Transcript
ESE 420/430 Operating Instructions 50454697 11.08
11.04 -
G
F
Foreword
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. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
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. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
Safety instructions and important explanations are indicated by the following graphics:
F
Used before safety instructions which must be observed to avoid danger to personnel.
M Z
Used before notices which must be observed to avoid material damage. Used before notices and explanations.
Used before safety instructions which must be observed to avoid danger to personnel. Used before notices which must be observed to avoid material damage. Used before notices and explanations.
t Used to indicate standard equipment.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
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 22047 Hamburg - GERMANY
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
www.jungheinrich.com
0108.GB
0108.GB
M Z
Foreword
0108.GB
0108.GB
A
Correct use and application
A
Correct use and application
B
Truck Description
B
Truck Description
1 2 2.1 3 3.1 3.2 3.3 3.4 3.5 4 4.1
Application ........................................................................................... B 1 Assemblies and Functional Description .............................................. B 2 Truck ................................................................................................... B 3 Standard Version Specifications ......................................................... B 5 Performance data ................................................................................ B 5 Dimensions ......................................................................................... B 6 EN norms ............................................................................................ B 7 Conditions of use ................................................................................ B 7 Technical Description – Load Handler ................................................ B 8 Identification points and data plates .................................................... B 8 Truck data plate .................................................................................. B 9
1 2 2.1 3 3.1 3.2 3.3 3.4 3.5 4 4.1
Application ........................................................................................... B 1 Assemblies and Functional Description .............................................. B 2 Truck ................................................................................................... B 3 Standard Version Specifications ......................................................... B 5 Performance data ................................................................................ B 5 Dimensions ......................................................................................... B 6 EN norms ............................................................................................ B 7 Conditions of use ................................................................................ B 7 Technical Description – Load Handler ................................................ B 8 Identification points and data plates .................................................... B 8 Truck data plate .................................................................................. B 9
C
Transport and Commissioning
C
Transport and Commissioning
1 2 3
Lifting by crane .................................................................................... C 1 Parking brake transport lock ............................................................... C 2 Commissioning .................................................................................... C 3
1 2 3
Lifting by crane .................................................................................... C 1 Parking brake transport lock ............................................................... C 2 Commissioning .................................................................................... C 3
D
Battery Maintenance, Charging & Replacement
D
Battery Maintenance, Charging & Replacement
1 2 3 4 5 6
Safety regulations for handling acid batteries ..................................... D 1 Battery types ....................................................................................... D 2 Exposing the battery ........................................................................... D 2 Charging the battery ............................................................................ D 3 Battery removal and installation .......................................................... D 4 Driver’s display .................................................................................... D 5
1 2 3 4 5 6
Safety regulations for handling acid batteries ..................................... D 1 Battery types ....................................................................................... D 2 Exposing the battery ........................................................................... D 2 Charging the battery ............................................................................ D 3 Battery removal and installation .......................................................... D 4 Driver’s display .................................................................................... D 5
0708.GB
Index
0708.GB
Index
I1
I1
E
Operation
E
Operation
1 2 3 3.1 4 4.1 4.2 4.3 4.4 5 6 6.1 6.2 7 7.1 7.2 7.3 8 9
Safety Regulations for the Operation of Forklift Trucks ...................... E 1 Controls and Displays ......................................................................... E 2 Starting up the truck ............................................................................ E 4 Emergency stop device ....................................................................... E 6 Industrial Truck Operation ................................................................... E 7 Safety regulations for truck operation ................................................. E 7 Travel, Steering, Braking ..................................................................... E 8 Collecting and depositing loads .......................................................... E 10 Parking the truck securely ................................................................... E 10 Truck recovery in the event of electric steering failure ........................ E 11 Display Components ........................................................................... E 12 Driver’s display (t) ............................................................................. E 12 Driver’s Display LED Buttons .............................................................. E 15 Keypad (CANCODE) (o) .................................................................... E 17 Code Lock ........................................................................................... E 17 Parameters .......................................................................................... E 18 Parameter Settings ............................................................................. E 19 Changing truck parameters ................................................................. E 22 Troubleshooting .................................................................................. E 23
1 2 3 3.1 4 4.1 4.2 4.3 4.4 5 6 6.1 6.2 7 7.1 7.2 7.3 8 9
Safety Regulations for the Operation of Forklift Trucks ...................... E 1 Controls and Displays ......................................................................... E 2 Starting up the truck ............................................................................ E 4 Emergency stop device ....................................................................... E 6 Industrial Truck Operation ................................................................... E 7 Safety regulations for truck operation ................................................. E 7 Travel, Steering, Braking ..................................................................... E 8 Collecting and depositing loads .......................................................... E 10 Parking the truck securely ................................................................... E 10 Truck recovery in the event of electric steering failure ........................ E 11 Display Components ........................................................................... E 12 Driver’s display (t) ............................................................................. E 12 Driver’s Display LED Buttons .............................................................. E 15 Keypad (CANCODE) (o) .................................................................... E 17 Code Lock ........................................................................................... E 17 Parameters .......................................................................................... E 18 Parameter Settings ............................................................................. E 19 Changing truck parameters ................................................................. E 22 Troubleshooting .................................................................................. E 23
F
Forklift Truck Maintenance
F
Forklift Truck Maintenance
1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 8
Operational safety and environmental protection ................................ F 1 Maintenance Safety Regulations ........................................................ F 1 Servicing and inspection ..................................................................... F 3 ESE 420/430 Maintenance Checklist ................................................. F 4 ESE 420/430 Lubrication Schedule .................................................... F 6 Fuels, coolants and lubricants ............................................................. F 7 Maintenance Instructions .................................................................... F 8 Preparing the truck for maintenance and repairs ................................ F 8 Opening the truck door o ................................................................... F 8 Lift up the door attachment ................................................................. F 9 Checking electrical fuses .................................................................... F 10 Recommissioning ................................................................................ F 11 Decommissioning the industrial truck .................................................. F 11 Prior to decommissioning: ................................................................... F 11 During decommissioning: .................................................................... F 11 Restoring the truck to operation after decommissioning ..................... F 12 Safety checks to be performed at regular intervals and following any unusual incidents .......................................................................... F 13 Final de-commissioning, disposal ....................................................... F 13
1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 7 7.1 7.2 7.3 8
Operational safety and environmental protection ................................ F 1 Maintenance Safety Regulations ........................................................ F 1 Servicing and inspection ..................................................................... F 3 ESE 420/430 Maintenance Checklist ................................................. F 4 ESE 420/430 Lubrication Schedule .................................................... F 6 Fuels, coolants and lubricants ............................................................. F 7 Maintenance Instructions .................................................................... F 8 Preparing the truck for maintenance and repairs ................................ F 8 Opening the truck door o ................................................................... F 8 Lift up the door attachment ................................................................. F 9 Checking electrical fuses .................................................................... F 10 Recommissioning ................................................................................ F 11 Decommissioning the industrial truck .................................................. F 11 Prior to decommissioning: ................................................................... F 11 During decommissioning: .................................................................... F 11 Restoring the truck to operation after decommissioning ..................... F 12 Safety checks to be performed at regular intervals and following any unusual incidents .......................................................................... F 13 Final de-commissioning, disposal ....................................................... F 13
I2
0708.GB
9
0708.GB
9
I2
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.
0506.GB
These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.
0506.GB
Z
Appendix
1
1
2 2 0506.GB
0506.GB
A Correct use and application
A Correct use and application
Z
Z
M
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.
The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. 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 personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.
The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. 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 personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as 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 the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual.
Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as 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 the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual.
M
Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer’s approval.
1104.GB
1104.GB
Attaching accessories: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer’s approval.
Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
A1
A1
A2 A2 1104.GB
1104.GB
B Truck Description
B Truck Description
1
1
Application
Application
The ESE 420_430 is a four-wheel, electric side-seated pallet truck with a drive unit and electrical steering with a steer motor. The truck is designed for use on level surfaces for transporting goods. The truck can pick up, outside the load wheel range, pallets with open bases or lateral boards, as well as trolleys. The capacity of the truck is shown on the data plate or the data capacity plate Qmax. The load fork dimensions are designed for the number and type of pallets or trolleys to be carried. Maximum emphasis has been placed on the ergonomic design of the operator position and work safety. The controls are intuitively and clearly arranged and are adapted to the task of transporting.
The ESE 420_430 is a four-wheel, electric side-seated pallet truck with a drive unit and electrical steering with a steer motor. The truck is designed for use on level surfaces for transporting goods. The truck can pick up, outside the load wheel range, pallets with open bases or lateral boards, as well as trolleys. The capacity of the truck is shown on the data plate or the data capacity plate Qmax. The load fork dimensions are designed for the number and type of pallets or trolleys to be carried. Maximum emphasis has been placed on the ergonomic design of the operator position and work safety. The controls are intuitively and clearly arranged and are adapted to the task of transporting.
Truck types and capacity:
Truck types and capacity: Type
Capacity
ESE 420
2000kg
ESE 420
2000kg
ESE 430
3000kg
ESE 430
3000kg
1108.GB
Capacity
1108.GB
Type
B1
B1
Assemblies and Functional Description 1
2
2
3
4
Assemblies and Functional Description 1
5
10 6
7
8
2
3
4
5
10 6
9
7
8
9
11
11
15
15
14
14 13
13 12
Item
Description
Description
Item
t t t t t
Accelerator pedal Driver's seat Lift mechanism Drive wheels Castor wheel
1 2 3 4 5
6
14
o
7 8
t Deadman button t Brake pedal
15
o
Emergency steering mode button Safety restraint belt
o = Optional Equipment
1108.GB
9 10 11 12 13
t = Standard equipment B2
Item
Driver’s display Hydraulic control button Parking brake Key switch Main switch / isolator (emergency disconnect) o Driver door
1 2 3 4 5
t t t t t
12 Description t t t t t
Description
9 10 11 12 13
t t t t t
Accelerator pedal Driver's seat Lift mechanism Drive wheels Castor wheel
6
14
o
7 8
t Deadman button t Brake pedal
15
o
Emergency steering mode button Safety restraint belt
t = Standard equipment B2
Item
Driver’s display Hydraulic control button Parking brake Key switch Main switch / isolator (emergency disconnect) o Driver door
o = Optional Equipment
1108.GB
2
Truck
2.1
Truck Safety mechanisms: Enclosed, smooth truck geometry. The wheels (12/13) are surrounded by a solid ram protection skirting. This protects the load in the event of a collision. The key switch (4) or isolator (emergency disconnect) (5) disconnects all electrical function in hazardous situations. Travelling is inhibited if the driver door is not closed.
Structure: The pallet truck is four-wheel, with a steered drive wheel (12) and a castor wheel (13). Easy opening door attachment with integrated fittings, drive compartment cover plus detachable panels provide easy access to all units for the service engineers. The controls are ergonomically arranged.
Structure: The pallet truck is four-wheel, with a steered drive wheel (12) and a castor wheel (13). Easy opening door attachment with integrated fittings, drive compartment cover plus detachable panels provide easy access to all units for the service engineers. The controls are ergonomically arranged.
Drive: The complete drive unit is enclosed in the vehicle chassis. A 6 kW fixed AC motor powers the drive wheel (12) via a bevel spur gearbox The electronic traction current controllers provide infinitely variable traction motor speed and as a result smooth, constant start-up, powerful acceleration and electrically controlled braking with energy recovery. The degree of energy recovery can be adjusted via the LISA.
Drive: The complete drive unit is enclosed in the vehicle chassis. A 6 kW fixed AC motor powers the drive wheel (12) via a bevel spur gearbox The electronic traction current controllers provide infinitely variable traction motor speed and as a result smooth, constant start-up, powerful acceleration and electrically controlled braking with energy recovery. The degree of energy recovery can be adjusted via the LISA.
Steering: Bevel gear steering with steering drive and fully electronic controller as standard. The pivoting gear unit can move 90° in either direction.
Steering: Bevel gear steering with steering drive and fully electronic controller as standard. The pivoting gear unit can move 90° in either direction.
Controls and Displays: Controls and displays are clearly arranged in the driver’s cab. The hydraulic control button (2) enables one-handed operation of the travel direction, lift/lower and horn functions. It is also used in conjunction with the accelerator for diagonal travel. The driver’s display (1) with a large LCD screen plus integrated hourmeter and battery discharge indicator with lift cutout.
Controls and Displays: Controls and displays are clearly arranged in the driver’s cab. The hydraulic control button (2) enables one-handed operation of the travel direction, lift/lower and horn functions. It is also used in conjunction with the accelerator for diagonal travel. The driver’s display (1) with a large LCD screen plus integrated hourmeter and battery discharge indicator with lift cutout.
Hydraulic system: Lifting and lowering are activated via the hydraulic control button. When lifting is activated, the pump unit starts to operate, supplying hydraulic oil from the oil reservoir to the lift cylinder.
