Removing the battery from the top
Battery removal Battery removal
– Park the truck securely, (see "Parking the truck securely" on page 49). – Park the truck securely, (see "Parking the truck securely" on page 49).
– Expose the battery, (see "Exposing the battery" on page 36). – Expose the battery, (see "Exposing the battery" on page 36).
Procedure Procedure
• Disconnect the battery connector from the truck connector. • Disconnect the battery connector from the truck connector.
Z Place the battery cable on the tray so that it cannot be severed when the battery is Z Place the battery cable on the tray so that it cannot be severed when the battery is
pulled out. pulled out.
• Undo the screw (40) of the battery retainer and remove the battery retainer (39). • Undo the screw (40) of the battery retainer and remove the battery retainer (39).
• Strap the crane lifting gear to the eyes (41). • Strap the crane lifting gear to the eyes (41).
Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must Z The crane lifting gear must exert a vertical pull. The hooks of the lifting gear must
never fall onto the battery cells. never fall onto the battery cells.
• Pull the battery up out of the battery compartment. • Pull the battery up out of the battery compartment.
The battery is now removed. The battery is now removed.
Z Installation is in the reverse order. When reinstalling the battery, note the proper Z Installation is in the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly. installation position and make sure the battery is connected correctly.
Z Screw torque (40): 45 Nm Z Screw torque (40): 45 Nm
40 39 41 40 39 41
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5.2 Removing the battery from the side 5.2 Removing the battery from the side
CAUTION! CAUTION!
Trapping hazard when removing and installing the battery. Trapping hazard when removing and installing the battery.
When removing and installing the battery do not put your hands between the When removing and installing the battery do not put your hands between the
battery and the chassis. battery and the chassis.
Battery removal Battery removal

42 42
– Park the truck securely, (see "Parking the truck – Park the truck securely, (see "Parking the truck
securely" on page 49). securely" on page 49).
– Expose the battery, (see "Exposing the battery" – Expose the battery, (see "Exposing the battery"
on page 36). on page 36).

– Battery replacement station / trolley – Battery replacement station / trolley
Procedure Procedure
• Disconnect the battery connector (37) from the • Disconnect the battery connector (37) from the
truck connector. truck connector.
• Undo the battery lock (42). • Undo the battery lock (42).
• Move the battery replacement station / trolley up • Move the battery replacement station / trolley up
to the side of the truck. to the side of the truck.
• Turn the battery lock as far as the stop. • Turn the battery lock as far as the stop.
• Carefully push the battery from off the truck onto the battery replacement station / • Carefully push the battery from off the truck onto the battery replacement station /
trolley. trolley.
The battery is now removed. The battery is now removed.
Battery installation Battery installation

42 42
– Park the truck securely, (see "Parking the truck – Park the truck securely, (see "Parking the truck
securely" on page 49). securely" on page 49).
– Expose the battery, (see "Exposing the battery" – Expose the battery, (see "Exposing the battery"
Procedure Procedure
Z Installation is in the reverse order. When Z Installation is in the reverse order. When
reinstalling the battery, note the proper reinstalling the battery, note the proper
installation position and make sure the battery is installation position and make sure the battery is
connected correctly. connected correctly.
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E Operation E Operation
1 Safety Regulations for the Operation of the 1 Safety Regulations for the Operation of the
Forklift Truck Forklift Truck
Driver authorisation Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to The truck may only be used by suitably trained personnel, who have demonstrated to
the proprietor or his representative that they can drive and handle loads and have the proprietor or his representative that they can drive and handle loads and have
been authorised to operate the truck by the proprietor or his representative. been authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities Driver’s rights, obligations and responsibilities
The driver must be informed of his duties and responsibilities and be instructed in the The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. The driver operation of the truck and shall be familiar with the operating instructions. The driver
shall be afforded all due rights. Safety shoes must be worn for pedestrian operated shall be afforded all due rights. Safety shoes must be worn for pedestrian operated
trucks. trucks.
Unauthorised use of truck Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver must The driver is responsible for the truck during the time it is in use. The driver must
prevent unauthorised persons from driving or operating the truck. Do not carry prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people. passengers or lift other people.
Damage and faults Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck or The supervisor must be immediately informed of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems) attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified. must not be used until they have been rectified.
Repairs Repairs
The driver must not carry out any repairs or alterations to the truck without the The driver must not carry out any repairs or alterations to the truck without the
necessary training and authorisation to do so. The driver must never disable or adjust necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches. safety mechanisms or switches.
Hazardous area Hazardous area
WARNING! WARNING!
Risk of accidents / injury in the hazardous area of the truck Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering itself. This also includes areas which can be reached by falling loads or lowering
operating equipment. operating equipment.
Instruct unauthorised people to leave the hazardous area. Instruct unauthorised people to leave the hazardous area.
Give a warning signal with plenty of time for people to leave. Give a warning signal with plenty of time for people to leave.
If unauthorised personnel are still within the hazardous area stop the truck If unauthorised personnel are still within the hazardous area stop the truck
immediately. immediately.
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Safety devices and warning labels Safety devices and warning labels
Safety devices, warning signs ((see "Identification points and data plates" on Safety devices, warning signs ((see "Identification points and data plates" on
page 25)) and warning instructions in the present operating instructions must be page 25)) and warning instructions in the present operating instructions must be
strictly observed. strictly observed.
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2 Displays and Controls 2 Displays and Controls
43 44 1 43 44 1
2 2
45 45 45 45
46 46 46 46
5 47 5 47
6 6
48 49 4, 50, 51, 3 48 49 4, 50, 51, 3
7 7
8 8
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Item Control / Display Function Item Control / Display Function
1 Travel switch t – Controls the travel direction and speed. 1 Travel switch t – Controls the travel direction and speed.
2 Tiller (“fixed operator t – Steers the truck. 2 Tiller (“fixed operator t – Steers the truck.
platform” version) platform” version)
Tiller (“fixed operator o – Steers the truck. Tiller (“fixed operator o – Steers the truck.
platform” version, height- platform” version, height-
adjustable, adjustable,
except for L tray high) except for L tray high)
Moving tiller (“folding t – Steers the truck. Moving tiller (“folding t – Steers the truck.
operator platform” – Decelerates the truck,(see "Brakes" on operator platform” – Decelerates the truck,(see "Brakes" on
version) page 56). version) page 56).
3 Charge display t – Battery charge status 3 Charge display t – Battery charge status
4 CanCode o Replaces the key switch 4 CanCode o Replaces the key switch
– Entering the code activates the truck – Entering the code activates the truck
– Travel program selection – Travel program selection
– Code setting – Code setting
– Parameter setting – Parameter setting
5 Key switch t – Activates the truck by applying the 5 Key switch t – Activates the truck by applying the
control voltage control voltage
– Removing the key prevents the truck – Removing the key prevents the truck
from being switched on by unauthorised from being switched on by unauthorised
personnel personnel
6 Emergency Disconnect t Disconnects the battery supply 6 Emergency Disconnect t Disconnects the battery supply
switch – All electric functions are deactivated and switch – All electric functions are deactivated and
the truck decelerates the truck decelerates
7 Folding side arm (“folding t When the side restraints are not unfolded 7 Folding side arm (“folding t When the side restraints are not unfolded
operator platform” and the operator platform is laden and operator platform” and the operator platform is laden and
version) unfolded: version) unfolded:
– travel speed restricted to max. – travel speed restricted to max.

6km/h. 6km/h.
8 Folding operator platform t Pedestrian mode 8 Folding operator platform t Pedestrian mode
– Operator platform folded up: – Operator platform folded up:
Pedestrian speed restricted to max. 4.0 Pedestrian speed restricted to max. 4.0
km/h. km/h.
Rider mode, operator platform acts as a Rider mode, operator platform acts as a
deadman: deadman:
– Operator platform down and vacated: – Operator platform down and vacated:
travel inhibited. travel inhibited.
– Operator platform down and laden by – Operator platform down and laden by
weight of operator (both restraints must weight of operator (both restraints must
be folded fully out or in): be folded fully out or in):
travel enabled. travel enabled.
43 Rigid side arm (“fixed t – Rider mode only available. 43 Rigid side arm (“fixed t – Rider mode only available.
operator platform” operator platform”
version) version)
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Item Control / Display Function Item Control / Display Function
44 Collision safety switch t Safety function 44 Collision safety switch t Safety function
– (“Fixed operator platform” version): – (“Fixed operator platform” version):
The truck brakes. The truck brakes.
Safety feature on the folding operator Safety feature on the folding operator
platform platform
– Pedestrian mode: – Pedestrian mode:
When pressed the truck travels for When pressed the truck travels for
approx. 3 seconds in the forks direction. approx. 3 seconds in the forks direction.
The parking brake then applies. The The parking brake then applies. The
truck remains switched off until the travel truck remains switched off until the travel
switch is set to neutral. switch is set to neutral.
– Rider mode: – Rider mode:
No function (optional safety collision No function (optional safety collision
switch function as in pedestrian mode) switch function as in pedestrian mode)
45 “Lower” button t – Lowers the lift mechanism. 45 “Lower” button t – Lowers the lift mechanism.
46 “Lift” button t – Raises the lift mechanism. 46 “Lift” button t – Raises the lift mechanism.
47 Warning signal (horn) t – “Warning” button 47 Warning signal (horn) t – “Warning” button
button button
48 Fixed platform (all t Rider mode only, pressure-sensitive mat 48 Fixed platform (all t Rider mode only, pressure-sensitive mat
functions released when acts as deadman switch: functions released when acts as deadman switch:
occupied) occupied)
– Pressure-sensitive mat laden: – Pressure-sensitive mat laden:
Travel and all functions enabled. Travel and all functions enabled.
– Pressure-sensitive mat unladen: – Pressure-sensitive mat unladen:
The truck coasts. The truck coasts.
49 Side skirt t – Driver protection 49 Side skirt t – Driver protection
50 CanDis o Display instrument 50 CanDis o Display instrument
– Battery charge status – Battery charge status
– Operating hours – Operating hours
– Warning messages – Warning messages
– Parameter settings – Parameter settings
51 ISM o Replaces the key switch 51 ISM o Replaces the key switch
– Activates the truck via a card / – Activates the truck via a card /
transponder transponder
– Displays readiness for operation – Displays readiness for operation
– Operational data acquisition – Operational data acquisition
– Data exchange with card / transponder – Data exchange with card / transponder
t = Standard equipment o = Optional equipment t = Standard equipment o = Optional equipment

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2.1 Battery discharge indicator 2.1 Battery discharge indicator
When the truck has been released via the key When the truck has been released via the key
switch, code lock or ISM, the battery charge status 52 switch, code lock or ISM, the battery charge status 52
is displayed. The LED (52) colours represent the is displayed. The LED (52) colours represent the
following conditions: following conditions:
LED colour Residual capacity LED colour Residual capacity

Green 40 - 100 % Green 40 - 100 %
Orange 30 - 40 % Orange 30 - 40 %
Flashing Flashing
20 - 30 % 20 - 30 %
green/orange 1Hz green/orange 1Hz
Red 0 - 20 % Red 0 - 20 %
Z If the LED is red, load units can no longer be lifted. Lifting is only enabled again Z If the LED is red, load units can no longer be lifted. Lifting is only enabled again
when the battery connected is at least 70% charged. when the battery connected is at least 70% charged.
If the LED flashes red and the truck is not ready for operation, inform the If the LED flashes red and the truck is not ready for operation, inform the
manufacturer's service department. Red flashing is a truck controller code. The manufacturer's service department. Red flashing is a truck controller code. The
flashing sequence indicates the type of fault. flashing sequence indicates the type of fault.
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3 Starting up the truck 3 Starting up the truck
3.1 Checks and operations to be performed before starting daily 3.1 Checks and operations to be performed before starting daily
operation operation
WARNING! WARNING!
Damage and other truck or attachment (special equipment) defects can result Damage and other truck or attachment (special equipment) defects can result
in accidents. in accidents.
If damage or other truck or attachment (special equipment) defects are discovered If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been during the following checks, the truck must be taken out of service until it has been
repaired. repaired.
Report any defects immediately to your supervisor. Report any defects immediately to your supervisor.
Tag out and decommission a faulty lift truck. Tag out and decommission a faulty lift truck.
Only return the truck to service when you have identified and rectified the fault. Only return the truck to service when you have identified and rectified the fault.
Pre-start inspections Pre-start inspections
Procedure Procedure
• Check the whole of the outside of the truck for signs of damage and leaks. • Check the whole of the outside of the truck for signs of damage and leaks.
Damaged hoses must be replaced immediately. Damaged hoses must be replaced immediately.
• Check the battery attachment and wire connections for damage and make sure • Check the battery attachment and wire connections for damage and make sure
they are secure. they are secure.
• Check the battery connectors are secure. • Check the battery connectors are secure.
• Check the load handler for visible signs of damage such as cracks, bent or severely • Check the load handler for visible signs of damage such as cracks, bent or severely
worn forks. worn forks.
• Check the drive wheel and load wheels for damage. • Check the drive wheel and load wheels for damage.
• Check that the markings and labels are present, clean and legible, (see • Check that the markings and labels are present, clean and legible, (see
"Identification points and data plates" on page 25). "Identification points and data plates" on page 25).
• Test the Emergency Disconnect switch. • Test the Emergency Disconnect switch.
• Check the control handle (damper) is restored to its normal position. • Check the control handle (damper) is restored to its normal position.
• Check the controls are automatically restored to zero after being applied. • Check the controls are automatically restored to zero after being applied.
• Test the warning signal. • Test the warning signal.
• Test the brakes. • Test the brakes.
• Test the collision safety switch. • Test the collision safety switch.
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3.2 Preparing the truck for operation 3.2 Preparing the truck for operation
Switching on the truck Switching on the truck
– For checks and operations to be performed before starting daily operation, (see – For checks and operations to be performed before starting daily operation, (see
"Checks and operations to be performed before starting daily operation" on "Checks and operations to be performed before starting daily operation" on
page 47). page 47).
Procedure Procedure
• Step onto the standing platform (48, 8). • Step onto the standing platform (48, 8).
• Pull out the Emergency Disconnect switch (6). • Pull out the Emergency Disconnect switch (6).
• Switch on the truck, to do this: • Switch on the truck, to do this:
• Insert the key in the key switch (53) and turn it to the right as far as it will go • Insert the key in the key switch (53) and turn it to the right as far as it will go
(position “I”) or for CANCODE (4,o) enter the activation code, (see "CanCode (position “I”) or for CANCODE (4,o) enter the activation code, (see "CanCode
keypad" on page 65). keypad" on page 65).
• Test the warning signal button (47). • Test the warning signal button (47).
• Test the travel switch (1). • Test the travel switch (1).
• Test the steering. • Test the steering.
The truck is operational. The truck is operational.
WARNING! WARNING!
Do not press the travel switch or the "pedestrian" button (o) when entering and Do not press the travel switch or the "pedestrian" button (o) when entering and
exiting the truck. exiting the truck.
Z The CANDID display instrument (50(o)) indicates the available battery capacity. Z The CANDID display instrument (50(o)) indicates the available battery capacity.
44 47 53 6 44 47 53 6
4, 50 4, 50
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3.3 Parking the truck securely 3.3 Parking the truck securely
WARNING! WARNING!
An unsecured truck can cause accidents An unsecured truck can cause accidents
Parking the truck on an incline, without the brakes applied or with a raised load / load Parking the truck on an incline, without the brakes applied or with a raised load / load
handler is dangerous and is strictly prohibited. handler is dangerous and is strictly prohibited.
Always park the truck on a level surface. In special cases the truck may need to be Always park the truck on a level surface. In special cases the truck may need to be
secured with wedges. secured with wedges.
Always lower the forks fully. Always lower the forks fully.
Select a place to park where no other people are at risk of injury from lowering Select a place to park where no other people are at risk of injury from lowering
forks. forks.
Parking the truck securely Parking the truck securely
Procedure Procedure
• Fully lower the load handler. • Fully lower the load handler.
• Set the drive wheel to “Straight ahead”. • Set the drive wheel to “Straight ahead”.
Z Set tiller to the "Forward position". Z Set tiller to the "Forward position".
• Turn off the key switch and remove the key. • Turn off the key switch and remove the key.
• For CANCODE, press the O key. • For CANCODE, press the O key.
• For ISM, press the red button. • For ISM, press the red button.
• Press the Emergency Disconnect. • Press the Emergency Disconnect.
The truck is parked. The truck is parked.
3.4 Battery discharge monitor 3.4 Battery discharge monitor

