Transcript
EKS 310k/310 Operating Instructions 52025067 07.08
07.04 -
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 of the truck
A
Correct use and application of the truck
B
Truck Description
B
Truck Description
1 2 2.1 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2
Application ........................................................................................... B 1 Assemblies and Operational Description ............................................ B 2 Truck ................................................................................................... B 3 Standard Version Specifications ......................................................... B 4 Performance data ................................................................................ B 4 Dimensions (as per data plate) ........................................................... B 6 Mast version ........................................................................................ B 6 EN norms ............................................................................................ B 7 Conditions of use ................................................................................ B 7 Identification points and data plates .................................................... B 8 Truck data plate .................................................................................. B 10 Capacity .............................................................................................. B 10
1 2 2.1 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2
Application ........................................................................................... B 1 Assemblies and Operational Description ............................................ B 2 Truck ................................................................................................... B 3 Standard Version Specifications ......................................................... B 4 Performance data ................................................................................ B 4 Dimensions (as per data plate) ........................................................... B 6 Mast version ........................................................................................ B 6 EN norms ............................................................................................ B 7 Conditions of use ................................................................................ B 7 Identification points and data plates .................................................... B 8 Truck data plate .................................................................................. B 10 Capacity .............................................................................................. B 10
C
Transport and Commissioning
C
Transport and Commissioning
1 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 4
Transport ............................................................................................. C 1 Lifting by crane .................................................................................... C 1 Crane points ........................................................................................ C 3 Lifting the battery by crane .................................................................. C 3 Securing the Truck for Transport. ....................................................... C 3 Basic truck transport safety ................................................................. C 4 Mast transport safety ........................................................................... C 5 Mast assembled .................................................................................. C 5 Commissioning .................................................................................... C 7 Moving the truck without a battery ...................................................... C 7 Installing and Removing / Assembling and Folding the Mast .............. C 7 Commissioning .................................................................................... C 7
1 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 4
Transport ............................................................................................. C 1 Lifting by crane .................................................................................... C 1 Crane points ........................................................................................ C 3 Lifting the battery by crane .................................................................. C 3 Securing the Truck for Transport. ....................................................... C 3 Basic truck transport safety ................................................................. C 4 Mast transport safety ........................................................................... C 5 Mast assembled .................................................................................. C 5 Commissioning .................................................................................... C 7 Moving the truck without a battery ...................................................... C 7 Installing and Removing / Assembling and Folding the Mast .............. C 7 Commissioning .................................................................................... C 7
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 Charging the battery ............................................................................ D 2 Battery removal and installation .......................................................... D 3 Check the battery condition, the acid level and acid density ............... D 5 Battery discharge indicator .................................................................. D 5
1 2 3 4 5 6
Safety Regulations for handling acid batteries .................................... D 1 Battery types ....................................................................................... D 2 Charging the battery ............................................................................ D 2 Battery removal and installation .......................................................... D 3 Check the battery condition, the acid level and acid density ............... D 5 Battery discharge indicator .................................................................. D 5
0708.GB
Table of contents
0708.GB
Table of contents
I1
I1
E
Operation
1 2 3 3.1 3.2 3.3 4 5 5.1 5.2 5.3 5.4 5.5 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9
Safety Regulations for the Operation of Forklift Trucks ...................... E 1 Control Panel Layout Variants ............................................................ E 2 Operating and Display Equipment ...................................................... E 4 Operating and display equipment on control panel ............................. E 4 Display unit controls and displays ...................................................... E 5 Truck operational status symbols ........................................................ E 9 Starting up the truck ............................................................................ E 11 Lift truck operation ............................................................................... E 12 Safety regulations for truck operation ................................................. E 12 Travelling, Steering, Braking ............................................................... E 13 Lifting – Lowering – outside and inside the rack aisles ....................... E 18 Order picking and stacking .................................................................. E 19 Park the truck securely ........................................................................ E 21 Troubleshooting .................................................................................. E 22 Emergency stop device ....................................................................... E 24 Driver’s cab / Aux. Lift emergency lowering ........................................ E 24 Exiting the driver's cab with the emergency abseil device .................. E 25 Bypassing the chain slack safety device ............................................. E 26 Bypassing the travel cutout (o) .......................................................... E 26 Lift cutout (o) ...................................................................................... E 26 Aisle end safety device (o) ................................................................. E 27 WG emergency operation ................................................................... E 27 Recovering the truck from a narrow aisle / Moving the truck without a battery .............................................................................................. E 29
1 2 3 3.1 3.2 3.3 4 5 5.1 5.2 5.3 5.4 5.5 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9
Safety Regulations for the Operation of Forklift Trucks ...................... E 1 Control Panel Layout Variants ............................................................ E 2 Operating and Display Equipment ...................................................... E 4 Operating and display equipment on control panel ............................. E 4 Display unit controls and displays ...................................................... E 5 Truck operational status symbols ........................................................ E 9 Starting up the truck ............................................................................ E 11 Lift truck operation ............................................................................... E 12 Safety regulations for truck operation ................................................. E 12 Travelling, Steering, Braking ............................................................... E 13 Lifting – Lowering – outside and inside the rack aisles ....................... E 18 Order picking and stacking .................................................................. E 19 Park the truck securely ........................................................................ E 21 Troubleshooting .................................................................................. E 22 Emergency stop device ....................................................................... E 24 Driver’s cab / Aux. Lift emergency lowering ........................................ E 24 Exiting the driver's cab with the emergency abseil device .................. E 25 Bypassing the chain slack safety device ............................................. E 26 Bypassing the travel cutout (o) .......................................................... E 26 Lift cutout (o) ...................................................................................... E 26 Aisle end safety device (o) ................................................................. E 27 WG emergency operation ................................................................... E 27 Recovering the truck from a narrow aisle / Moving the truck without a battery .............................................................................................. E 29
I2
0708.GB
Operation
0708.GB
E
I2
F
Maintenance of the forklift truck
F
Maintenance of the forklift truck
1 2 3 4 4.1 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 6 6.1 6.2 6.3 7
Operational safety and environmental protection ................................ F 1 Maintenance Safety Regulations ........................................................ F 1 Servicing and inspection ..................................................................... F 3 EKS 310 maintenance checklist .......................................................... F 4 Fuels, coolants and lubricants ............................................................. F 8 Maintenance and Repairs ................................................................... F 9 Preparing the truck for maintenance and repairs ................................ F 9 Securing the driver’s position carriage ................................................ F 10 Maintaining the lift chains .................................................................... F 10 Inspecting the lift chains ...................................................................... F 10 Cleaning the discharge filter ................................................................ F 11 Replacing the hydraulic oil filter .......................................................... F 11 Hydraulic oil ......................................................................................... F 12 Hydraulic hoses ................................................................................... F 13 Check brake fluid ................................................................................ F 13 Checking electrical fuses .................................................................... F 14 Recommissioning ................................................................................ F 15 Decommissioning the forklift truck ...................................................... F 15 Prior to decommissioning: ................................................................... F 15 During decommissioning: .................................................................... F 16 Recommissioning ................................................................................ F 16 Safety checks to be performed at regular intervals and following any unusual incidents ................................................................................ F 17 Final de-commissioning, disposal ....................................................... F 17
1 2 3 4 4.1 5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 6 6.1 6.2 6.3 7
Operational safety and environmental protection ................................ F 1 Maintenance Safety Regulations ........................................................ F 1 Servicing and inspection ..................................................................... F 3 EKS 310 maintenance checklist .......................................................... F 4 Fuels, coolants and lubricants ............................................................. F 8 Maintenance and Repairs ................................................................... F 9 Preparing the truck for maintenance and repairs ................................ F 9 Securing the driver’s position carriage ................................................ F 10 Maintaining the lift chains .................................................................... F 10 Inspecting the lift chains ...................................................................... F 10 Cleaning the discharge filter ................................................................ F 11 Replacing the hydraulic oil filter .......................................................... F 11 Hydraulic oil ......................................................................................... F 12 Hydraulic hoses ................................................................................... F 13 Check brake fluid ................................................................................ F 13 Checking electrical fuses .................................................................... F 14 Recommissioning ................................................................................ F 15 Decommissioning the forklift truck ...................................................... F 15 Prior to decommissioning: ................................................................... F 15 During decommissioning: .................................................................... F 16 Recommissioning ................................................................................ F 16 Safety checks to be performed at regular intervals and following any unusual incidents ................................................................................ F 17 Final de-commissioning, disposal ....................................................... F 17
0708.GB
8
0708.GB
8
I3
I3
I4 I4 0708.GB
0708.GB
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 of the truck
A Correct use and application of the truck
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 in places which can result in corrosion or produce 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 in places which can result in corrosion or produce dust.
Proprietor responsibilities: The “proprietor” within the meaning of this operator manual 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 only used for the purpose it is designed for and that all dangers to life and limb of the user and third parties are avoided. 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: The “proprietor” within the meaning of this operator manual 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 only used for the purpose it is designed for and that all dangers to life and limb of the user and third parties are avoided. 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.
Mounting attachments: 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.
0504.GB
0504.GB
Mounting attachments: 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 0504.GB
0504.GB
B Truck Description
B Truck Description
1
1
Application
Application
The EKS 310 is an electric powered stockpicker. It is designed to be used on level surfaces in accordance with DIN 15185 to transport and pick goods. Open or cross board pallets can be lifted outside the contour of the load wheels or trolley.