Hydraulic system: Lifting and lowering are activated via the hydraulic control button. When lifting is activated, the pump unit starts to operate, supplying hydraulic oil from the oil reservoir to the lift cylinder.
Electrical System: 48 volt system acting as a two wire network. An infinitely variable electronic traction current controller and an electric steering controller are standard.
Electrical System: 48 volt system acting as a two wire network. An infinitely variable electronic traction current controller and an electric steering controller are standard.
Brake system: The electric brake system consists of independent brake systems. Applying the brake pedal results in inversion braking (plugging) in the traction motor. The parking brake is electrically operated and acts mechanically (compression spring) on a magnet brake mounted on the drive unit. This brake is also used for emergency braking. A warning light appears when the brake is applied. Steering and braking faults are shown on the driver’s display.
Brake system: The electric brake system consists of independent brake systems. Applying the brake pedal results in inversion braking (plugging) in the traction motor. The parking brake is electrically operated and acts mechanically (compression spring) on a magnet brake mounted on the drive unit. This brake is also used for emergency braking. A warning light appears when the brake is applied. Steering and braking faults are shown on the driver’s display.
1108.GB
Safety mechanisms: Enclosed, smooth truck geometry. The wheels (12/13) are surrounded by a solid ram protection skirting. This protects the load in the event of a collision. The key switch (4) or isolator (emergency disconnect) (5) disconnects all electrical function in hazardous situations. Travelling is inhibited if the driver door is not closed.
1108.GB
2.1
B3
B3
B4
1108.GB
Emergency Stop Safety Feature: The emergency stop is governed by the brake controller. The steering controller transmits a system status signal which is monitored by the brake controller. If the signal fails to appear or a fault is identified the truck automatically brakes until it comes to rest. Control displays on the driver’s display indicate the emergency stop. Every time the truck is switched on, the system performs a self-diagnosis which only releases the parking brake (emergency stop) if the functional test is positive.
1108.GB
Emergency Stop Safety Feature: The emergency stop is governed by the brake controller. The steering controller transmits a system status signal which is monitored by the brake controller. If the signal fails to appear or a fault is identified the truck automatically brakes until it comes to rest. Control displays on the driver’s display indicate the emergency stop. Every time the truck is switched on, the system performs a self-diagnosis which only releases the parking brake (emergency stop) if the functional test is positive.
B4
3
Standard Version Specifications
3
Standard Version Specifications
Z
Technical data specified in accordance with VDI 2198. Technical modifications and additions reserved.
Z
Technical data specified in accordance with VDI 2198. Technical modifications and additions reserved.
3.1
Performance data
3.1
Performance data
Description
ESE 420
ESE 430
Q Rated capacity
2000
3000
kg
ESE 420
ESE 430
Q Rated capacity
2000
3000
kg
1200
1200
mm
c
Load centre distance with standard fork length *)
1200
1200
mm
Travel speed with / without rated load
14.0/14.0 13.0**)/13.0**)
14.0/14.0 13.0**)/13.0**)
km/h
Travel speed with / without rated load
14.0/14.0 13.0**)/13.0**)
14.0/14.0 13.0**)/13.0**)
km/h
Lift speed with / without rated load
5.6/6.0
5.6/6.0
cm/s
Lift speed with / without rated load
5.6/6.0
5.6/6.0
cm/s
Lowering speed with / without rated load
5.2 / 5.0
5.2 / 5.0
cm/s
Lowering speed with / without rated load
5.2 / 5.0
5.2 / 5.0
cm/s
*) Load evenly distributed over the entire fork length. **) Fork overhang > 560
*) Load evenly distributed over the entire fork length. **) Fork overhang > 560
l
l
272
y
L1
L1 l
l
y
272 L1
L1
105 a _ 2
1108.GB
1108.GB
105 a _ 2
Wa
b5
975
b2 b10
b5
b11
975
e
445 e
445
a _ 2
Q
h13
Q
h3
784
1730
l2
y
b2 b10
Q
Q
m2
m2
l2 272
1200
Q
750 kg 750 kg 750 kg 750 kg
h13
Q
h3
784
Q
1495
x
750 kg 750 kg 750 kg 750 kg 1200
1730
1495
x
Q
h13
m2
l2
y
h3
784
1200
1730 h3
m2
l2
Q
h13
Q
272
1495
x
784
1200
1730
1495
x
b11
c
Load centre distance with standard fork length *)
Description
Ast
B5
a _ 2
Wa
Ast
B5
3.2
Dimensions
3.2
(all dimensions in mm) Description Lift
h7
Seat height
h13
Lowered fork height
l1 l2
(all dimensions in mm) ESE 420
ESE 430
Description
115
115
h3
Lift
1200
1200
h7
Seat height
90
95
h13
Lowered fork height
Overall length
4825
4825
l1
Headlength
1225
1225
l2
b2
Truck width
1000
1000
b5
Width across forks
520/560
b10
Track width, drive
604
b11
Track width, load section
380
Wa
Turning radius
2760
Ast
Aisle with for pallets 800 x 1200 length
3870
a
Safety distance
200
B6
ESE 430
115
115
1200
1200
90
95
Overall length
4825
4825
Headlength
1225
1225
b2
Truck width
1000
1000
580
b5
Width across forks
520/560
580
604
b10
Track width, drive
604
604
380
b11
Track width, load section
380
380
2760
Wa
Turning radius
2760
2760
3870
Ast
Aisle with for pallets 800 x 1200 length
3870
3870
200
a
Safety distance
200
200
See truck data plate
Net weight:
1108.GB
Net weight:
ESE 420
See truck data plate
1108.GB
h3
Dimensions
B6
3.3
EN norms Noise emission:
3.3 68 dB(A)
EN norms Noise emission:
in accordance with EN 12053 as harmonised with ISO 4871.
Z
in accordance with EN 12053 as harmonised with ISO 4871.
Z
The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear.
Vibration:
0.96 m/s2
The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear.
Vibration:
In accordance with EN 13059.
Z
68 dB(A)
0.96 m/s2 In accordance with EN 13059.
Z
The vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated when travelling over bumps at constant speed. Electromagnetic compatibility (EMC)
The vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated when travelling over bumps at constant speed. Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein.
The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein.
Z
No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.
Z
No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.
3.4
Conditions of use
3.4
Conditions of use
Ambient temperature
Ambient temperature - operating at 5 °C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations.
1108.GB
Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations.
1108.GB
Z
- operating at 5 °C to 40 °C
B7
B7
Technical Description – Load Handler
3.5
Lift mechanism: The lift mechanism (11) and load fork is connected to the chassis via the lift cylinder and the lift linkage. The load forks are raised when the lift cylinder is extended while simultaneously moving the load wheel support through the lift linkage. 4
Technical Description – Load Handler Lift mechanism: The lift mechanism (11) and load fork is connected to the chassis via the lift cylinder and the lift linkage. The load forks are raised when the lift cylinder is extended while simultaneously moving the load wheel support through the lift linkage.
Identification points and data plates
4
Identification points and data plates
Qmax 3000kg 15
Qmax 3000kg 15
16
16
17
17 17
17
19
19 18
18
17
17 17
B8
Description Truck data plate Capacity Qmax Strap point for crane lifting “Risk of trapping” label Test sticker (o)
Item 15 16 17 18 19
1108.GB
Item 15 16 17 18 19
17
B8
Description Truck data plate Capacity Qmax Strap point for crane lifting “Risk of trapping” label Test sticker (o)
1108.GB
3.5
4.1
Truck data plate
4.1
Truck data plate
20
31 30
20
31 30
21
29
21
29
22
28
22
28
23
27
23
27
24
24
26
25 Item 20 21 22 23 24 25
Item 26 27 28 29 30 31
Description Manufacturer’s logo Min./max. battery weight (kg) Output (kW) Load centre of gravity (mm) Year of manufacture Option
Item 20 21 22 23 24 25
Z
Description Type Serial no. Rated capacity (kg) Battery voltage (V) Net weight excl. battery Manufacturer
Item 26 27 28 29 30 31
Description Manufacturer’s logo Min./max. battery weight (kg) Output (kW) Load centre of gravity (mm) Year of manufacture Option
For queries regarding the truck or ordering spare parts please quote the truck serial number (21).
1108.GB
For queries regarding the truck or ordering spare parts please quote the truck serial number (21).
1108.GB
Z
Description Type Serial no. Rated capacity (kg) Battery voltage (V) Net weight excl. battery Manufacturer
26
25
B9
B9
B 10 B 10 1108.GB
1108.GB
C Transport and Commissioning
C Transport and Commissioning
1
Lifting by crane
1
Lifting by crane
M
Only use lifting gear with sufficient capacity (for transport weight see truck data plate).
M
Only use lifting gear with sufficient capacity (for transport weight see truck data plate).
M
The lifting gear must be attached to the attachment points in such a manner that it cannot slip under any circumstances and cannot come into contact with any attachments of the truck when the truck is lifted.
M
The lifting gear must be attached to the attachment points in such a manner that it cannot slip under any circumstances and cannot come into contact with any attachments of the truck when the truck is lifted.
– Remove the dummy plugs from the load section and screw in the two ring screws (1). – If loading the truck with crane lifting gear, attach the load hooks to the ring screws (1) on either side and also to the lift mechanism (2). – Park the truck securely (see Chapter E). – Secure the truck with wedges to prevent it from rolling away.
– Remove the dummy plugs from the load section and screw in the two ring screws (1). – If loading the truck with crane lifting gear, attach the load hooks to the ring screws (1) on either side and also to the lift mechanism (2). – Park the truck securely (see Chapter E). – Secure the truck with wedges to prevent it from rolling away.
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Parking brake transport lock
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Parking brake transport lock
F
If a truck is supplied without a battery or with an uncharged battery, the transport lock (2xM5) must be removed before starting to use the truck. The transport lock is used to lock the compression spring which activates the parking brake, so that the truck is not braked when de-energised. It consists of two bolts screwed into the magnetic brake (on the drive motor). This prevents the compression spring from activating the brake.
F
If a truck is supplied without a battery or with an uncharged battery, the transport lock (2xM5) must be removed before starting to use the truck. The transport lock is used to lock the compression spring which activates the parking brake, so that the truck is not braked when de-energised. It consists of two bolts screwed into the magnetic brake (on the drive motor). This prevents the compression spring from activating the brake.
Removing the Transport Locks
Removing the Transport Locks
– Push the driver’s seat out of the guide towards the steering wheel. – Disconnect the fan connector on the seat panel. – Remove seat panel (see Chapter F). – Disconnect the two-pin connector from the magnetic brake. – Unscrew the brake release screws from the magnetic brake and insert them in the drive plate holes.
– Push the driver’s seat out of the guide towards the steering wheel. – Disconnect the fan connector on the seat panel. – Remove seat panel (see Chapter F). – Disconnect the two-pin connector from the magnetic brake. – Unscrew the brake release screws from the magnetic brake and insert them in the drive plate holes.
The brake now operates without current. The truck can now longer be moved without the battery.
The brake now operates without current. The truck can now longer be moved without the battery.
– – – – – –
– – – – – –
Connect the two-pin connector to the magnetic brake. Fit the seat panel. Connect the fan connector on the seat panel. Position the driver’s seat in the guide. Fit and connect the battery. Switch on the isolator and key switch
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The truck is now operational.
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The truck is now operational.
Connect the two-pin connector to the magnetic brake. Fit the seat panel. Connect the fan connector on the seat panel. Position the driver’s seat in the guide. Fit and connect the battery. Switch on the isolator and key switch
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Moving the truck without a battery
Moving the truck without a battery
– – – – – –
– – – – – –
Disconnect the battery. Push the driver’s seat out of the guide towards the steering wheel. Disconnect the fan connector on the seat panel. Remove seat panel (see Chapter F). Disconnect the two-pin connector from the magnetic brake. Unscrew the brake release screws from the drive plate and insert them in the magnetic brake holes.
Disconnect the battery. Push the driver’s seat out of the guide towards the steering wheel. Disconnect the fan connector on the seat panel. Remove seat panel (see Chapter F). Disconnect the two-pin connector from the magnetic brake. Unscrew the brake release screws from the drive plate and insert them in the magnetic brake holes.
Z
The brake can now be released without current. The truck can now be pulled or pushed without a battery.
Z
The brake can now be released without current. The truck can now be pulled or pushed without a battery.
M
After moving the truck, remove the brake release screws again.
M
After moving the truck, remove the brake release screws again.
Z
The truck is now operational.
Z
The truck is now operational.
3
Commissioning
3
Commissioning
F
Before commissioning the truck ensure that the mast is correctly assembled and the hydraulic hoses have been connected to the basic truck / mast interface.
F
Before commissioning the truck ensure that the mast is correctly assembled and the hydraulic hoses have been connected to the basic truck / mast interface.
M
Only operate the truck with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6m long.
M
Only operate the truck with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6m long.