Z The standard setting for the battery discharge indicator / discharge monitor is Z The standard setting for the battery discharge indicator / discharge monitor is
based on standard batteries. When using maintenance-free or special batteries the based on standard batteries. When using maintenance-free or special batteries the
display and cutout points of the battery discharge monitor must be set by display and cutout points of the battery discharge monitor must be set by
authorised specialist personnel. If this adjustment is not made the battery may authorised specialist personnel. If this adjustment is not made the battery may
become damaged through excessive depletion. become damaged through excessive depletion.
If the residual capacity falls below the required level, lifting is inhibited. An alternating If the residual capacity falls below the required level, lifting is inhibited. An alternating
display (52) appears. Lifting is only released when the battery connected is at least display (52) appears. Lifting is only released when the battery connected is at least
70% charged. 70% charged.
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4 Industrial Truck Operation 4 Industrial Truck Operation
4.1 Safety regulations for truck operation 4.1 Safety regulations for truck operation
Travel routes and work areas Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose. specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger 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 to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting. areas of insufficient lighting.
DANGER! DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes. Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist. At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading. during loading / unloading.
Travel conduct Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in 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 control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area. beyond the working and operating area.
Travel visibility Travel visibility
The driver must look in the direction of travel and must always have a clear view of The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck. the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
If this is not possible, a second person must walk alongside the truck as a lookout to If this is not possible, a second person must walk alongside the truck as a lookout to
observe the travel route while maintaining eye contact with the driver. Proceed only observe the travel route while maintaining eye contact with the driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye at walking pace and with particular care. Stop the truck as soon as you lose eye
contact. contact.
Negotiating slopes and inclines Negotiating slopes and inclines
Negotiating slopes or inclines is only permitted if they are specifically designed as Negotiating slopes or inclines is only permitted if they are specifically designed as
travel routes, are clean and have a non-slip surface and providing they can be safely travel routes, are clean and have a non-slip surface and providing they can be safely
travelled along in accordance with the truck's technical specifications. The truck must travelled along in accordance with the truck's technical specifications. The truck must
always be driven with the load unit facing uphill. The industrial truck must not be always be driven with the load unit facing uphill. The industrial truck must not be
turned, operated at an angle or parked on inclines or slopes. Inclines must only be turned, operated at an angle or parked on inclines or slopes. Inclines must only be
negotiated at slow speed, with the driver ready to brake at any moment. negotiated at slow speed, with the driver ready to brake at any moment.
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Negotiating lifts and docks Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of must take up a position which does not allow it to come into contact with the walls of
the lift shaft. People travelling in the lift with the forklift truck must only enter the lift the lift shaft. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading. / unloading.
Type of loads to be carried Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. of the load from tipping or falling down.
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4.2 Emergency Disconnect, Travel, Steering, Braking 4.2 Emergency Disconnect, Travel, Steering, Braking
4.2.1 Emergency Disconnect (battery connector) 4.2.1 Emergency Disconnect (battery connector)
NOTE NOTE
The Emergency Disconnect safety function is performed by the battery connector that The Emergency Disconnect safety function is performed by the battery connector that
can be accessed from the outside. can be accessed from the outside.
Pressing the Emergency Disconnect switch Pressing the Emergency Disconnect switch
Procedure Procedure
CAUTION! CAUTION!
Accident risk Accident risk
The operation of the Emergency Disconnect switch must not be affected by any The operation of the Emergency Disconnect switch must not be affected by any
objects placed in its way. objects placed in its way.
Z Do not use the Emergency Disconnect switch (6) as a service brake. Z Do not use the Emergency Disconnect switch (6) as a service brake.
• Press the Emergency Disconnect (6). • Press the Emergency Disconnect (6).
All electrical functions are deactivated. The truck brakes to a halt. All electrical functions are deactivated. The truck brakes to a halt.
Releasing the Emergency Disconnect switch Releasing the Emergency Disconnect switch
Procedure Procedure
• Pull the Emergency Disconnect (6) to unlock it. • Pull the Emergency Disconnect (6) to unlock it.
All electrical functions are enabled and the truck is operational again (assuming the All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed). truck was not operational before the Emergency Disconnect was pressed).
For CanCode and ISM the truck remains switched off. For CanCode and ISM the truck remains switched off.
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V V
0 0
44 1 44 1
R R
V V
6 6
R R
48 B 48 B
2 2
F F
1 1
44 44
BB BB
7 7
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4.2.2 Travel 4.2.2 Travel
CAUTION! CAUTION!
Do not drive the truck unless the panels are closed and properly locked. Do not drive the truck unless the panels are closed and properly locked.
Trucks with a fixed operator platform Trucks with a fixed operator platform
– Start up the truck, (see "Starting up the truck" on page 47) – Start up the truck, (see "Starting up the truck" on page 47)
Procedure Procedure
• Step onto the operator platform (48). • Step onto the operator platform (48).
• Set the travel switch (1) to the desired travel direction: forward (V) or reverse (R). • Set the travel switch (1) to the desired travel direction: forward (V) or reverse (R).
Z When the travel switch is release it automatically returns to its original position. Z When the travel switch is release it automatically returns to its original position.
• Control the travel speed with the travel switch (1). • Control the travel speed with the travel switch (1).
The brakes are released and the truck moves in the selected direction. The brakes are released and the truck moves in the selected direction.
Industrial trucks with a folding standing platform and moving tiller Industrial trucks with a folding standing platform and moving tiller
We distinguish between two travel modes: We distinguish between two travel modes:
– Travel in pedestrian mode – Travel in pedestrian mode

– Travel in rider mode – Travel in rider mode
WARNING! WARNING!

Be extremely careful when driving and steering, especially if parts of your body Be extremely careful when driving and steering, especially if parts of your body
extend outside the border of the truck. extend outside the border of the truck.
Do not reach between the standing platform and the truck frame when you fold up Do not reach between the standing platform and the truck frame when you fold up
the platform. the platform.
In pedestrian mode make sure you have sufficient distance from the industrial In pedestrian mode make sure you have sufficient distance from the industrial
truck. truck.
Travelling in pedestrian mode Travelling in pedestrian mode
Procedure Procedure
• Move both folding side arms (7) in. • Move both folding side arms (7) in.
Z Both side arms must always be folded in, otherwise all functions are deactivated Z Both side arms must always be folded in, otherwise all functions are deactivated
(E-1926). (E-1926).
• Fold up the operator platform (8). • Fold up the operator platform (8).
• Set the tiller (2) to the travel zone (F). • Set the tiller (2) to the travel zone (F).
Z When the travel switch is released it automatically returns to its original position. Z When the travel switch is released it automatically returns to its original position.
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Z In pedestrian mode the truck can only operate at reduced speed. Z In pedestrian mode the truck can only operate at reduced speed.
Travelling in rider mode Travelling in rider mode

Procedure Procedure
• Move the folding side restraints (7) out. • Move the folding side restraints (7) out.
• Fold down the operator platform (8). • Fold down the operator platform (8).
• Set the tiller (2) to the travel zone (F). • Set the tiller (2) to the travel zone (F).
Z When the travel switch is released it automatically returns to its original position. Z When the travel switch is released it automatically returns to its original position.
Z Preventing the truck from “rolling downhill”: Z Preventing the truck from “rolling downhill”:
If the truck rolls backwards on an incline the controller detects the situation and the If the truck rolls backwards on an incline the controller detects the situation and the
travel switch brake applies automatically after a short jerk. travel switch brake applies automatically after a short jerk.
NOTE NOTE
Travelling is inhibited when the operator platform is unladen and the side arms are Travelling is inhibited when the operator platform is unladen and the side arms are
not folded out. not folded out.
If the standing platform is occupied and the gates are not folded out, the industrial If the standing platform is occupied and the gates are not folded out, the industrial
truck can only be operated at reduced speed. truck can only be operated at reduced speed.
If the operator platform is occupied and only one gate is folded out, travelling is If the operator platform is occupied and only one gate is folded out, travelling is
inhibited. inhibited.
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4.2.3 Steering 4.2.3 Steering
Procedure Procedure
• Move the tiller (2) to the left or right. • Move the tiller (2) to the left or right.
The truck is steered in the required direction. The truck is steered in the required direction.
4.2.4 Brakes 4.2.4 Brakes

The braking pattern of the truck depends largely on the travel conditions and the load. The braking pattern of the truck depends largely on the travel conditions and the load.
The driver must take this into account when travelling. The driver must take this into account when travelling.
The truck can brake in different ways: The truck can brake in different ways:
– By inversion braking (controller) – By inversion braking (controller)

– By regenerative braking (coasting) – By regenerative braking (coasting)
– With the stop button (fixed operator platform) – With the stop button (fixed operator platform)
– With the tiller set to the "B" zone (folding operator platform only) – With the tiller set to the "B" zone (folding operator platform only)
– With the Emergency Disconnect (in emergencies) – With the Emergency Disconnect (in emergencies)
Inversion braking Inversion braking
Procedure Procedure
• During travel, set the travel switch (1) to the opposite direction. • During travel, set the travel switch (1) to the opposite direction.
The truck brakes regeneratively until it starts to move in the opposite direction. The truck brakes regeneratively until it starts to move in the opposite direction.
Z The brake force can be set by the manufacturer’s service department. Z The brake force can be set by the manufacturer’s service department.
Regenerative braking Regenerative braking
Procedure Procedure
• If the travel switch is set to 0, the truck automatically brakes regeneratively. • If the travel switch is set to 0, the truck automatically brakes regeneratively.
The truck brakes to a halt regeneratively via the coasting brake. The parking brake The truck brakes to a halt regeneratively via the coasting brake. The parking brake
then applies. then applies.
Z With regenerative braking energy is recuperated to the battery, ensuring a longer Z With regenerative braking energy is recuperated to the battery, ensuring a longer
service time. service time.
Braking with the stop button Braking with the stop button
Procedure Procedure
• Press the stop button (44) or set the travel switch to the 0 position. • Press the stop button (44) or set the travel switch to the 0 position.
The truck brakes. The truck brakes.
Z This braking mode is only available with fixed platform trucks. Z This braking mode is only available with fixed platform trucks.
Braking with the tiller in the "B" zone Braking with the tiller in the "B" zone
Procedure Procedure
• Move the tiller up or down to one of the brake zones (B). • Move the tiller up or down to one of the brake zones (B).
Z Z
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Initially the truck brakes regeneratively. The mechanical brake is only applied when Initially the truck brakes regeneratively. The mechanical brake is only applied when
this brake fails to achieve the necessary braking force. this brake fails to achieve the necessary braking force.
56 56
The truck will decelerate at the maximum rate and the brake will apply. The truck will decelerate at the maximum rate and the brake will apply.
Z This braking mode is only available with folding platform trucks. Z This braking mode is only available with folding platform trucks.
Braking with the Emergency Disconnect Braking with the Emergency Disconnect
CAUTION! CAUTION!
Only brake with the Emergency Disconnect in emergency situations. The truck Only brake with the Emergency Disconnect in emergency situations. The truck
brakes at maximum force. brakes at maximum force.
Procedure Procedure
• Press the Emergency Disconnect (6) down. • Press the Emergency Disconnect (6) down.
The circuit is disconnected, all electrical functions are cut out and the industrial truck The circuit is disconnected, all electrical functions are cut out and the industrial truck
brakes automatically (magnetic brake). brakes automatically (magnetic brake).
Z The truck can only start again when the Emergency Disconnect (6) has been Z The truck can only start again when the Emergency Disconnect (6) has been
unlocked again by pulling it up. unlocked again by pulling it up.
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4.3 Lifting, transporting and depositing loads 4.3 Lifting, transporting and depositing loads
WARNING! WARNING!
Unsecured and incorrectly positioned loads can cause accidents Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must ensure that it has been correctly palletised Before lifting a load unit the driver must ensure that it has been correctly palletised
and does not exceed the truck’s capacity. and does not exceed the truck’s capacity.
Instruct other people to move out of the hazardous area of the industrial truck. Stop Instruct other people to move out of the hazardous area of the industrial truck. Stop
working with the truck if people do not leave the hazardous area. working with the truck if people do not leave the hazardous area.
Only carry loads that have been correctly secured and positioned. Use suitable Only carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down. protection measure to prevent parts of the load from tipping or falling down.
Damaged loads must not be transported. Damaged loads must not be transported.
Never exceed the maximum loads specified on the capacity chart. Never exceed the maximum loads specified on the capacity chart.
Never stand underneath a raised load handler. Never stand underneath a raised load handler.
Do not stand on the load handler. Do not stand on the load handler.
Do not lift other people on the load handler. Do not lift other people on the load handler.
Insert the load handler as far as possible underneath the load. Insert the load handler as far as possible underneath the load.
NOTE NOTE
Adapt a slower speed when stacking and retrieving. Adapt a slower speed when stacking and retrieving.
NOTE NOTE
The operator platform (10) must be occupied by the operator for lifting/lowering to be The operator platform (10) must be occupied by the operator for lifting/lowering to be
enabled. enabled.
4.3.1 Lifting load units 4.3.1 Lifting load units
– Load unit correctly palletised. – Load unit correctly palletised.
– Load unit weight matches the truck's capacity. – Load unit weight matches the truck's capacity.
– Forks evenly loaded for heavy loads. – Forks evenly loaded for heavy loads.
Procedure Procedure
• Drive the truck carefully up to the pallet. • Drive the truck carefully up to the pallet.
• Slowly insert the forks into the pallet until the 45 46 46 45 • Slowly insert the forks into the pallet until the 45 46 46 45
fork shank touches the pallet. fork shank touches the pallet.
Z The load unit must not extend by more than 50 Z The load unit must not extend by more than 50
mm beyond the fork tips. mm beyond the fork tips.
• Press the “Lift” button (46) until you reach the desired lift height. • Press the “Lift” button (46) until you reach the desired lift height.
The load unit is raised. The load unit is raised.
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4.3.2 Transport the load unit. 4.3.2 Transport the load unit.
Transporting load units Transporting load units
– Load unit correctly lifted. – Load unit correctly lifted.
– Good ground conditions. – Good ground conditions.
Procedure Procedure
• Accelerate and decelerate gradually. • Accelerate and decelerate gradually.
• Adapt your travel speed to the conditions of the route and the load you are • Adapt your travel speed to the conditions of the route and the load you are
transporting. transporting.
• Travel at a constant speed. • Travel at a constant speed.
• Watch out for other traffic at crossings and passageways. • Watch out for other traffic at crossings and passageways.
• Always travel with a lookout at blind spots. • Always travel with a lookout at blind spots.
• On slopes and inclines always carry the load facing uphill, never approach at an • On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn. angle or turn.
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4.3.3 Lowering the load unit 4.3.3 Lowering the load unit
Depositing load units Depositing load units
NOTE NOTE
Loads must not be deposited on travel or escape routes, in front of safety Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times. mechanisms or operating equipment that must be accessible at all times.
– Warehouse location suitable for storing the load. – Warehouse location suitable for storing the load.
Procedure Procedure
• Drive carefully up to the storage location. • Drive carefully up to the storage location.
• Press the "Lower load handler" button until the forks are clear of the load. • Press the "Lower load handler" button until the forks are clear of the load.
Z Avoid depositing the load to avoid damaging the load and the load handler. Z Avoid depositing the load to avoid damaging the load and the load handler.
• Carefully remove the forks from the pallet. • Carefully remove the forks from the pallet.
The load unit is lowered. The load unit is lowered.
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5 Troubleshooting 5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the effects of This chapter enables the user to identify and rectify basic faults and the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the incorrect operation. When trying to locate a fault, proceed in the order shown in the
table. table.
Z If, after carrying out the following remedial action, the truck cannot be restored to Z If, after carrying out the following remedial action, the truck cannot be restored to
operation or if a fault in the electronics system is displayed with a corresponding operation or if a fault in the electronics system is displayed with a corresponding
error code, contact the manufacturer’s service department. error code, contact the manufacturer’s service department.
Additional troubleshooting must only be performed by the manufacturer’s specialist Additional troubleshooting must only be performed by the manufacturer’s specialist
service engineers. The manufacturer's customer service department is specially service engineers. The manufacturer's customer service department is specially
trained to carry out these operations. trained to carry out these operations.
In order for customer services to react quickly and specifically to the fault, the In order for customer services to react quickly and specifically to the fault, the
following information is essential: following information is essential:
- Truck serial number - Truck serial number
- Error number on the display unit (if applicable) - Error number on the display unit (if applicable)
- Error description - Error description
- Current location of truck - Current location of truck
5.1 Truck does not start 5.1 Truck does not start
Possible Cause Remedy Possible Cause Remedy

Battery connector not plugged in Check the battery connector Battery connector not plugged in Check the battery connector
and connect if necessary and connect if necessary
Emergency Disconnect pressed Unlock the Emergency Disconnect Emergency Disconnect pressed Unlock the Emergency Disconnect
Key switch set to O. Set the key switch to “I” Key switch set to O. Set the key switch to “I”
Battery charge too low Check battery charge, Battery charge too low Check battery charge,
Charge the battery as required Charge the battery as required
Faulty fuse Check fuses Faulty fuse Check fuses
Incorrect ISM access module transponder Incorrect ISM access module transponder
Use correct transponder Use correct transponder
used used
Incorrect CANCode PIN entered Enter correct PIN Incorrect CANCode PIN entered Enter correct PIN
Tiller not in brake position when truck Set tiller to upper / lower brake position Tiller not in brake position when truck Set tiller to upper / lower brake position
switched on switched on
(E-0914) (E-0914)
Switch in mast implausible (E-2124) Emergency recovery (travel at max. 1.5 Switch in mast implausible (E-2124) Emergency recovery (travel at max. 1.5
km/h and lowering possible when truck is km/h and lowering possible when truck is
in rider mode). Contact the in rider mode). Contact the
manufacturer's service department. manufacturer's service department.
5.2 Load cannot be lifted 5.2 Load cannot be lifted

Truck not operational Carry out all measures listed under “Truck Truck not operational Carry out all measures listed under “Truck
does not start”. does not start”.
Hydraulic oil level too low Checking the hydraulic oil level Hydraulic oil level too low Checking the hydraulic oil level
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Battery discharge monitor has switched Charge the battery Battery discharge monitor has switched Charge the battery
off off
Faulty fuse Check fuses Faulty fuse Check fuses
Excessive load Note maximum capacity, see data plate. Excessive load Note maximum capacity, see data plate.
Switch in mast implausible (E-2124) Emergency recovery (travel at max. 1.5 Switch in mast implausible (E-2124) Emergency recovery (travel at max. 1.5
km/h and lowering possible when truck is km/h and lowering possible when truck is
in rider mode). Contact the in rider mode). Contact the
manufacturer's service department. manufacturer's service department.
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6 Operating the truck without its own drive system 6 Operating the truck without its own drive system
WARNING! WARNING!
Uncontrolled truck movement Uncontrolled truck movement

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

– Two M5 screws – Two M5 screws
– Spanner wrench – Spanner wrench
Procedure Procedure
• Turn of the key switch, CanCode or ISM. • Turn of the key switch, CanCode or ISM.
• Press the Emergency Disconnect switch. • Press the Emergency Disconnect switch.
• Prevent the truck from rolling away. • Prevent the truck from rolling away.
• Open the battery panel. • Open the battery panel.
• Disconnect the battery. • Disconnect the battery.
• Lift off the front panel (54) and put it to one side, (see "Removing the front panel" • Lift off the front panel (54) and put it to one side, (see "Removing the front panel"
• Insert two M5 screws (55) as far as the stop and lift up the anchor plate. • Insert two M5 screws (55) as far as the stop and lift up the anchor plate.
The brake is now released and the truck can be moved. The brake is now released and the truck can be moved.
Applying the brake Applying the brake
Procedure Procedure
• Unscrew the two M5 (55) screws again. • Unscrew the two M5 (55) screws again.
• Refit front panel (54). • Refit front panel (54).
Braking is now restored again. Braking is now restored again.
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64
54
55
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54
55
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7 Optional equipment 7 Optional equipment
7.1 CanCode keypad 7.1 CanCode keypad
CanCode keypad CanCode keypad
The keypad consists of 10 digit keys, a Set key and a o The keypad consists of 10 digit keys, a Set key and a o
key. key.
1 2 3 1 2 3
The O key indicates the follow operating statuses via a The O key indicates the follow operating statuses via a
red / green LED: 4 5 6 red / green LED: 4 5 6
– Code lock function (starting up the truck). – Code lock function (starting up the truck).
7 8 9 7 8 9
– Adjusting the travel program depending on the setting – Adjusting the travel program depending on the setting
and truck. Set 0 and truck. Set 0
– Setting and changing parameters. – Setting and changing parameters.
7.1.1 Keypad 7.1.1 Keypad