The EKS 310 is an electric powered stockpicker. It is designed to be used on level surfaces in accordance with DIN 15185 to transport and pick goods. Open or cross board pallets can be lifted outside the contour of the load wheels or trolley.
Loads can be stacked and unstacked and transported over long distances.
Loads can be stacked and unstacked and transported over long distances.
The driver's cab is raised together with the load lifting device to provide excellent visibility and easy access to the rack levels.
The driver's cab is raised together with the load lifting device to provide excellent visibility and easy access to the rack levels.
The racks must be suitable for the EKS 310. The safety distances stipulated by the manufacturer (e. g. EN 1726-2 item 7.3.2) must be observed. The ground surface must comply with DIN 15185. Guide rails must be installed in the narrow aisles for the rail guidance system. Vulkollan guide rollers attached to the truck chassis guide the truck between the guide rails. A guidance wire must be routed in the ground for the wire guidance system. The signals from the wire are received on the chassis and processed in the on-board computer.
The racks must be suitable for the EKS 310. The safety distances stipulated by the manufacturer (e. g. EN 1726-2 item 7.3.2) must be observed. The ground surface must comply with DIN 15185. Guide rails must be installed in the narrow aisles for the rail guidance system. Vulkollan guide rollers attached to the truck chassis guide the truck between the guide rails. A guidance wire must be routed in the ground for the wire guidance system. The signals from the wire are received on the chassis and processed in the on-board computer.
The capacity is shown on the data plate.
The capacity is shown on the data plate.
Type EKS 310k EKS 310
Capacity 1000 kg 1000 kg
Load centre of gravity 400 mm 600 mm
Type EKS 310k EKS 310
Capacity 1000 kg 1000 kg
Load centre of gravity 400 mm 600 mm
Travel direction definition
Travel direction definition
The following determinations have been made for travel direction specification.
The following determinations have been made for travel direction specification.
Left
Left
Load direction
Drive direction
Load direction
Drive direction
0708.GB
Right
0708.GB
Right
B1
B1
Assemblies and Operational Description
2
5 Pos. 1 2 3 4 5
1
1
2
2
3
3
4
5
Bezeichnung t t t t t
Pos. 1 2 3 4 5
Mast Aux. lift Control panel Battery Chassis o = Optional Equipment
B2
4
Bezeichnung t t t t t
Mast Aux. lift Control panel Battery Chassis
t = Series Equipment
0708.GB
t = Series Equipment
Assemblies and Operational Description
o = Optional Equipment
0708.GB
2
B2
Truck
2.1
Truck Safety devices: An enclosed truck contour with rounded edges ensures safe handling of the truck. The overhead guard protects the driver from falling objects. The Emergency Disconnect switch immediately cuts out all truck movements in hazardous situations. Safety gates on either side of the cab interrupt all truck movements as soon as they are opened. Travelling and lifting/lowering can only be activated when the foot switch is pressed.
Drive: 4.4 kW (S2 60 min) vertically mounted, heavy duty threephase motor (asynchronous). The motor is directly attached to the single-wheel driving gear, ensuring rapid and trouble-free maintenance.
Drive: 4.4 kW (S2 60 min) vertically mounted, heavy duty threephase motor (asynchronous). The motor is directly attached to the single-wheel driving gear, ensuring rapid and trouble-free maintenance.
Brake system:
Brake system:
– The truck can be braked gently and without inducing wear by pushing back the travel selection switch or steering in the opposite direction. This feeds energy into the battery (operating brake). – The electromagnetic spring pressure brake acting on the drive motor serves as a parking and handbrake.
– The truck can be braked gently and without inducing wear by pushing back the travel selection switch or steering in the opposite direction. This feeds energy into the battery (operating brake). – The electromagnetic spring pressure brake acting on the drive motor serves as a parking and handbrake.
Steering:
Steering:
Especially smooth steering with threephase drive system. The practical steering wheel is integrated within the control panel. With the mechanical rail guidance system the drive wheel is set to the straight-ahead position at the press of a button.The position of the steered drive wheel is shown in the display unit. The steering angle is +/- 90°, offering maximum manoeuvrability in narrow main aisles.
Especially smooth steering with threephase drive system. The practical steering wheel is integrated within the control panel. With the mechanical rail guidance system the drive wheel is set to the straight-ahead position at the press of a button.The position of the steered drive wheel is shown in the display unit. The steering angle is +/- 90°, offering maximum manoeuvrability in narrow main aisles.
In wire guidance systems, steering is automatically managed by the truck controller, manual steering is not available.
In wire guidance systems, steering is automatically managed by the truck controller, manual steering is not available.
Controls and display units: The functions are activated via ergonomic thumb movements to ensure fatigue-free operation without straining the wrists; sensitive application of travel and hydraulic movements to spare and position the goods exactly. The display unit is used to display all the important driver information such as steering wheel position, overall lift, truck status reports (e. g. faults), service hours, battery capacity, time and wire guidance status etc..
Controls and display units: The functions are activated via ergonomic thumb movements to ensure fatigue-free operation without straining the wrists; sensitive application of travel and hydraulic movements to spare and position the goods exactly. The display unit is used to display all the important driver information such as steering wheel position, overall lift, truck status reports (e. g. faults), service hours, battery capacity, time and wire guidance status etc..
Hydraulic system:
Hydraulic system:
All hydraulic movements are controlled by a maintenance-free 9.5 kW threephase motor with a flanged low emission gear pump. Oil is distributed via magnetic switch valves. The varying oil requirements are controlled by the speed of the motor. When the truck performs a lowering operation, the hydraulic pump drives the motor which then acts as a generator (regenerative lowering). The energy produced is then fed back to the battery.
All hydraulic movements are controlled by a maintenance-free 9.5 kW threephase motor with a flanged low emission gear pump. Oil is distributed via magnetic switch valves. The varying oil requirements are controlled by the speed of the motor. When the truck performs a lowering operation, the hydraulic pump drives the motor which then acts as a generator (regenerative lowering). The energy produced is then fed back to the battery.
0708.GB
Safety devices: An enclosed truck contour with rounded edges ensures safe handling of the truck. The overhead guard protects the driver from falling objects. The Emergency Disconnect switch immediately cuts out all truck movements in hazardous situations. Safety gates on either side of the cab interrupt all truck movements as soon as they are opened. Travelling and lifting/lowering can only be activated when the foot switch is pressed.
0708.GB
2.1
B3
B3
Electrical System:
Electrical System:
Service laptop connection interface:
Service laptop connection interface:
– Configures all key truck data (lift limit damping, lift cutout, retardation and acceleration patterns, cut-outs, etc.) rapidly and reliably. – Reads off the error log to analyse fault causes. – Simulates and analyses program operations. – Simple function extention by releasing code numbers.
– Configures all key truck data (lift limit damping, lift cutout, retardation and acceleration patterns, cut-outs, etc.) rapidly and reliably. – Reads off the error log to analyse fault causes. – Simulates and analyses program operations. – Simple function extention by releasing code numbers.
The controller is fitted with a CAN Bus and a constantly measuring sensor system.
The controller is fitted with a CAN Bus and a constantly measuring sensor system.
The controller provide smooth starting and braking of the load in all limit positions through lift limit and intermediate dampers.
The controller provide smooth starting and braking of the load in all limit positions through lift limit and intermediate dampers.
Highly efficient threephase technology with energy retention for the traction and lift motors provides high travel and lift speeds and better use of energy.
Highly efficient threephase technology with energy retention for the traction and lift motors provides high travel and lift speeds and better use of energy.
The 48 volt MOSFET threephase controller provides a smooth start to each movement.
The 48 volt MOSFET threephase controller provides a smooth start to each movement.
For drive battery options see chapter D.
For drive battery options see chapter D.