– Unscrew the brake release screws from the magnetic brake and insert them in the drive plate holes. – Connect the two-pin connector to the magnetic brake. – Fit the seat panel. – Connect the fan connector on the seat panel. – Position the driver’s seat in the guide. – Connect the battery. – Turn the EMERGENCY DISCONNECT switch and key switch on.
– Unscrew the brake release screws from the magnetic brake and insert them in the drive plate holes. – Connect the two-pin connector to the magnetic brake. – Fit the seat panel. – Connect the fan connector on the seat panel. – Position the driver’s seat in the guide. – Connect the battery. – Turn the EMERGENCY DISCONNECT switch and key switch on.
To prepare the truck after delivery or transport the following tasks must be carried out:
To prepare the truck after delivery or transport the following tasks must be carried out:
– – – –
– – – –
Install battery (where required). Do not damage battery cable. Charge the battery (see Chapter D). If necessary, remove the transport lock from the parking brake. Commission the truck in accordance with instructions (see Chapter E).
Install battery (where required). Do not damage battery cable. Charge the battery (see Chapter D). If necessary, remove the transport lock from the parking brake. Commission the truck in accordance with instructions (see Chapter E).
Z
If supplied without a battery, the truck can only be steered with the steering crank (see Chapter E, “Truck Recovery”).
Z
You may hear slight brake grinding noises after the truck is used for the first time.
Z
You may hear slight brake grinding noises after the truck is used for the first time.
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If supplied without a battery, the truck can only be steered with the steering crank (see Chapter E, “Truck Recovery”).
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D Battery Maintenance, Replacement 1
Charging
&
D Battery Maintenance, Replacement
Safety regulations for handling acid batteries
1
Charging
&
Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: 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.
Maintenance personnel: 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.
Fire protection: 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.
Fire protection: 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.
Battery maintenance: The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease. Batteries with non insulated terminals must be covered with a non slip insulation mat.
Battery maintenance: The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease. Batteries with non insulated terminals must be covered with a non slip insulation mat.
Battery Disposal: Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.
Battery Disposal: Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.
M F
Before closing the battery cover make sure that the battery lead cannot be damaged.
M F
Only batteries with a sealed battery container may be used.
Batteries contain an acid solution which is poisonous and corrosive. Therefore, always wear protective clothing and eye protection when carrying out work on batteries. Above all avoid any contact with battery acid. Nevertheless, should 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 neutralise any spilled battery acid.
Before closing the battery cover make sure that the battery lead cannot be damaged.
M F
Only batteries with a sealed battery container may be used.
Batteries contain an acid solution which is poisonous and corrosive. Therefore, always wear protective clothing and eye protection when carrying out work on batteries. Above all avoid any contact with battery acid. Nevertheless, should 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 neutralise any spilled battery acid.
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.
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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.
M F
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Battery types
2
The truck will be equipped with different battery types, depending on the application. The following table shows which combinations can be included as standard:
Battery types The truck will be equipped with different battery types, depending on the application. The following table shows which combinations can be included as standard:
48V - PzS battery, low maintenance
560 Ah
48V - PzS battery, low maintenance
560 Ah
48V - PzS battery, maintenance-free
560 Ah
48V - PzS battery, maintenance-free
560 Ah
The battery weights can be taken from the battery data plate. Batteries with non insulated terminals must be covered with a non slip insulation mat.
The battery weights can be taken from the battery data plate. Batteries with non insulated terminals must be covered with a non slip insulation mat.
F
The weight and dimensions of the battery have a considerable affect on the operational safety of the truck. Battery equipment may only be replaced with the agreement of the manufacturer.
F
The weight and dimensions of the battery have a considerable affect on the operational safety of the truck. Battery equipment may only be replaced with the agreement of the manufacturer.
3
Exposing the battery
3
Exposing the battery
F
Park the truck securely (see Chapter E).
F
Park the truck securely (see Chapter E).
Only connect and disconnect the battery connector and the socket when the mains and charger are switched off. – If necessary open the door. – Remove the hex. socket screws (1). – Lift up the door attachment (2).
– If necessary open the door. – Remove the hex. socket screws (1). – Lift up the door attachment (2).
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Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.
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Charging the battery
4
– Park the truck securely (see Chapter E).
F
– Park the truck securely (see Chapter E).
F
When charging the low maintenance battery, the tops of the battery cells must be exposed to provide sufficient ventilation. This is not necessary for maintenance-free batteries. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. – Connect the charging cable (4) of the battery charging station to the battery connector (3) and switch on the charger. – Charge the battery in accordance with the battery and charging station manufacturers’ instructions.
F
Charging the battery
When charging the low maintenance battery, the tops of the battery cells must be exposed to provide sufficient ventilation. This is not necessary for maintenance-free batteries. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. – Connect the charging cable (4) of the battery charging station to the battery connector (3) and switch on the charger. – Charge the battery in accordance with the battery and charging station manufacturers’ instructions.
F
It is essential to follow the safety regulations of the battery and charging station manufacturers.
3
It is essential to follow the safety regulations of the battery and charging station manufacturers.
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Battery removal and installation
5
– Expose the battery (see Section 3).
F
– Expose the battery (see Section 3).
F
To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. When replacing a battery with a crane, make sure the crane has sufficient capacity (see battery weight on the battery data plate on the container). The lifting gear must exert a vertical pull so that the battery container is not compressed. Hooks shall be fitted so that when the crane lifting gear is slackened, they do not fall onto the battery cells. – Attach crane lifting gear (5). – Lift out the battery.
F
F
When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position.
When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position. Assembly is the reverse order.
F
After installing the battery again, check all cables and plug connections for visible signs of damage.
After installing the battery again, check all cables and plug connections for visible signs of damage.
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To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. When replacing a battery with a crane, make sure the crane has sufficient capacity (see battery weight on the battery data plate on the container). The lifting gear must exert a vertical pull so that the battery container is not compressed. Hooks shall be fitted so that when the crane lifting gear is slackened, they do not fall onto the battery cells. – Attach crane lifting gear (5). – Lift out the battery.
Assembly is the reverse order.
F
Battery removal and installation
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Driver’s display
6
Battery Discharge Indicator: The battery charge status of the battery (7) is shown on the driver’s display.
M
Battery Discharge Indicator: The battery charge status of the battery (7) is shown on the driver’s display.
M
The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries.
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Driver’s display
The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries.
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11 When a battery is discharged to the permissible discharge level, the battery symbol is displayed empty.
When a battery is discharged to the permissible discharge level, the battery symbol is displayed empty.
Battery Discharge Monitor: If the residual capacity falls below the required level, lifting is inhibited. A message will be shown on the driver’s display.
Battery Discharge Monitor: If the residual capacity falls below the required level, lifting is inhibited. A message will be shown on the driver’s display.
Z
Lifting is only released when the battery connected is at least 70% charged.
Lifting is only released when the battery connected is at least 70% charged. Time: The battery symbol indicates the time (8).
Travel program The current travel program (10) is shown on the right hand side of the display.
Travel program The current travel program (10) is shown on the right hand side of the display.
Operating hours: The number of operating hours (11) since the last reset are shown below the battery symbol.
Operating hours: The number of operating hours (11) since the last reset are shown below the battery symbol.
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Time: The battery symbol indicates the time (8).
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E Operation
E Operation
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F
Safety Regulations for the Operation of Forklift Trucks
Safety Regulations for the Operation of Forklift Trucks
Driver authorisation: The forklift 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 been authorised to operate the truck by the proprietor or his representative.
Driver authorisation: The forklift 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 been authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities: 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 operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.
Driver’s rights, obligations and responsibilities: 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 operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.
Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. He shall prevent unauthorised persons from driving or operating the truck. It is forbidden to carry passengers or lift personnel.
Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. He shall prevent unauthorised persons from driving or operating the truck. It is forbidden to carry passengers or lift personnel.
Damage and Faults: The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment. Trucks not safe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.
Damage and Faults: The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment. Trucks not safe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches.
Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches.
Hazardous area: A 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 itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
Hazardous area: A 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 itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
F
Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed.
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Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed.
Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.
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Controls and Displays Item Control /Display 1 Steering wheel 2 Driver’s display 3 4
Switch for driver seat heating Crawl speed control light
5 6 7 8 9 10
Crawl speed switch Hydraulic control button Warning button Travel direction button Parking brake button Key switch
11 Main switch / isolator (emergency disconnect) 12 Control light emergency steering mode 13 Control light driver seat heating 14 Deadman button
15 Accelerator pedal 16 Brake pedal 17 Driver's seat longitudinal setting 18 Invertebral disc support 19 Backrest adjustment 20 Driver's seat damping
Function t Steers truck in desired direction. t Displays key travel and lift parameters, warnings, notification of incorrect operation and service displays (see Section 5). o Switches driver seat heating on and off.
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Controls and Displays Item Control /Display 1 Steering wheel 2 Driver’s display 3
t When lit, indicates that the maximum travel speed has been reduced. t Switches crawl mode on and off. t Lifting and lowering, reach and rotate. t Triggers a warning when applied. t Pre-selects required direction. t Applies / releases parking brake. t To switch the battery supply to the truck on and off. Red key (No. 702): - for the operator Grey key (No. 738): - for service and workshop t The supply current is interrupted, all electrical functions are deactivated and the truck is automatically braked. t When lit, indicates that emergency steering mode is applied.
4
Switch for driver seat heating Crawl speed control light
5 6 7 8 9 10
Crawl speed switch Hydraulic control button Warning button Travel direction button Parking brake button Key switch
11 Main switch / isolator (emergency disconnect) 12 Control light emergency steering mode 13 Control light driver seat heating 14 Deadman button
o When lit, indicates that the driver’s seat heating is on. t – Deadman button pressed: truck ready for operation. – Deadman button released: truck brakes. t Controls travel speed infinitely.
15 Accelerator pedal
t Truck decelerates. t Set for each journey.
16 Brake pedal 17 Driver's seat longitudinal setting 18 Invertebral disc support 19 Backrest adjustment
t The back padding can be individually set. t The backrest on the driver’s seat can be adjusted. t Sets the driver's weight for optimum seat damping. The set weight is displayed.
20 Driver's seat damping
o = Optional Equipment
t = Standard equipment
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Function t Steers truck in desired direction. t Displays key travel and lift parameters, warnings, notification of incorrect operation and service displays (see Section 5). o Switches driver seat heating on and off. t When lit, indicates that the maximum travel speed has been reduced. t Switches crawl mode on and off. t Lifting and lowering, reach and rotate. t Triggers a warning when applied. t Pre-selects required direction. t Applies / releases parking brake. t To switch the battery supply to the truck on and off. Red key (No. 702): - for the operator Grey key (No. 738): - for service and workshop t The supply current is interrupted, all electrical functions are deactivated and the truck is automatically braked. t When lit, indicates that emergency steering mode is applied. o When lit, indicates that the driver’s seat heating is on. t – Deadman button pressed: truck ready for operation. – Deadman button released: truck brakes. t Controls travel speed infinitely. t Truck decelerates. t Set for each journey. t The back padding can be individually set. t The backrest on the driver’s seat can be adjusted. t Sets the driver's weight for optimum seat damping. The set weight is displayed. o = Optional Equipment
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Starting up the truck
3
Starting up the truck
F
Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.
F
Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.
Z
Checks and operations to be performed before starting daily work
Checks and operations to be performed before starting daily work
– The entire truck (in particular wheels and load lifting devices) must be inspected for damage. – Visually inspect the battery attachment and cable connections.
– The entire truck (in particular wheels and load lifting devices) must be inspected for damage. – Visually inspect the battery attachment and cable connections.
Adjusting the driver’s seat
Adjusting the driver’s seat
20
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Z
To achieve optimal seat damping the driver’s seat must be adjusted according to the driver’s weight. Set the driver's weight when the seat is unoccupied. – Bring forward the weight adjustment lever (20) and set the driver’s weight (can be checked in the display window). – Restore the weight adjustment lever to its original position. – Sit on the driver’s seat. – Pull up the locking adjuster (17) and push the driver’s seat forwards or backwards to the desired position. – Engage the locking lever. – Turn the handwheel (18) to the right or left to adjust the back padding individually. – Pull the backrest adjustment lever (19). Set the backrest to the required position and release the lever. – Raise the driver’s seat up to the required height and engage it.
20
17 18 22 19
To achieve optimal seat damping the driver’s seat must be adjusted according to the driver’s weight. Set the driver's weight when the seat is unoccupied. – Bring forward the weight adjustment lever (20) and set the driver’s weight (can be checked in the display window). – Restore the weight adjustment lever to its original position. – Sit on the driver’s seat. – Pull up the locking adjuster (17) and push the driver’s seat forwards or backwards to the desired position. – Engage the locking lever. – Turn the handwheel (18) to the right or left to adjust the back padding individually. – Pull the backrest adjustment lever (19). Set the backrest to the required position and release the lever. – Raise the driver’s seat up to the required height and engage it.
Z
If the driver’s seat is raised above the last stage (stop), the driver's seat will lower itself to the lowest position.