When the correct code is entered, the truck is ready for use. You can allocate an When the correct code is entered, the truck is ready for use. You can allocate an
individual code to each truck, operator or group of operators. When the truck is individual code to each truck, operator or group of operators. When the truck is
supplied from the factory, the code is indicated on a sticker. Change the master and supplied from the factory, the code is indicated on a sticker. Change the master and
operator codes when you use the truck for the first time. operator codes when you use the truck for the first time.
Z Set different codes for rider and pedestrian trucks. Z Set different codes for rider and pedestrian trucks.
56 57 58 56 57 58
Starting the truck Starting the truck
Procedure Procedure
• Switching on the Emergency • Switching on the Emergency
Disconnect. 1 2 3 Disconnect. 1 2 3
LED (61) lights up red. LED (61) lights up red.
4 5 6 4 5 6
• Enter the code. • Enter the code.
7 8 9 7 8 9
When you enter the correct operator When you enter the correct operator
code the LED (61) turns green. If the Set 0 59 code the LED (61) turns green. If the Set 0 59
LED (61) flashes red this means the 60 LED (61) flashes red this means the 60
wrong code has been entered. Try wrong code has been entered. Try
again. again.
61 61
The truck is switched on The truck is switched on
Z The Set key (60) has no function in operating mode. Z The Set key (60) has no function in operating mode.
Switching the truck off Switching the truck off
Procedure Procedure
• Press the O key. • Press the O key.
The truck is switched off. The truck is switched off.
Z The truck can switch off automatically after a set time. To do this the relevant code Z The truck can switch off automatically after a set time. To do this the relevant code
lock parameters must be entered, (see "Parameter Settings" on page 66). lock parameters must be entered, (see "Parameter Settings" on page 66).
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7.1.2 Parameters 7.1.2 Parameters
The keypad enables parameters to be adjusted in programming mode. The keypad enables parameters to be adjusted in programming mode.
Parameter Groups Parameter Groups
The parameter number is composed of three digits. The first digit refers to the The parameter number is composed of three digits. The first digit refers to the
parameter group as shown in Table 1. The second and third digits are numbered in parameter group as shown in Table 1. The second and third digits are numbered in
sequence from 00 to 99. sequence from 00 to 99.
No. Parameter Groups No. Parameter Groups

0XX Code lock settings (codes, travel program release, automatic cutout, etc.) 0XX Code lock settings (codes, travel program release, automatic cutout, etc.)
7.1.3 Parameter Settings 7.1.3 Parameter Settings

To change the truck settings you must enter the master code. To change the truck settings you must enter the master code.
Z The master code factory setting is 7-2-9-5. Change the master code the first time Z The master code factory setting is 7-2-9-5. Change the master code the first time
you use the truck. you use the truck.
Z Set different codes for rider and pedestrian trucks. Z Set different codes for rider and pedestrian trucks.
Changing the truck settings Changing the truck settings
Procedure Procedure
• Press the O key (59). • Press the O key (59).
• Enter the master code. • Enter the master code.
• Enter the three-digit parameter number. • Enter the three-digit parameter number.
• Confirm with the SET key (60). • Confirm with the SET key (60).
• Enter the setting as per parameter list. • Enter the setting as per parameter list.
Z If the entry is incorrect, the LED (61) of the O key (59) turns red. Z If the entry is incorrect, the LED (61) of the O key (59) turns red.
• Enter the parameter number again. • Enter the parameter number again.
• Enter the setting again or change it. • Enter the setting again or change it.
• Repeat the procedure for other parameters. • Repeat the procedure for other parameters.
• Then press the O key (59). • Then press the O key (59).
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Parameter list Parameter list
No. Function Setting range Standard Procedure No. Function Setting range Standard Procedure
setting setting
000 Change master code: 0000 - 9999 7295 – (LED 56 flashes) 000 Change master code: 0000 - 9999 7295 – (LED 56 flashes)
The length (4-6 digits) of or Confirm current The length (4-6 digits) of or Confirm current
the master code also 00000 - 99999 code entry the master code also 00000 - 99999 code entry
determines the length of or – determines the length of or –
the operator code (4-6 000000 - 999999 (Set 60) the operator code (4-6 000000 - 999999 (Set 60)
digits). Provided the – (LED 57 flashes) digits). Provided the – (LED 57 flashes)
operator codes are Enter a new code operator codes are Enter a new code
programmed, only new – programmed, only new –
codes of the same (Set 60) codes of the same (Set 60)
length can be entered. If length can be entered. If
– (LED 58 flashes) – (LED 58 flashes)
you wish to change the you wish to change the
repeat new code repeat new code
code length, you must code length, you must
first delete all the – first delete all the –
operator codes. (Set 60) operator codes. (Set 60)
001 Add code (max. 250) 0000 - 9999 2580 – (LED 57 flashes) 001 Add code (max. 250) 0000 - 9999 2580 – (LED 57 flashes)
or Confirm code or Confirm code
00000 - 99999 entry 00000 - 99999 entry
or – or –
000000 - 999999 (Set 60) 000000 - 999999 (Set 60)
repeat code entry repeat code entry
– –
(Set 60) (Set 60)
002 Change code 0000 - 9999 – (LED 56 flashes) 002 Change code 0000 - 9999 – (LED 56 flashes)
or Confirm current or Confirm current
00000 - 99999 code entry 00000 - 99999 code entry
or – or –
000000 - 999999 (Set 60) 000000 - 999999 (Set 60)
Confirm new code Confirm new code
entry entry
– –
(Set 60) (Set 60)
Confirm code re- Confirm code re-
entry entry
– –
(Set 60) (Set 60)
LEDs 56-58 are located in keypads 1-3. LEDs 56-58 are located in keypads 1-3.
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setting setting
003 Delete code 0000 - 9999 – (LED 57 flashes) 003 Delete code 0000 - 9999 – (LED 57 flashes)
or Confirm new code or Confirm new code
00000 - 99999 entry 00000 - 99999 entry
or – or –
000000 - 999999 (Set 60) 000000 - 999999 (Set 60)
repeat code entry repeat code entry
– –
(Set 60) (Set 60)
004 Delete code log (deletes 3265 – 3265 = delete 004 Delete code log (deletes 3265 – 3265 = delete
all codes) – other inputs = do all codes) – other inputs = do
not delete not delete
010 Automatic timeout 00-31 00 – 00 = No timeout 010 Automatic timeout 00-31 00 – 00 = No timeout
– 01 - 30 = Timeout – 01 - 30 = Timeout
in minutes in minutes
– 31 = Timeout after – 31 = Timeout after
10 seconds 10 seconds
LEDs 56-58 are located in keypads 1-3. LEDs 56-58 are located in keypads 1-3.
Assigning the starting travel program (depending on the truck) Assigning the starting travel program (depending on the truck)
The travel programs are connected to the code. The travel programs can be The travel programs are connected to the code. The travel programs can be
individually released or blocked for each code. A starting travel program can be individually released or blocked for each code. A starting travel program can be
assigned to each code. assigned to each code.
Once a user code has been set up, all travel programs are globally released, the valid Once a user code has been set up, all travel programs are globally released, the valid
start travel program is travel program 2. start travel program is travel program 2.
The code configuration can then be changed with program number 024. The code configuration can then be changed with program number 024.
setting setting
024 Code configuration 1112 024 Code configuration 1112
1. digit: travel program 1 release (0 = blocked or 1 = released) 1. digit: travel program 1 release (0 = blocked or 1 = released)
2nd digit: travel program 2 release (0 = blocked or 1 = released) 2nd digit: travel program 2 release (0 = blocked or 1 = released)
3rd digit: travel program 3 release (0 = blocked or 1 = released) 3rd digit: travel program 3 release (0 = blocked or 1 = released)
4th digit: start travel program (0, 1, 2 or 3) 4th digit: start travel program (0, 1, 2 or 3)
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Setting the travel program configuration to a code Setting the travel program configuration to a code
Procedure Procedure
• Press the O key (59). • Press the O key (59).
• Enter the master code. • Enter the master code.
• Enter the three-digit parameter number 024. • Enter the three-digit parameter number 024.
• Enter the code to be changed and confirm with SET. • Enter the code to be changed and confirm with SET.
• Enter the configuration (4 digit) and confirm with SET. • Enter the configuration (4 digit) and confirm with SET.
• Enter the configuration (4 digit) again and confirm with SET. • Enter the configuration (4 digit) again and confirm with SET.
• Repeat the procedure for other codes. • Repeat the procedure for other codes.
• Then press the O key. • Then press the O key.
The travel programs are assigned to the codes The travel programs are assigned to the codes
Keypad event messages Keypad event messages
The LED (61) flashes red to indicate the following events: The LED (61) flashes red to indicate the following events:
– New master code is already in use. – New master code is already in use.
– New code is already the master code – New code is already the master code
– Code to be changed does not exist – Code to be changed does not exist
– Attempt to change the code to one that already exists. – Attempt to change the code to one that already exists.
– Attempt to delete a code that does not exist – Attempt to delete a code that does not exist
– Code memory full. – Code memory full.
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7.2 Setting the truck parameters with CanCode 7.2 Setting the truck parameters with CanCode
CAUTION! CAUTION!
Faulty entry Faulty entry
Without CanDis only CanCode internal parameters can be changed. Traction Without CanDis only CanCode internal parameters can be changed. Traction
controller parameters can only be changed with CanDis, without CanDis the settings controller parameters can only be changed with CanDis, without CanDis the settings
must be performed by the manufacturer's service department. must be performed by the manufacturer's service department.
CAUTION! CAUTION!
Altering travel parameters can cause accidents Altering travel parameters can cause accidents
Increasing the settings for travel and hydraulic functions can result in accidents. Increasing the settings for travel and hydraulic functions can result in accidents.
Carry out a test run in a secure environment. Carry out a test run in a secure environment.
This requires greater attention on the part of the operator. This requires greater attention on the part of the operator.
Parameter setting example: Parameter setting example:
The following example shows the parameter setting for the acceleration of travel The following example shows the parameter setting for the acceleration of travel
program 1 (parameter 0256). program 1 (parameter 0256).
Acceleration example Acceleration example
Procedure Procedure
• Enter four-digit parameter number "0256" and confirm with the SET key (60). • Enter four-digit parameter number "0256" and confirm with the SET key (60).
• Enter sub-index (enter "2") and confirm with the SET key (60). • Enter sub-index (enter "2") and confirm with the SET key (60).
Z The parameter and sub index are displayed alternately with the current reading Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-3). (0256-2<->0000-3).
• Enter the parameter according to the parameter list and confirm with the Set key • Enter the parameter according to the parameter list and confirm with the Set key
(60). (60).
Z The LED (61) of the O key (59) switches briefly to steady light and start flashing Z The LED (61) of the O key (59) switches briefly to steady light and start flashing
again after approx. 2 seconds. again after approx. 2 seconds.
Z If the entry is incorrect, the LED (61) of the O key (59) turns red. Enter the Z If the entry is incorrect, the LED (61) of the O key (59) turns red. Enter the
parameter number again to repeat the setting. parameter number again to repeat the setting.
Z The parameter and sub index are displayed alternately with the current reading Z The parameter and sub index are displayed alternately with the current reading
(0256-2<->0000-5). (0256-2<->0000-5).
The travel parameter is now set. The travel parameter is now set.
Repeat the procedure to enter further parameters as soon as the LED (61) of the O Repeat the procedure to enter further parameters as soon as the LED (61) of the O
key (59) flashes. key (59) flashes.
Z Travel is disabled while the parameters are being entered. Z Travel is disabled while the parameters are being entered.
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Checking the settings in programming mode Checking the settings in programming mode
Procedure Procedure
• Select the travel program to be worked on after changing the parameter value, and • Select the travel program to be worked on after changing the parameter value, and
confirm with the Set key (60). confirm with the Set key (60).
The truck is now in travel mode and can be checked. The truck is now in travel mode and can be checked.
Z To continue setting, confirm with the Set key (60) again. Z To continue setting, confirm with the Set key (60) again.
Saving travel parameters Saving travel parameters
– Enter all parameters. – Enter all parameters.
Procedure Procedure
• Run "SaveParameters" by pressing 1-2-3-Set. • Run "SaveParameters" by pressing 1-2-3-Set.
• Confirm with the O key (59). • Confirm with the O key (59).
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7.3 Traction controller AS2412i parameters 7.3 Traction controller AS2412i parameters
Travel program 1 - Fixed Platform Travel program 1 - Fixed Platform
No. Function Setting Standard Comments No. Function Setting Standard Comments
range setting range setting
0256 Rider mode 0-9 2 0256 Rider mode 0-9 2
acceleration acceleration
0264 Maximum forward 0-9 2 0264 Maximum forward 0-9 2
speed using travel (8.5 - 13.0 9.5 km/h speed using travel (8.5 - 13.0 9.5 km/h
switch km/h) switch km/h)
0268 Maximum reverse 0-9 9 0268 Maximum reverse 0-9 9
0260 Rider mode coasting 0-9 2 0260 Rider mode coasting 0-9 2
brake brake
0262 Inversion brake 0-9 7 0262 Inversion brake 0-9 7
Travel program 1 - Folding Platform Travel program 1 - Folding Platform
0256 Rider mode 0-9 2 Platform folded out, 0256 Rider mode 0-9 2 Platform folded out,
acceleration side arm folded out acceleration side arm folded out
0260 Rider mode coasting 0-9 2 0260 Rider mode coasting 0-9 2
brake brake
0257 Rider mode 0-9 4 Platform folded in, side 0257 Rider mode 0-9 4 Platform folded in, side
acceleration arm folded in acceleration arm folded in
speed using travel (1.5 - 4.5 km/ 4.0 km/h speed using travel (1.5 - 4.5 km/ 4.0 km/h
switch h) switch h)
0269 Maximum pedestrian 0-9 8 0269 Maximum pedestrian 0-9 8
reverse speed using (1.5 - 4.5 km/ 4.0 km/h reverse speed using (1.5 - 4.5 km/ 4.0 km/h
travel switch h) travel switch h)
0261 Pedestrian mode 0-9 7 0261 Pedestrian mode 0-9 7
coasting brake coasting brake
0267 Special travel speed, 0-9 9 Platform folded out, 0267 Special travel speed, 0-9 9 Platform folded out,
forward (1.5 - 6.0 km/ 6.0 km/h side arm folded in. forward (1.5 - 6.0 km/ 6.0 km/h side arm folded in.
h) h)
0271 Special travel speed, 0-9 9 0271 Special travel speed, 0-9 9
reverse (1.5 - 6.0 km/ 6.0 km/h reverse (1.5 - 6.0 km/ 6.0 km/h
h) h)
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Travel program 2 - fixed travel program Travel program 2 - fixed travel program
0262 Reversible brake 0-9 7 0262 Reversible brake 0-9 7
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0272 Rider mode 0-9 6 Platform folded out, 0272 Rider mode 0-9 6 Platform folded out,
acceleration side restraint folded acceleration side restraint folded
0280 Maximum forward 0-9 8 out 0280 Maximum forward 0-9 8 out
0273 Rider mode 0-9 4 Platform folded in, 0273 Rider mode 0-9 4 Platform folded in,
acceleration side restraint folded in acceleration side restraint folded in
0285 Maximum 0-9 8 0285 Maximum 0-9 8
pedestrian reverse (1.5 - 4.5 4.0 km/h pedestrian reverse (1.5 - 4.5 4.0 km/h
speed using travel km/h) speed using travel km/h)
switch switch
0277 Pedestrian mode 0-9 7 0277 Pedestrian mode 0-9 7
0283 Special travel 0-9 9 Platform folded out, 0283 Special travel 0-9 9 Platform folded out,
speed, forward (1.5 - 6.0 6.0 km/h side restraint folded in speed, forward (1.5 - 6.0 6.0 km/h side restraint folded in
km/h) km/h)
0287 Special travel 0-9 9 0287 Special travel 0-9 9
speed, reverse (1.5 - 6.0 6.0 km/h speed, reverse (1.5 - 6.0 6.0 km/h
km/h) km/h)
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Travel program 3 - fixed travel program Travel program 3 - fixed travel program
0262 Reversible brake 0-9 7 0262 Reversible brake 0-9 7
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0288 Rider mode Platform folded out, 0288 Rider mode Platform folded out,
0-9 8 0-9 8
acceleration side arm folded out acceleration side arm folded out
0296 Maximum forward 0-9 0296 Maximum forward 0-9
8 8
speed using travel (8.5 - 13.0 speed using travel (8.5 - 13.0
12.5 km/h 12.5 km/h
0300 Maximum reverse 0-9 0300 Maximum reverse 0-9
8 8
speed using travel (8.5 - 13.0 speed using travel (8.5 - 13.0
12.5 km/h 12.5 km/h
0292 Rider mode coasting 0292 Rider mode coasting
0-9 8 0-9 8
brake brake
0289 Pedestrian mode Platform folded in, side 0289 Pedestrian mode Platform folded in, side
0-9 4 0-9 4
acceleration arm folded in acceleration arm folded in
0297 Maximum reverse 0-9 0297 Maximum reverse 0-9
8 8
speed using travel (1.5 - 4.5 km/ speed using travel (1.5 - 4.5 km/
4.0 km/h 4.0 km/h
switch h) switch h)
0301 Maximum pedestrian 0-9 0301 Maximum pedestrian 0-9
8 8
reverse speed using (1.5 - 4.5 km/ reverse speed using (1.5 - 4.5 km/
4.0 km/h 4.0 km/h
travel switch h) travel switch h)
0293 Pedestrian mode 0293 Pedestrian mode
0-9 7 0-9 7
0299 Special travel speed, 0-9 Platform folded out, 0299 Special travel speed, 0-9 Platform folded out,
9 9
forward (1.5 - 6.0 km/ side arm folded in. forward (1.5 - 6.0 km/ side arm folded in.
6.0 km/h 6.0 km/h
h) h)
0303 Special travel speed, 0-9 0303 Special travel speed, 0-9
9 9
reverse (1.5 - 6.0 km/ reverse (1.5 - 6.0 km/
6.0 km/h 6.0 km/h
h) h)
PM2402z steering controller battery parameters PM2402z steering controller battery parameters
1377 Battery type 0-2 1 0 = Normal (wet) 1377 Battery type 0-2 1 0 = Normal (wet)
(normal / high (normal / high
performance / dry) 1 = High performance performance / dry) 1 = High performance
(wet) (wet)
2 = Dry (maintenance- 2 = Dry (maintenance-