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 Q Capacity (where C = 600 mm) c Load centre of gravity distance Travel speed without load (RG) Travel speed with load (RG) Travel speed without load (IG) Travel speed with load (IG) Lift speed without load Lift speed with load Lowering speed with load Lowering speed without load
kg mm km/h km/h km/h km/h m/s m/s m/s m/s
B4
EKS 310k EKS 310 1000 1000 400 600 9 10,5 8,8 10,0 7,0 9,0 6,8 8,8 0,22 0,37 0,18 0,32 0,32 0,37 0,3 0,34
kg mm km/h km/h km/h km/h m/s m/s m/s m/s
0708.GB
EKS 310k EKS 310 1000 1000 400 600 9 10,5 8,8 10,0 7,0 9,0 6,8 8,8 0,22 0,37 0,18 0,32 0,32 0,37 0,3 0,34
0708.GB
Description Q Capacity (where C = 600 mm) c Load centre of gravity distance Travel speed without load (RG) Travel speed with load (RG) Travel speed without load (IG) Travel speed with load (IG) Lift speed without load Lift speed with load Lowering speed with load Lowering speed without load
B4
B5 B5
0708.GB
0708.GB
Dimensions (as per data plate)
3.2
Description
EKS 310k
EKS 310
h1
Mast height retracted
3005
3830
mm
h1
Mast height retracted
3005
3830
mm
h3 h4
Lift Mast height extended
4250 6550
5500 7820
mm mm
h3 h4
Lift Mast height extended
4250 6550
5500 7820
mm mm
h7 h9
Seat height / standing height Aux. lift
290 840
290 840
mm mm
h7 h9
Seat height / standing height Aux. lift
290 840
290 840
mm mm
h10 Overall lift
5090
6340
mm
h10 Overall lift
5090
6340
mm
h15 Stockpicking height Ast Working aisle width for pallets 1000 x 1200 traverse
6140 1400
7390 1400
mm mm
h15 Stockpicking height Ast Working aisle width for pallets 1000 x 1200 traverse
6140 1400
7390 1400
mm mm
b2
Overall width
1015
1100
mm
b2
Overall width
1015
1100
mm
b5
Width across forks (PAL width 1200)
830
830
mm
b5
Width across forks (PAL width 1200)
830
830
mm
b6 l1
Width across guide rollers Overall length w.o. load (PAL width 1200)
1200 2667
1200 2870
mm mm
b6 l1
Width across guide rollers Overall length w.o. load (PAL width 1200)
1200 2667
1200 2870
mm mm
1867
1970
mm
l2
1867
1970
mm
800 1530 67
800 1723 67
mm mm mm
800 1530 67
800 1723 67
mm mm mm
2800
3500
kg
2800
3500
kg
l2
Length incl. fork back (PAL width 1200) l Fork length Wa Turning radius m2 Ground clearance centre wheelbase Net weight incl. battery, w.o. load
Description
B6
EKS 310k
Length incl. fork back (PAL width 1200) l Fork length Wa Turning radius m2 Ground clearance centre wheelbase Net weight incl. battery, w.o. load
Mast version
3.3
Description h1 Retracted height (ZT)
EKS 310k 2380 - 3005
EKS 310 2380 - 5530
mm
h3 Lift h4 Extended height h6 Height above overhead guard h9 Aux. lift h10 Overall lift height h15 Stockpicking height
3000 - 4250 5300 - 6550 2300
3000 - 8500 5300 - 10800 2300
mm mm mm
840 3840 - 5090 4890 - 6140
840 3840 - 9340 4890 - 10390
mm mm mm
0708.GB
3.3
Dimensions (as per data plate) EKS 310
Mast version Description h1 Retracted height (ZT)
EKS 310k 2380 - 3005
EKS 310 2380 - 5530
mm
h3 Lift h4 Extended height h6 Height above overhead guard h9 Aux. lift h10 Overall lift height h15 Stockpicking height
3000 - 4250 5300 - 6550 2300
3000 - 8500 5300 - 10800 2300
mm mm mm
840 3840 - 5090 4890 - 6140
840 3840 - 9340 4890 - 10390
mm mm mm
0708.GB
3.2
B6
3.4
EN norms Noise emission:
3.4 65 dB(A)
EN norms Noise emission:
in accordance with EN 12053 as harmonised with ISO 4871.
Z
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:
65 dB(A)
1,11 m/s2 in accordance with EN 13059
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:
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 during travel over bumps at constant speed. Electromagnetic compatibility (EMC)
1,11 m/s2 in accordance with EN 13059
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 during travel 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 electrical or electronic components or their assembly may be made without the written agreement of the manufacturer.
Z
No changes to electrical or electronic components or their assembly may be made without the written agreement of the manufacturer.
3.5
Conditions of use
3.5
Conditions of use
Ambient temperature
Ambient temperature - operating at 5°C to 40 °C
Z
Special equipment and a special approval are required if fork-lifttrucks are operated under continued extreme temperature or humidity fluctuations.
Special equipment and a special approval are required if fork-lifttrucks are operated under continued extreme temperature or humidity fluctuations. The truck is not authorised for use in cold stores.
The truck may only be used in closed areas. The following applies:
The truck may only be used in closed areas. The following applies:
– Average ambient temperature over 24 hours: max. 25 °C – max. air humidity (inside) 70%, non-condensing.
– Average ambient temperature over 24 hours: max. 25 °C – max. air humidity (inside) 70%, non-condensing.
0708.GB
The truck is not authorised for use in cold stores.
0708.GB
Z
- operating at 5°C to 40 °C
B7
B7
4
Identification points and data plates
4
Identification points and data plates
F
Warning and information labels, such as capacity diagrams, attachment points and identification plates, must be readable at all times or be replaced, if necessary.
F
Warning and information labels, such as capacity diagrams, attachment points and identification plates, must be readable at all times or be replaced, if necessary.
6
6
7
18
8
7
18 h3 (mm)
Q (kg)
h3 (mm)
8
D (mm)
Q (kg)
D (mm)
10a 9
10a 9
10b
10b
11
11
mV
mV
1,5 V
1,5 V
12
12
17
17 9
9
16
16
15
15
14
14 13a 13a
13a
13b
Item 6 7 8 9 10a 10b 11
B8
13b
Description Strapping points for lifting by crane Truck data plate Decal: Capacity Decal: “Abseil device” "Do not lean out" notice Decal: “No passengers” Test sticker (o)
0708.GB
Description Strapping points for lifting by crane Truck data plate Decal: Capacity Decal: “Abseil device” "Do not lean out" notice Decal: “No passengers” Test sticker (o)
0708.GB
Item 6 7 8 9 10a 10b 11
13a
B8
6
6
7
18
8
7
18 h3 (mm)
Q (kg)
h3 (mm)
8
D (mm)
Q (kg)
D (mm)
10a 9
10a 9
10b
10b
11
11
mV
mV
1,5 V
1,5 V
12
12
17
17 9
9
16
16
15
15
14
14 13a 13a
13a
13b
Item 12 13a 13b 14 15 16 17 18
13b
Description Decal: Do not step onto or beneath the load, risk of trapping Jack contact point Serial number (engraved in chassis underneath the battery cover) Decal: Add hydraulic oil Decal: Emergency drain Decal: Emergency drain key Decal: “Caution: Low voltage electronics system" “Read Operating Instructions” label
0708.GB
Description Decal: Do not step onto or beneath the load, risk of trapping Jack contact point Serial number (engraved in chassis underneath the battery cover) Decal: Add hydraulic oil Decal: Emergency drain Decal: Emergency drain key Decal: “Caution: Low voltage electronics system" “Read Operating Instructions” label
0708.GB
Item 12 13a 13b 14 15 16 17 18
13a
B9
B9
4.1
Truck data plate
4.1
19
30
19
30
20
29
20
29
21
28
21
28
22
27
22
27
23
26
23
26
Item Description
25
25
24
24
Item Description
Item Description
Type Serial no.
25 26
Manufacturer Min./Max. battery weight (kg)
19 20
Type Serial no.
25 26
Manufacturer Min./Max. battery weight (kg)
21 22 23 24
Rated capacity (kg) Battery voltage (V) Net weight w.o. battery (kg) Manufacturer’s logo
27 28 29 30
Drive output (kw) Load centre of gravity (mm) Year of manufacture Option
21 22 23 24
Rated capacity (kg) Battery voltage (V) Net weight w.o. battery (kg) Manufacturer’s logo
27 28 29 30
Drive output (kw) Load centre of gravity (mm) Year of manufacture Option
For queries regarding the truck or spare part orders, please quote the serial number (20).
Capacity
4.2
The plate (8) gives the capacity (Q in kg) of the truck as a function of the load centre of gravity distance (D in mm) and lift height (H in mm) in tabular form.
Capacity The plate (8) gives the capacity (Q in kg) of the truck as a function of the load centre of gravity distance (D in mm) and lift height (H in mm) in tabular form.
8
8 h3 (mm)
Q (kg)
h3 (mm)
Q (kg)
0708.GB
D (mm)
0708.GB
D (mm)
B 10
Item Description
19 20
For queries regarding the truck or spare part orders, please quote the serial number (20). 4.2
Truck data plate
B 10
C Transport and Commissioning
C Transport and Commissioning
1
1
Transport
Transport
The truck can be transported in three different ways, depending on the height of the mast and the local conditions.
The truck can be transported in three different ways, depending on the height of the mast and the local conditions.
– Vertically, with mast and load lifting device assembled (for low heights) – Vertically, with mast and load lifting device disassembled (for large heights) – Standing, with collapsed mast.
– Vertically, with mast and load lifting device assembled (for low heights) – Vertically, with mast and load lifting device disassembled (for large heights) – Standing, with collapsed mast.
M
Only personnel trained by the manufacturer may assemble the truck on site, commission it and instruct the driver.
M
Only personnel trained by the manufacturer may assemble the truck on site, commission it and instruct the driver.
2
Lifting by crane
2
Lifting by crane
M
Only use lifting gear with sufficient capacity (for truck weight see truck data plate. See Chapter B).
M
Only use lifting gear with sufficient capacity (for truck weight see truck data plate. See Chapter B).
M
The truck must only be lifted by crane with the battery removed.
M
The truck must only be lifted by crane with the battery removed.
Park the truck securely (See Chapter E).
Park the truck securely (See Chapter E).
Crane loading with mast assembled
Crane loading with mast assembled
Attach the crane slings to the strap points (1,2) so that it cannot slip under any circumstances!
Attach the crane slings to the strap points (1,2) so that it cannot slip under any circumstances!
1
1
0504.GB
2
0504.GB
2
C1
C1
M
M
Crane loading with collapsed mast
Crane loading with collapsed mast
– When the mast is collapsed the crane lifting gear must be attached to the top and bottom mast cross members. – If the truck is attached to the crane with the mast collapsed, the transport parts must be attached to it.