F
The driver’s seat must be securely engaged in the set position. The driver’s seat setting must not be changed during travel.
F
The driver’s seat must be securely engaged in the set position. The driver’s seat setting must not be changed during travel.
Z
The procedure for adjusting the driver’s seat applies to standard models. For other models, follow the manufacturer’s setting instructions. When adjusting, ensure that all controls are within easy reaching distance.
Z
The procedure for adjusting the driver’s seat applies to standard models. For other models, follow the manufacturer’s setting instructions. When adjusting, ensure that all controls are within easy reaching distance.
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If the driver’s seat is raised above the last stage (stop), the driver's seat will lower itself to the lowest position.
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Attaching the safety restraint belt
F
Attaching the safety restraint belt
F
The safety belt (21) must be worn at all times when travelling. The belt must audibly lock in place when closed. Place the safety belt (21) taught over your hips (not over fixed or fragile objects in the pockets of your clothes). The safety belt (21) should be as close as possible to your hips.
The safety belt (21) must be worn at all times when travelling. The belt must audibly lock in place when closed. Place the safety belt (21) taught over your hips (not over fixed or fragile objects in the pockets of your clothes). The safety belt (21) should be as close as possible to your hips.
Unlocking the safety restraint belt
Unlocking the safety restraint belt
– Press the red button in the lock section.
– Press the red button in the lock section.
F
The safety belt (21) must not jam or strike any sharp objects.
Z
When the truck is parked, the surface of the tyres will flatten. The flattening will disappear after a short period of operation.
Switching on the truck
F
The safety belt (21) must not jam or strike any sharp objects.
Z
When the truck is parked, the surface of the tyres will flatten. The flattening will disappear after a short period of operation.
Switching on the truck
– Pull out the main switch / isolator (11). – Insert the key in the key switch (10) and turn it clockwise as far as it will go to the “I” position. – Test the horn (7).
– Pull out the main switch / isolator (11). – Insert the key in the key switch (10) and turn it clockwise as far as it will go to the “I” position. – Test the horn (7).
The truck is now operational. The existing battery capacity is shown in the driver’s display (2).
The truck is now operational. The existing battery capacity is shown in the driver’s display (2).
– Check the operation of the brake pedal (15) and the parking brake (9) (see Section 4.2). – The current steering position is shown on the driver's display (2).
– Check the operation of the brake pedal (15) and the parking brake (9) (see Section 4.2). – The current steering position is shown on the driver's display (2).
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3.1
Emergency stop device
3.1
Emergency stop device
Z
The truck is fitted with an emergency stop device. After you switch on the isolator (11) and the key switch (10) there is an automatic safety prompt from the steering controller.
Z
The truck is fitted with an emergency stop device. After you switch on the isolator (11) and the key switch (10) there is an automatic safety prompt from the steering controller. Emergency stop activation
If a fault occurs in the steering system while travelling which affects the safety of the operator, the truck will brake in a controlled manner until it comes to a halt.
If a fault occurs in the steering system while travelling which affects the safety of the operator, the truck will brake in a controlled manner until it comes to a halt.
Emergency Stop Reset.
Emergency Stop Reset.
– Switch the isolator and key switch off and on again.
– Switch the isolator and key switch off and on again.
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If the truck is in a hazardous area or aisle when the emergency stop is activated, it can only be operated by the emergency mechanical steering system for recovery purposes (see Section 6).
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If the truck is in a hazardous area or aisle when the emergency stop is activated, it can only be operated by the emergency mechanical steering system for recovery purposes (see Section 6).
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Emergency stop activation
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Industrial Truck Operation
4
Industrial Truck Operation
4.1
Safety regulations for truck operation
4.1
Safety regulations for truck operation
Driving conduct: 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 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 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. It is forbidden to lean out of or reach beyond the working and operating area.
Driving conduct: 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 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 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. It is forbidden to lean out of or reach beyond the working and operating area.
Travel visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. Loads which affect visibility must be stored at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
Travel visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. Loads which affect visibility must be stored at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if such roads are clean and have a non-slip surface and providing such journeys are safely undertaken in accordance with the technical specifications for the truck in question. The truck must 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 negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if such roads are clean and have a non-slip surface and providing such journeys are safely undertaken in accordance with the technical specifications for the truck in question. The truck must 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 negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating lifts and docks: Lifts and docks must only be used 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 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 the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck.
Negotiating lifts and docks: Lifts and docks must only be used 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 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 the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck.
Nature of loads to be carried: Only carry properly secured loads. Never transport loads stacked higher than the top of the fork carriage or the load guard.
Nature of loads to be carried: Only carry properly secured loads. Never transport loads stacked higher than the top of the fork carriage or the load guard.
Towing trailers: Do not exceed the maximum trailer load specified for the forklift truck for trailers with or without brakes. The trailer load must be secured in accordance with regulations and must not exceed the dimensions permitted for that roadway. After coupling and before starting the driver shall ensure that the trailer coupling cannot become detached. Forklift trucks pulling a load must be driven such that the trailing vehicle is driven safely and can be stopped under any conditions.
Towing trailers: Do not exceed the maximum trailer load specified for the forklift truck for trailers with or without brakes. The trailer load must be secured in accordance with regulations and must not exceed the dimensions permitted for that roadway. After coupling and before starting the driver shall ensure that the trailer coupling cannot become detached. Forklift trucks pulling a load must be driven such that the trailing vehicle is driven safely and can be stopped under any conditions.
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Travel routes and work areas: Only use lanes and routes specifically designated for truck traffic. Unauthorised persons must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
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Travel routes and work areas: Only use lanes and routes specifically designated for truck traffic. Unauthorised persons must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
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4.2
F
Travel, Steering, Braking
4.2
Emergency stop
Emergency stop
– Press the isolator (11) down.
– Press the isolator (11) down.
All electrical functions are deactivated.
All electrical functions are deactivated.
Door contact switch
Door contact switch
The door contact switch must be applied (door closed) for all operating functions. If the door contact switch is not applied, all functions, except for the battery discharge indicator, are deactivated.
The door contact switch must be applied (door closed) for all operating functions. If the door contact switch is not applied, all functions, except for the battery discharge indicator, are deactivated.
Travel
Travel
F
Do not get up from the driver’s seat during travel. Do not drive the truck unless the panels are closed and properly locked. – Start up the truck (see section 3). – Release the parking brake switch (9) by pressing it. – Set the travel direction button (8) to the required direction (forward or reverse).
Z
Z
The current steering setting is shown in the driver’s display (2). – Apply the accelerator (14).
The current steering setting is shown in the driver’s display (2). – Apply the accelerator (14). The truck will start in the desired direction.
Z F
The travel speed is governed by the accelerator (14). Bends must be negotiated with controlled, adjusted (slow) speed (see Section 4.1). Steering – Turn the steering wheel to the left or right.
2
Do not get up from the driver’s seat during travel. Do not drive the truck unless the panels are closed and properly locked. – Start up the truck (see section 3). – Release the parking brake switch (9) by pressing it. – Set the travel direction button (8) to the required direction (forward or reverse).
The truck will start in the desired direction.
Z F
Travel, Steering, Braking
The travel speed is governed by the accelerator (14). Bends must be negotiated with controlled, adjusted (slow) speed (see Section 4.1). Steering – Turn the steering wheel to the left or right.
8
2
9
8
9
11
11
R
R
V
V
R
R
16
16
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V
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Braking
F
Z F
Braking
F
The braking pattern of the truck depends largely on the state of the ground. The driver must take this into account when operating the truck.
The braking pattern of the truck depends largely on the state of the ground. The driver must take this into account when operating the truck.
The truck can be braked in two different ways:
The truck can be braked in two different ways:
– using the service brake – using the reversing brake
– using the service brake – using the reversing brake
Braking with the Service Brake:
Braking with the Service Brake:
– Press the accelerator (15).
– Press the accelerator (15).
Braking with the Reversing Brake:
Braking with the Reversing Brake:
– Set the travel direction button (8) to the opposite direction while travelling.
– Set the travel direction button (8) to the opposite direction while travelling.
The truck brakes via the traction controller until it starts to travel in the opposite direction.
The truck brakes via the traction controller until it starts to travel in the opposite direction.
Z F
The brake force is controlled by the accelerator (16). In hazardous situations only apply the service brake.
The brake force is controlled by the accelerator (16). In hazardous situations only apply the service brake.
8
8
15
Z
The current steering setting is shown in the driver’s display (2).
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The current steering setting is shown in the driver’s display (2).
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15
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4.3
Collecting and depositing loads
4.3
Collecting and depositing loads
F
Before picking up a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded.
F
Before picking up a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded.
Z
– Drive the truck with forks as far as possible underneath the load.
– Drive the truck with forks as far as possible underneath the load.
Lift
Lift
– Press the “Raise Load Forks” hydraulic control button (6) until you reach the desired height.
– Press the “Raise Load Forks” hydraulic control button (6) until you reach the desired height.
Lower
Lower
– Press the “Lower Load Forks” hydraulic control button (6) until you reach the desired height.
– Press the “Lower Load Forks” hydraulic control button (6) until you reach the desired height.
Z
The lowering speed is fixed and cannot be adjusted.
The lowering speed is fixed and cannot be adjusted.
6
4.4
6
Parking the truck securely
4.4
When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
– – – –
Apply the parking brake button (9). Lower the load forks. Set the isolator (11) “OFF” (press it in). Set the key switch (10) to the "0" position and remove the key.
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Do not park the truck on a slope. The load must always be lowered to the ground. – – – –
Apply the parking brake button (9). Lower the load forks. Set the isolator (11) “OFF” (press it in). Set the key switch (10) to the "0" position and remove the key.
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F
Do not park the truck on a slope. The load must always be lowered to the ground.
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F
Parking the truck securely
E 10
5
Truck recovery in the event of electric steering failure
5
Truck recovery in the event of electric steering failure
F
Recovery must only be undertaken by maintenance personnel who have been trained to operate the system.
F
Recovery must only be undertaken by maintenance personnel who have been trained to operate the system.
– Turn the EMERGENCY DISCONNECT switch and key switch off. – Prevent the truck from rolling away. – Push the driver’s seat out of the guide towards the steering wheel. – Disconnect the system. – Remove the seat panel (the seat panel can be removed once the 3 mounting screws have been unscrewed).
– Turn the EMERGENCY DISCONNECT switch and key switch off. – Prevent the truck from rolling away. – Push the driver’s seat out of the guide towards the steering wheel. – Disconnect the system. – Remove the seat panel (the seat panel can be removed once the 3 mounting screws have been unscrewed).
Release the magnetic brake. To do this:
Release the magnetic brake. To do this:
– Disconnect the two-pin connector from the magnetic brake. – Unscrew the brake release screws from the drive plate and insert them in the magnetic brake holes. – Removing the protective cap from over the centre screw.
– Disconnect the two-pin connector from the magnetic brake. – Unscrew the brake release screws from the drive plate and insert them in the magnetic brake holes. – Removing the protective cap from over the centre screw.
Z
Before recovering the truck, the drive wheel can be turned to the required direction using a steering crank via the centre screw of the steering motor.
Z
Before recovering the truck, the drive wheel can be turned to the required direction using a steering crank via the centre screw of the steering motor.
F
Steering the truck when idle tensions the drive wheel tyre. When the crank is released, this can create a correcting moment.
F
Steering the truck when idle tensions the drive wheel tyre. When the crank is released, this can create a correcting moment.
– Assemble the steering crank (22) in accordance with the tool set table. – Place the steering crank on the steering drive and turn the drive wheel to the required steering position.
– Assemble the steering crank (22) in accordance with the tool set table. – Place the steering crank on the steering drive and turn the drive wheel to the required steering position.
22
F
22
22
When the truck reaches its destination, restore the brake system to its operating condition. The truck must not be parked with the brake released.
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When the truck reaches its destination, restore the brake system to its operating condition. The truck must not be parked with the brake released.
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22
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6
Display Components
6
Display Components
6.1
Driver’s display (t)
6.1
Driver’s display (t)
The driver’s display represents the operator interface to the truck. It is both a display and control unit for the operator and the service engineer.
The driver’s display represents the operator interface to the truck. It is both a display and control unit for the operator and the service engineer.
Press the four short stroke keys (37, 38, 39, 40) to operate the driver's display and hence the truck. The LEDs of the 4 luminous buttons (23 - 26) can show 3 conditions: active and flashing or off.
Press the four short stroke keys (37, 38, 39, 40) to operate the driver's display and hence the truck. The LEDs of the 4 luminous buttons (23 - 26) can show 3 conditions: active and flashing or off.
All displays are shown as text or as symbols. The meaning of the various symbols is explained in section 6.2.
All displays are shown as text or as symbols. The meaning of the various symbols is explained in section 6.2.
A colour contrasting display gives information on the travel direction, steering angle, battery charge condition and other selected truck parameters.