free) free)
1389 Discharge monitor 0 /1 1 0 = Not active 1389 Discharge monitor 0 /1 1 0 = Not active
function 1 = Active function 1 = Active
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7.4 AS2412iS combi controller parameters 7.4 AS2412iS combi controller parameters
0256 Rider mode 42 0256 Rider mode 42
32 -104 32 -104
acceleration 0.42 m/s2 acceleration 0.42 m/s2
0264 Maximum forward Side restraints folded 0264 Maximum forward Side restraints folded
95 95
speed using travel 45 - 130 out. speed using travel 45 - 130 out.
9.5 km/h 9.5 km/h
switch switch
0268 Maximum reverse Side restraints folded 0268 Maximum reverse Side restraints folded
95 95
speed using travel 45 - 130 out speed using travel 45 - 130 out
9.5 km/h 9.5 km/h
switch switch
0260 Rider mode coasting 80 0260 Rider mode coasting 80
56 - 330 56 - 330
brake 0.8 m/s2 brake 0.8 m/s2
0262 Inversion brake 180 0262 Inversion brake 180
112 - 220 112 - 220
1.8 m/s2 1.8 m/s2
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32 - 104 32 - 104
95 95
9.5 km/h 9.5 km/h
switch switch
95 95
9.5 km/h 9.5 km/h
switch switch
56 - 330 56 - 330
4 - 21 4 - 21
0265 Forward pedestrian 0265 Forward pedestrian
40 40
speed using travel 5 - 45 speed using travel 5 - 45
4.0 km/h 4.0 km/h
switch switch
0269 Reverse pedestrian 0269 Reverse pedestrian
40 40
4.0 km/h 4.0 km/h
switch switch
0261 Pedestrian mode 80 0261 Pedestrian mode 80
56 - 330 56 - 330
coasting brake 0.8 m/s2 coasting brake 0.8 m/s2
0267 Special forward 60 Side restraints folded in 0267 Special forward 60 Side restraints folded in
15 - 60 15 - 60
speed 6.0 km/h speed 6.0 km/h
0271 Special reverse 60 Side restraints folded in 0271 Special reverse 60 Side restraints folded in
15 - 60 15 - 60
112 - 220 112 - 220
1.8 m/s2 1.8 m/s2
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32 -104 32 -104
125 125
12.5 km/h 12.5 km/h
switch switch
125 125
12.5 km/h 12.5 km/h
switch switch
56 - 330 56 - 330
112 - 220 112 - 220
1.8 m/s2 1.8 m/s2
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32 - 104 32 - 104
125 125
speed using travel 45 -130 out speed using travel 45 -130 out
12.5 km/h 12.5 km/h
switch switch
125 125
12.5 km/h 12.5 km/h
switch switch
56 -330 56 -330
4 - 21 4 - 21
42 42
4.2 km/h 4.2 km/h
switch switch
42 42
4.2 km/h 4.2 km/h
switch switch
56 -330 56 -330
15 - 60 15 - 60
15 - 60 15 - 60
112 - 220 112 - 220
1.8 m/s2 1.8 m/s2
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80 80
32 -104 32 -104
125 125
12.5 km/h 12.5 km/h
switch switch
125 125
12.5 km/h 12.5 km/h
switch switch
56 - 330 56 - 330
112 - 220 112 - 220
1.8 m/s2 1.8 m/s2
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32 - 104 32 - 104
125 125
12.5 km/h 12.5 km/h
switch switch
125 125
12.5 km/h 12.5 km/h
switch switch
56 -330 56 -330
4 - 21 4 - 21
42 42
4.2 km/h 4.2 km/h
switch switch
42 42
4.2 km/h 4.2 km/h
switch switch
56 -330 56 -330
15 - 60 15 - 60
15 - 60 15 - 60
112 - 220 112 - 220
1.8 m/s2 1.8 m/s2
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Battery parameters Battery parameters
1377 Battery type 0-7 1 0 = Normal (wet) 1377 Battery type 0-7 1 0 = Normal (wet)
(normal / high (normal / high
performance / 1 = High performance (wet) performance / 1 = High performance (wet)
dry) dry)
2 = Dry (maintenance-free) 2 = Dry (maintenance-free)
3 = US "Flat Plate" 3 = US "Flat Plate"
type type
4 = US "Pallet Pro" 4 = US "Pallet Pro"

type type
5 = US "Tubular Plate"/dry 5 = US "Tubular Plate"/dry
battery battery
type type
6 = Banner DB69 (dry battery) 6 = Banner DB69 (dry battery)
7 = Exide GF12 063 Y (dry 7 = Exide GF12 063 Y (dry

battery) battery)
1389 Discharge 0-4 1 0 = Not active 1389 Discharge 0-4 1 0 = Not active
monitor monitor
function 1 = Active function 1 = Active
2 = Display and lift cutout 2 = Display and lift cutout

active (except for digital lift active (except for digital lift
input) input)

active (except for MFC05 lift active (except for MFC05 lift
setpoints) setpoints)

active (except for MFC05 lift active (except for MFC05 lift
setpoints and digital lift input) setpoints and digital lift input)
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7.5 CanDis display instrument 7.5 CanDis display instrument
The instrument indicates: The instrument indicates:
Battery charge display (on board charger Battery charge display (on board charger
62 62
only) only)
Capacity display bars 62 63 Capacity display bars 62 63
63 63
Battery residual charge status Battery residual charge status
64 65 64 65
Warning - pre-warning symbol, Warning - pre-warning symbol,
64 64
Battery charge recommended 66 67 Battery charge recommended 66 67
Stop symbol; lift cut-out, Stop symbol; lift cut-out,
65 65
Battery charge required Battery charge required
T symbol appears during operation when T symbol appears during operation when
66 the discharge indicator is set to 66 the discharge indicator is set to
maintenance-free battery maintenance-free battery
6 digit LCD display; 6 digit LCD display;
67 Hour meter, input display; 67 Hour meter, input display;
Error display Error display
In addition, service messages for the electronic components and parameter changes In addition, service messages for the electronic components and parameter changes
are displayed. are displayed.
Discharge status display Discharge status display
Setting limits for the additional “Warning” (64) and “Stop” (65) displays will depend on Setting limits for the additional “Warning” (64) and “Stop” (65) displays will depend on
the battery type. the battery type.
The available capacity is shown via 8 LED bars. The available capacity is shown via 8 LED bars.
The current battery capacity is shown by the illuminated LED bars. 8 bars correspond The current battery capacity is shown by the illuminated LED bars. 8 bars correspond
to full battery capacity, 1 bar corresponds to the minimum available capacity. to full battery capacity, 1 bar corresponds to the minimum available capacity.
If only one LED bar is lit, the battery capacity is almost depleted and the “Warning” If only one LED bar is lit, the battery capacity is almost depleted and the “Warning”
indicator (64) is lit. The battery must be charged immediately. indicator (64) is lit. The battery must be charged immediately.
If no more LED bars are illuminated, the “Stop” indicator (65) lights up. Lifting is now If no more LED bars are illuminated, the “Stop” indicator (65) lights up. Lifting is now
inhibited. The battery must be charged. inhibited. The battery must be charged.
7.5.1 Discharge monitor function 7.5.1 Discharge monitor function

When the discharge monitor function is enabled, lifting is cut out when reaching the When the discharge monitor function is enabled, lifting is cut out when reaching the
discharge limit is reached (the Stop LED goes on). Travel and lowering are still discharge limit is reached (the Stop LED goes on). Travel and lowering are still
possible. possible.
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7.5.2 Service hour display 7.5.2 Service hour display
Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are
logged. This is a backlit display. logged. This is a backlit display.
Z For maintenance-free batteries a “T” symbol is shown in the hourmeter Z For maintenance-free batteries a “T” symbol is shown in the hourmeter
display (66). display (66).
7.5.3 Event Messages 7.5.3 Event Messages

The service hours display is also used to display event messages. The error display The service hours display is also used to display event messages. The error display
starts with an ”E” for Event and a four-digit error number. starts with an ”E” for Event and a four-digit error number.
If several events occur simultaneously, they are displayed one after the other. The If several events occur simultaneously, they are displayed one after the other. The
events are displayed until they are rectified. Event messages overwrite the service events are displayed until they are rectified. Event messages overwrite the service
hour display. Most events cause the Emergency Stop to be activated. Events remain hour display. Most events cause the Emergency Stop to be activated. Events remain
displayed until the control circuit is switched off (key switch). displayed until the control circuit is switched off (key switch).
If no CanDis is present, the event code is displayed by the flashing of the discharge If no CanDis is present, the event code is displayed by the flashing of the discharge
monitor LED. monitor LED.
Z The manufacturer’s service department has detailed component descriptions with Z The manufacturer’s service department has detailed component descriptions with
event codes. event codes.
7.5.4 Power up test 7.5.4 Power up test

On power up the display shows: On power up the display shows:
– The software version of the display instrument (briefly), – The software version of the display instrument (briefly),
– The service hours, – The service hours,
– The battery charge status. – The battery charge status.
7.6 ISM access module (o) 7.6 ISM access module (o)
Z If the truck is equipped with an ISM access module or Can Code refer to the “ISM Z If the truck is equipped with an ISM access module or Can Code refer to the “ISM
Access Module” operator manual. Access Module” operator manual.
7.7 Curve Control 7.7 Curve Control

The Curve Control option assists the driver to operating the truck with regard to safety The Curve Control option assists the driver to operating the truck with regard to safety
regulations. At corners the maximum travel speed is adapted to the steer angle. regulations. At corners the maximum travel speed is adapted to the steer angle.
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86
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F Industrial Truck Maintenance F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection 1 Operational Safety and Environmental Protection
The checks and servicing operations contained in this chapter must be performed in The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists. accordance with the intervals as indicated in the servicing checklists.
WARNING! WARNING!
Risk of accidents and damage to components Risk of accidents and damage to components
All modifications to the forklift truck assemblies, in particular the safety mechanisms, All modifications to the forklift truck assemblies, in particular the safety mechanisms,
are prohibited. The operating speeds of the truck must not be increased under any are prohibited. The operating speeds of the truck must not be increased under any
circumstances. circumstances.
NOTE NOTE
Only original spare parts have been certified by our quality assurance department. To Only original spare parts have been certified by our quality assurance department. To
ensure safe and reliable operation of the truck, use only the manufacturer's spare ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts. parts.
For safety reasons, only components which have been specially agreed by the For safety reasons, only components which have been specially agreed by the
manufacturer for this truck may be installed near the computer, controllers and wire manufacturer for this truck may be installed near the computer, controllers and wire
guidance sensors (antennae). These components (computers, controllers, wire guidance sensors (antennae). These components (computers, controllers, wire
guidance sensors (antennae)) must therefore not be replaced either by similar guidance sensors (antennae)) must therefore not be replaced either by similar
components from other trucks of the same series. components from other trucks of the same series.
2 Maintenance Safety Regulations 2 Maintenance Safety Regulations

Maintenance personnel Maintenance personnel
The truck should only be serviced and repaired by the manufacturer's specialist The truck should only be serviced and repaired by the manufacturer's specialist
customer service personnel who have been trained to do this. We therefore customer service personnel who have been trained to do this. We therefore
recommend that you enter into a maintenance contract with the manufacturer’s local recommend that you enter into a maintenance contract with the manufacturer’s local
sales office. sales office.
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Lifting and jacking up Lifting and jacking up
WARNING! WARNING!
Lifting and jacking up the truck safely Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose. provided for this purpose.
You may only work under a raised load handler / raised cab if they have been secured You may only work under a raised load handler / raised cab if they have been secured
with a sufficiently strong chain or the fastening bolt. with a sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows: In order to raise and jack up the truck safely, proceed as follows:
Jack up the truck only on a level surface and prevent it from moving accidentally. Jack up the truck only on a level surface and prevent it from moving accidentally.
Always use a jack with sufficient capacity. When jacking up the truck, take Always use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges, appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks). wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the points In order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Transport and Commissioning" on specially provided for this purpose, (see "Transport and Commissioning" on
page 29). page 29).
When jacking up the truck, take appropriate measures to prevent it from slipping or When jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks). tipping over (e.g. wedges, wooden blocks).
Cleaning Cleaning
CAUTION! CAUTION!
Fire hazard Fire hazard
Do not use flammable liquids to clean the industrial truck. Do not use flammable liquids to clean the industrial truck.
Always disconnect the battery before starting cleaning work. Always disconnect the battery before starting cleaning work.
Carry out all necessary safety measures to prevent sparking before cleaning (e.g. Carry out all necessary safety measures to prevent sparking before cleaning (e.g.
by short-circuiting). by short-circuiting).
CAUTION! CAUTION!
Risk of electrical system damage Risk of electrical system damage

The electrical system can be damaged if it is cleaning with water. It is prohibited to The electrical system can be damaged if it is cleaning with water. It is prohibited to
clean the electrical system with water. clean the electrical system with water.
Do not clean the electrical system with water. Do not clean the electrical system with water.
Clean the electrical system with weak suction or compressed air (use a compressor Clean the electrical system with weak suction or compressed air (use a compressor
with a water trap) and not a conductive, anti-static brush. with a water trap) and not a conductive, anti-static brush.
CAUTION! CAUTION!
Risk of component damage when cleaning the truck Risk of component damage when cleaning the truck
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can and electronic components must be carefully covered beforehand as moisture can
cause malfunctions. Do not clean with pressurised water. cause malfunctions. Do not clean with pressurised water.
Z After cleaning, carry out the operations detailed in “Recommissioning the truck after Z After cleaning, carry out the operations detailed in “Recommissioning the truck after
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cleaning or maintenance work” ((see "Restoring the truck to service after cleaning or maintenance work” ((see "Restoring the truck to service after
maintenance and repairs" on page 112)). maintenance and repairs" on page 112)).
88 88
Electrical system Electrical system
WARNING! WARNING!
Only suitably trained electricians may operate on the truck's electrical system. Only suitably trained electricians may operate on the truck's electrical system.
Before working on the electrical system, take all precautionary measures to avoid Before working on the electrical system, take all precautionary measures to avoid
electric shocks. electric shocks.
Always disconnect the battery before starting cleaning operations. Always disconnect the battery before starting cleaning operations.
WARNING! WARNING!
Electric currents can cause accidents Electric currents can cause accidents
Make sure the electrical system is voltage-free before starting work on it. Before Make sure the electrical system is voltage-free before starting work on it. Before
starting maintenance on the electrical system: starting maintenance on the electrical system:
Park the truck securely ((see "Parking the truck securely" on page 49)). Park the truck securely ((see "Parking the truck securely" on page 49)).
Press the Emergency Disconnect. Press the Emergency Disconnect.
 Disconnect the battery.  Disconnect the battery.
Remove any rings or metal bracelets etc. before working on electrical components. Remove any rings or metal bracelets etc. before working on electrical components.
Consumables and used parts Consumables and used parts
CAUTION! CAUTION!
Consumables and used parts are an environmental hazard Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task. customer service department, who have been specially trained for this task.
Note the safety regulations when handling these materials. Note the safety regulations when handling these materials.
Welding Welding
Remove electrical and electronic components from the truck before performing Remove electrical and electronic components from the truck before performing
welding operations, to avoid damage. welding operations, to avoid damage.
Settings Settings
When repairing or replacing hydraulic, electric or electronic components or When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings. assemblies, always note the truck-specific settings.
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Wheels Wheels
WARNING! WARNING!
The use of wheels that do not match the manufacturer's specifications can The use of wheels that do not match the manufacturer's specifications can
result in accidents. result in accidents.
The quality of wheels affects the stability and performance of the truck. The quality of wheels affects the stability and performance of the truck.
Uneven wear affects the truck's stability and increases the stopping distance. Uneven wear affects the truck's stability and increases the stopping distance.
When replacing wheels make sure the truck is not skewed. When replacing wheels make sure the truck is not skewed.
Always replace wheels in pairs, i.e. left and right at the same time. Always replace wheels in pairs, i.e. left and right at the same time.
Z When replacing wheels fitted at the factory, only use the manufacturer’s original 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. spare parts. Otherwise the truck's rated performance cannot be ensured.
Hydraulic hoses Hydraulic hoses
WARNING! WARNING!
Leaky hydraulic systems can result in accidents Leaky hydraulic systems can result in accidents
Hydraulic oil can escape from leaky and faulty hydraulic systems. Hydraulic oil can escape from leaky and faulty hydraulic systems.
Mark defective truck and take out of service. Mark defective truck and take out of service.
Do not return the industrial truck to service until you have identified and rectified the Do not return the industrial truck to service until you have identified and rectified the
fault. fault.
Remove any spilled hydraulic immediately with an appropriate bonding agent. Remove any spilled hydraulic immediately with an appropriate bonding agent.
The bonding agent / consumable mixture must be disposed of in accordance with The bonding agent / consumable mixture must be disposed of in accordance with
regulations. regulations.
WARNING! WARNING!
Faulty hydraulic hoses can result in injury and infection Faulty hydraulic hoses can result in injury and infection
Pressurised hydraulic oil can escape from fine holes or hairline cracks in the hydraulic 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 hoses. Brittle hydraulic hoses can burst during operation. People standing near the
truck can be injured by the hydraulic oil. truck can be injured by the hydraulic oil.
Call for a doctor immediately in the event of an injury. Call for a doctor immediately in the event of an injury.
Do not touch pressurised hydraulic hoses. Do not touch pressurised hydraulic hoses.
Mark defective truck and take it out of service. Mark defective truck and take it out of service.
Do not return the industrial truck to service until you have identified and rectified the Do not return the industrial truck to service until you have identified and rectified the
fault. fault.
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NOTE NOTE
Testing and replacing hydraulic hoses Testing and replacing hydraulic hoses
Hydraulic hoses can become brittle through age and must be checked at regular Hydraulic hoses can become brittle through age and must be checked at regular
intervals. The application conditions of the industrial truck have a considerable impact intervals. The application conditions of the industrial truck have a considerable impact
on the ageing of the hydraulic hoses. on the ageing of the hydraulic hoses.
Check the hydraulic hoses at least annually and replace if necessary. Check the hydraulic hoses at least annually and replace if necessary.
If the operating conditions become more arduous the inspection intervals must be If the operating conditions become more arduous the inspection intervals must be
reduced accordingly. reduced accordingly.
In normal operating conditions a precautionary replacement of the hydraulic hoses In normal operating conditions a precautionary replacement of the hydraulic hoses
is recommended after 6. The owner must carry out a risk assessment to ensure is recommended after 6. The owner must carry out a risk assessment to ensure
safe, prolonged use. The resulting protection measures must be observed and the safe, prolonged use. The resulting protection measures must be observed and the
inspection interval reduced accordingly. inspection interval reduced accordingly.
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3 Servicing and Inspection 3 Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment. failure and poses a potential hazard to personnel and equipment.
WARNING! WARNING!
The application conditions of an industrial truck have a considerable impact on the The application conditions of an industrial truck have a considerable impact on the
wear of the service components. wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage application analysis on site to work out specific service intervals to prevent damage
due to wear. due to wear.
The service intervals stated are based on single shift operation under normal The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts. conditions of extreme dust, temperature fluctuations or multiple shifts.
The following servicing checklist indicates the operations to be performed and the The following servicing checklist indicates the operations to be performed and the
respective intervals to be observed. Maintenance intervals are defined as: respective intervals to be observed. Maintenance intervals are defined as:
W = Every 50 service hours, at least weekly W = Every 50 service hours, at least weekly
A = Every 500 service hours A = Every 500 service hours
B = Every 1000 service hours, or at least annually B = Every 1000 service hours, or at least annually
C = Every 2000 service hours, or at least annually C = Every 2000 service hours, or at least annually
t = Standard maintenance interval t = Standard maintenance interval
Cold store maintenance interval (in addition to standard maintenance Cold store maintenance interval (in addition to standard maintenance
k = k =
interval) interval)
Z W maintenance intervals must be performed by the owner. Z W maintenance intervals must be performed by the owner.
During the run-in period – after approx. 100 service hours – the owner must check the During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts / bolts and re-tighten if necessary. wheel nuts / bolts and re-tighten if necessary.
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4 Maintenance checklist ERE 225 fixed platform 4 Maintenance checklist ERE 225 fixed platform
4.1 Proprietor 4.1 Proprietor
4.1.1 Standard equipment 4.1.1 Standard equipment
Brakes W A B C Brakes W A B C
1 Test brakes. t 1 Test brakes. t
Electrical System W A B C Electrical System W A B C

