Jungheinrich EZS 350 XL User manual

08.09 -
11.14
51133023
EZS 350 / 350 XL / C40
Operating instructions G
EZS 350 XL
EZS C40
EZS 350

3
11.14 EN
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or agent acting in the European Union
Additional information
On behalf of
Date
GEU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.
Type Option Serial no. Year of
manufacture
EZS 350
EZS 350 XL
EZS C40
3
11.14 EN
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or agent acting in the European Union
Additional information
On behalf of
Date
GEU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.
Type Option Serial no. Year of
manufacture
EZS 350
EZS 350 XL
EZS C40

11.14 EN
4
11.14 EN
4

5
11.14 EN
Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
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
operating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
5
11.14 EN
Foreword
Notes on the operating instructions
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter and the pages are
numbered continuously.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
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
operating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment

11.14 EN
6
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com
11.14 EN
6
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com

7
11.14 EN
Table of contents
A Correct Use and Application ................................................... 9
1 General.................................................................................................... 9
2 Correct application................................................................................... 9
3 Approved application conditions.............................................................. 9
4 Proprietor responsibilities ........................................................................ 10
5 Adding attachments and/or accessories.................................................. 10
B Truck Description .................................................................... 11
1 Application ............................................................................................... 11
2 Assemblies and Functional Description................................................... 12
2.1 Assembly Overview ................................................................................. 12
2.2 Functional Description ............................................................................. 14
3 Technical Specifications .......................................................................... 16
3.1 Performance data .................................................................................... 16
3.2 Dimensions.............................................................................................. 17
3.3 Weights.................................................................................................... 19
3.4 Tyre type.................................................................................................. 19
3.5 EN norms................................................................................................. 20
3.6 Conditions of use..................................................................................... 21
4 Identification points and data plates ........................................................ 22
4.1 Data plate ................................................................................................ 23
C Transport and Commissioning ................................................ 25
1 Lifting by crane ........................................................................................ 25
2 Transport ................................................................................................. 26
3 Using the Truck for the First Time ........................................................... 27
D Battery - Servicing, Recharging, Replacement ....................... 29
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 29
2 Battery types............................................................................................ 30
3 Exposing the battery................................................................................ 32
4 Charging the battery ................................................................................ 33
5 Battery removal and installation .............................................................. 35
E Operation ................................................................................ 39
1 Safety Regulations for the Operation of the Forklift Truck....................... 39
2 Displays and Controls.............................................................................. 41
2.1 Battery discharge indicator ...................................................................... 43
3 Starting up the truck ................................................................................ 44
7
11.14 EN
Table of contents
A Correct Use and Application ................................................... 9
1 General.................................................................................................... 9
2 Correct application................................................................................... 9
3 Approved application conditions.............................................................. 9
4 Proprietor responsibilities ........................................................................ 10
5 Adding attachments and/or accessories.................................................. 10
B Truck Description .................................................................... 11
1 Application ............................................................................................... 11
2 Assemblies and Functional Description................................................... 12
2.1 Assembly Overview ................................................................................. 12
2.2 Functional Description ............................................................................. 14
3 Technical Specifications .......................................................................... 16
3.1 Performance data .................................................................................... 16
3.2 Dimensions.............................................................................................. 17
3.3 Weights.................................................................................................... 19
3.4 Tyre type.................................................................................................. 19
3.5 EN norms................................................................................................. 20
3.6 Conditions of use..................................................................................... 21
4 Identification points and data plates ........................................................ 22
4.1 Data plate ................................................................................................ 23
C Transport and Commissioning ................................................ 25
1 Lifting by crane ........................................................................................ 25
2 Transport ................................................................................................. 26
3 Using the Truck for the First Time ........................................................... 27
D Battery - Servicing, Recharging, Replacement ....................... 29
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 29
2 Battery types............................................................................................ 30
3 Exposing the battery................................................................................ 32
4 Charging the battery ................................................................................ 33
5 Battery removal and installation .............................................................. 35
E Operation ................................................................................ 39
1 Safety Regulations for the Operation of the Forklift Truck....................... 39
2 Displays and Controls.............................................................................. 41
2.1 Battery discharge indicator ...................................................................... 43
3 Starting up the truck ................................................................................ 44