A colour contrasting display gives information on the travel direction, steering angle, battery charge condition and other selected truck parameters.
Set time:
Set time:
The display (30) via the battery shows the current time.
The display (30) via the battery shows the current time.
– – – – –
– – – – –
Press the shift key for 8 seconds until the “Set Time” menu is displayed. Set the hours with the “Up” (40) & “Down” (39) keys. Confirm with the shift key (38). Set the minutes with the “Up” (40) & “Down” (39) keys. Confirm with the shift (38) or profile key (37) to return to normal operating mode.
25
26
27
28
Press the shift key for 8 seconds until the “Set Time” menu is displayed. Set the hours with the “Up” (40) & “Down” (39) keys. Confirm with the shift key (38). Set the minutes with the “Up” (40) & “Down” (39) keys. Confirm with the shift (38) or profile key (37) to return to normal operating mode.
29 30 31 32
25
27
28
29 30 31 32
33
33
34
34
35
24
26
35
24
23
23 36
38
37
40
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39
38
37
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36
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26 27 28 29 30 31 32 33 34 35 36
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37 38 39 40
Description Overtemperature (red graphic symbol) Deadman button not applied (yellow graphic symbol) Slow travel (green graphic symbol) Service mode active (yellow spanner graphic symbol) Service interval exceeded (flashing graphic symbol) Steering angle display in 30° increments in arrow form Travel direction display No function Time display (hours : minutes The battery discharge status Discharge indicator Set speed (drive direction) for current performance profile (in bar form 1 to 5) No function Profile number (travel / lift profile 1, 2 or 3) Text warnings and error messages (14 segment display) and information messages Profile key to select travel mode Shift key for changing display and accessing service mode No function Slow travel
Item 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Description Overtemperature (red graphic symbol) Deadman button not applied (yellow graphic symbol) Slow travel (green graphic symbol) Service mode active (yellow spanner graphic symbol) Service interval exceeded (flashing graphic symbol) Steering angle display in 30° increments in arrow form Travel direction display No function Time display (hours : minutes The battery discharge status Discharge indicator Set speed (drive direction) for current performance profile (in bar form 1 to 5) No function Profile number (travel / lift profile 1, 2 or 3) Text warnings and error messages (14 segment display) and information messages Profile key to select travel mode Shift key for changing display and accessing service mode No function Slow travel
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Item 23 24 25
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You can use the four short stroke keys to:
You can use the four short stroke keys to:
– derate the travel speed (slow travel switch), – change the display to service mode (shift key) and – select travel and lift modes.
– derate the travel speed (slow travel switch), – change the display to service mode (shift key) and – select travel and lift modes.
The display shows:
The display shows:
– – – – – – – – – –
– – – – – – – – – –
The steering angle in 30° increments in arrow form. The travel / lift profile (1, 2 or 3). The set speed (drive direction) for the current profile (in bar form 1 to 5). Battery discharge status. Battery discharge warning (flashing battery symbol and buzzing sound). Service hours (complete hours). Time (hours: minutes). Text warnings and error messages (14 segment display). Parameters (service mode). Diagnostics (service mode).
The coloured luminous surfaces indicate:
The coloured luminous surfaces indicate:
– – – – –
– – – – –
Slow travel (green graphic symbol). Deadman switch not applied (yellow graphic symbol). Service mode active (yellow spanner graphic symbol). Service interval exceeded (flashing yellow spanner graphic symbol). Overtemperature (red graphic symbol).
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Slow travel (green graphic symbol). Deadman switch not applied (yellow graphic symbol). Service mode active (yellow spanner graphic symbol). Service interval exceeded (flashing yellow spanner graphic symbol). Overtemperature (red graphic symbol).
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E 14
The steering angle in 30° increments in arrow form. The travel / lift profile (1, 2 or 3). The set speed (drive direction) for the current profile (in bar form 1 to 5). Battery discharge status. Battery discharge warning (flashing battery symbol and buzzing sound). Service hours (complete hours). Time (hours: minutes). Text warnings and error messages (14 segment display). Parameters (service mode). Diagnostics (service mode).
E 14
6.2
Driver’s Display LED Buttons
6.2
Driver’s Display LED Buttons
SYMBOL Slow travel (green graphic symbol)
SYMBOL Slow travel (green graphic symbol)
SYMBOL Deadman button not applied (yellow graphic symbol)
SYMBOL Deadman button not applied (yellow graphic symbol)
SYMBOL Service mode active (yellow spanner graphic symbol)
SYMBOL Service mode active (yellow spanner graphic symbol)
SYMBOL Overtemperature (red graphic symbol)
SYMBOL Overtemperature (red graphic symbol)
Driver’s Display Switches
Driver’s Display Switches
Handbrake applied / release (brake switch)
Handbrake applied / release (brake switch)
Change display to service mode (shift key)
Change display to service mode (shift key)
Select travel and lift modes
Select travel and lift modes
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Travel speed derated (slow travel switch),
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Travel speed derated (slow travel switch),
E 15
E 15
Driver’s Display Warning Messages
25
26
27
Driver’s Display Warning Messages
28
29 30 31 32
25
27
28
29 30 31 32
33
33
34
34
35
24
26
35
24
23
23 36
40
Display Other action
39
38
36
37
40
Meaning
Display Other action
38
LED 31 flashing Battery empty, main lift cutout
LED 24 on
LED 24 on
Safety switch not pressed
37
Meaning
LED 31 flashing Battery empty, main lift cutout
Safety switch not pressed
INFO 07 LED 25 flashing
At least 1 control not in home position when system starts
INFO 07 LED 25 flashing
At least 1 control not in home position when system starts
INFO 09 LED 25 on
Crawl speed applied or forced by battery latching
INFO 09 LED 25 on
Crawl speed applied or forced by battery latching
INFO 10 LED 23 on
Drive motor overtemperature
INFO 10 LED 23 on
Drive motor overtemperature
INFO 11 LED 23 on
Lift motor overtemperature
INFO 11 LED 23 on
Lift motor overtemperature
INFO 12 LED 23 on
Steer motor overtemperature
INFO 12 LED 23 on
Steer motor overtemperature
INFO 25 LED 23 flashing Traction controller overtemperature
INFO 26 LED 23 flashing Lift controller overtemperature
INFO 26 LED 23 flashing Lift controller overtemperature
INFO 27 LED 23 flashing Steering controller overtemperature
INFO 27 LED 23 flashing Steering controller overtemperature
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INFO 25 LED 23 flashing Traction controller overtemperature
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39
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7
Keypad (CANCODE) (o) The keypad consists of 10 number keys, a Set key and a o key.
1
2
3
The o key indicates operating statuses via a red/ green LED.
4
5
6
It contains the following functions:
7
8
9
Set
0
– Code lock function (starting up the truck).
7.1
7
Keypad (CANCODE) (o) The keypad consists of 10 number keys, a Set key and a o key.
1
2
3
The o key indicates operating statuses via a red/ green LED.
4
5
6
It contains the following functions:
7
8
9
Set
0
– Code lock function (starting up the truck).
Code Lock
7.1
When the correct code has been entered, the machine is ready for use. You can allocate an individual code to each truck, driver or group of drivers.
Code Lock When the correct code has been entered, the machine is ready for use. You can allocate an individual code to each truck, driver or group of drivers.
Z
When the truck is initially delivered, the operator code for the driver’s display and CANCODE (o) (factory setting 2-5-8-0-7) is shown on a sticker.
m
When starting the truck for the first time, change the master and operating codes.
m
When starting the truck for the first time, change the master and operating codes.
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When the truck is initially delivered, the operator code for the driver’s display and CANCODE (o) (factory setting 2-5-8-0-7) is shown on a sticker.
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Z
E 17
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Z
Starting the truck for the first time
Starting the truck for the first time
After switching on the isolator and if necessary the key switch, the LED (41) turns red.
After switching on the isolator and if necessary the key switch, the LED (41) turns red.
When you enter the correct operator code the LED (41) turns green.
When you enter the correct operator code the LED (41) turns green.
If the wrong code is entered LED (41) flashes red for two seconds. The correct code can then be entered.
If the wrong code is entered LED (41) flashes red for two seconds. The correct code can then be entered.
Switching off
43
To switch the truck off, press the o switch (46).
Z
7.2
Z
The Set key (42) has no function in operating mode
The truck can switch off automatically after a pre-determined time. To do this, you need to set the corresponding code lock parameter. (see Section 7.3).
Parameters
42
44
Switching off
45
2
3
4
5
6
7
8
9
Set
0
Z
The truck can switch off automatically after a pre-determined time. To do this, you need to set the corresponding code lock parameter. (see Section 7.3).
46 7.2
Parameters
42
44
45
1
2
3
4
5
6
7
8
9
Set
0
In programming mode you can set the code lock functions via the keypad.
41
46
41
Parameter Groups
Parameter Groups
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 sequence from 00 to 99.
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 sequence from 00 to 99.
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No. Parameter Group 0xx Code Lock Settings (Codes, travel program release, automatic cutout, etc.)
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No. Parameter Group 0xx Code Lock Settings (Codes, travel program release, automatic cutout, etc.)
E 18
43
To switch the truck off, press the o switch (46).
1
In programming mode you can set the code lock functions via the keypad.
The Set key (42) has no function in operating mode
E 18
7.3
Parameter Settings
7.3
To change the truck setting you must enter the master code.
Z m
Z
Parameter Settings To change the truck setting you must enter the master code.
Z m
The factory setting for the master code is 7-2-9-5. When starting the truck for the first time change the master code.
The factory setting for the master code is 7-2-9-5. When starting the truck for the first time change the master code.
To enter the master code:
To enter the master code:
– Press the o key – Enter master code
– Press the o key – Enter master code
Code Lock Parameters
Code Lock Parameters
Truck setting procedure:
Truck setting procedure:
– Enter the three digit parameter number, confirm with the Set key (42). – Enter the setting according to the parameter list or change and confirm with the Set key (42).
– Enter the three digit parameter number, confirm with the Set key (42). – Enter the setting according to the parameter list or change and confirm with the Set key (42).
Z
If the entry is incorrect, the LED (40) of the o key (46) flashes red. If you enter the parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To complete your entry, press the o key (46).
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To enter more parameters, repeat the procedure. To complete your entry, press the o key (46).
If the entry is incorrect, the LED (40) of the o key (46) flashes red. If you enter the parameter number again the setting can be entered or changed.
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The following parameters may be entered.
The following parameters may be entered.
Code Lock Parameter List
Code Lock Parameter List
Function
Range of Setting
Code Lock 000 Change Master Code 0000 - 9999 The length (4-6 digits) of or the master code also pre- 00000 - 99999 determines the length of or the operator code (4-6 000000 - 999999 digits). Provided the operator codes are programmed, only news codes of the same length can be entered. If the code length is to be changed, all operator codes must first be deleted.
0000 - 9999 or 00000 - 99999 or 000000 - 999999
Comments Procedure
7295
(LED 43 flashes) Enter current code
No.
Confirm (Set) (LED 44 flashes) Enter new code Confirm (Set) (LED 45 flashes) Repeat new code
2580
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Function
Range of Setting
Code Lock 000 Change Master Code 0000 - 9999 The length (4-6 digits) of or the master code also pre- 00000 - 99999 determines the length of or the operator code (4-6 000000 - 999999 digits). Provided the operator codes are programmed, only news codes of the same length can be entered. If the code length is to be changed, all operator codes must first be deleted.
Confirm (Set) (LED 44 flashes) Enter code
001 Add operator code (max. 600)
Confirm (Set)
0000 - 9999 or 00000 - 99999 or 000000 - 999999
Standard Setting
Comments Procedure
7295
(LED 43 flashes) Enter current code Confirm (Set) (LED 44 flashes) Enter new code Confirm (Set) (LED 45 flashes) Repeat new code
2580
Confirm (Set) (LED 44 flashes) Enter code Confirm (Set)
(LED 45 flashes) Repeat code entry
(LED 45 flashes) Repeat code entry
Confirm (Set)
Confirm (Set)
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001 Add operator code (max. 600)
Standard Setting
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No.
Function
Code Lock 002 Change Operator Code
003 Delete Operator Code
Range of Setting
Standard Setting
0000 - 9999 or 00000 - 99999 or 000000 - 999999
Comments Procedure
No.