Test warning and safety devices in accordance with operating Test warning and safety devices in accordance with operating
1 t 1 t
instructions. instructions.
2 Test Emergency Disconnect switch. t 2 Test Emergency Disconnect switch. t
Power Supply W A B C Power Supply W A B C

Check battery cable connections are secure, grease terminals if Check battery cable connections are secure, grease terminals if
1 t 1 t
necessary. necessary.
2 Check battery and battery components. t 2 Check battery and battery components. t
Check battery connector for damage, test it and make sure it is Check battery connector for damage, test it and make sure it is
3 t 3 t
secure. secure.
Travel W A B C Travel W A B C
1 Check wheels for wear and damage. t 1 Check wheels for wear and damage. t
Chassis and superstructure W A B C Chassis and superstructure W A B C

1 Check doors and/or covers. t 1 Check doors and/or covers. t
2 Check labels are legible and complete. t 2 Check labels are legible and complete. t
Hydraulic operations W A B C Hydraulic operations W A B C

1 Test hydraulic system. t 1 Test hydraulic system. t
2 Check hydraulic oil level and top up if necessary. t 2 Check hydraulic oil level and top up if necessary. t
3 Check forks or load handler for wear and damage. t 3 Check forks or load handler for wear and damage. t
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4.2 Customer Service 4.2 Customer Service
2 Check magnetic brake air gap. t 2 Check magnetic brake air gap. t

1 Test cable and motor attachments. t 1 Test cable and motor attachments. t
2 t 2 t
3 Test displays and controls. t 3 Test displays and controls. t
4 Test micro switch and adjust if necessary. t 4 Test micro switch and adjust if necessary. t
6 Check contactors and/or relays. t 6 Check contactors and/or relays. t
7 Check fuse ratings. t 7 Check fuse ratings. t
Check carbon brushes and replace if necessary. Note: when Check carbon brushes and replace if necessary. Note: when
8 t 8 t
replacing the carbon brushes apply compressed air to the motor. replacing the carbon brushes apply compressed air to the motor.
9 Carry out a frame leakage test. t 9 Carry out a frame leakage test. t
Check electric wiring for damage (insulation damage, connections). Check electric wiring for damage (insulation damage, connections).
10 t 10 t
Make sure wire connections are secure. Make sure wire connections are secure.

1 t 1 t
3 Check acid density and battery voltage. t 3 Check acid density and battery voltage. t
4 t 4 t
secure. secure.
1 Test Deadman switch. t 1 Test Deadman switch. t
2 Checking bedding and attachment of the drive system. t 2 Checking bedding and attachment of the drive system. t
3 Check transmission for noise and leakage. t 3 Check transmission for noise and leakage. t
4 Note: Replace transmission oil after 10000 service hours. 4 Note: Replace transmission oil after 10000 service hours.
6 Check wheel suspension and attachment. t 6 Check wheel suspension and attachment. t
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1 Check chassis and screw connections for damage. t 1 Check chassis and screw connections for damage. t
4 Test the operator platform and check for damage. t 4 Test the operator platform and check for damage. t
5 Check operator mat and steps are non-slip and damage-free. t 5 Check operator mat and steps are non-slip and damage-free. t

Test "hydraulic" controls and make sure the labels are present, Test "hydraulic" controls and make sure the labels are present,
1 t 1 t
legible and complete. legible and complete.
2 Test lift cutout, check for damage and make sure it is secure. t 2 Test lift cutout, check for damage and make sure it is secure. t
3 Test lifting mechanism, check for wear, damage and test the settings. t 3 Test lifting mechanism, check for wear, damage and test the settings. t
Check cylinders and piston rods for damage and leaks, and make Check cylinders and piston rods for damage and leaks, and make
4 t 4 t
sure they are secure. sure they are secure.
6 Replace hydraulic oil filter, ventilation/discharge filter. k t 6 Replace hydraulic oil filter, ventilation/discharge filter. k t
Check that hydraulic ports, hose and pipe lines are secure, check for Check that hydraulic ports, hose and pipe lines are secure, check for
7 t 7 t
leaks and damage. leaks and damage.
9 Test relief valve and adjust if necessary. t 9 Test relief valve and adjust if necessary. t
10 Replace hydraulic oil. k t 10 Replace hydraulic oil. k t
12 Check tie / plunger rods. t 12 Check tie / plunger rods. t
Agreed performance levels W A B C Agreed performance levels W A B C

Carry out a test run with rated load, if necessary with a customer- Carry out a test run with rated load, if necessary with a customer-
1 t 1 t
specific load. specific load.
2 Lubricate truck according to the lubrication schedule. t 2 Lubricate truck according to the lubrication schedule. t
3 Demonstration after servicing. t 3 Demonstration after servicing. t
Steering W A B C Steering W A B C
1 Test electric steering and its components. t 1 Test electric steering and its components. t
2 Check mechanical parts of steering column. t 2 Check mechanical parts of steering column. t
4.2.2 Optional equipment 4.2.2 Optional equipment

Aquamatik Aquamatik

Test Aquamatik plug, hose connections and float and check for Test Aquamatik plug, hose connections and float and check for
1 t 1 t
leaks. leaks.
2 Test flow indicator and check for leaks. t 2 Test flow indicator and check for leaks. t
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Automatic crawl speed Automatic crawl speed
Check that sensors / switches are secured, not damaged, clean and Check that sensors / switches are secured, not damaged, clean and
1 t 1 t
operational. operational.
Battery refill system Battery refill system

1 Test battery refill system and check for leaks. t 1 Test battery refill system and check for leaks. t
Data recorder Data recorder

1 Check data recorder is secure and check for damage. t 1 Check data recorder is secure and check for damage. t
Entry skids / rollers Entry skids / rollers

Check entry skids or entry rollers for damage and wear, and test Check entry skids or entry rollers for damage and wear, and test
1 t 1 t
operation. operation.
Electrolyte recirculation Electrolyte recirculation

1 Replace air filter wadding. t 1 Replace air filter wadding. t
2 Check hose connections and test the pump. t 2 Check hose connections and test the pump. t
Load backrest Load backrest

Check attachment is properly secured to the truck and the Check attachment is properly secured to the truck and the
1 t 1 t
supporting elements. supporting elements.
Impact sensor Impact sensor

1 Check impact sensor is secure and check for damage. t 1 Check impact sensor is secure and check for damage. t
Lateral battery removal Lateral battery removal

1 Test battery lock / battery attachment. t 1 Test battery lock / battery attachment. t
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Access module Access module

1 Test access module, check for damage and make sure it is secure. t 1 Test access module, check for damage and make sure it is secure. t
Issued on: 19.04.2012 11:22:49 Issued on: 19.04.2012 11:22:49

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5 Maintenance checklist ERE 225 folding platform 5 Maintenance checklist ERE 225 folding platform
5.1 Proprietor 5.1 Proprietor

1 t 1 t

1 t 1 t
3 t 3 t
secure. secure.


1 Check tiller recuperating function. t 1 Check tiller recuperating function. t
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5.2 Customer Service 5.2 Customer Service
2 Check magnetic brake air gap. t 2 Check magnetic brake air gap. t

1 Test cable and motor attachments. t 1 Test cable and motor attachments. t
2 t 2 t
3 Test displays and controls. t 3 Test displays and controls. t
4 Test micro switch and adjust if necessary. t 4 Test micro switch and adjust if necessary. t
6 Check contactors and/or relays. t 6 Check contactors and/or relays. t
7 Check fuse ratings. t 7 Check fuse ratings. t
Check carbon brushes and replace if necessary. Note: when Check carbon brushes and replace if necessary. Note: when
8 t 8 t
replacing the carbon brushes apply compressed air to the motor. replacing the carbon brushes apply compressed air to the motor.
9 Carry out a frame leakage test. t 9 Carry out a frame leakage test. t
Check electric wiring for damage (insulation damage, connections). Check electric wiring for damage (insulation damage, connections).
10 t 10 t
Make sure wire connections are secure. Make sure wire connections are secure.

1 t 1 t
3 Check acid density and battery voltage. t 3 Check acid density and battery voltage. t
4 t 4 t
secure. secure.
1 Checking bedding and attachment of the drive system. t 1 Checking bedding and attachment of the drive system. t
2 Check transmission for noise and leakage. t 2 Check transmission for noise and leakage. t
3 Note: Replace transmission oil after 10000 service hours. 3 Note: Replace transmission oil after 10000 service hours.
5 Check wheel suspension and attachment. t 5 Check wheel suspension and attachment. t
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1 Check chassis and screw connections for damage. t 1 Check chassis and screw connections for damage. t
4 Test the operator platform and check for damage. t 4 Test the operator platform and check for damage. t
5 Check operator mat and steps are non-slip and damage-free. t 5 Check operator mat and steps are non-slip and damage-free. t

Test "hydraulic" controls and make sure the labels are present, Test "hydraulic" controls and make sure the labels are present,
1 t 1 t
legible and complete. legible and complete.
2 Test lift cutout, check for damage and make sure it is secure. t 2 Test lift cutout, check for damage and make sure it is secure. t
3 Test lifting mechanism, check for wear, damage and test the settings. t 3 Test lifting mechanism, check for wear, damage and test the settings. t
Check cylinders and piston rods for damage and leaks, and make Check cylinders and piston rods for damage and leaks, and make
4 t 4 t
sure they are secure. sure they are secure.
6 Replace hydraulic oil filter, ventilation/discharge filter. k t 6 Replace hydraulic oil filter, ventilation/discharge filter. k t
Check that hydraulic ports, hose and pipe lines are secure, check for Check that hydraulic ports, hose and pipe lines are secure, check for
7 t 7 t
leaks and damage. leaks and damage.
9 Test relief valve and adjust if necessary. t 9 Test relief valve and adjust if necessary. t
10 Replace hydraulic oil. k t 10 Replace hydraulic oil. k t
12 Check tie / plunger rods. t 12 Check tie / plunger rods. t
Agreed performance levels W A B C Agreed performance levels W A B C

Carry out a test run with rated load, if necessary with a customer- Carry out a test run with rated load, if necessary with a customer-
1 t 1 t
specific load. specific load.
2 Lubricate truck according to the lubrication schedule. t 2 Lubricate truck according to the lubrication schedule. t
3 Demonstration after servicing. t 3 Demonstration after servicing. t
1 Check tiller recuperating function. t 1 Check tiller recuperating function. t
2 Test electric steering and its components. t 2 Test electric steering and its components. t
3 Check mechanical parts of steering column. t 3 Check mechanical parts of steering column. t
5.2.2 Optional equipment 5.2.2 Optional equipment

Aquamatik Aquamatik

Test Aquamatik plug, hose connections and float and check for Test Aquamatik plug, hose connections and float and check for
1 t 1 t
leaks. leaks.
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2 Test flow indicator and check for leaks. t 2 Test flow indicator and check for leaks. t
100 100
Automatic crawl speed Automatic crawl speed
Check that sensors / switches are secured, not damaged, clean and Check that sensors / switches are secured, not damaged, clean and
1 t 1 t
operational. operational.
Battery refill system Battery refill system

1 Test battery refill system and check for leaks. t 1 Test battery refill system and check for leaks. t
Data recorder Data recorder

1 Check data recorder is secure and check for damage. t 1 Check data recorder is secure and check for damage. t
Entry skids / rollers Entry skids / rollers

Check entry skids or entry rollers for damage and wear, and test Check entry skids or entry rollers for damage and wear, and test
1 t 1 t
operation. operation.
Electrolyte recirculation Electrolyte recirculation

1 Replace air filter wadding. t 1 Replace air filter wadding. t
2 Check hose connections and test the pump. t 2 Check hose connections and test the pump. t
Load backrest Load backrest

Check attachment is properly secured to the truck and the Check attachment is properly secured to the truck and the
1 t 1 t
supporting elements. supporting elements.
Impact sensor Impact sensor

1 Check impact sensor is secure and check for damage. t 1 Check impact sensor is secure and check for damage. t
Lateral battery removal Lateral battery removal

1 Test battery lock / battery attachment. t 1 Test battery lock / battery attachment. t
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Access module Access module

1 Test access module, check for damage and make sure it is secure. t 1 Test access module, check for damage and make sure it is secure. t
Issued on: 05.06.2012 14:31:05 Issued on: 05.06.2012 14:31:05
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6 Lubricants and Lubrication Schedule 6 Lubricants and Lubrication Schedule
6.1 Handling consumables safely 6.1 Handling consumables safely
Handling consumables Handling consumables
Consumables must always be handled correctly. Follow the manufacturer’s Consumables must always be handled correctly. Follow the manufacturer’s
WARNING! WARNING!
Improper handling is hazardous to health, life and the environment Improper handling is hazardous to health, life and the environment
Consumables can be flammable. Consumables can be flammable.
Keep consumables away from hot components and naked flames. Keep consumables away from hot components and naked flames.
Always keep consumables in prescribed containers. Always keep consumables in prescribed containers.
Always fill consumables in clean containers. Always fill consumables in clean containers.
Do not mix up different grades of consumable. The only exception to this is when Do not mix up different grades of consumable. The only exception to this is when
mixing is expressly stipulated in the operating instructions. mixing is expressly stipulated in the operating instructions.
CAUTION! CAUTION!
Spilled liquids can cause slipping and endanger the environment Spilled liquids can cause slipping and endanger the environment
Risk of slipping from spilled liquids. The risk is greater when combined with water. Risk of slipping from spilled liquids. The risk is greater when combined with water.
Do not spill fluids. Do not spill fluids.
Spilled fluids must be removed immediately with an appropriate bonding agent. Spilled fluids must be removed immediately with an appropriate bonding agent.
WARNING! WARNING!
Oils (chain spray / hydraulic oil) are flammable and poisonous. Oils (chain spray / hydraulic oil) are flammable and poisonous.
Dispose of used oils in accordance with regulations. Store used oil safely until it can Dispose of used oils in accordance with regulations. Store used oil safely until it can
be disposed of in accordance with regulations. be disposed of in accordance with regulations.
Do not spill oil. Do not spill oil.
Spilled fluids must be removed immediately with an appropriate bonding agent. Spilled fluids must be removed immediately with an appropriate bonding agent.
Observe national regulations when handling oils. Observe national regulations when handling oils.
Wear safety gloves when handling oils. Wear safety gloves when handling oils.
Prevent oil from coming into contact with hot motor parts. Prevent oil from coming into contact with hot motor parts.
Do not smoke when handling oil. Do not smoke when handling oil.
Avoid contact and digestion. If you swallow oil do not induce vomiting but call for a Avoid contact and digestion. If you swallow oil do not induce vomiting but call for a
doctor immediately. doctor immediately.
Seek fresh air after breathing in oil fumes or vapours. Seek fresh air after breathing in oil fumes or vapours.
If oil has come into contact with your skin, rinse your skin with water. If oil has come into contact with your skin, rinse your skin with water.
If oil has come into contact with your eyes, rinse them with water and call for a If oil has come into contact with your eyes, rinse them with water and call for a
doctor immediately. doctor immediately.
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Replace oil-soaked clothing and shoes immediately. Replace oil-soaked clothing and shoes immediately.
103 103
Consumables and used parts Consumables and used parts
CAUTION! CAUTION!
Consumables and used parts are an environmental hazard Consumables and used parts are an environmental hazard
Used parts, oils and fuels must be disposed of in accordance with the relevant Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. To change the oil contact the manufacturer's environmental protection regulations. To change the oil contact the manufacturer's
customer service department, who have been specially trained for this task. customer service department, who have been specially trained for this task.
Note the safety regulations when handling these materials. Note the safety regulations when handling these materials.
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6.2 Lubrication Schedule 6.2 Lubrication Schedule
1) 1)
A+C A A+C A
0,7l 0,7l
E E
E E
B 1,05 l B 1,05 l
a a
Contact surfaces Cold Store Application Contact surfaces Cold Store Application
s Grease nipple Hydraulic oil filler neck s Grease nipple Hydraulic oil filler neck
a Transmission oil drain plug a Transmission oil drain plug