– When the mast is collapsed the crane lifting gear must be attached to the top and bottom mast cross members. – If the truck is attached to the crane with the mast collapsed, the transport parts must be attached to it.
Attach the crane slings to the strap points (1) so that it cannot slip under any circumstances.
M
1 1
Crane loading with mast disassembled
Crane loading with mast disassembled
– When the mast is disassembled, attach the crane slings to either side of the frame (2) and the top mast bearing (3).
– When the mast is disassembled, attach the crane slings to either side of the frame (2) and the top mast bearing (3).
M
Attach the crane slings to the strap points (2, 3) so that it cannot slip under any circumstances.
3
1 1
Attach the crane slings to the strap points (2, 3) so that it cannot slip under any circumstances.
3
0504.GB
2
0504.GB
2
C2
Attach the crane slings to the strap points (1) so that it cannot slip under any circumstances.
C2
2.1
2.2
Crane points
2.1
Crane points
The crane points (1) are the eyes in the mast.
The crane points (1) are the eyes in the mast.
Crane points (2) are located on either side of the frame and crane points (3) are located on the top mast bearing respectively. Suitable ring screws must be screwed in at this point.
Crane points (2) are located on either side of the frame and crane points (3) are located on the top mast bearing respectively. Suitable ring screws must be screwed in at this point.
When lifting by crane, use the following crane points:
When lifting by crane, use the following crane points:
– Crane points for complete truck with mast assembled: points (1) and (2) (for weight see data plate) – Crane points for the basic truck: points (2) and (3) (weight 1200 kg) – Crane points incl. cab and load lifting device: points (1) (weight 3000 kg)
– Crane points for complete truck with mast assembled: points (1) and (2) (for weight see data plate) – Crane points for the basic truck: points (2) and (3) (weight 1200 kg) – Crane points incl. cab and load lifting device: points (1) (weight 3000 kg)
Lifting the battery by crane
2.2
Lifting the battery by crane
When lifting the battery with a crane attach suitable lifting gear to the four eyes of the battery container (for weight see battery data plate).
When lifting the battery with a crane attach suitable lifting gear to the four eyes of the battery container (for weight see battery data plate).
For battery removal see Chapter D, Section 4.
For battery removal see Chapter D, Section 4.
2.3
Securing the Truck for Transport.
2.3
Securing the Truck for Transport.
F
When transported on a lorry or a trailer the truck must be securely fastened down. The lorry or trailer must have fastening rings.
F
When transported on a lorry or a trailer the truck must be securely fastened down. The lorry or trailer must have fastening rings.
M
Loading shall be carried out by staff especially trained for that purpose in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case correct measurements shall be determined and appropriate safety measures adopted.
0504.GB
Loading shall be carried out by staff especially trained for that purpose in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case correct measurements shall be determined and appropriate safety measures adopted.
0504.GB
M
C3
C3
2.4
Basic truck transport safety
2.4
Basic truck transport safety
M
The mast must only be disassembled by the manufacturer’s authorised service department.
M
The mast must only be disassembled by the manufacturer’s authorised service department.
To ensure secure transport of a disassembled EKS 310 use the prescribed attachment points for fastening/quick release belts.
Z M M
To ensure secure transport of a disassembled EKS 310 use the prescribed attachment points for fastening/quick release belts.
Z M M
Only use belts with a rated capacity of >5 tonnes. During transport always discharge the drive wheel and secure the load wheels (5). If the truck battery is supplied in the chassis, disconnect the battery. Fastening belts should be attached to at least 4 different lorry eyes (6).
Only use belts with a rated capacity of >5 tonnes. During transport always discharge the drive wheel and secure the load wheels (5). If the truck battery is supplied in the chassis, disconnect the battery. Fastening belts should be attached to at least 4 different lorry eyes (6).
4
5
6
5
6
5
C4
6
5
6
Belts placed over “sharp” edges must be protected by a suitable support material, e. g. foam.
Belts placed over “sharp” edges must be protected by a suitable support material, e. g. foam.
The top holes of the counterweight attachment (10) can be used as attachment points for the rear end of the truck chassis.
The top holes of the counterweight attachment (10) can be used as attachment points for the rear end of the truck chassis.
The tensioning belts are tightened over the battery compartment. To do this, remove the side parts and pack them separately.
The tensioning belts are tightened over the battery compartment. To do this, remove the side parts and pack them separately.
The tensioning belt above the upper chassis section is routed behind the two mast attachment bars (4).
Note the cable routing and cover sharp edges with a suitable material. The tensioning belt above the upper chassis section is routed behind the two mast attachment bars (4).
0504.GB
M
Note the cable routing and cover sharp edges with a suitable material.
0504.GB
M
4
C4
2.5
Mast transport safety
2.5
Mast transport safety
M
Secure the driver’s position carriage (13) to prevent it from slipping.
M
Secure the driver’s position carriage (13) to prevent it from slipping.
M 2.6
If the mast is stored on a pallet(s), fasten them securely to the mast (11).
If the mast is stored on a pallet(s), fasten them securely to the mast (11).
Use the lower attachment bracket (10) as the "mast bottom" strap point for securing to the lorry eyes (12).
Use the lower attachment bracket (10) as the "mast bottom" strap point for securing to the lorry eyes (12).
Route the belt over the lift cylinder/chains to act as the "mast top” strap point.
Route the belt over the lift cylinder/chains to act as the "mast top” strap point.
Protect the belt placed over the lift chains with a suitable material (8). Any supplied parts (forks (9), guide rollers etc.) can be attached to a pallet, which can then be fastened to the mast. Mast assembled
M
Protect the belt placed over the lift chains with a suitable material (8).
2.6
Mast assembled
Safely transporting the truck with the mast assembled
Any supplied parts (forks (9), guide rollers etc.) can be attached to a pallet, which can then be fastened to the mast.
Safely transporting the truck with the mast assembled
M
If the truck battery is supplied in the chassis, disconnect the
M
If the truck battery is supplied in the chassis, disconnect the
Z
Only use belts with a rated capacity of >5 to.
Z
Only use belts with a rated capacity of >5 to.
0504.GB
At least 4 belts, 2 on the left and 2 on the right (14,15) must be attached to the mast.
0504.GB
At least 4 belts, 2 on the left and 2 on the right (14,15) must be attached to the mast.
C5
C5
Safely transporting the truck with the mast collapsed!
Z
Safely transporting the truck with the mast collapsed!
Z
Only use belts with a rated capacity of >5 tonnes. The fastening belts should be attached to at least 4 different lorry / truck eyes (16).
F
The fastening belts should be attached to at least 4 different lorry / truck eyes (16).
Warning: Risking of tipping through high centre of gravity The tensioning belts are tightened over the battery compartment. To do this, remove the side parts and pack them separately.
Only use belts with a rated capacity of >5 tonnes.
16
17
F
16
Warning: Risking of tipping through high centre of gravity The tensioning belts are tightened over the battery compartment. To do this, remove the side parts and pack them separately.
18
16
17
16
18
Z
Use wooden beams (17) to ensure a positive fit from the load wheels to the front end of the transporter.
Z
Place the whole surface of a wooden beam (18) underneath the counterweight, at least the chassis width to relieve the drive wheel.
Z
Place the whole surface of a wooden beam (18) underneath the counterweight, at least the chassis width to relieve the drive wheel.
C6
0504.GB
Use wooden beams (17) to ensure a positive fit from the load wheels to the front end of the transporter.
0504.GB
Z
C6
3
Commissioning
3
Commissioning
3.1
Moving the truck without a battery
3.1
Moving the truck without a battery
M M
This operation must only be performed by suitably trained maintenance personnel.
M M
This operation must only be performed by suitably trained maintenance personnel.
3.2
Installing and Removing / Assembling and Folding the Mast
3.2
Installing and Removing / Assembling and Folding the Mast
M
This operation must only be performed by the manufacturer or a customer service team authorised by the manufacturer.
M
This operation must only be performed by the manufacturer or a customer service team authorised by the manufacturer.
4
Commissioning
4
Commissioning
M
Operate the truck only with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6m in length.
M
Operate the truck only with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6m in length.
M
This operation is forbidden on slopes and inclines (no brakes). See also Chapter E, Section 6.9
This operation is forbidden on slopes and inclines (no brakes). See also Chapter E, Section 6.9
To prepare the truck after delivery or after transport, proceed as follows:
To prepare the truck after delivery or after transport, proceed as follows:
– If necessary, install and charge the battery (see Chapter D, Sections 4 and 3). – Commission the truck as per instructions (See Chapter E, Section 4).
– If necessary, install and charge the battery (see Chapter D, Sections 4 and 3). – Commission the truck as per instructions (See Chapter E, Section 4).
M
Before commissioning, check the truck to ensure the tilt safety device (19) is present. Check that all safety devices are present and operational.
0504.GB
19
0504.GB
19
Before commissioning, check the truck to ensure the tilt safety device (19) is present. Check that all safety devices are present and operational.
C7
C7
C8 C8 0504.GB
0504.GB
D Battery Maintenance, Replacement 1
Charging
&
Safety Regulations for handling acid batteries
1
&
Safety Regulations for handling acid batteries Before any work is carried out on the batteries the truck must be safely parked (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. Observe the operator manual and the manufacturer’s regulations concerning batteries and charging stations when carrying out this work.
Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. Observe the operator manual and the manufacturer’s regulations concerning batteries and charging stations when carrying out this work.
Fire protection: Do not smoke and avoid naked flames when working with batteries Wherever a truck is parked for charging there must be no inflammable material or consumables capable of creatings sparks within 2 metres around the truck. The area must be well ventilated. Fire protection equipment must be provided.
Fire protection: Do not smoke and avoid naked flames when working with batteries Wherever a truck is parked for charging there must be no inflammable material or consumables capable of creatings 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.
Before closing the battery cover make sure that the battery lead cannot be damaged.
M
Only batteries with a sealed battery container may be used.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
M
Only batteries with a sealed battery container may be used.
F
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 all 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 - if the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.
F
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 all 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 - if the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.
The weight and dimensions of the battery have a considerable influence on the operational safety of the truck. Battery equipment changes may only be made with the agreement of the manufacturer.
0504.GB
The weight and dimensions of the battery have a considerable influence on the operational safety of the truck. Battery equipment changes may only be made with the agreement of the manufacturer.
0504.GB
F
Charging
Before any work is carried out on the batteries the truck must be safely parked (see Chapter E).
M
F
D Battery Maintenance, Replacement
D1
D1
2
Battery types
2
The EKS 310 can be fitted with a range of battery types. All the batteries correspond to DIN 43531-A. The following table indicates the capacities to show which combinations can be used as standard: Battery type 48 V 3 E PzS 420 48 V 4 E PzS 560
The EKS 310 can be fitted with a range of battery types. All the batteries correspond to DIN 43531-A. The following table indicates the capacities to show which combinations can be used as standard:
Truck type EKS 310k EKS 310
Battery type 48 V 3 E PzS 420 48 V 4 E PzS 560
The battery weights can be taken from the battery data plate.
F
Battery types
Truck type EKS 310k EKS 310
The battery weights can be taken from the battery data plate.
F
The weight and dimensions of the battery have a considerable influence on the operational safety of the truck. Battery equipment changes may only be made with the agreement of the manufacturer.
The weight and dimensions of the battery have a considerable influence on the operational safety of the truck. Battery equipment changes may only be made with the agreement of the manufacturer.
3
Charging the battery
3
Charging the battery
F
Park the truck securely (See Chapter E).
F
Park the truck securely (See Chapter E).
F
Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.
F
– Turn the key switch to "0" (Zero) and press the EMERGENCY DISCONNECT switch. – Fully open the battery panels. Only connect and disconnect the battery connector and the socket when the mains and charger are switched off. – Disconnect the battery. – If necessary, remove the insulating mat from the battery.
F
– Disconnect the battery. – If necessary, remove the insulating mat from the battery.
F
When charging, the top surfaces of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. – Connect the charger lead of the battery charger station with the battery connector. – Switch on the charger. – Charge the battery in accordance with the battery and charger station manufacturers’ instructions.
D2
When charging, the top surfaces of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. – Connect the charger lead of the battery charger station with the battery connector. – Switch on the charger. – Charge the battery in accordance with the battery and charger station manufacturers’ instructions. It is essential to follow the safety regulations of the battery and charger station manufacturers.
0504.GB
F
It is essential to follow the safety regulations of the battery and charger station manufacturers.
0504.GB
F
– Turn the key switch to "0" (Zero) and press the EMERGENCY DISCONNECT switch. – Fully open the battery panels.
D2
4
F F F F
Battery removal and installation
4
F
Only batteries with insulated cells and terminal connectors may be used. When replacing the battery always use the same battery type. Extra weights must not be removed and must remain in the same position.
F F F
The truck must be horizontral to prevent the battery from falling out when the battery retainer is removed. Only connect and disconnect the battery connector and the socket when the mains and charger are switched off. When replacing/installing the battery make sure the battery is securely located in the battery compartment of the truck.
Only batteries with insulated cells and terminal connectors may be used. When replacing the battery always use the same battery type. Extra weights must not be removed and must remain in the same position. The truck must be horizontral to prevent the battery from falling out when the battery retainer is removed. Only connect and disconnect the battery connector and the socket when the mains and charger are switched off. When replacing/installing the battery make sure the battery is securely located in the battery compartment of the truck. – Turn the key switch (1) to "0" (Zero) and press the EMERGENCY DISCONNECT switch (2). – Open the battery covers (4). – Disconnect the battery (4). – Remove the battery covers (3).
0504.GB
0504.GB
– Turn the key switch (1) to "0" (Zero) and press the EMERGENCY DISCONNECT switch (2). – Open the battery covers (4). – Disconnect the battery (4). – Remove the battery covers (3).
Battery removal and installation
D3
D3
5
5
6
6
7
F
7
– Undo and remove the battery retainers (5;7). – Pull the battery (6) onto the side of the prepared battery transporter.
– Undo and remove the battery retainers (5;7). – Pull the battery (6) onto the side of the prepared battery transporter.
Assembly is the reverse order.
Assembly is the reverse order.
F
After installing again, check all cables and connectors for signs of visible damage and before using the truck again check that:
D4
0504.GB
– the battery retainers are inserted and secured, – the battery cover is properly closed.
0504.GB
– the battery retainers are inserted and secured, – the battery cover is properly closed.
After installing again, check all cables and connectors for signs of visible damage and before using the truck again check that:
D4
5
Check the battery condition, the acid level and acid density
5
– The battery manufacturer’s maintenance instructions apply. – Check the battery housing for cracks and any spilled acid. – Remove any oxydation residue from the battery terminals and apply an acid-free grease to the battery terminals. – Unscrew the stops and check the acid level. The acid level should be at least 10-15 mm above the top of the plates. – Check the acid density in accordance with the battery manufacturer’s instructions and then refit the stops. – If necessary, charge up the battery.
– The battery manufacturer’s maintenance instructions apply. – Check the battery housing for cracks and any spilled acid. – Remove any oxydation residue from the battery terminals and apply an acid-free grease to the battery terminals. – Unscrew the stops and check the acid level. The acid level should be at least 10-15 mm above the top of the plates. – Check the acid density in accordance with the battery manufacturer’s instructions and then refit the stops. – If necessary, charge up the battery.
Battery discharge indicator When you turn the key in the keyswitch clockwise and pull the EMERGENCY DISCONNECT switch, the battery discharge indicator will show the residual capacity available. The display starts to flash when the battery has reached a residual capacity of 30%. Lift cut-out occurs at a 20% capacity display.
-
Battery discharge indicator When you turn the key in the keyswitch clockwise and pull the EMERGENCY DISCONNECT switch, the battery discharge indicator will show the residual capacity available. The display starts to flash when the battery has reached a residual capacity of 30%. Lift cut-out occurs at a 20% capacity display.
+ 50%
0504.GB
For maintenance-free and special batteries the display and cutout points can be adjusted by authorised personnel by assigning parameters.
6
For maintenance-free and special batteries the display and cutout points can be adjusted by authorised personnel by assigning parameters.
-
+ 50%
0504.GB
6
Check the battery condition, the acid level and acid density
D5
D5
D6 D6 0504.GB
0504.GB
E Operation
E Operation
1
1
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: Report any damage or faults concerning the forklift truck or its attachments to a supervisor immediately. Trucks not safe for operation (e.g. wheel or brake problems) shall not be used until they have been rectified.
Damage and Faults: Report any damage or faults concerning the forklift truck or its attachments to a supervisor immediately. Trucks not safe for operation (e.g. wheel or brake problems) shall 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 authoristion to do so. On no account may the driver 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 authoristion to do so. On no account may the driver disable or adjust safety mechanisms or switches.
Danger area: A danger area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load lifting device (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
Danger area: A danger area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load lifting device (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 danger area. Where there is danger to personnel, a warning must be sounded in good time. If unauthorised personnel are still within the danger area the truck shall be brought to rest immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed.
0206.GB
0206.GB
Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed.
Unauthorised persons must be kept away from the danger area. Where there is danger to personnel, a warning must be sounded in good time. If unauthorised personnel are still within the danger area the truck shall be brought to rest immediately.
E1
E1
Control Panel Layout Variants
2
E2
Control Panel Layout Variants Variant I
The control panels are arranged as standard at the front, i.e. before the aux. lift. Accordingly, the display unit is below the overhead guard also in the load direction
The control panels are arranged as standard at the front, i.e. before the aux. lift. Accordingly, the display unit is below the overhead guard also in the load direction
Variant II
Variant II
The control panels and information display are arranged on the mast side. The display unit is arranged below the overhead guard.
The control panels and information display are arranged on the mast side. The display unit is arranged below the overhead guard.
Variant III
Variant III
Diagonal arrangement of controls. The driver looks out to the left in the load direction. The “Steering” control panel module is arranged on the load side. The display unit is located on the load side below the overhead guard. The aux. lift is operated from the load side.
Diagonal arrangement of controls. The driver looks out to the left in the load direction. The “Steering” control panel module is arranged on the load side. The display unit is located on the load side below the overhead guard. The aux. lift is operated from the load side.