Function
Code Lock 002 Change Operator Code
(LED 43 flashes) Enter current code Confirm (Set)
Standard Setting
0000 - 9999 or 00000 - 99999 or 000000 - 999999
(LED 43 flashes) Enter current code Confirm (Set) (LED 44 flashes) Enter new code
Confirm (Set)
Confirm (Set)
(LED 45 flashes) Repeat code entry
(LED 45 flashes) Repeat code entry
003 Delete Operator Code
Confirm (Set)
confirm (LED 44 flashes) Enter code
0000 - 9999 or 00000 - 99999 or 000000 - 999999
Confirm (Set)
(LED 45 flashes) Repeat code entry
004 Delete code memory (Deletes all user codes )
010 Automatic time cutout
00 - 31
(LED 45 flashes) Repeat code entry
Confirm (Set) 3265 = delete
3265
00
Comments Procedure
(LED 44 flashes) Enter new code
confirm (LED 44 flashes) Enter code
0000 - 9999 or 00000 - 99999 or 000000 - 999999
Range of Setting
004 Delete code memory (Deletes all user codes )
other inputs= do not delete 00 = no cutout
010 Automatic time cutout
Confirm (Set) 3265 = delete
3265
00 - 31
00
other inputs= do not delete 00 = no cutout
01 to 30 = Cutout time in minutes
01 to 30 = Cutout time in minutes
31 = Cutout after 10 seconds
31 = Cutout after 10 seconds
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LEDs 43-45 are located in key fields 1-3 (see Section 7)
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LEDs 43-45 are located in key fields 1-3 (see Section 7)
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Error messages on keypad
Error messages on keypad
LED (41) flashes red to indicate the following errors:
LED (41) flashes red to indicate the following errors:
– – – – – –
– – – – – –
New master code is already an operator code. New operator code is already a master code. Operator code to be changed does not exist. Tried to change the operator code to an existing operator code. Tried to delete an operator code that does not exist. Code memory full.
New master code is already an operator code. New operator code is already a master code. Operator code to be changed does not exist. Tried to change the operator code to an existing operator code. Tried to delete an operator code that does not exist. Code memory full.
8
Changing truck parameters
8
Changing truck parameters
F
Changing the truck parameters will affect the behaviour of the truck. This must be taken into account when starting up the truck. Parameters may only be changed when the truck is idle and not lifting.
F
Changing the truck parameters will affect the behaviour of the truck. This must be taken into account when starting up the truck. Parameters may only be changed when the truck is idle and not lifting.
With the driver’s display (t) it is also possible to change certain truck parameters (acceleration, coasting brake, reverse braking, drive direction speed, fork direction speed and lift speed) and hence the truck’s characteristics.
With the driver’s display (t) it is also possible to change certain truck parameters (acceleration, coasting brake, reverse braking, drive direction speed, fork direction speed and lift speed) and hence the truck’s characteristics.
t Trucks with driver’s display and key switch
t Trucks with driver’s display and key switch
For trucks with a key switch, use the grey service spanner to access the travel and lift parameters.
For trucks with a key switch, use the grey service spanner to access the travel and lift parameters.
o Trucks with driver’s display and key switch
E 22
Before entering the SERVICE MENU / PARAMETER MENU you will be asked for your pin. The factory setting for trucks with CANCODE is (o) PIN 2580.
To switch on the truck, enter your Pin. Before entering the SERVICE MENU / PARAMETER MENU you will then no longer be asked for your PIN. The parameter settings are saved under your PIN.
To switch on the truck, enter your Pin. Before entering the SERVICE MENU / PARAMETER MENU you will then no longer be asked for your PIN. The parameter settings are saved under your PIN.
You can set 15 different parameters (change of driver or change of program). To select other parameter settings, the truck must log off and on again or be switched off and on again. Enter the next PIN.
You can set 15 different parameters (change of driver or change of program). To select other parameter settings, the truck must log off and on again or be switched off and on again. Enter the next PIN.
m
Changes to the service mode may only be made by the manufacturer’s service department.
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m
Z
Before entering the SERVICE MENU / PARAMETER MENU you will be asked for your pin. The factory setting for trucks with CANCODE is (o) PIN 2580.
Changes to the service mode may only be made by the manufacturer’s service department.
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o Trucks with driver’s display and key switch
E 22
Troubleshooting
Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table.
This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Possible cause Truck does not – Battery not connected. start – Isolator (emergency disconnect) pressed.
Fault Possible cause Truck does not – Battery not connected. start – Isolator (emergency disconnect) pressed.
– Key switch in “0” position. – Battery charge too low. – Door contact switch not applied. – Faulty fuse. Load cannot be lifted
– Truck not operational. – Hydraulic oil level too low. – Faulty fuse.
Action – Check the battery connector, and connect if necessary. – Unlock isolator (emergency disconnect). – Set key switch to “I”. – Check battery charge and if necessary charge battery. – Close driver’s door.
– Key switch in “0” position. – Battery charge too low. – Door contact switch not applied. – Faulty fuse.
– Check fuses F1 and 1F1. – Carry out all measures listed under “Truck does not start”. – Check the hydraulic oil level. – Check fuse 2F1.
Load cannot be lifted
– Truck not operational. – Hydraulic oil level too low. – Faulty fuse.
Z
If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service department, as any further troubleshooting can only be performed by specially trained and qualified service personnel.
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9
Action – Check the battery connector, and connect if necessary. – Unlock isolator (emergency disconnect). – Set key switch to “I”. – Check battery charge and if necessary charge battery. – Close driver’s door. – Check fuses F1 and 1F1. – Carry out all measures listed under “Truck does not start”. – Check the hydraulic oil level. – Check fuse 2F1.
If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service department, as any further troubleshooting can only be performed by specially trained and qualified service personnel.
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E 23
E 23
E 24 E 24 0706.GB
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F Forklift Truck Maintenance
F Forklift Truck Maintenance
1
1
Operational safety and environmental protection The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists.
Operational safety and environmental protection The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.
M
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the forklift truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.
M
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the forklift truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.
After inspection and maintenance work, carry out the operations listed in the “Recommissioning” section (see Section 6.5).
2
M
After inspection and maintenance work, carry out the operations listed in the “Recommissioning” section (see Section 6.5).
Maintenance Safety Regulations
2
Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Maintenance personnel: Industrial trucks must only be serviced and maintained by the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath a raised load handler if it is supported by a sufficiently strong chain.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath a raised load handler if it is supported by a sufficiently strong chain.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, implement all necessary safety measures to prevent sparking (e.g. through short circuits). For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, implement all necessary safety measures to prevent sparking (e.g. through short circuits). For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies.
M
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 cause malfunctions. Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.
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After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.
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 cause malfunctions. Do not clean with pressurised water.
F1
F1
Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.
Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.
Tyres: The quality of tyres affects the stability and performance of the truck. When replacing tyres fitted at the factory, only use the manufacturer’s original spare parts. Otherwise the data sheet specifications of the truck cannot be guaranteed. When changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing wheels always left and right simultaneously).
Tyres: The quality of tyres affects the stability and performance of the truck. When replacing tyres fitted at the factory, only use the manufacturer’s original spare parts. Otherwise the data sheet specifications of the truck cannot be guaranteed. When changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing wheels always left and right simultaneously).
Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.
Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.
Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.
Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.
F2
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Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.
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Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.
F2
3
Servicing and inspection
3
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 failure and poses a potential hazard to personnel and equipment.
M
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 conditions of extreme dust, temperature fluctuations or multiple shifts.
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 conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as:
The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as:
W A B C
W A B C
= Every = Every = Every = Every
50 500 1000 2000
service hours, at least weekly service hours service hours, or at least annually service hours, or at least annually
Z
W service intervals are to be performed by the customer. In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.
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Z
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 failure and poses a potential hazard to personnel and equipment.
= Every = Every = Every = Every
50 500 1000 2000
service hours, at least weekly service hours service hours, or at least annually service hours, or at least annually
W service intervals are to be performed by the customer. In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.
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Servicing and inspection
F3
F3
ESE 420/430 Maintenance Checklist
Chassis/ Structure: Drive:
Wheels:
1.1 1.2 2.1 2.2 2.3 2.4 3.1 3.2
Steering:
4.1 4.2 4.3 4.4 4.5
Brake system:
5.1 5.2 5.3 5.4
Hydraulic System:
6.1 6.2 6.3
F4
ESE 420/430 Maintenance Checklist
C Chassis/ Structure: Drive: t Wheels:
1.1 1.2 2.1 2.2 2.3 2.4 3.1 3.2
Steering:
4.1 4.2 4.3 4.4 4.5
Brake system:
5.1 5.2 5.3 5.4
Hydraulic System:
6.1 6.2 6.3 6.4 6.5 6.6
t t
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6.4 6.5 6.6
Maintenance intervals Standard = t W A B Cold Store = k Check all load bearing components for damage t Check screw connections t Check the transmission for noises and leakage t Check transmission oil level t Change transmission oil l Check that drive plate and bolts are secure t Check wheels for wear and damage t Check the wheel bearings and ensure wheels are l t securely fastened Check steering toothing for wear and lubricate. t Check mechanical parts of steering head t Test steering t Check gearwheel and toothed belt for wear and adjust t Only replace oil in steering transmission when carrying out repairs Test operation and settings t Check the brake lining wear t Check the brake linkage; adjust and grease l t Make sure gas pressure springs are sealed and t check for damage Test operation k t Check all connections for leakage and damage k t Check hydraulic cylinder for leaks and damage and k t make sure it is secure Check oil level k t Replace the hydraulic oil and the filter cartridge t Test pressure relief valves k
4
Maintenance intervals Standard = t W A B Cold Store = k Check all load bearing components for damage t Check screw connections t Check the transmission for noises and leakage t Check transmission oil level t Change transmission oil l Check that drive plate and bolts are secure t Check wheels for wear and damage t Check the wheel bearings and ensure wheels are l t securely fastened Check steering toothing for wear and lubricate. t Check mechanical parts of steering head t Test steering t Check gearwheel and toothed belt for wear and adjust t Only replace oil in steering transmission when carrying out repairs Test operation and settings t Check the brake lining wear t Check the brake linkage; adjust and grease l t Make sure gas pressure springs are sealed and t check for damage Test operation k t Check all connections for leakage and damage k t Check hydraulic cylinder for leaks and damage and k t make sure it is secure Check oil level k t Replace the hydraulic oil and the filter cartridge t Test pressure relief valves k
C
t
t t
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4
F4
7.1 7.2 7.3 7.4
Electric motors: Battery:
Lift mechanism: Lubrication: General Measurements:
9.1 Check acid density, acid level and cell voltage 9.2 Check terminals are secure and apply terminal screw grease 9.3 Clean battery connections, ensure they are secure 9.4 Check battery cables for damage, replace if necessary 9.5 Check battery lock 10.1 Check operation, wear and setting 10.2 Visually inspect rollers, slide pieces and stops 10.3 Check forks and fork carriage for wear and damage 11.1 Lubricate truck in accordance with Lubrication Schedule 12.1 Check electrical system for frame leakage 12.2 Test travel speed and braking distance 12.3 Test lift and lowering speeds 12.4 Test safety devices and cutouts 13.1 Test run with rated load 13.2 After completing maintenance, present the truck to the supervisor
l l
t t
l
l l l
t t t t t t t
l
t t t
7.1 7.2 7.3 7.4
Electric motors: Battery:
Lift mechanism: Lubrication: General Measurements:
t t t
Demonstration:
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Demonstration:
7.5 7.6 8.1
Electrical System:
7.5 7.6 8.1
Maintenance intervals Standard = t W A B C Cold Store = k Test operation t Make sure wire connections are secure and check for t damage Check fuse ratings t Test operation of switches and trip cams and make sure t they are secure Test operation of warning devices and safety switches k t Check contactors, replace any worn parts t Check motor attachment t
9.1 Check acid density, acid level and cell voltage 9.2 Check terminals are secure and apply terminal screw grease 9.3 Clean battery connections, ensure they are secure 9.4 Check battery cables for damage, replace if necessary 9.5 Check battery lock 10.1 Check operation, wear and setting 10.2 Visually inspect rollers, slide pieces and stops 10.3 Check forks and fork carriage for wear and damage 11.1 Lubricate truck in accordance with Lubrication Schedule 12.1 Check electrical system for frame leakage 12.2 Test travel speed and braking distance 12.3 Test lift and lowering speeds 12.4 Test safety devices and cutouts 13.1 Test run with rated load 13.2 After completing maintenance, present the truck to the supervisor
l l
t t
l
l l l
t t t t t t t
l
t t t
t t t
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Electrical System:
Maintenance intervals Standard = t W A B C Cold Store = k Test operation t Make sure wire connections are secure and check for t damage Check fuse ratings t Test operation of switches and trip cams and make sure t they are secure Test operation of warning devices and safety switches k t Check contactors, replace any worn parts t Check motor attachment t
F5
F5
5
ESE 420/430 Lubrication Schedule
5
D 0,2 l
ESE 420/430 Lubrication Schedule
D 0,2 l
s g s E
1)
A
A+C
s g s
F
0,7 l
E
1)
A
A+C
E
F
0,7 l F
F
2,9 l B+C
2,9 l 1)
B
B+C
1)
B
195 -10 Nm
b a t
195 -10 Nm
g s
Contact surfaces Grease nipples Hydraulic oil filler plug Transmission oil filler neck Transmission oil drain plug Cold store application Brake fluid filler neck
t
1) Compound
ratio for cold store usage 1:1 0708.GB
1) Compound
b a
F6
Contact surfaces Grease nipples Hydraulic oil filler plug Transmission oil filler neck Transmission oil drain plug Cold store application Brake fluid filler neck ratio for cold store usage 1:1 0708.GB
g s
E
F6
5.1
Fuels, coolants and lubricants
5.1
Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions.