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1 Compound ratio for cold store usage 1:1 1 Compound ratio for cold store usage 1:1
105 105
6.3 Consumables 6.3 Consumables
Code Order no. Package Component Used for Code Order no. Package Component Used for
quantity quantity
A 50 449 669 5.0 l H-LPD 46, DIN Hydraulic System A 50 449 669 5.0 l H-LPD 46, DIN Hydraulic System
51524 51524
B 50 380 904 5.0 l Fuchs Titan Cytrac transmission B 50 380 904 5.0 l Fuchs Titan Cytrac transmission
HSY 75W-90 *) HSY 75W-90 *)
C 29 200 810 5.0 l H-LP 10, Hydraulic System C 29 200 810 5.0 l H-LP 10, Hydraulic System
DIN 51524 DIN 51524
E 29 202 050 1.0 kg Grease, Polylube Lubrication E 29 202 050 1.0 kg Grease, Polylube Lubrication
GA 352P GA 352P
*) also for cold store applications *) also for cold store applications
Grease guidelines Grease guidelines
Code Saponification Dew point Worked NLG1 class Application Code Saponification Dew point Worked NLG1 class Application
°C penetration temperature °C penetration temperature
at 25 °C °C at 25 °C °C
E Lithium >220 280 - 310 2 -35/+120 E Lithium >220 280 - 310 2 -35/+120
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7 Maintenance and repairs 7 Maintenance and repairs
7.1 Preparing the truck for maintenance and repairs 7.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made: maintenance and repairs. The following preparations must be made:
Procedure Procedure
• Park the truck on a level surface. • Park the truck on a level surface.
• Fully lower the main and auxiliary lift. • Fully lower the main and auxiliary lift.
• Park the truck securely, (see "Parking the truck securely" on page 49). • Park the truck securely, (see "Parking the truck securely" on page 49).
• Disconnect the battery to prevent the truck from being switched on accidentally. • Disconnect the battery to prevent the truck from being switched on accidentally.
• When working under a raised lift truck, secure it to prevent it from lowering, tipping • When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away. or sliding away.
WARNING! WARNING!
Risk of accidents when working under the load handler, driver's cab and lift Risk of accidents when working under the load handler, driver's cab and lift
truck truck
When working under a raised load handler, driver's cab or a raised truck, secure When working under a raised load handler, driver's cab or a raised truck, secure
them to prevent the truck from from lowering, tipping or sliding away. them to prevent the truck from from lowering, tipping or sliding away.
When raising the truck, follow the instructions, (see "Transport and When raising the truck, follow the instructions, (see "Transport and
Commissioning" on page 29). When working on the parking brake, prevent the Commissioning" on page 29). When working on the parking brake, prevent the
truck from accidentally rolling away (e.g. with wedges). truck from accidentally rolling away (e.g. with wedges).
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7.2 Replacing the drive wheel 7.2 Replacing the drive wheel
Z The drive wheel must only be replaced by authorised service personnel. Z The drive wheel must only be replaced by authorised service personnel.
7.3 Checking the hydraulic oil level 7.3 Checking the hydraulic oil level
Check oil level Check oil level
– Lower the load handler. – Lower the load handler.
– Prepare the truck for maintenance – Prepare the truck for maintenance
and repairs, (see "Preparing the and repairs, (see "Preparing the
truck for maintenance and repairs" truck for maintenance and repairs"
on page 107). max on page 107). max
– Open the battery panel, (see min

– Open the battery panel, (see min
"Exposing the battery" on page 36). 73 "Exposing the battery" on page 36). 73
– Lift off the front cover, (see – Lift off the front cover, (see
"Removing the front panel" on "Removing the front panel" on
page 108) page 108)
Procedure Procedure
• Check oil level on hydraulic reservoir (73). • Check oil level on hydraulic reservoir (73).
Z The hydraulic oil level in the tank should be between the "Max" and "Min" marks Z The hydraulic oil level in the tank should be between the "Max" and "Min" marks
with the load handler lowered. with the load handler lowered.
• If necessary add hydraulic oil of the correct grade, (see "Consumables" on • If necessary add hydraulic oil of the correct grade, (see "Consumables" on
page 106) (see also table). page 106) (see also table).
Oil level is checked. Oil level is checked.
7.4 Removing the front panel 7.4 Removing the front panel
Remove the front cover (industrial truck with folding standing platform) Remove the front cover (industrial truck with folding standing platform)
– Open the battery panel, (see "Exposing the battery" on page 36). – Open the battery panel, (see "Exposing the battery" on page 36).
Procedure Procedure
• Fold down the standing platform (8). • Fold down the standing platform (8).
• Carefully lift up the dashboard (74) at all four corners and remove it from the • Carefully lift up the dashboard (74) at all four corners and remove it from the
industrial truck. industrial truck.
• Pull the front cover (54) out of its bracket using the grip shells and then pull it up out • Pull the front cover (54) out of its bracket using the grip shells and then pull it up out
of the bottom retainers. of the bottom retainers.
The front panel is now disassembled. The front panel is now disassembled.
Z Assembly is the reverse order. Z Assembly is the reverse order.
Remove the front cover (industrial truck with fixed standing platform) Remove the front cover (industrial truck with fixed standing platform)
– Open the battery panel, (see "Exposing the battery" on page 36). – Open the battery panel, (see "Exposing the battery" on page 36).
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Procedure Procedure
• Carefully lift up the dashboard (74) at all four corners and remove it from the • Carefully lift up the dashboard (74) at all four corners and remove it from the
industrial truck. industrial truck.
• Pull the front cover (54) out of its bracket using the grip shells and then pull it up out • Pull the front cover (54) out of its bracket using the grip shells and then pull it up out
of the bottom retainers. of the bottom retainers.
The front panel is now disassembled. The front panel is now disassembled.
Z Assembly is the reverse order. Z Assembly is the reverse order.
74 74
54 54
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7.5 Checking electrical fuses 7.5 Checking electrical fuses
Check fuses Check fuses
– Truck prepared for maintenance and repairs, (see "Preparing the truck for – Truck prepared for maintenance and repairs, (see "Preparing the truck for
maintenance and repairs" on page 107). maintenance and repairs" on page 107).
– Front cover removed, (see "Removing the front panel" on page 108). – Front cover removed, (see "Removing the front panel" on page 108).
Procedure Procedure
• Check the fuse ratings against the table and replace if necessary. • Check the fuse ratings against the table and replace if necessary.
The fuses are now checked. The fuses are now checked.
Traction controller AS2412i fuses Traction controller AS2412i fuses
75 76 75 76
77 77
78 78
79 79
80 80
Traction controller AS2412i fuses Traction controller AS2412i fuses
Item Component To protect Rating (A) Item Component To protect Rating (A)
75 2F1 Lift motor 150 75 2F1 Lift motor 150
76 1F1 Drive motor 300 76 1F1 Drive motor 300
77 3F1 Steering auxiliary motor fuse 30 77 3F1 Steering auxiliary motor fuse 30
78 F1 Overall fuse 10 78 F1 Overall fuse 10
79 9F21 Electric/mechanical components 3 79 9F21 Electric/mechanical components 3
80 6F1 Battery discharge indicator / battery hour meter 2 80 6F1 Battery discharge indicator / battery hour meter 2
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Combi controller AS2412iS fuses Combi controller AS2412iS fuses
76 76
89 89
77 77
78 78
80 80
Combi controller AS2412iS fuses Combi controller AS2412iS fuses
Item Component To protect Rating (A) Item Component To protect Rating (A)
89 F17 Radio data transmission (o) 10 89 F17 Radio data transmission (o) 10
78 F1 Overall control circuit fuse 10 78 F1 Overall control circuit fuse 10
77 9F22 Sensor system fuse 10 77 9F22 Sensor system fuse 10
80 6F1 Battery Discharge Indicator 2 80 6F1 Battery Discharge Indicator 2
76 1F1 Drive / lift motor 300 76 1F1 Drive / lift motor 300
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7.6 Restoring the truck to service after maintenance and repairs 7.6 Restoring the truck to service after maintenance and repairs
Procedure Procedure
• Thoroughly clean the truck. • Thoroughly clean the truck.
• Lubricate the truck according to the lubrication schedule, (see "Lubrication • Lubricate the truck according to the lubrication schedule, (see "Lubrication
Schedule" on page 105). Schedule" on page 105).
• Clean the battery, grease the terminals and connect the battery. • Clean the battery, grease the terminals and connect the battery.
• Check the transmission oil for condensation water and replace if necessary. • Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary. • Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out Z The manufacturer's customer service department is specially trained to carry out
these operations. these operations.
WARNING! WARNING!
Faulty brakes can cause accidents Faulty brakes can cause accidents
As soon as the truck has been started, test the brakes several times. As soon as the truck has been started, test the brakes several times.
Tag out and decommission the faulty industrial truck. Tag out and decommission the faulty industrial truck.
• Start up the truck, (see "Starting up the truck" on page 47). • Start up the truck, (see "Starting up the truck" on page 47).
Z If there are switching problems in the electrical system, apply contact spray to the Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly. applying them repeatedly.
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8 Safety tests to be performed at intervals and after unusual 8 Safety tests to be performed at intervals and after unusual
incidents incidents
Z Perform a safety check in accordance with national regulations. Jungheinrich Z Perform a safety check in accordance with national regulations. Jungheinrich
recommends the truck be checked to FEM guideline 4.004. The Jungheinrich recommends the truck be checked to FEM guideline 4.004. The Jungheinrich
safety department has trained personnel who are able to carry out inspections. safety department has trained personnel who are able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess the inspector (be sure to comply with national regulations). The inspector shall assess the
condition of the truck from purely a safety viewpoint, without regard to operational or condition of the truck from purely a safety viewpoint, without regard to operational or
economic circumstances. The inspector shall be sufficiently instructed and economic circumstances. The inspector shall be sufficiently instructed and
experienced to be able to assess the condition of the truck and the effectiveness of experienced to be able to assess the condition of the truck and the effectiveness of
the safety mechanisms based on the technical regulations and principles governing the safety mechanisms based on the technical regulations and principles governing
the inspection of forklift trucks. the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections. for at least the next 2 inspections.
The owner is responsible for ensuring that faults are rectified immediately. The owner is responsible for ensuring that faults are rectified immediately.
Z A test plate is attached to the truck as proof that it has passed the safety inspection. Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection. This plate indicates the due date for the next inspection.
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9 Decommissioning the industrial truck 9 Decommissioning the industrial truck
Z If the truck is to be out of service for more than a month, e.g. for commercial Z If the truck is to be out of service for more than a month, e.g. for commercial
reasons, it must be stored in a frost-free and dry room. All necessary measures reasons, it must be stored in a frost-free and dry room. All necessary measures
must be taken before, during and after decommissioning as described hereafter. must be taken before, during and after decommissioning as described hereafter.
WARNING! WARNING!
Lifting and jacking up the truck safely Lifting and jacking up the truck safely
In order to raise the truck, the lifting gear must only be secured to the points specially In order to raise the truck, the lifting gear must only be secured to the points specially
provided for this purpose. provided for this purpose.
You may only work under a raised load handler if it has been secured with a You may only work under a raised load handler if it has been secured with a
sufficiently strong chain or the fastening bolt. sufficiently strong chain or the fastening bolt.
In order to raise and jack up the truck safely, proceed as follows: In order to raise and jack up the truck safely, proceed as follows:
Jack up the truck only on a level surface and prevent it from moving accidentally. Jack up the truck only on a level surface and prevent it from moving accidentally.
Always use a jack with sufficient capacity. When jacking up the truck, take Always use a jack with sufficient capacity. When jacking up the truck, take
appropriate measures to prevent it from slipping or tipping over (e.g. wedges, appropriate measures to prevent it from slipping or tipping over (e.g. wedges,
wooden blocks). wooden blocks).
In order to raise the truck, the lifting gear must only be secured to the points In order to raise the truck, the lifting gear must only be secured to the points
specially provided for this purpose, (see "Transport and Commissioning" on specially provided for this purpose, (see "Transport and Commissioning" on
page 29). page 29).
When jacking up the truck, take appropriate measures to prevent it from slipping or When jacking up the truck, take appropriate measures to prevent it from slipping or
tipping over (e.g. wedges, wooden blocks). tipping over (e.g. wedges, wooden blocks).
When the truck is out of service it must be jacked up so that all the wheels are clear 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 of the ground. This is the only way of ensuring that the wheels and wheel bearings
are not damaged. are not damaged.
If the truck is to be out of service for more than 6 months, agree further measures with If the truck is to be out of service for more than 6 months, agree further measures with
the manufacturer's customer service department. the manufacturer's customer service department.
9.1 Before taking the truck out of service 9.1 Before taking the truck out of service
Procedure Procedure
WARNING! WARNING!
• Test the brakes. • Test the brakes.

• Check the hydraulic oil level and replenish if necessary, (see "Checking the • Check the hydraulic oil level and replenish if necessary, (see "Checking the
hydraulic oil level" on page 108). hydraulic oil level" on page 108).
• Apply a thin layer of oil or grease to any non-painted mechanical components. • Apply a thin layer of oil or grease to any non-painted mechanical components.
11.14 DE
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• Disconnect the battery, clean it and grease the terminals. • Disconnect the battery, clean it and grease the terminals.
114 114
Z In addition, follow the battery manufacturer’s instructions. Z In addition, follow the battery manufacturer’s instructions.
• Spay all exposed electrical contacts with a suitable contact spray. • Spay all exposed electrical contacts with a suitable contact spray.
9.2 Action to be taken during decommissioning 9.2 Action to be taken during decommissioning
NOTE NOTE
Full discharge can damage the battery Full discharge can damage the battery
Self-discharge can cause the battery to fully discharge. Full discharge shortens the Self-discharge can cause the battery to fully discharge. Full discharge shortens the
useful life of the battery. useful life of the battery.
Charge the battery at least every 2 months. Charge the battery at least every 2 months.
Z Charge the battery, (see "Charging the battery" on page 37). Z Charge the battery, (see "Charging the battery" on page 37).
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115 115
9.3 Restoring the truck to service after decommissioning 9.3 Restoring the truck to service after decommissioning
Procedure Procedure
• Clean the battery, grease the terminals and connect the battery. • Clean the battery, grease the terminals and connect the battery.
• Check the transmission oil for condensation water and replace if necessary. • Check the transmission oil for condensation water and replace if necessary.
• Check the hydraulic oil for condensation water and replace if necessary. • Check the hydraulic oil for condensation water and replace if necessary.
Z The manufacturer's customer service department is specially trained to carry out Z The manufacturer's customer service department is specially trained to carry out
these operations. these operations.
WARNING! WARNING!
• Start up the truck, (see "Starting up the truck" on page 47). • Start up the truck, (see "Starting up the truck" on page 47).
Z If there are switching problems in the electrical system, apply contact spray to the Z If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the controls by exposed contacts and remove any oxide layers on the contacts of the controls by
applying them repeatedly. applying them repeatedly.
10 Final de-commissioning, disposal 10 Final de-commissioning, disposal

Z Final de-commissioning or disposal of the truck in must be performed in Z Final de-commissioning or disposal of the truck in must be performed in
accordance with the regulations of the country of use. In particular, regulations accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems governing the disposal of batteries, fuels and electronic and electrical systems
must be observed. must be observed.
The truck must only be disassembled by trained personnel in accordance with the The truck must only be disassembled by trained personnel in accordance with the
procedures as specified by the manufacturer. Note the manufacturer’s safety procedures as specified by the manufacturer. Note the manufacturer’s safety
instructions as specified in the service documentation. instructions as specified in the service documentation.
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116 116
11 Human vibration measurement 11 Human vibration measurement
Z Vibrations that affect the driver during operation over the course of the day are Z Vibrations that affect the driver during operation over the course of the day are
known as human vibrations. Excessive human vibrations will cause the driver long known as human vibrations. Excessive human vibrations will cause the driver long
term health problems. The European "2002/44/EC/Vibration" operator directive has term health problems. The European "2002/44/EC/Vibration" operator directive has
therefore been established to protect drivers. therefore been established to protect drivers.
To help operators to assess the application situation, the manufacturer offers a To help operators to assess the application situation, the manufacturer offers a
service of measuring these human vibrations. service of measuring these human vibrations.
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117 117
A Traction Battery Appendix A Traction Battery Appendix
Contents Contents
A Traction Battery Appendix....................................................... 1 A Traction Battery Appendix....................................................... 1