0206.GB
Variant I
0206.GB
2
E2
Load side and diagonal arrangement of controls. The driver looks directly in the load direction or diagonally to the left in the load direction. The “Steering” control panel module is also present on the mast side. The display unit is located on the load side below the overhead guard. The aux. lift is operated from the load side.
Load side and diagonal arrangement of controls. The driver looks directly in the load direction or diagonally to the left in the load direction. The “Steering” control panel module is also present on the mast side. The display unit is located on the load side below the overhead guard. The aux. lift is operated from the load side.
Variant V
Variant V
Mast side and diagonal arrangement of controls. The driver looks directly in the mast direction or diagonally to the left in the mast direction. The “Steering” control panel module is also present on the load side. The display unit is located on the mast side below the overhead guard. The aux. lift is operated from the load side.
Mast side and diagonal arrangement of controls. The driver looks directly in the mast direction or diagonally to the left in the mast direction. The “Steering” control panel module is also present on the load side. The display unit is located on the mast side below the overhead guard. The aux. lift is operated from the load side.
Variant VI
Variant VI
Twin arrangement of controls both in load and mast directions. The display unit is arranged on either the load or mast side. The aux. lift is operated from the load and the mast sides.
Twin arrangement of controls both in load and mast directions. The display unit is arranged on either the load or mast side. The aux. lift is operated from the load and the mast sides.
0206.GB
Variant IV
0206.GB
Variant IV
E3
E3
3
Operating and Display Equipment
3
Operating and Display Equipment
3.1
Operating and display equipment on control panel
3.1
Operating and display equipment on control panel
7 8 9 10
t Interrupts the main supply, all truck movements are disabled t Steers the truck in the required direction. t Two-hand operation o Automatic lift cutout is deactivated. RG Sets the drive wheel to straight ahead position
WG Activates the aligning process (and frequency selection for multi-frequencies) Travel selection switch t Controls the travel direction and speed of the truck “Warning” switch t Activates a warning. Hydraulic control switch t Raising and lowering of Main and Aux. lift, reach and swivel of load forks Keyswitch t Switches control voltage on and off. Removing the key prevents the truck from being switched on by unauthorised personnel. Optional t Activates or confirms the function related to function keys the symbol displayed above it t = Standard equipment
E4
Item Operating / Display Equipment 1 EMERGENCY DISCONNECT switch 2 Steering wheel 3 Support handle 4 “Lift cutout override” switch 5 Guidance On „switch“
o = Optional Equipment
6 7 8 9 10
Function t Interrupts the main supply, all truck movements are disabled t Steers the truck in the required direction. t Two-hand operation o Automatic lift cutout is deactivated. RG Sets the drive wheel to straight ahead position
WG Activates the aligning process (and frequency selection for multi-frequencies) Travel selection switch t Controls the travel direction and speed of the truck “Warning” switch t Activates a warning. Hydraulic control switch t Raising and lowering of Main and Aux. lift, reach and swivel of load forks Keyswitch t Switches control voltage on and off. Removing the key prevents the truck from being switched on by unauthorised personnel. Optional t Activates or confirms the function related to function keys the symbol displayed above it t = Standard equipment
0206.GB
6
Function
E4
o = Optional Equipment
0206.GB
Item Operating / Display Equipment 1 EMERGENCY DISCONNECT switch 2 Steering wheel 3 Support handle 4 “Lift cutout override” switch 5 Guidance On „switch“
3.2
Display unit controls and displays 13
3.2
14 15
16
17
13
12
12
11
11
20
19
18
Item Symbol Operating / Display Equipment 11 Displays possible travel speeds: Turtle Rabbit
14 15
20
Upper range symbols
16
17
19
18
Upper range symbols Function
Item Symbol Operating / Display Equipment 11 Displays possible travel speeds: Turtle Rabbit
t Creep mode Max. travel speed
Function t Creep mode Max. travel speed
12
“Guidance wire recognition” display
WG Sensors which have detected the guidance wire have a dark background
12
“Guidance wire recognition” display
13
Steering angle display t Indicates the current steering angle with reference to the centre position RG Centre position is permanently displayed once the truck is in the track WG The steering angle display fades and is replaced by guidance wire symbols changes with display – “Tracking in WG – when the truck is governed by the progress ” guidance wire (inductive guidance) – “Guidance wire led” WG – when the truck is automatically guided by the guidance wire – “Deviation from WG – when the truck deviates without guidance wire” guidance from the guidance wire and automatic guidance
13
Steering angle display t Indicates the current steering angle with reference to the centre position RG Centre position is permanently displayed once the truck is in the track WG The steering angle display fades and is replaced by guidance wire symbols changes with display – “Tracking in WG – when the truck is governed by the progress ” guidance wire (inductive guidance) – “Guidance wire led” WG – when the truck is automatically guided by the guidance wire – “Deviation from WG – when the truck deviates without guidance wire” guidance from the guidance wire and automatic guidance
E5
0206.GB
0206.GB
Display unit controls and displays
WG Sensors which have detected the guidance wire have a dark background
E5
Item Symbol Operating / Display Equipment 14 Display “Overall lift” “Referencing required” display: Main lift - lift
15 16 17 19 20
Function
Item Symbol Operating / Display Equipment 14 Display “Overall lift” “Referencing required” display: Main lift - lift
t Displays the lift height of the forks
Requests Main Lift to lift
t Displays the lift height of the forks
Requests Main Lift to lift
Main lift - lower
Requests Main Lift to lower
Main lift - lower
Requests Main Lift to lower
Aux. lift - lift
Requests Aux. Lift to lift
Aux. lift - lift
Requests Aux. Lift to lift
Aux. lift - lower
Requests Aux. Lift to lower
Aux. lift - lower
Requests Aux. Lift to lower
“Operating hours” display “Time” display Battery discharge indicator Optional function Optional function
t Displays the number of operating hours since the truck was commissioned t Shows the time t Displays the battery charge condition (residual capacity as a percentage) o o
15 16 17 19 20
“Operating hours” display “Time” display Battery discharge indicator Optional function Optional function
t Displays the number of operating hours since the truck was commissioned t Shows the time t Displays the battery charge condition (residual capacity as a percentage) o o
Activates switch (10) under the respective symbols (18) displayed or confirms the related function. The symbol will be given a dark background.
Lower range symbols and keys
Lower range symbols and keys
Symbol Operating / display unit Function Warnings “Chain slack safety t Displayed when the chain slack safety device” display device engages “Chain slack safety Bypasses the chain slack safety device to device bypass” switch lift the driver's position freely “Fwd./Rev. travel only” t Displayed when the lift cutout device is display actvated due to low battery capacity and only forward or reverse travel is possible. “Acknowledge lift cutout Confirms the lift cutout due to low battery due to battery discharge” capacity and releases travel (the Fwd./Rev. switch travel only display has a dark background) Display o Displayed when the height dependent lift “Lift limit” cutout is activated “Lift limitoverride”switch Overrides the height dependent lift cutout (display has a dark background). Observe the maximum passage heights “Lower limit” display o Indicates that the automatic lowering limit has been activated. “Lowering limit bypass” Bypasses the lowering limit, controlled by switch hydraulic control switch
Symbol Operating / display unit Function Warnings “Chain slack safety t Displayed when the chain slack safety device” display device engages “Chain slack safety Bypasses the chain slack safety device to device bypass” switch lift the driver's position freely “Fwd./Rev. travel only” t Displayed when the lift cutout device is display actvated due to low battery capacity and only forward or reverse travel is possible. “Acknowledge lift cutout Confirms the lift cutout due to low battery due to battery discharge” capacity and releases travel (the Fwd./Rev. switch travel only display has a dark background) Display o Displayed when the height dependent lift “Lift limit” cutout is activated “Lift limitoverride”switch Overrides the height dependent lift cutout (display has a dark background). Observe the maximum passage heights “Lower limit” display o Indicates that the automatic lowering limit has been activated. “Lowering limit bypass” Bypasses the lowering limit, controlled by switch hydraulic control switch 0206.GB
Activates switch (10) under the respective symbols (18) displayed or confirms the related function. The symbol will be given a dark background.