11.14 EN
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3.1 Checks and operations to be performed before starting daily operation . 44
3.2 Preparing the truck for operation ............................................................. 45
3.3 Parking the truck securely ....................................................................... 46
3.4 Battery discharge monitor........................................................................ 46
4 Industrial Truck Operation ....................................................................... 47
4.1 Safety regulations for truck operation...................................................... 47
4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 49
4.3 Pedestrian mode ..................................................................................... 53
4.4 Coupling Types........................................................................................ 54
4.5 Travelling with trailers.............................................................................. 56
4.6 Seat (o) (XL and C40 only)..................................................................... 57
5 Troubleshooting....................................................................................... 58
5.1 Truck does not start................................................................................. 58
6 Operating the truck without its own drive system .................................... 59
7 Optional equipment ................................................................................. 60
7.1 CanDis display instrument....................................................................... 60
7.2 CanCode keypad..................................................................................... 62
7.3 Setting the truck parameters with CanCode............................................ 67
7.4 ISM access module (o)........................................................................... 68
7.5 Parameters .............................................................................................. 69
F Industrial Truck Maintenance .................................................. 77
1 Operational Safety and Environmental Protection................................... 77
2 Maintenance Safety Regulations............................................................. 77
3 Servicing and Inspection ......................................................................... 83
4 Maintenance checklist ............................................................................. 84
4.1 Owner ...................................................................................................... 84
4.2 Customer Service .................................................................................... 86
5 Lubricants and Lubrication Schedule ...................................................... 90
5.1 Handling consumables safely.................................................................. 90
5.2 Lubrication Schedule ............................................................................... 92
5.3 Consumables........................................................................................... 93
6 Maintenance and repairs ......................................................................... 94
6.1 Preparing the truck for maintenance and repairs .................................... 94
6.2 Tightening the wheel nuts........................................................................ 95
6.3 Removing the front panel ........................................................................ 96
6.4 Checking electrical fuses......................................................................... 97
6.5 Restoring the truck to service after maintenance and repairs ................. 98
7 Decommissioning the industrial truck ...................................................... 99
7.1 Prior to decommissioning ........................................................................ 99
7.2 During decommissioning ......................................................................... 100
7.3 Restoring the truck to service after decommissioning ............................. 101
8 Safety tests to be performed at intervals and after unusual incidents ..... 102
9 Final de-commissioning, disposal............................................................ 102
10 Human vibration measurement ............................................................... 102
11.14 EN
8
3.1 Checks and operations to be performed before starting daily operation . 44
3.2 Preparing the truck for operation ............................................................. 45
3.3 Parking the truck securely ....................................................................... 46
3.4 Battery discharge monitor........................................................................ 46
4 Industrial Truck Operation ....................................................................... 47
4.1 Safety regulations for truck operation...................................................... 47
4.2 Emergency Disconnect, Travel, Steering, Braking .................................. 49
4.3 Pedestrian mode ..................................................................................... 53
4.4 Coupling Types........................................................................................ 54
4.5 Travelling with trailers.............................................................................. 56
4.6 Seat (o) (XL and C40 only)..................................................................... 57
5 Troubleshooting....................................................................................... 58
5.1 Truck does not start................................................................................. 58
6 Operating the truck without its own drive system .................................... 59
7 Optional equipment ................................................................................. 60
7.1 CanDis display instrument....................................................................... 60
7.2 CanCode keypad..................................................................................... 62
7.3 Setting the truck parameters with CanCode............................................ 67
7.4 ISM access module (o)........................................................................... 68
7.5 Parameters .............................................................................................. 69
F Industrial Truck Maintenance .................................................. 77
1 Operational Safety and Environmental Protection................................... 77
2 Maintenance Safety Regulations............................................................. 77
3 Servicing and Inspection ......................................................................... 83
4 Maintenance checklist ............................................................................. 84
4.1 Owner ...................................................................................................... 84
4.2 Customer Service .................................................................................... 86
5 Lubricants and Lubrication Schedule ...................................................... 90
5.1 Handling consumables safely.................................................................. 90
5.2 Lubrication Schedule ............................................................................... 92
5.3 Consumables........................................................................................... 93
6 Maintenance and repairs ......................................................................... 94
6.1 Preparing the truck for maintenance and repairs .................................... 94
6.2 Tightening the wheel nuts........................................................................ 95
6.3 Removing the front panel ........................................................................ 96
6.4 Checking electrical fuses......................................................................... 97
6.5 Restoring the truck to service after maintenance and repairs ................. 98
7 Decommissioning the industrial truck ...................................................... 99
7.1 Prior to decommissioning ........................................................................ 99
7.2 During decommissioning ......................................................................... 100
7.3 Restoring the truck to service after decommissioning ............................. 101
8 Safety tests to be performed at intervals and after unusual incidents ..... 102
9 Final de-commissioning, disposal............................................................ 102
10 Human vibration measurement ............................................................... 102

1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB
2
0506.GB
2

9
11.14 EN
A Correct Use and Application
1 General
The truck described in the present operating instructions is an industrial truck
designed for towing trailer loads.
It must be applied, operated and serviced in accordance with the instructions
contained in the present manual. Any other type of use is beyond the scope of
application and can result in damage to personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum tow load is shown on the data plate and must not be exceeded.
The load must be coupled to a trailer coupling or an attachment approved by the
manufacturer.
– Towing loads.
– Do not carry passengers.
– Loads may only be pushed with the trailer coupling.
3 Approved application conditions
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor.
– Negotiating inclines up to a maximum of 15 %.
– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
– Operation in partially public traffic.
WARNING!
Extreme conditions
Special equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
The truck is not authorised for use in areas at risk of explosion.
In adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
9
11.14 EN
A Correct Use and Application
1 General
The truck described in the present operating instructions is an industrial truck
designed for towing trailer loads.
It must be applied, operated and serviced in accordance with the instructions
contained in the present manual. Any other type of use is beyond the scope of
application and can result in damage to personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum tow load is shown on the data plate and must not be exceeded.
The load must be coupled to a trailer coupling or an attachment approved by the
manufacturer.
– Towing loads.
– Do not carry passengers.
– Loads may only be pushed with the trailer coupling.
3 Approved application conditions
– Operation in industrial and commercial environments.
– Permissible temperature range 5°C to 40°C.
– Operation only on secure, level surfaces with sufficient capacity.
– Operation only on routes that are visible and approved by the proprietor.
– Negotiating inclines up to a maximum of 15 %.
– Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
– Operation in partially public traffic.
WARNING!
Extreme conditions
Special equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
The truck is not authorised for use in areas at risk of explosion.
In adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.