1 Correct Use and Application.................................................................... 2 1 Correct Use and Application.................................................................... 2
2 Data plate ................................................................................................ 2 2 Data plate ................................................................................................ 2
3 Safety Instructions, Warning Indications and other Notes ....................... 3 3 Safety Instructions, Warning Indications and other Notes ....................... 3
4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 4 4 Lead acid batteries with armour plated cells and liquid electrolyte.......... 4
4.1 Description............................................................................................... 4 4.1 Description............................................................................................... 4
4.2 Operation................................................................................................. 5 4.2 Operation................................................................................................. 5
4.3 Servicing lead-acid batteries with armour plated cells............................. 8 4.3 Servicing lead-acid batteries with armour plated cells............................. 8
5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 9 5 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 9
5.1 Description............................................................................................... 9 5.1 Description............................................................................................... 9
5.2 Operation................................................................................................. 10 5.2 Operation................................................................................................. 10
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated 5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated
cells ......................................................................................................... 13 cells ......................................................................................................... 13
6 Aquamatik water replenishment system.................................................. 14 6 Aquamatik water replenishment system.................................................. 14
6.1 Water replenishment system design ....................................................... 14 6.1 Water replenishment system design ....................................................... 14
6.3 Adding water............................................................................................ 15 6.3 Adding water............................................................................................ 15
6.4 Water pressure ........................................................................................ 15 6.4 Water pressure ........................................................................................ 15
6.5 Filling time ............................................................................................... 16 6.5 Filling time ............................................................................................... 16
6.6 Water quality............................................................................................ 16 6.6 Water quality............................................................................................ 16
6.7 Battery tubing .......................................................................................... 16 6.7 Battery tubing .......................................................................................... 16
6.8 Operating temperature ............................................................................ 16 6.8 Operating temperature ............................................................................ 16
6.9 Cleaning measures.................................................................................. 17 6.9 Cleaning measures.................................................................................. 17
6.10 Service mobile vehicle............................................................................. 17 6.10 Service mobile vehicle............................................................................. 17
7 Electrolyte circulation............................................................................... 18 7 Electrolyte circulation............................................................................... 18
8 Cleaning batteries.................................................................................... 20 8 Cleaning batteries.................................................................................... 20
9 Storing the battery ................................................................................... 22 9 Storing the battery ................................................................................... 22
10 Troubleshooting....................................................................................... 22 10 Troubleshooting....................................................................................... 22
11 Disposal................................................................................................... 22 11 Disposal................................................................................................... 22
03.13 EN
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1 1
1 Correct Use and Application 1 Correct Use and Application
Failure to observe the operating instructions, carrying out repairs with non-original Failure to observe the operating instructions, carrying out repairs with non-original
spare parts, tampering with the battery or using electrolyte additives will invalidate the spare parts, tampering with the battery or using electrolyte additives will invalidate the
warranty. warranty.
Observe the instructions for maintaining the safety rating during operation for Observe the instructions for maintaining the safety rating during operation for
batteries in accordance with Ex I and Ex II (see relevant certification). batteries in accordance with Ex I and Ex II (see relevant certification).
1,2 3 1,2 3
4 5 4 5
6 7 6 7
8 9 8 9
10 15 10 15
11 11
13 13
12 12
14 14
1 Battery name 1 Battery name

2 Battery type 2 Battery type
3 Production week/year manf. 3 Production week/year manf.
5 Supplier number 5 Supplier number
6 Rated voltage 6 Rated voltage
7 Rated capacity 7 Rated capacity
9 Battery weight in kg 9 Battery weight in kg
8 Number of cells 8 Number of cells
15 Electrolyte volume in litres 15 Electrolyte volume in litres
10 Battery number 10 Battery number
11 Manufacturer 11 Manufacturer
13 Manufacturer's logo 13 Manufacturer's logo
12 CE mark only for batteries beyond 75 volts 12 CE mark only for batteries beyond 75 volts
14 Safety instructions and warning information 14 Safety instructions and warning information
03.13 EN
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2 2
3 Safety Instructions, Warning Indications and other Notes 3 Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste. Used batteries must be treated as hazardous waste.
These batteries are marked with the recycling symbol and the sign These batteries are marked with the recycling symbol and the sign
showing a crossed-out rubbish bin, and should not be disposed of showing a crossed-out rubbish bin, and should not be disposed of
with ordinary household waste. with ordinary household waste.
waste. waste.
Buy-back terms and type of recycling are to be agreed with the Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation. manufacturer as described in § 8 of the battery legislation.
Do not smoke! Do not smoke!
No naked flames, glowing embers or sparks near the battery - fire No naked flames, glowing embers or sparks near the battery - fire
and explosion hazard! and explosion hazard!
Avoid fire and explosion hazards and short circuits due to Avoid fire and explosion hazards and short circuits due to
overheating! overheating!
Keep away from naked flames and strong heat sources. Keep away from naked flames and strong heat sources.
Always wear protective clothing (e.g. safety goggles and safety Always wear protective clothing (e.g. safety goggles and safety
gloves) when working on cells and batteries. gloves) when working on cells and batteries.
batteries. batteries.
Always wash your hands after completing the work. Use insulated Always wash your hands after completing the work. Use insulated
tools only. Do not physically tools only. Do not physically
alter the battery, strike, crush, compress, notch, dent or modify it in alter the battery, strike, crush, compress, notch, dent or modify it in
any way. any way.
Hazardous electric voltage! The metal parts of the battery cells are Hazardous electric voltage! The metal parts of the battery cells are
permanently live. Therefore do not place any foreign objects or tools permanently live. Therefore do not place any foreign objects or tools
on the battery. on the battery.
Observe national health and safety regulations. Observe national health and safety regulations.
If the materials leak, do not inhale the fumes. Wear safety gloves. If the materials leak, do not inhale the fumes. Wear safety gloves.
Follow the user instructions and keep them in a visible position in the Follow the user instructions and keep them in a visible position in the
charging area. charging area.
Work on the batteries should be performed only as instructed by Work on the batteries should be performed only as instructed by
specialist personnel. specialist personnel.
03.13 EN
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3 3
4 Lead acid batteries with armour plated cells and liquid 4 Lead acid batteries with armour plated cells and liquid
electrolyte electrolyte
4.1 Description 4.1 Description
Jungheinrich traction batteries are lead acid batteries with armour plated cells and Jungheinrich traction batteries are lead acid batteries with armour plated cells and
liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM. liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.
Electrolyte Electrolyte
The rated density of the electrolyte assumes a temperature of 30°C and the rated The rated density of the electrolyte assumes a temperature of 30°C and the rated
electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures electrolyte level is fully charged. Higher temperatures will reduce, lower temperatures
will increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g. will increase the electrolyte density. The 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. electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.
The electrolyte must conform to DIN 43530 Part 2 purity regulations. The electrolyte must conform to DIN 43530 Part 2 purity regulations.
4.1.1 Battery nominal data 4.1.1 Battery nominal data
1. Product Traction battery 1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells 2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate 3. Rated capacity C5 See data plate
4. Discharge current C5/5h 4. Discharge current C5/5h
5. Nominal electrolyte density1 1.29 kg/l 5. Nominal electrolyte density1 1.29 kg/l
6. Nominal temperature2 30 °C 6. Nominal temperature2 30 °C
7. System rated electrolyte level up to "Max" electrolyte level marking 7. System rated electrolyte level up to "Max" electrolyte level marking
Limit temperature3 55°C Limit temperature3 55°C
1. Reached within the first 10 cycles. 1. Reached within the first 10 cycles.
2. Higher temperatures shorten the useful life, lower temperatures reduce 2. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity. the available capacity.
3. Not permissible as operating temperature. 3. Not permissible as operating temperature.
03.13 EN
03.13 EN
4 4
4.2 Operation 4.2 Operation
4.2.1 Commissioning unfilled batteries 4.2.1 Commissioning unfilled batteries

Z The operations required must be carried out by the manufacturer's customer Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the service department or a customer service organisation authorised by the
4.2.2 Commissioning filled and charged batteries 4.2.2 Commissioning filled and charged batteries
Checks and operations to be performed before starting daily work Checks and operations to be performed before starting daily work
Procedure Procedure
• Make sure the battery is in physically good condition. • Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative) • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure. and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and • Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. connectors.
• Charge up the battery. • Charge up the battery.
• Check the electrolyte level. • Check the electrolyte level.
Z The electrolyte level must be above the cell baffle or the top of the separator. Z The electrolyte level must be above the cell baffle or the top of the separator.
• Add electrolyte with distilled water up to the nominal level. • Add electrolyte with distilled water up to the nominal level.
Checks completed. Checks completed.
4.2.3 Discharging the battery 4.2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% of Z To achieve an optimum useful life avoid operational discharge of more than 80% of
nominal capacity (full discharge). This corresponds to a minimum electrolyte nominal capacity (full discharge). This corresponds to a minimum electrolyte
density of 1.13 kg/l at the end of the discharge. Recharge a discharged battery density of 1.13 kg/l at the end of the discharge. Recharge a discharged battery
immediately. immediately.
03.13 EN
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5 5
4.2.4 Charging the battery 4.2.4 Charging the battery
WARNING! WARNING!
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
Always disconnect the charger and truck before connecting or disconnecting the Always disconnect the charger and truck before connecting or disconnecting the
charger and battery. charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology. and battery technology.
Battery cell surfaces must remain exposed during charging in order to ensure Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery. Battery.
Wherever an industrial truck is parked for charging there must be no inflammable Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of material or consumables capable of creating sparks within a minimum distance of
2 m from the truck. 2 m from the truck.
Fire protection equipment must be available. Fire protection equipment must be available.
Do not place any metallic objects on the battery. Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station Always follow the safety regulations of the battery and charger station
NOTE NOTE
The battery must only be charged with DC current. All charging processes in The battery must only be charged with DC current. All charging processes in
accordance with DIN 41773 and DIN 41774 are permissible. accordance with DIN 41773 and DIN 41774 are permissible.
03.13 EN
03.13 EN
6 6
Z The electrolyte temperature rises by approx. 10 K during charging. Charging should Z The electrolyte temperature rises by approx. 10 K during charging. Charging should
therefore only begin when the electrolyte temperature is below 45°C. The therefore only begin when the electrolyte temperature is below 45°C. The
electrolyte temperature of batteries must be at least +10°C before charging. electrolyte temperature of batteries must be at least +10°C before charging.
Otherwise the battery will not charge correctly. Below 10°C the battery is Otherwise the battery will not charge correctly. Below 10°C the battery is
insufficiently charged with standard charging systems. insufficiently charged with standard charging systems.
Charging the battery Charging the battery
– Electrolyte temperature min. 10°C to max. 45°C – Electrolyte temperature min. 10°C to max. 45°C
Procedure Procedure
• Open or take off the tray lid or covers from the battery compartment. • Open or take off the tray lid or covers from the battery compartment.
Z Deviations are outlined in the truck's operating instructions. The plugs remain on Z Deviations are outlined in the truck's operating instructions. The plugs remain on
the cells or remain closed. the cells or remain closed.
• Connect the battery to the switched off charger, ensuring the terminals are connect • Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative). (positive to positive and negative to negative).
• Switch on the charger. • Switch on the charger.
Battery charged Battery charged
Z Charging is considered to be complete when the electrolyte density and battery Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours. voltage remain constant for more than 2 hours.
Compensation charging Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. The maximum compensation full discharge and repeated insufficient charging. The maximum compensation
charge current is 5 A/100 Ah rated capacity. charge current is 5 A/100 Ah rated capacity.
Z Compensation charging should be carried out weekly. Z Compensation charging should be carried out weekly.
Trickle charging Trickle charging
Battery trickle charging is partial charging that extends the daily application time. Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which reduce the useful Higher average temperatures occur during trickle charging which reduce the useful
life of the batteries. life of the batteries.
Z Trickle charges should only be performed when the charge level is below 60 %. Use Z Trickle charges should only be performed when the charge level is below 60 %. Use
replacement batteries instead of regular trickle charging. replacement batteries instead of regular trickle charging.
03.13 EN
03.13 EN
7 7
4.3 Servicing lead-acid batteries with armour plated cells 4.3 Servicing lead-acid batteries with armour plated cells
Water quality Water quality
Z The quality of the water used to fill up electrolyte must correspond to purified or Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte. exchangers and is then suitable for the production of electrolyte.
4.3.1 Daily 4.3.1 Daily

– Charge the battery after each discharge. – Charge the battery after each discharge.
– After charging, check the electrolyte level. – After charging, check the electrolyte level.
– If necessary, add purified water up to the rated level after charging. – If necessary, add purified water up to the rated level after charging.
Z The height of the electrolyte level should not be below the cell baffle or above the Z The height of the electrolyte level should not be below the cell baffle or above the
top of the separator, or the "Min" and "Max" electrolyte markings respectively. top of the separator, or the "Min" and "Max" electrolyte markings respectively.
4.3.2 Weekly 4.3.2 Weekly

– After re-charging, carry out a visual inspection for dirt and physical damage. – After re-charging, carry out a visual inspection for dirt and physical damage.
– If the battery is charged regularly according to the IU characteristic, carry out a – If the battery is charged regularly according to the IU characteristic, carry out a
compensation charge. compensation charge.
4.3.3 Monthly 4.3.3 Monthly

– Towards the end of the charging process measure and record the voltages of all – Towards the end of the charging process measure and record the voltages of all
the cells with the charger switched on. the cells with the charger switched on.
– After charging measure and record the electrolyte density and the electrolyte – After charging measure and record the electrolyte density and the electrolyte
temperature in all the cells. temperature in all the cells.
– Compare the results with the previous ones. – Compare the results with the previous ones.
Z If you find significant differences compared with the previous measurements or Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service differences between the cells, contact the manufacturer's customer service
department. department.
4.3.4 Annually 4.3.4 Annually

– Measure the truck insulation resistance in accordance with EN 1175-1. – Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1. – Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage. less than 50 Ω per volt of rated voltage.
03.13 EN
03.13 EN
8 8
5 PzV and PzV-BS lead-acid batteries with sealed armour 5 PzV and PzV-BS lead-acid batteries with sealed armour
plated cells plated cells
5.1 Description 5.1 Description
PzV batteries are sealed batteries with fixed electrolytes, to which no water can be PzV batteries are sealed batteries with fixed electrolytes, to which no water can be
added over the entire lifespan of the battery. Relief valves are used as plugs which added over the entire lifespan of the battery. Relief valves are used as plugs which
are destroyed when opened. During operation the same safety requirements apply to are destroyed when opened. During operation the same safety requirements apply to
the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric the sealed batteries as for batteries with liquid electrolyte. This is to avoid electric
shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if shock, explosion of the electrolyte charging gases or hazardous electrolyte burns if
the cell vessels are destroyed. the cell vessels are destroyed.
Z PzV batteries are low gassing, but not gassing-free. Z PzV batteries are low gassing, but not gassing-free.
Electrolyte Electrolyte
The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolyte
cannot be measured. cannot be measured.
5.1.1 Battery nominal data 5.1.1 Battery nominal data
1. Product Traction battery 1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells 2. Nominal voltage 2.0 V x no. of cells
3. Rated capacity C5 See data plate 3. Rated capacity C5 See data plate
4. Discharge current C5/5h 4. Discharge current C5/5h
5. Rated temperature 30 °C 5. Rated temperature 30 °C
Limit temperature1 45°C, not permissible as operating Limit temperature1 45°C, not permissible as operating
temperature. temperature.
6. Rated density of the electrolyte Cannot be measured 6. Rated density of the electrolyte Cannot be measured
7. System rated electrolyte level Cannot be measured 7. System rated electrolyte level Cannot be measured
1. Higher temperatures shorten the useful life, lower temperatures reduce 1. Higher temperatures shorten the useful life, lower temperatures reduce
the available capacity. the available capacity.
03.13 EN
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9 9
5.2 Operation 5.2 Operation
5.2.1 Commissioning 5.2.1 Commissioning

Checks and operations to be performed before starting daily work Checks and operations to be performed before starting daily work
Procedure Procedure
• Make sure the battery is in physically good condition. • Make sure the battery is in physically good condition.
• Make sure the terminals are correct (positive to positive and negative to negative) • Make sure the terminals are correct (positive to positive and negative to negative)
and check that contacts on the battery terminal conducting system are secure. and check that contacts on the battery terminal conducting system are secure.
• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and • Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and
connectors. connectors.
• Re-charge the battery. • Re-charge the battery.
• Charge the battery. • Charge the battery.
Check completed. Check completed.
5.2.2 Discharging the battery 5.2.2 Discharging the battery

Z To achieve an optimum useful life avoid operational discharges of more than 60% Z To achieve an optimum useful life avoid operational discharges of more than 60%
of nominal capacity. of nominal capacity.
Z If the battery is discharged during operation by more than 80% of rated capacity the Z If the battery is discharged during operation by more than 80% of rated capacity the
useful life of the battery will reduce significantly. Fully or partially discharged useful life of the battery will reduce significantly. Fully or partially discharged
batteries must be re-charged immediately and not left unattended. batteries must be re-charged immediately and not left unattended.
5.2.3 Charging the battery 5.2.3 Charging the battery
WARNING! WARNING!
The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during
Always disconnect the charger and truck before connecting or disconnecting the Always disconnect the charger and truck before connecting or disconnecting the
charger and battery. charger and battery.
The charger must be adapted to the battery in terms of voltage, charge capacity The charger must be adapted to the battery in terms of voltage, charge capacity
and battery technology. and battery technology.
Battery cell surfaces must remain exposed during charging in order to ensure Battery cell surfaces must remain exposed during charging in order to ensure
sufficient ventilation, see truck operating instructions, chapter D, Charging the sufficient ventilation, see truck operating instructions, chapter D, Charging the
Battery. Battery.
Wherever an industrial truck is parked for charging there must be no inflammable Wherever an industrial truck is parked for charging there must be no inflammable
material or consumables capable of creating sparks within a minimum distance of material or consumables capable of creating sparks within a minimum distance of
2 m from the truck. 2 m from the truck.
Fire protection equipment must be available. Fire protection equipment must be available.
Do not place any metallic objects on the battery. Do not place any metallic objects on the battery.
Always follow the safety regulations of the battery and charger station Always follow the safety regulations of the battery and charger station
03.13 EN
03.13 EN
10 10
NOTE NOTE
Charging the battery incorrectly can result in material damage. Charging the battery incorrectly can result in material damage.
Incorrect battery charging can result in overloading of the electric wires and contacts, Incorrect battery charging can result in overloading of the electric wires and contacts,
hazardous gas formation and electrolyte leakage from the cells. hazardous gas formation and electrolyte leakage from the cells.
Always charge the battery with DC current. Always charge the battery with DC current.
All DIN 41773 charging procedures are permitted in the format approved by the All DIN 41773 charging procedures are permitted in the format approved by the
Always connect the battery to a charger that is appropriate to the size and type of Always connect the battery to a charger that is appropriate to the size and type of
the battery. the battery.
If necessary have the charger checked by the manufacturer's customer service If necessary have the charger checked by the manufacturer's customer service
department for suitability. department for suitability.
Do not exceed limit currents in the gassing area in accordance with DIN EN 50272- Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-
3. 3.
03.13 EN
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11 11
Charging the battery Charging the battery
– Electrolyte temperature between +15°C and 35°C – Electrolyte temperature between +15°C and 35°C
Procedure Procedure
• Open or take off the tray lid or covers from the battery compartment. • Open or take off the tray lid or covers from the battery compartment.
• Connect the battery to the switched off charger, ensuring the terminals are connect • Connect the battery to the switched off charger, ensuring the terminals are connect
(positive to positive and negative to negative). (positive to positive and negative to negative).
• Switch on the charger. • Switch on the charger.
Z The electrolyte temperature rises by approx. 10 K during charging. If the Z The electrolyte temperature rises by approx. 10 K during charging. If the
temperatures are permanently higher than 40°C or lower than 15°C, a temperature- temperatures are permanently higher than 40°C or lower than 15°C, a temperature-
dependent constant voltage control of the charger is required. The adjustment dependent constant voltage control of the charger is required. The adjustment
factor must be applied with -0.004 V/C per K. factor must be applied with -0.004 V/C per K.
Battery charged Battery charged
Z Charging is considered to be complete when the electrolyte density and battery Z Charging is considered to be complete when the electrolyte density and battery
voltage remain constant for more than 2 hours. voltage remain constant for more than 2 hours.
Compensation charging Compensation charging
Compensation charging is used to ensure the useful life and maintain capacity after Compensation charging is used to ensure the useful life and maintain capacity after
full discharge and repeated insufficient charging. full discharge and repeated insufficient charging.
Z Compensation charging should be carried out weekly. Z Compensation charging should be carried out weekly.
Trickle charging Trickle charging
Battery trickle charging is partial charging that extends the daily application time. Battery trickle charging is partial charging that extends the daily application time.
Higher average temperatures occur during trickle charging which can reduce the Higher average temperatures occur during trickle charging which can reduce the
useful life of the batteries. useful life of the batteries.
Z Trickle charges should only be performed when the charge level is below 50%. Use Z Trickle charges should only be performed when the charge level is below 50%. Use
replacement batteries instead of regular trickle charging. replacement batteries instead of regular trickle charging.
Z Avoid trickle charging with PzV batteries. Z Avoid trickle charging with PzV batteries.
03.13 EN
03.13 EN
12 12
5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour 5.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour
plated cells plated cells
Z Do not add water! Z Do not add water!
5.3.1 Daily 5.3.1 Daily