0206.GB
E6
Function
E6
Symbol Operating / display unit Function “Travel cutout” display o Indicates that automatic, height dependent travel cutout has been activated “Travel cutout bypass” Bypasses the automatic, height dependent switch travel cutout “Aisle end safety device” o Indicates that the aisle end safety device display (option) has been activated. The truck brakes. “Personal safety system” display (PSA) “Personalsafety system” switch (PSA)
Select “Warning submenu” display Quit “warnings” submenu. Quit “warnings” submenu. “Cancel warnings submenu” switch Guidance systems “Guidance on” display (dark background when activated)
Symbol Operating / display unit Function “Travel cutout” display o Indicates that automatic, height dependent travel cutout has been activated “Travel cutout bypass” Bypasses the automatic, height dependent switch travel cutout “Aisle end safety device” o Indicates that the aisle end safety device display (option) has been activated. The truck brakes.
o Indicates that the personal safety system has identified persons or objects in the aisle. The truck brakes. Bypasses the protective function and enables creep mode if there is sufficient distance from the obstacle. If a personal safety system is fitted, read the accompanying operator manual. o Indicates that several warnings (e.g. chain slack safety device height dependent lift cutout) have been issued. Displays individual warnings
“Personal safety system” display (PSA) “Personalsafety system” switch (PSA)
Select “Warning submenu” display Quit “warnings” submenu. Quit “warnings” submenu. “Cancel warnings submenu” switch Guidance systems “Guidance on” display (dark background when activated)
o Indicates that the sub-menu can be quit. Sets the “warnings” sub-menu to the standard menu t Displays automatic guidance in the aisle: RG Rail guidance display (drive wheel set straight ahead)
WG Indicates that wire guidance is activated RG Sets the drive wheel to straight ahead position WG Activates the aligning process (and frequency selection for multi-frequencies) Displays “Select o Indicates that guidance is possible through Frequency 1” (similar to Frequency 1 other frequencies) WG (“Guidance on” submenu) “Select Frequency 1” Activates guidance through Frequency 1 switch (similar to other (sub-menu is quit automatically after 1 sec. frequencies) duration) “Special attachment” o Indicates that the special attachment can be display controlled “Special attachment” Activates control of the special attachment, switch controlled via the hydraulic control switch
E7
o Indicates that the sub-menu can be quit. Sets the “warnings” sub-menu to the standard menu t Displays automatic guidance in the aisle: RG Rail guidance display (drive wheel set straight ahead)
WG Indicates that wire guidance is activated RG Sets the drive wheel to straight ahead position WG Activates the aligning process (and frequency selection for multi-frequencies) Displays “Select o Indicates that guidance is possible through Frequency 1” (similar to Frequency 1 other frequencies) WG (“Guidance on” submenu) “Select Frequency 1” Activates guidance through Frequency 1 switch (similar to other (sub-menu is quit automatically after 1 sec. frequencies) duration) “Special attachment” o Indicates that the special attachment can be display controlled “Special attachment” Activates control of the special attachment, switch controlled via the hydraulic control switch “Guidance on” switch
0206.GB
0206.GB
“Guidance on” switch
o Indicates that the personal safety system has identified persons or objects in the aisle. The truck brakes. Bypasses the protective function and enables creep mode if there is sufficient distance from the obstacle. If a personal safety system is fitted, read the accompanying operator manual. o Indicates that several warnings (e.g. chain slack safety device height dependent lift cutout) have been issued. Displays individual warnings
E7
Symbol Operating / display unit Function Attachment fork adjustment “Symmetrical fork o Indicates that fork adjustment can be adjustment” display operated “Symmetrical fork Activates fork adjustment with simultaneous adjustment” switch operation of hydraulic control switch, Right turn = forks turn in; Left turn = forks turn out “Asymmetrical fork o Indicates that it is possible to change to the adjustment menu “Asymmetrical fork adjustment” menu change” display “Asymmetrical fork Changes the display unit menu to adjustment menu “asymmetrical fork adjustment” functions change” switch
t = Standard equipment RG = Rail guidance
E8
o = Optional Equipment IG = Wire guidance
0206.GB
o = Optional Equipment IG = Wire guidance
0206.GB
t = Standard equipment RG = Rail guidance
Symbol Operating / display unit Function Attachment fork adjustment “Symmetrical fork o Indicates that fork adjustment can be adjustment” display operated “Symmetrical fork Activates fork adjustment with simultaneous adjustment” switch operation of hydraulic control switch, Right turn = forks turn in; Left turn = forks turn out “Asymmetrical fork o Indicates that it is possible to change to the adjustment menu “Asymmetrical fork adjustment” menu change” display “Asymmetrical fork Changes the display unit menu to adjustment menu “asymmetrical fork adjustment” functions change” switch
E8
Truck operational status symbols
3.3
Truck operational status symbols The operational status of the truck when it has been switched on is indicated by symbols in the display unit.
Safety gates open
Safety gates open
Foot switch not pressed
Foot switch not pressed
Attachment in home position
Attachment in home position
When the following symbols are displayed you must carry out a reference movement in accordance with the display, i.e. the Main Lift must be raised approx. 10 cm and lowered again. This is the only way for the controller to release all the truck movements at full speed.
When the following symbols are displayed you must carry out a reference movement in accordance with the display, i.e. the Main Lift must be raised approx. 10 cm and lowered again. This is the only way for the controller to release all the truck movements at full speed.
0206.GB
The operational status of the truck when it has been switched on is indicated by symbols in the display unit.
0206.GB
3.3
E9
E9
F
Referencing: Main lift - lift
Referencing: Main lift - lift
Referencing: Main lift - lower
Referencing: Main lift - lower
Referencing: Aux. lift - lift
Referencing: Aux. lift - lift
Referencing: Aux. lift - lower
Referencing: Aux. lift - lower
Lift cutout during referencing
Lift cutout during referencing
F
When disabling the lift cutout the driver must look out for obstacles when the mast is extended.
E 10
0206.GB
Pressing the “bypass lift cutout” switch disables the lift cutout mechanism.
0206.GB
Pressing the “bypass lift cutout” switch disables the lift cutout mechanism.
When disabling the lift cutout the driver must look out for obstacles when the mast is extended.
E 10
4
Starting up the truck
4
Starting up the truck
F
Before the truck can be put into operation, operated or a load unit lifted, the driver must ensure that there is nobody within the danger area.
F
Before the truck can be put into operation, operated or a load unit lifted, the driver must ensure that there is nobody within the danger area.
F
Checks and operations to be performed before starting daily work
Checks and operations to be performed before starting daily work
– Check the entire truck on the outside for signs of visible damage and leaks. – Check the battery attachment and wire connections for damage, make sure they are secure. – Check the battery connector is fixed. – Check the overhead guard for damage. – Check the load lifting device for visible damage such as cracks, bent or severely worn load forks. – Check the load wheels for damage. – Make sure the load chains are evenly tensioned. – Make sure all safety mechanisms are correct and functional. – Test the operating and parking brake. – Check the brake fluide. – For rail guidance systems check the guidance rollers are smooth and check for damage.
– Check the entire truck on the outside for signs of visible damage and leaks. – Check the battery attachment and wire connections for damage, make sure they are secure. – Check the battery connector is fixed. – Check the overhead guard for damage. – Check the load lifting device for visible damage such as cracks, bent or severely worn load forks. – Check the load wheels for damage. – Make sure the load chains are evenly tensioned. – Make sure all safety mechanisms are correct and functional. – Test the operating and parking brake. – Check the brake fluide. – For rail guidance systems check the guidance rollers are smooth and check for damage.
Preparing the truck for operation – – – – – –
F
F
It is forbidden for more than one person to enter the driver’s cab at a time.
Close the safey gates securely on both sides. Turn the EMERGENCY DISCONNECT switch (1) to undo it. Insert the key in the keyswitch (9) and turn it clockwise. Test the warning device (horn). Test the operating and parking brake. Carry out a test movement of the lift mast to adjust the height display.
Preparing the truck for operation – – – – – –
F
Press the EMERGENCY DISCONNECT switch immediately if the truck starts to move or lift when it is switched on.
Close the safey gates securely on both sides. Turn the EMERGENCY DISCONNECT switch (1) to undo it. Insert the key in the keyswitch (9) and turn it clockwise. Test the warning device (horn). Test the operating and parking brake. Carry out a test movement of the lift mast to adjust the height display.
Press the EMERGENCY DISCONNECT switch immediately if the truck starts to move or lift when it is switched on.
1
0206.GB
1
0206.GB
It is forbidden for more than one person to enter the driver’s cab at a time.
9 E 11
9 E 11
5
Lift truck operation
5
Lift truck operation
5.1
Safety regulations for truck operation
5.1
Safety regulations for truck operation
M M
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.
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.
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.
Visibility when travelling outside the narrow aisle: The driver must look in the direction of travel and must always have a clear view of the route ahead. When carrying loads which affect visibility, these 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.
Visibility when travelling outside the narrow aisle: The driver must look in the direction of travel and must always have a clear view of the route ahead. When carrying loads which affect visibility, these 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.
M M
Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines. Negotiating docks: It is forbidden to negotiate docks. Negotiating lifts: Lifts may only be negotiated 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.
E 12
Negotiating docks: It is forbidden to negotiate docks. Negotiating lifts: Lifts may only be negotiated 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.
0206.GB
Type of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down.
0206.GB
Type of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down.
Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines.
E 12
5.2
Travelling, Steering, Braking
5.2
EMERGENCY DISCONNECT
EMERGENCY DISCONNECT
– Press the EMERGENCY DISCONNECT switch (1) down. All truck movements are inhibited. The switch operation must not be affected by any objects placed in its way.
– Press the EMERGENCY DISCONNECT switch (1) down. All truck movements are inhibited. The switch operation must not be affected by any objects placed in its way.
Travelling
Travelling
1
The truck can be driven in 3 modes: Free travel in apron, with wire or rail guidance. The operating mode used depends on the guidance system of the racking system operated.
1
The truck can be driven in 3 modes: Free travel in apron, with wire or rail guidance. The operating mode used depends on the guidance system of the racking system operated.
M
Do not drive the truck unless the panels are closed and properly locked. The foot switch must be kept depressed for travel.
Do not drive the truck unless the panels are closed and properly locked. The foot switch must be kept depressed for travel.
Travelling in apron field
Travelling in apron field
– Close the safety gates. – Turn the EMERGENCY DISCONNECT switch (1) to undo it. – Insert the key in the keyswitch and turn clockwise; the “operational” display lamp goes on. – Apply the foot switch (21). – Carry out a test run, see Seite E9.