F
Fuels, coolants and lubricants Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions.
F
Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.
Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Instructions.
Only use clean containers when filling up with consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Instructions.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be disposed of in accordance with regulations.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be disposed of in accordance with regulations.
Code
Order no.
Code
Order no.
A
50 449 669
5.0 l
H-LP 46, DIN 51524
A
50 449 669
5.0 l
H-LP 46, DIN 51524
B
50 380 904
5.0 l
Fuchs Titan Cytrac Transmission HSY 75W-90
B
50 380 904
5.0 l
Fuchs Titan Cytrac Transmission HSY 75W-90
C
29 200 810
5.0 l
H-LP 10, DIN 51524
C
29 200 810
5.0 l
H-LP 10, DIN 51524
E
29 201 430
1.0 kg
Grease, DIN 51825 Lubrication
E
29 201 430
1.0 kg
Grease, DIN 51825 Lubrication
F
29 200 100
1.0 kg
Grease, TTF52
F
29 200 100
1.0 kg
Grease, TTF52
Quantity
Description
Used for Hydraulic system
Hydraulic system
Lubrication
Grease guidelines Code Saponification
Quantity
Description
Used for Hydraulic system
Hydraulic system
Lubrication
Grease guidelines Dew point °C
Worked penetration at 25°C
NLG1 class
Applicationtemperature °C
Code Saponification
Dew point °C
Worked penetration at 25°C
NLG1 class
Applicationtemperature °C
185
265-295
2
-35/+120
E
Lithium
185
265-295
2
-35/+120
F
--
--
310-340
1
-52/+100
F
--
--
310-340
1
-52/+100
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Lithium
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E
F7
F7
6
Maintenance Instructions
6
Maintenance Instructions
6.1
Preparing the truck for maintenance and repairs
6.1
Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:
All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:
– Park the truck securely (see Chapter E). – Disconnect the battery plug so that the truck cannot be started by unauthorised persons (see chapter D).
– Park the truck securely (see Chapter E). – Disconnect the battery plug so that the truck cannot be started by unauthorised persons (see chapter D).
F
When working under a raised load fork or a raised truck, secure them to prevent them from lowering, tipping or sliding away. When raising the truck also refer to the instructions in the “Transport and Commissioning” section. When working on the service/parking brake, prevent the truck from rolling away.
F
When working under a raised load fork or a raised truck, secure them to prevent them from lowering, tipping or sliding away. When raising the truck also refer to the instructions in the “Transport and Commissioning” section. When working on the service/parking brake, prevent the truck from rolling away.
6.2
Opening the truck door o
6.2
Opening the truck door o
– Open the truck door (1).
– Open the truck door (1).
F8
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1
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1
F8
Z
Lift up the door attachment
6.3
Lift up the door attachment
– if necessary open the truck door (1).
– if necessary open the truck door (1).
– Push the driver’s seat to the furthest stop at the front.
– Push the driver’s seat to the furthest stop at the front.
– Loosen and unscrew the hex. socket screws (2).
– Loosen and unscrew the hex. socket screws (2).
– Lift up the door attachment (3).
– Lift up the door attachment (3).
Z
The battery is accessible for servicing.
3
2
4
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2
The battery is accessible for servicing.
3
4
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6.3
F9
F9
Checking electrical fuses
6.4
– Prepare the truck for maintenance and repairs (see Section 6.1). – Open the steering controller (see Section 6.4). – Check rating of all fuses in accordance with table, replace if necessary.
Checking electrical fuses – Prepare the truck for maintenance and repairs (see Section 6.1). – Open the steering controller (see Section 6.4). – Check rating of all fuses in accordance with table, replace if necessary.
10 11 12 13 14 15 16
10 11 12 13 14 15 16
17 18 19 20 21 22 23
17 18 19 20 21 22 23
24
24
25 26
25 27
26
28
F 10
Description Vacant 3F1
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
4F13 9F2 3F2 1F12 4F10 Vacant 1F13 4F12 2F17 5F7 4F11 F17 2F1 F8 3F1 F1 1F1
To protect:
28
Rating
Measurement Discharge indicator/ hourmeter Emergency Disconnect Seat heating Steering controller Traction controller Seat socket fan
2A 5A 7.5A 3A 2A 3A
Valve, pump contactor, traction controller Horn Traction controller fan Option Diagnostics Radio Pump motor Main fuse Steering controller Power up contactor Traction controller
7.5A 2A 2A 10A 5A 7.5A 160A 355A 50A 30A 250A
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Item 10 11
27
F 10
Item 10 11
Description Vacant 3F1
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
4F13 9F2 3F2 1F12 4F10 Vacant 1F13 4F12 2F17 5F7 4F11 F17 2F1 F8 3F1 F1 1F1
To protect:
Rating
Measurement Discharge indicator/ hourmeter Emergency Disconnect Seat heating Steering controller Traction controller Seat socket fan
2A 5A 7.5A 3A 2A 3A
Valve, pump contactor, traction controller Horn Traction controller fan Option Diagnostics Radio Pump motor Main fuse Steering controller Power up contactor Traction controller
7.5A 2A 2A 10A 5A 7.5A 160A 355A 50A 30A 250A
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6.4
6.5
7
Recommissioning
6.5
The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed.
The truck may only be recommissioned after cleaning or repair work, once the following operations have been performed.
– – – –
– – – –
Test horn. Test main switch operation. Test brake. Lubricate the truck in accordance with the lubrication schedule.
Decommissioning the industrial truck
7
If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.
M
M
On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.
In addition, follow the battery manufacturer’s instructions.
7.2
During decommissioning:
On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.
Prior to decommissioning: – – – – – – –
– Spay all exposed electrical contacts with a suitable contact spray.
Thoroughly clean the truck. Check the brakes. Check the hydraulic oil level and top up if required (see section 5). Apply a thin layer of oil or grease to any non-painted mechanical components. Lubricate the truck in accordance with the lubrication schedule (see chapter F). Charge the battery (see Chapter D). Disconnect the battery, clean it and grease the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
7.2
During decommissioning:
– Spay all exposed electrical contacts with a suitable contact spray.
Every 2 months:
Every 2 months:
– Charge the battery (see Chapter D).
– Charge the battery (see Chapter D).
M
Battery powered trucks: The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.
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Battery powered trucks: The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.
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M
7.1
Thoroughly clean the truck. Check the brakes. Check the hydraulic oil level and top up if required (see section 5). Apply a thin layer of oil or grease to any non-painted mechanical components. Lubricate the truck in accordance with the lubrication schedule (see chapter F). Charge the battery (see Chapter D). Disconnect the battery, clean it and grease the terminals.
Z
Decommissioning the industrial truck
If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.
Prior to decommissioning: – – – – – – –
Test horn. Test main switch operation. Test brake. Lubricate the truck in accordance with the lubrication schedule.
If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.
If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.
7.1
Recommissioning
F 11
F 11
7.3
Restoring the truck to operation after decommissioning – – – – – – –
7.3
Thoroughly clean the truck. Lubricate the truck in accordance with the lubrication schedule (see chapter F). Clean the battery, grease the terminals and connect the battery. Charge the battery (see Chapter D). Check transmission oil for condensed water and replace if necessary. Check hydraulic oil for condensed water and replace if necessary. Start up the truck (see Chapter E).
Restoring the truck to operation after decommissioning – – – – – – –
Thoroughly clean the truck. Lubricate the truck in accordance with the lubrication schedule (see chapter F). Clean the battery, grease the terminals and connect the battery. Charge the battery (see Chapter D). Check transmission oil for condensed water and replace if necessary. Check hydraulic oil for condensed water and replace if necessary. Start up the truck (see Chapter E).
Z
Battery powered trucks: 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 operating controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
F
Perform several brake tests immediately after re-commissioning the truck.
F 12
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Battery powered trucks: 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 operating controls by applying them repeatedly.
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Z
F 12
8
Safety checks to be performed at regular intervals and following any unusual incidents
8
Safety checks to be performed at regular intervals and following any unusual incidents
Z
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.
Z
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.
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.
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.
The owner is responsible for ensuring that faults are immediately rectified.
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.
9
Final de-commissioning, disposal
9
Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
Z
Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
0708.GB
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.
0708.GB
Z
F 13
F 13
Instructions for use
Instructions for use
Jungheinrich traction battery
Jungheinrich traction battery
Table of contents
Table of contents
1
1
Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB ..........................................2-6
with positive tubular plates type EPzS and EPzB ..........................................2-6
Type plate Jungheinrich traction battery............................................7
Type plate Jungheinrich traction battery............................................7
Instruction for use
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
Aquamatic/BFS III water refilling system ......................................................8-12
Jungheinrich traction battery
2
Jungheinrich traction battery Maintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17
Type plate Jungheinrich traction battery............................................17
Type plate Jungheinrich traction battery............................................17
0506.GB
Maintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS ............................................................................................13-17
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Jungheinrich traction battery
1
1
Jungheinrich traction battery
1
with positive tubular plates type EPzS and EPzB
with positive tubular plates type EPzS and EPzB
Rating Data
Rating Data
1. 2. 3. 4.
Nominal capacity C5: Nominal voltage: Discharge current:: Nominal S.G. of electrolyte* Type EPzS: Type EPzB: 5. Rated temperature: 6. Nominal electrolyte level:
See type plate 2,0 V x No of cells C5/5h
1. 2. 3. 4.
Nominal capacity C5: Nominal voltage: Discharge current:: Nominal S.G. of electrolyte* Type EPzS: Type EPzB: 5. Rated temperature: 6. Nominal electrolyte level:
1,29 kg/l 1,29 kg/l 30° C up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
See type plate 2,0 V x No of cells C5/5h 1,29 kg/l 1,29 kg/l 30° C up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery! •Work on batteries to be carried out by skilled personnel only!
•Pay attention to the operation instruction and fix them close to the battery! •Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries! •Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN 50110-1!
•Use protective glasses and clothes when working on batteries! •Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN 50110-1!
•No smoking! •Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the battery to explode!
•No smoking! •Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately! •Clothing contaminated by acid should be washed in water.
•Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately! •Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy! •Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.
•Batteries and cells are heavy! •Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.
•Dangerous electrical voltage! •Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
•Dangerous electrical voltage! •Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery! 0506.GB
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Jungheinrich traction battery
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2
Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void.
Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate).
For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled batteries see separate instructions!
1. Commissioning filled and charged batteries. For commissioning of unfilled batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The charger cables must be connected to ensure a good contact, taking care that the polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors are:
The specified torque loading for the polscrews of the charger cables and connectors are:
steel 23 ± 1 Nm
M 10
steel 23 ± 1 Nm
The level of the electrolyte must be checked. If it is below the antisurge baffle or the top of the separator it must first be topped up to this height with purified water.
The level of the electrolyte must be checked. If it is below the antisurge baffle or the top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies to the operation traction batteries in industrial trucks.
2.1 Discharging
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit condition.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit condition.
To achieve the optimum life for the battery, operating discharges of more than 80% of the rated capacity should be avoided (deep discharge).
To achieve the optimum life for the battery, operating discharges of more than 80% of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left discharged. This also applies to partially discharged batteries.
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the discharge. Discharged batteries must be recharged immediately and must not be left discharged. This also applies to partially discharged batteries.
2.2 Charging
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts, unacceptable gassing and the escape of electrolyte from the cells.
Only direct current must be used for charging. All charging procedures in accordance with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts, unacceptable gassing and the escape of electrolyte from the cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its suitability checked by the manufacturers service department. When charging, proper provision must be made for venting of the charging gases.
In the gassing stage the current limits given in DIN EN 50272-3 must not be exceeded. If the charger was not purchased together with the battery it is best to have its suitability checked by the manufacturers service department. When charging, proper provision must be made for venting of the charging gases.
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M 10
3
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the electrolyte rises by about 10°C, so charging should only begin if the electrolyte temperature is below 45°C. The electrolyte temperature of batteries should be at least +10°C before charging otherwise a full charge will not be achieved.
With the charger switched off connect up the battery, ensuring that the polarity is correct. (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the electrolyte rises by about 10°C, so charging should only begin if the electrolyte temperature is below 45°C. The electrolyte temperature of batteries should be at least +10°C before charging otherwise a full charge will not be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past.
A charge is finished when the specific gravity of the electrolyte and the battery voltage have remained constant for two hours. Special instructions for the operation of batteries in hazardous areas. This concerns batteries which are used in accordance with EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). During charging and subsequent gassing the container lids must be removed or opened so that the explosive mixture of gases loses its flammability due to adequate ventilation. The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its capacity. They are necessary after deep discharges, repeated incomplete recharges and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Equalising charges are used to safeguard the life of the battery and to maintain its capacity. They are necessary after deep discharges, repeated incomplete recharges and charges to an IU characteristic curve. Equalising charges are carried out following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (end of charge - see point 2.2).
