The brake pattern of the truck depends largely on the ground conditions. The driver must take this into account when operating the truck. The truck can brake in three different ways: In emergencies, always brake with the service brake. During normal operation, the generator brake and plugging can be applied. These methods of braking reduce wear and require less energy (energy recovery). Braking with the service brake: The truck brakes at the maximum rate until it comes to a halt. The mechanical brake is only applied when this brake fails to achieve the necessary braking force. The truck can only start again when the controller has been set to “0”. Release the controller (6) - the controller assumes the zero position. Depending on the setting, the truck brakes via the generator brake, coasting to a stop. For the standard truck, the rate of deceleration can be adjusted by the manufacturer’s service department. For trucks with CANCODE and CANDIS it can be adjusted by entering the appropriate code. The truck brakes regeneratively until it starts to move in the opposite direction. The brake force depends on the position of the controller. Prepare the truck for maintenance and repairs (see Chapter 6.1). Remove the front panel (see Section 6.3). Referring to the table, check all fuses for correct rating and damage; replace fuses where required. Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks. A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections. The owner is responsible for ensuring that faults are immediately rectified. 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. 2.4 Make sure wire connections are secure check for damage. 2.5 Test micro switch setting Step onto the operator platform. After releasing the Jet Pilot adjuster, set the Jet Pilot to the required position and then release the tiller adjuster again. Pull out the main switch / isolator (1). Enter the code in the code lock (o) (11), and if required apply the key switch (13). Test the horn (2). Check the controller (6) (see section 4.3). The truck is now operational. The diode in the battery discharge indicator or the display instrument (CANDIS (12) (o)) shows the battery charge status. 2.8 Wire and motor attachment 2.9 Check carbon brush wear, replace if necessary To charge the battery, the truck must be parked in a closed and properly ventilated room. – Expose the battery (see Section 3). The battery connector (4) and the charging cable (6) of the battery charging station must only be connected or disconnected when the truck and the battery charger are switched off. The isolator (5) must also only be applied when the truck and the battery charger are switched off. When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. All safety instructions given by the battery and battery charger manufacturers must be strictly observed. Pull out the battery plug (4) from the holder. Remove any insulating mats from the battery. Connect the charging cable (6) of the battery charging station to the battery connector (4) and switch on the charger. Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier. 3.2 Check battery cable connections are secure, grease terminals if necessary. Park the truck securely before carrying out any work on the batteries (see Chapter E). Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. Smoking and naked flames must be avoided when working with batteries Wherever a truck is parked for charging there shall be no inflammable material or operating fluids capable of creating sparks within 2 metres around the truck. The area must be well ventilated. Fire protection equipment must be provided. 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. Batteries with non insulated terminals must be covered with a non slip insulating mat. Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed. Before closing the battery panel make sure that the battery lead cannot be damaged. Batteries contain an acid solution which is poisonous and corrosive. Therefore, always wear protective clothing and eye protection when carrying out work on batteries. Avoid all contact with battery acid. Should however clothing, skin or eyes come in contact with acid the affected parts should be rinsed with plenty of clean water - where the skin or eyes are affected call a doctor immediately. Immediately neutralize any spilled battery acid. Only batteries with a sealed battery container may be used. The weight and dimensions of the battery have considerable affect on the operational safety of the truck. Battery equipment may only be replaced with the agreement of the manufacturer. Do not drive the truck unless the panels are closed and properly locked. Start up the truck (refer to section 3). Set the controller (6) to the desired travel direction: forward (V) or reverse (R). The truck starts to travel in the direction selected. The travel speed is governed by the controller (6). For trucks with “pedestrian operation” (o) the truck can be operated at reduced speed without having to stand on the platform. Loads must always be carried on the end of the truck facing uphill. With the controller (6) set to neutral, the service brake automatically applies after a short jerk (the controller detects downhill motion on an incline). The service brake is released again via the controller (6), which is also used to select the speed and the travel direction. 4.4 Check wheels for wear and damage 4.5 Check wheel suspension and attachment. In conjunction with pedestrian operation 5.2 Check chassis for damage. 5.3 Check labels. 6,2 Test operation of lift mechanism 6.3 Test hydraulic system. 6.5 Check cylinders and piston rods for damage and leaks, and make sure they are secure 6.6 Check hydraulic oil level. 6.9 Check the load chain 6.10 Check the scissor lift Agreed Performance Level 1) Cold store mix ratio 1:1 2) Transmission oil values are guidelines only. The spur wheel should be dipped approx. 2 mm in the oil. The quantity specified is provided by the manufacturer. Capacity deviations may result from the manufacture of the gear unit housing (casting). 7.2 Test run 7.3 Demonstration after servicing Be extremely careful when driving and steering, especially when operating outside the geometry of the truck. The electric steering system is self-monitoring. The steering controller monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering controller reduces the travel speed of the truck to slow travel If such a fault occurs, the travel speed is not reset to normal travel by switching the truck off and on again. This prevents a fault being cancelled without being rectified. As the steering system is a safety-critical component, the fault must be rectified by the manufacturer's service department. Push the isolator (1) down All electrical functions are deactivated.