– Charge the battery after each discharge. – Charge the battery after each discharge.
5.3.2 Weekly 5.3.2 Weekly

– Visually inspect for dirt and physical damage. – Visually inspect for dirt and physical damage.
5.3.3 Every three months 5.3.3 Every three months

– Measure and record the overall voltage. – Measure and record the overall voltage.
– Measure and record the individual voltages. – Measure and record the individual voltages.
– Compare the results with the previous ones. – Compare the results with the previous ones.
Z Carry out the measurements after full charging and subsequent resting for at least Z Carry out the measurements after full charging and subsequent resting for at least
5 hours. 5 hours.
Z If you find significant differences compared with the previous measurements or Z If you find significant differences compared with the previous measurements or
differences between the cells, contact the manufacturer's customer service differences between the cells, contact the manufacturer's customer service
department. department.
5.3.4 Annually 5.3.4 Annually

– Measure the truck insulation resistance in accordance with EN 1175-1. – Measure the truck insulation resistance in accordance with EN 1175-1.
– Measure the battery insulation resistance in accordance with EN 1987-1. – Measure the battery insulation resistance in accordance with EN 1987-1.
Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be Z In accordance with DIN EN 50272-3 the battery insulation resistance should not be
less than 50 Ω per volt of rated voltage. less than 50 Ω per volt of rated voltage.
03.13 EN
03.13 EN
13 13
6 Aquamatik water replenishment system 6 Aquamatik water replenishment system
6.1 Water replenishment system design 6.1 Water replenishment system design
15 15
16 16
17 17
>3m 18 >3m 18
19 19
20 20
+ - + -
15 Water container 15 Water container

16 Tap connection with ball cock 16 Tap connection with ball cock
17 Flow indicator 17 Flow indicator
18 Shut-off cock 18 Shut-off cock
19 Locking coupling 19 Locking coupling
20 Battery lock connector 03.13 EN 20 Battery lock connector
03.13 EN
14 14
The Aquamatik water replenishment system is used to adjust the rated electrolyte The Aquamatik water replenishment system is used to adjust the rated electrolyte
level automatically on traction batteries for industrial trucks. level automatically on traction batteries for industrial trucks.
The battery cells are interconnected through hoses and are attached to the water The battery cells are interconnected through hoses and are attached to the water
supply (e.g. water container) through a plug connection. When the shut-off cock is supply (e.g. water container) through a plug connection. When the shut-off cock is
opened all the cells are filled with water. The Aquamatik plug controls the amount of opened all the cells are filled with water. The Aquamatik plug controls the amount of
water required and, at the relevant water pressures, ensures the water supply is shut water required and, at the relevant water pressures, ensures the water supply is shut
off and the valve is closed securely. off and the valve is closed securely.
The plug systems have an optical level indicator, a diagnostic port to measure the The plug systems have an optical level indicator, a diagnostic port to measure the
temperature and electrolyte density and a degassing port. temperature and electrolyte density and a degassing port.
6.3 Adding water 6.3 Adding water

Water should be added to the batteries just before the battery is fully charged. This 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. ensures that the amount of water added is mixed with the electrolyte.
6.4 Water pressure 6.4 Water pressure

The water replenishment system must be operated with a water pressure in the water The water replenishment system must be operated with a water pressure in the water
line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges will line of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges will
affect the operation of the systems. affect the operation of the systems.
Water drop Water drop
Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1 Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1
bar bar
Pressure water Pressure water
The pressure regulating valve is adjusted to suit the system and must lie between 0.3 The pressure regulating valve is adjusted to suit the system and must lie between 0.3
- 1.8 bar. - 1.8 bar.
03.13 EN
03.13 EN
15 15
6.5 Filling time 6.5 Filling time
The filling time for a battery depends on the electrolyte level, the ambient temperature The filling time for a battery depends on the electrolyte level, the ambient temperature
and the filling pressure. Filling ends automatically. The water supply line must be and the filling pressure. Filling ends automatically. The water supply line must be
disconnected from the battery when the water has been filled. disconnected from the battery when the water has been filled.
6.6 Water quality 6.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified or Z The quality of the water used to fill up electrolyte must correspond to purified or
distilled water. Purified water can be produced through distillation or ion distilled water. Purified water can be produced through distillation or ion
exchangers and is then suitable for the production of electrolyte. exchangers and is then suitable for the production of electrolyte.
6.7 Battery tubing 6.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit. No The tubing of the individual plugs is in accordance with the existing electric circuit. No
changes should be made. changes should be made.
6.8 Operating temperature 6.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in rooms Batteries with automatic water replenishment systems should only be stored in rooms
with temperatures > 0°C, as otherwise the systems could freeze. with temperatures > 0°C, as otherwise the systems could freeze.
03.13 EN
03.13 EN
16 16
6.9 Cleaning measures 6.9 Cleaning measures
The plug systems must only be cleaned with purified water in accordance with DIN The plug systems must only be cleaned with purified water in accordance with DIN
43530-4. No parts of the plugs must come into contact with solvent-based materials 43530-4. No parts of the plugs must come into contact with solvent-based materials
or soap. or soap.
6.10 Service mobile vehicle 6.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. The Mobile water filling vehicle with pump and filling gun to fill individual cells. The
immersion pump in the container generates the necessary filling pressure. The immersion pump in the container generates the necessary filling pressure. The
service mobile must be at exactly the same height as the battery base. service mobile must be at exactly the same height as the battery base.
03.13 EN
03.13 EN
17 17
7 Electrolyte circulation 7 Electrolyte circulation
Electrolyte circulation ensures the supply of air during charging to mix the electrolyte, Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,
thereby preventing any acid layer, shortening the charge time (charge factor approx. thereby preventing any acid layer, shortening the charge time (charge factor approx.
1.07) and reducing the formation of gas during charging. The charger must be 1.07) and reducing the formation of gas during charging. The charger must be
suitable for the battery and electrolyte circulation. suitable for the battery and electrolyte circulation.
A pump in the charger produces the necessary compressed air which is introduced A pump in the charger produces the necessary compressed air which is introduced
to the battery cells via a hose system. The electrolyte is circulated via the inlet air and to the battery cells via a hose system. The electrolyte is circulated via the inlet air and
the electrolyte density level is constant over the entire length of the electrode. the electrolyte density level is constant over the entire length of the electrode.
Pump Pump
In the event of a fault, e.g. if the pressure control system responds for an unknown In the event of a fault, e.g. if the pressure control system responds for an unknown
reason, the filters must be checked and replaced if necessary. reason, the filters must be checked and replaced if necessary.
Battery connection Battery connection
A hose is attached to the pump module which together with the charge leads is routed 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 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 electrolyte circulation coupling ducts in the connector. When routing make sure the
hose is not bent. hose is not bent.
Pressure monitoring module Pressure monitoring module
The electrolyte circulation pump is activated when charging begins. The pressure The electrolyte circulation pump is activated when charging begins. The pressure
monitoring module monitors the build up of pressure during charging. This ensures monitoring module monitors the build up of pressure during charging. This ensures
that the required air pressure is provided for electrolyte circulation charging. that the required air pressure is provided for electrolyte circulation charging.
In the event of malfunctions such as: In the event of malfunctions such as:
– Battery air coupling not connected to circulation module (if coupling is separate) or – Battery air coupling not connected to circulation module (if coupling is separate) or
faulty. faulty.
– Leaky or faulty hose connections on battery or – Leaky or faulty hose connections on battery or
– Intake filter contaminated – Intake filter contaminated
a visual error message appears on the charger. a visual error message appears on the charger.
03.13 EN
03.13 EN
18 18
NOTE NOTE
If an installed electrolyte circulation system is seldom used or not used at all, If an installed electrolyte circulation system is seldom used or not used at all,
or if the battery is subjected to severe temperature fluctuations, the electrolyte or if the battery is subjected to severe temperature fluctuations, the electrolyte
may flow back into the hose system. may flow back into the hose system.
Attach a separate coupling system to the air inlet line, such as: locking coupling on Attach a separate coupling system to the air inlet line, such as: locking coupling on
the battery side and through-coupling on the air supply side. the battery side and through-coupling on the air supply side.
Schematic illustration Schematic illustration
Electrolyte circulation on the battery and air supply via the charger. Electrolyte circulation on the battery and air supply via the charger.
03.13 EN
03.13 EN
19 19
8 Cleaning batteries 8 Cleaning batteries
Batteries and trays must be cleaned in order to Batteries and trays must be cleaned in order to
– maintain cell insulation and protect cells from ground or external conductive parts. – maintain cell insulation and protect cells from ground or external conductive parts.
– Avoid damage from corrosion and stray currents. – Avoid damage from corrosion and stray currents.
– Avoid excessive and varying automatic discharge of the individual cells or block – Avoid excessive and varying automatic discharge of the individual cells or block
batteries due to stray currents. batteries due to stray currents.
– Avoid electric sparking due to stray currents. – Avoid electric sparking due to stray currents.
When cleaning the batteries make sure that: When cleaning the batteries make sure that:
– The assembly site chosen for cleaning is close to a drainage system for processing – The assembly site chosen for cleaning is close to a drainage system for processing
the electrolytic rinsing water. the electrolytic rinsing water.
– All health and safety as well as water and waste disposal regulations are observed – All health and safety as well as water and waste disposal regulations are observed
when disposing of used electrolyte or rinsing water. when disposing of used electrolyte or rinsing water.
– Protective goggles and clothing are worn. – Protective goggles and clothing are worn.
– Cell plugs are not removed or opened. – Cell plugs are not removed or opened.
– Clean the plastic components of the battery, in particular the cell containers, only – Clean the plastic components of the battery, in particular the cell containers, only
with water or water-based cloths without any additives. with water or water-based cloths without any additives.
– After cleaning, the top of the battery is dried with suitable equipment, e.g. – After cleaning, the top of the battery is dried with suitable equipment, e.g.
compressed air or cloths. compressed air or cloths.
– Any fluid that has entered the battery box must be suctioned off and disposed of in – Any fluid that has entered the battery box must be suctioned off and disposed of in
accordance with the above-mentioned regulations. accordance with the above-mentioned regulations.
03.13 EN
03.13 EN
20 20
Cleaning the battery with a high pressure cleaner Cleaning the battery with a high pressure cleaner
– Cell connectors tight, plugged in securely – Cell connectors tight, plugged in securely
– Cell plugs closed – Cell plugs closed
Procedure Procedure
• Follow the high pressure cleaner's user instructions. • Follow the high pressure cleaner's user instructions.
• Do not use any cleaning additives. • Do not use any cleaning additives.
• Observe the permissible cleaning device temperature setting of 140°C. • Observe the permissible cleaning device temperature setting of 140°C.
Z This generally ensures that the temperature does not exceed 60°C at a distance of Z This generally ensures that the temperature does not exceed 60°C at a distance of
30cm behind the outlet nozzle. 30cm behind the outlet nozzle.
• Observe the maximum operating pressure of 50 bar. • Observe the maximum operating pressure of 50 bar.
• Observe a minimum distance of 30 cm from the top of the battery. • 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 • The battery should be sprayed over its entire surface to avoid localised
overheating. overheating.
Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the
maximum battery surface temperature of 60°C. maximum battery surface temperature of 60°C.
• After cleaning dry the battery surface with suitable materials e.g. compressed air or • After cleaning dry the battery surface with suitable materials e.g. compressed air or
cleaning cloths. cleaning cloths.
Battery cleaned. Battery cleaned.
03.13 EN
03.13 EN
21 21
9 Storing the battery 9 Storing the battery
NOTE NOTE
The battery should not be stored for longer than 3 months without charging as The battery should not be stored for longer than 3 months without charging as
otherwise it will no longer be functional. otherwise it will no longer be functional.
If the battery is to be taken out of service for a long period, it should be stored fully If the battery is to be taken out of service for a long period, it should be stored fully
charged in a dry room protected from frost. To ensure the availability of the battery charged in a dry room protected from frost. To ensure the availability of the battery
the following charges can be selected: the following charges can be selected:
– Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge – Monthly compensation charge for PzS and PzB batteries or 3-monthly full charge
for PzV batteries. for PzV batteries.
– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB – Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzB
batteries or 2.25 volts x no. of cells for PzV batteries. batteries or 2.25 volts x no. of cells for PzV batteries.
If the battery is to be taken out of service for a long period ( > 3 months), it should, as 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 far as possible, be charged to 50% of its charge level and stored in a dry room
protected from frost. protected from frost.
10 Troubleshooting 10 Troubleshooting
If any faults are found on the battery or charger, contact the manufacturer's customer If any faults are found on the battery or charger, contact the manufacturer's customer
service department immediately. service department immediately.
Z The operations required must be carried out by the manufacturer's customer Z The operations required must be carried out by the manufacturer's customer
service department or a customer service organisation authorised by the service department or a customer service organisation authorised by the
11 Disposal 11 Disposal
Batteries marked with the recycling symbol and the sign showing a Batteries marked with the recycling symbol and the sign showing a
crossed-out rubbish bin should not be disposed of with ordinary crossed-out rubbish bin should not be disposed of with ordinary
household waste. household waste.
Buy-back terms and type of recycling are to be agreed with the Buy-back terms and type of recycling are to be agreed with the
manufacturer as described in § 8 of the battery legislation. manufacturer as described in § 8 of the battery legislation.
03.13 EN
03.13 EN
22 22

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ERE 225 10.

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t Indicates standard equipment t Indicates standard equipment

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

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

C Transport and Commissioning ................................................ 29 C Transport and Commissioning ................................................ 29

F Industrial Truck Maintenance .................................................. 87 F Industrial Truck Maintenance .................................................. 87

JH Traction Battery Operating Instructions JH Traction Battery Operating Instructions

2 Correct application 2 Correct application

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

3 Approved application conditions 3 Approved application conditions

5 Adding attachments and/or accessories 5 Adding attachments and/or accessories

Item Component Item Component Item Component Item Component

o ISM 12 o Skirt o ISM 12 o Skirt

5 t Key switch 13 t Drive wheel 5 t Key switch 13 t Drive wheel

t = Standard version o = Option t = Standard version o = Option

– 24 volt system. – 24 volt system.

3.1 Performance data 3.1 Performance data

ERE 225 ERE 225

ERE 225 ERE 225

b1 Truck width 770 mm b1 Truck width 770 mm

(all dimensions in mm) (all dimensions in mm)

l l12) y 1)2) x 1) l6 Wa1) 2) Ast2) l l12) y 1)2) x 1) l6 Wa1) 2) Ast2)

l l12) y 1)2) x 1) l6 Wa1)2)3) Ast2)3) l l12) y 1)2) x 1) l6 Wa1)2)3) Ast2)3)

ERE 225 ERE 225 ERE 225 ERE 225

3.4 Tyre type 3.4 Tyre type

– ERE 225: 0,81 m/s² – ERE 225: 0,81 m/s²

Electromagnetic compatibility (EMC) Electromagnetic compatibility (EMC)

3.6 Conditions of use 3.6 Conditions of use

– operating at -10°C to 40°C – operating at -10°C to 40°C

3.7 Electrical requirements 3.7 Electrical requirements

Qmax XXX kg Qmax XXX kg

Item Component Item Component

Item Component Item Component

Item Description Item Description Item Description Item Description

3.8.2 Truck load chart 3.8.2 Truck load chart

Lifting the truck by crane Lifting the truck by crane

Tools and Material Required Tools and Material Required

Accidental movement during transport Accidental movement during transport

Tools and Material Required Tools and Material Required

Cold store trucks Cold store trucks

Fire protection Fire protection

Battery maintenance Battery maintenance

Battery disposal Battery disposal

Trapping hazard Trapping hazard

Charge the battery Charge the battery

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

5 Battery removal and installation 5 Battery removal and installation

Z Screw torque (40): 45 Nm Z Screw torque (40): 45 Nm

Battery removal Battery removal

Tools and Material Required Tools and Material Required

Battery installation Battery installation

Unauthorised use of truck Unauthorised use of truck

Damage and faults Damage and faults

Hazardous area Hazardous area

48 49 4, 50, 51, 3 48 49 4, 50, 51, 3

– travel speed restricted to max. – travel speed restricted to max.

t = Standard equipment o = Optional equipment t = Standard equipment o = Optional equipment

LED colour Residual capacity LED colour Residual capacity

Pre-start inspections Pre-start inspections

Parking the truck securely Parking the truck securely

3.4 Battery discharge monitor 3.4 Battery discharge monitor

Travel conduct Travel conduct

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