Watch the temperature!
Watch the temperature!
2.4 Temperature
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
An electrolyte temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it. The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C and the nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce the specified gravity of the electrolyte, lower temperatures increase it. The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
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Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
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Battery container lids and the covers of battery compartments must be opened or removed. The vent plugs should stay on the cells and remain closed.
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3.1 Daily
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“ level mark.
Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“ level mark.
3.2 Weekly
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be carried out (see point 2.3).
Visual inspection after recharging for signs of dirt and mechanical damage. If the battery is charged regularly with a IU characteristic curve an equalising charge must be carried out (see point 2.3).
3.3 Monthly
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured with the charger switched on, and recorded. After charging has ended the specific gravity and the temperature of the electrolyte in all cells should be measured and recorded.
At the end of the charge the voltages of all cells or bloc batteries should be measured with the charger switched on, and recorded. After charging has ended the specific gravity and the temperature of the electrolyte in all cells should be measured and recorded.
If significant changes from earlier measurements or differences between the cells or bloc batteries are found further testing and maintenance by the service department should be requested.
If significant changes from earlier measurements or differences between the cells or bloc batteries are found further testing and maintenance by the service department should be requested.
3.4 Annually
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of the truck and the battery must be checked by an electrical specialist.
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance with DIN EN 60254-1.
The tests on the insulation resistance of the battery must be conducted in accordance with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of 50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
The insulation resistance of the battery thus determined must not be below a value of 50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of Vehicle Traction batteries».
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call in our service department for this.
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call in our service department for this.
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3. Maintenance
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3. Maintenance
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5. Storage
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made:
If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage time should be taken into account when considering the life of the battery.
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage time should be taken into account when considering the life of the battery.
6. Malfunctions
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
If malfunctions are found on the battery or the charger our service department should be called in without delay. The measurements taken in point 3.3 will facilitate fault finding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
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We reserve the right make technical modification.
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We reserve the right make technical modification.
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7. Type plate, Jungheinrich traction battery
2/3 4 10 12 7 8
1
2
Typ Type
6 5 11 13
Baujahr Year of manufacture
Serien-Nr. Serial-Nr.
3
Lieferanten Nr. Supplier No. 5
Kapazität Capacity
Nennspannung Nominal Voltage 7
9
6 5
Batteriegewicht min/max Battery mass min/max
Zellenzahl Number of Cells
Hersteller Manufacturer
4
8
2/3 4 10 12
Jungheinrich AG, D-22047 Hamburg, Germany Pb
Designation Logo Battery designation Battery type Battery number Battery tray number Delivery date Battery manufacturer's logo
7 1
Pb
9
Item 1 2 3 4 5 6 7
7. Type plate, Jungheinrich traction battery
8
2
Designation Recycling symbol Dustbin/material Nominal battery voltage Nominal battery capacity Number of battery cells Battery weight Safety instructions and warnings
Item 1 2 3 4 5 6 7
Lieferanten Nr. Supplier No. 5
Kapazität Capacity
Nennspannung Nominal Voltage 7
9
6 5
Batteriegewicht min/max Battery mass min/max
Zellenzahl Number of Cells
Hersteller Manufacturer
4
8
Jungheinrich AG, D-22047 Hamburg, Germany Pb
1
Pb
Designation Logo Battery designation Battery type Battery number Battery tray number Delivery date Battery manufacturer's logo
14
Item 8 9 10 11 12 13 14
Designation Recycling symbol Dustbin/material Nominal battery voltage Nominal battery capacity Number of battery cells Battery weight Safety instructions and warnings
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* CE mark is only for batteries with a nominal voltage greater than 75 volt.
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* CE mark is only for batteries with a nominal voltage greater than 75 volt.
6 5 11 13
Baujahr Year of manufacture 3
9
14
Item 8 9 10 11 12 13 14
1
Typ Type Serien-Nr. Serial-Nr.
7
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Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
Aquamatic plug arrangement for the Operating Instructions
Cell series* EPzS EPzB 2/120 – 10/ 600 2/ 42 – 12/ 252 2/160 – 10/ 800 2/ 64 – 12/ 384 – 2/ 84 – 12/ 504 – 2/110 – 12/ 660 – 2/130 – 12/ 780 – 2/150 – 12/ 900 – 2/172 – 12/1032 – 2/200 – 12/1200 – 2/216 – 12/1296 2/180 – 10/900 – 2/210 – 10/1050 – 2/230 – 10/1150 – 2/250 – 10/1250 – 2/280 – 10/1400 – 2/310 – 10/1550 –
Aquamatic plug type (length) Frötek (yellow) BFS (black) 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 56,0 mm 56,0 mm 56,0 mm 56,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 72,0 mm 66,0 mm 72,0 mm 66,0 mm
Cell series* EPzS EPzB 2/120 – 10/ 600 2/ 42 – 12/ 252 2/160 – 10/ 800 2/ 64 – 12/ 384 – 2/ 84 – 12/ 504 – 2/110 – 12/ 660 – 2/130 – 12/ 780 – 2/150 – 12/ 900 – 2/172 – 12/1032 – 2/200 – 12/1200 – 2/216 – 12/1296 2/180 – 10/900 – 2/210 – 10/1050 – 2/230 – 10/1150 – 2/250 – 10/1250 – 2/280 – 10/1400 – 2/310 – 10/1550 –
Aquamatic plug BFS III with diagnostics hole
Aquamatic plug with diagnostics hole
length
stroke
length
stroke
length
These are cells with the positive plate 60Ah. The type designation of a cell is e.g. 2 EPzS 120.
stroke
These are cells with the positive plate 60Ah. The type designation of a cell is e.g. 2 EPzS 120.
length
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column EPzS. 2/120 - 10/600.
stroke
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column EPzS. 2/120 - 10/600.
Aquamatic plug with diagnostics hole
Aquamatic plug BFS III with diagnostics hole
Non-adherence to the operating instructions, repairs carried out with non-original spare parts, unauthorised interference, and the use of additives for the electrolytes (alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification). 0506.GB
Non-adherence to the operating instructions, repairs carried out with non-original spare parts, unauthorised interference, and the use of additives for the electrolytes (alleged improvement agents) will invalidate any claim for warranty.
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Aquamatic plug type (length) Frötek (yellow) BFS (black) 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 50,5 mm 51,0 mm 56,0 mm 56,0 mm 56,0 mm 56,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 61,0 mm 72,0 mm 66,0 mm 72,0 mm 66,0 mm
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Equipment for the water refilling system
Equipment for the water refilling system
1. Water tank
1. Water tank
2. Level switch
2. Level switch
3. Discharge point with ball valve
3. Discharge point with ball valve
4. Discharge point with solenoid valve
4. Discharge point with solenoid valve 5. Charger
6. Sealing coupler
6. Sealing coupler
7. Closing nipple
7. Closing nipple
8. Ion exchange cartridge with conductance meter and solenoid valve
8. Ion exchange cartridge with conductance meter and solenoid valve
9. Connection for untreated water
9. Connection for untreated water
10. Charging lead
10. Charging lead
1. Design
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases which arise during charging. In addition to the optical level indicator, the plug systems also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing coupler through the hose connections in the individual Aquamatic/BFS plugs.
The Aquamatic/BFS battery water refilling systems are used for automatically adjusting the nominal electrolyte level. Venting holes are provided for letting off the gases which arise during charging. In addition to the optical level indicator, the plug systems also have a diagnostics hole for measuring the temperature and the electrolyte density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/BFS filling systems. The water can be refilled by means of a central sealing coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for forklift trucks. The water refilling system is provided with a central water connection for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection sleeves located on the T or < pieces.
The Aquamatic/BFS battery water refilling system is used in traction batteries for forklift trucks. The water refilling system is provided with a central water connection for the water supply. Soft PVC hose is used for this connection and for the hose connections for the individual plugs. The hose ends are put onto the hose connection sleeves located on the T or < pieces.
3. Function
3. Function
The quantity of water required in the refilling process is controlled by the valve located in the plug in combination with the float and the float rods. In the Aquamatic System the existing water pressure at the valve turns off the water supply and ensures that the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times the buoyant force and consequently interrupt the water supply reliably.
The quantity of water required in the refilling process is controlled by the valve located in the plug in combination with the float and the float rods. In the Aquamatic System the existing water pressure at the valve turns off the water supply and ensures that the valve closes securely. When the maximum filling level is reached in the BFS system, the float and the float rods through a lever system close the valve with five times the buoyant force and consequently interrupt the water supply reliably.
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5. Charger
at least 3 m
Diagrammatic view
at least 3 m
Diagrammatic view
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The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week.
The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair the system's functional reliability. This wide pressure range permits three types of filling.
The water refilling unit is to be operated in such a way that the water pressure in the water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair the system's functional reliability. This wide pressure range permits three types of filling.
5.1 Falling water
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For the Aquamatic System the installation height is 2 m to 6 m and for the BFS system the installation height is 3 m to 18 m over the battery surface.
The height of the tank is chosen to suit whichever water refilling system is used. For the Aquamatic System the installation height is 2 m to 6 m and for the BFS system the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars and from 0.3 bars to 1.8 bars in the BFS system.
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary filling pressure. No difference in height is permitted between the standing level of the ServiceMobil and the standing level of the battery.
The submergible pump located in the ServiceMobil's tank generates the necessary filling pressure. No difference in height is permitted between the standing level of the ServiceMobil and the standing level of the battery.
6. Filling duration
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which the battery is used, the ambient temperatures and the type of filling and/or the filling pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
The length of time needed to fill the batteries depends on the conditions under which the battery is used, the ambient temperatures and the type of filling and/or the filling pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the water feed pipe must be separated from the battery after filling.
7. Water quality
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For safety reasons it is recommendable to insert a filter element (optional) with a max. passage opening of 100 to 300 µm into the battery's main supply pipe.
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For safety reasons it is recommendable to insert a filter element (optional) with a max. passage opening of 100 to 300 µm into the battery's main supply pipe.
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4. Filling (manual/automatic)
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4. Filling (manual/automatic)
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Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made.
Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made.
9. Operating temperature
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a temperature range of > 0° C to a maximum of 55° C.
CAUTION: Batteries with automatic water refilling systems may only be operated in rooms with temperatures > 0° C (as there is otherwise a danger that the systems may freeze).
CAUTION: Batteries with automatic water refilling systems may only be operated in rooms with temperatures > 0° C (as there is otherwise a danger that the systems may freeze).
9.1 Diagnostics hole
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a 7.5 mm-diameter (BFS plugs).
To be able to measure the acid density and temperature easily, the water refilling systems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a 7.5 mm-diameter (BFS plugs).
9.2 Float
9.2 Float
Different floats are used depending on the cell design and type.
Different floats are used depending on the cell design and type.
9.3 Cleaning
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come in contact with soap or fabrics which contain solvents.
The plug systems may only be cleaned with water. No parts of the plugs may come in contact with soap or fabrics which contain solvents.
10. Accessories
10. Accessories
10.1 Flow indicator
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe on the battery side. During the filling process, the paddlewheel is turned by the flowing water. When the filling process ends, the wheel stops and this indicates the end of the filling process. (ident no.: 50219542).
To monitor the filling process, a flow indicator can be inserted into the water feed pipe on the battery side. During the filling process, the paddlewheel is turned by the flowing water. When the filling process ends, the wheel stops and this indicates the end of the filling process. (ident no.: 50219542).
10.2 Plug lifter
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to prevent any damage to the plug systems.
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to prevent any damage to the plug systems.
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8. Battery hose connections
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8. Battery hose connections
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10.2.1 Clamping ring tool
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
The clamping ring tool is used to push on a clamping ring to increase the contact pressure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum passage cross-section of 100 to 300 µm and is designed as a bag filter.
For safety reasons a filter element (ident no.: 50307282) can be fitted into the battery's main supply pipe for supplying battery water. This filter element has a maximum passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging station by means of a sealing coupler system. On the battery side a closing nipple (ident no.: 50219538) is mounted and the customer must place a sealing coupler construction on the water supply side (obtainable under ident. no.: 50219537).
The water is supplied to the water refilling systems (Aquamatic/BFS) through a central supply pipe. This is connected to the water supply system at the battery charging station by means of a sealing coupler system. On the battery side a closing nipple (ident no.: 50219538) is mounted and the customer must place a sealing coupler construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none D
BFS system none
- rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D
D1 - maximum permissible leakage rate in the closed valve when the pressure is at 0.1 bars: 2 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at 0.1 bars: 2 ml/min
T
T
- permissible temperature range: 0° C to a maximum of 65° C
- permissible temperature range: 0° C to a maximum of 65° C
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Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and operating pressure range: 0.3 to 1.8 bars in the BFS system.
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Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and operating pressure range: 0.3 to 1.8 bars in the BFS system.
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- rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
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