– Close the safety gates. – Turn the EMERGENCY DISCONNECT switch (1) to undo it. – Insert the key in the keyswitch and turn clockwise; the “operational” display lamp goes on. – Apply the foot switch (21). – Carry out a test run, see Seite E9.
21
21
21
0206.GB
21
0206.GB
M
Travelling, Steering, Braking
E 13
E 13
– Fully lower the Aux. lift and raise the Main lift with the hydraulic control switch (8) until the forks are clear of the ground. – Slowly turn the travel selection switch (6) with the right thumb. Turn clockwise = forward travel Turn anti-clockwise = reverse travel – You can control the travel speed by continuing to turn or retracting the travel selection switch.
6
8 2
Use the steering wheel (2) to steer the truck in the required direction.
Use the steering wheel (2) to steer the truck in the required direction.
Steering
Steering
Use the steering wheel to steer the truck outside narrow aisles. The position of the drive wheel is shown in the display unit (13).
M E 14
13
Braking
Z
The braking pattern of the truck depends largely on the ground conditions. The driver must take this into consideration when handling the truck.
The braking pattern of the truck depends largely on the ground conditions. The driver must take this into consideration when handling the truck.
– The truck can be braked in three different ways: - with the operating brake - with the parking brake - with the main switch.
– The truck can be braked in three different ways: - with the operating brake - with the parking brake - with the main switch.
Braking with the operating brake
Braking with the operating brake
While driving set the travel direction switch to the zero position or the opposite travel direction; the traction current controller will cause the truck to brake.
While driving set the travel direction switch to the zero position or the opposite travel direction; the traction current controller will cause the truck to brake.
Braking with the foot switch
Braking with the foot switch
Releasing the foot switch causes the truck to brake.
Releasing the foot switch causes the truck to brake.
Z
This type of braking can only be used as a parking brake and not as an operating brake.
This type of braking can only be used as a parking brake and not as an operating brake.
Braking with the EMERGENCY DISCONNECT switch
Braking with the EMERGENCY DISCONNECT switch
Applying the EMERGENCY DISCONNECT switch will cause the truck to brake suddenly until it comes to a halt.
Applying the EMERGENCY DISCONNECT switch will cause the truck to brake suddenly until it comes to a halt.
The EMERGENCY DISCONNECT switch must only be used in dangerous situations.
0206.GB
Z
8 2
Use the steering wheel to steer the truck outside narrow aisles. The position of the drive wheel is shown in the display unit (13).
13
Braking
Z
6
M E 14
The EMERGENCY DISCONNECT switch must only be used in dangerous situations.
0206.GB
– Fully lower the Aux. lift and raise the Main lift with the hydraulic control switch (8) until the forks are clear of the ground. – Slowly turn the travel selection switch (6) with the right thumb. Turn clockwise = forward travel Turn anti-clockwise = reverse travel – You can control the travel speed by continuing to turn or retracting the travel selection switch.
Negotiating narrow aisles
Negotiating narrow aisles
M
It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm) or for personnel to cross through them. These work areas must be marked and identified accordingly. Carry out a daily inspection of the safety devices on the truck or the racking sysem to avoid hazards and protect personnel. These must not be made ineffective, misused, adjusted or removed. Immediately report and rectify any missing safety devices.
M
It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm) or for personnel to cross through them. These work areas must be marked and identified accordingly. Carry out a daily inspection of the safety devices on the truck or the racking sysem to avoid hazards and protect personnel. These must not be made ineffective, misused, adjusted or removed. Immediately report and rectify any missing safety devices.
M Z
Observe the instructions of DIN 15185 Part 2.
M Z
Observe the instructions of DIN 15185 Part 2.
Z
Only enter narrow aisles in trucks which are designated for such use. If a narrow aisle is equipped with a non-mechanical wire guidance system, if the system is faulty or switched off, the truck may only be removed from the narrow aisle at creep speed.
Z
Only enter narrow aisles in trucks which are designated for such use. If a narrow aisle is equipped with a non-mechanical wire guidance system, if the system is faulty or switched off, the truck may only be removed from the narrow aisle at creep speed.
Before entering a narrow aisle, the driver must look for people or other trucks in the aisle. Never enter an aisle where there are people or other trucks. If there are people in the aisle, stop the truck immediately.
Rail guidance truck
Rail guidance truck
Rail guidance trucks are equipped with sensors which activate aisle recognition when they enter the racking lanes. – Approach the aisle at reduced speed so that the truck is aligned with the narrow aisle and is within the demarcation. Observe the notices attached along the route.
Rail guidance trucks are equipped with sensors which activate aisle recognition when they enter the racking lanes.
23
– Approach the aisle at reduced speed so that the truck is aligned with the narrow aisle and is within the demarcation.
22 23
Z
22
Observe the notices attached along the route.
23 22 23
22
– Slowly enter the narrow aisle.
Ensure that the truck guide rollers enter the narrow aisle guidance rails.
Ensure that the truck guide rollers enter the narrow aisle guidance rails.
– Press the “guidance on” (22) switch. – The drive wheel is automatically set straight ahead and the “guidance on” lamp (23) is lit. Manual steering is disabled. – To prepare for travel, grab the hand rest with the left hand (two-handed operation). – Slowly turn the travel selection switch in the travel direction required. Right turn =Forward travel; Left turn = Reverse travel – Continue to travel along the narrow aisle at your required speed.
– Press the “guidance on” (22) switch. – The drive wheel is automatically set straight ahead and the “guidance on” lamp (23) is lit. Manual steering is disabled. – To prepare for travel, grab the hand rest with the left hand (two-handed operation). – Slowly turn the travel selection switch in the travel direction required. Right turn =Forward travel; Left turn = Reverse travel – Continue to travel along the narrow aisle at your required speed.
0206.GB
– Slowly enter the narrow aisle.
0206.GB
Z
Before entering a narrow aisle, the driver must look for people or other trucks in the aisle. Never enter an aisle where there are people or other trucks. If there are people in the aisle, stop the truck immediately.
E 15
E 15
Wire guidance trucks
F F F
Wire guidance trucks
F F
When starting or continuing to travel after disconnecting the wire guidance, check the position of the drive wheel as manual steering is now activated again. If an automatically guided wire guidance truck is switched off, the wire guidance is no longer active when it is switched on again. Risk of accidents! When the truck continues a warning is sounded and the speed reduced. Apply pushbutton (22) to reactivate the wire guidance (“Wire Guidance Active” display light (23) is lit) and re-track the truck.
F
When re-tracking the truck, the rear section may move out if the front sensor (25) has already crossed over the guidance wire before the "Wire Guidance On" switch is pressed.
When starting or continuing to travel after disconnecting the wire guidance, check the position of the drive wheel as manual steering is now activated again. If an automatically guided wire guidance truck is switched off, the wire guidance is no longer active when it is switched on again. Risk of accidents! When the truck continues a warning is sounded and the speed reduced. Apply pushbutton (22) to reactivate the wire guidance (“Wire Guidance Active” display light (23) is lit) and re-track the truck. When re-tracking the truck, the rear section may move out if the front sensor (25) has already crossed over the guidance wire before the "Wire Guidance On" switch is pressed.
– Approach the guidance wire (26) at an angle at reduced speed.
– Approach the guidance wire (26) at an angle at reduced speed.
When the truck is correctly positioned it should not be parallel to the guidance wire; the ideal angle is between 10° and 50°.
When the truck is correctly positioned it should not be parallel to the guidance wire; the ideal angle is between 10° and 50°.
Tracking should preferably be forward, as this involves less time and distance.
26
Tracking should preferably be forward, as this involves less time and distance.
25 24
When the truck is close to the guidance wire, switch on the wire guidance with pressure switch „Guidance On“ (22).
23
The “wire guidance active” (23) lamp goes on.
The “wire guidance active” (23) lamp goes on.
When the guidance wire is reached the truck is automatically guided.
When the guidance wire is reached the truck is automatically guided. When the guidance wire is reached tracking automtically ensues at reduced speed. The “tracking on” (27) display appears. The audible tracking signal is sounded.
23
22
0206.GB
22
0206.GB
E 16
25 24
When the truck is close to the guidance wire, switch on the wire guidance with pressure switch „Guidance On“ (22).
When the guidance wire is reached tracking automtically ensues at reduced speed. The “tracking on” (27) display appears. The audible tracking signal is sounded.
26
E 16
Inductive automatic steering takes over the steering and applies it to the guidance wire.
Inductive automatic steering takes over the steering and applies it to the guidance wire.
28
Tracking is completed once the truck has been set to the guidance wire. The display (28) changes to “guidance wire applied”. The tracking signal is no longer sounded. The track is now automatically guided.
Z
Z
Travel and hydraulic operations can only be activated in the narrow aisle with twohanded operation. Hold onto the support handle (3) of the “Steering” control panel module and the hydraulic control switch (8). Turn the travel selection switch (6) to change travel speed and direction.
3
3
6
Diagonal travel
8
Diagonal travel is possible (simultaneous travelling and lifting / lowering) when both control switches (6 and 8) are pressed simultaneously).
2
Press the pressure switch (22) to quit the guidance wire. The display (23) goes out.
F
Travel and hydraulic operations can only be activated in the narrow aisle with twohanded operation. Hold onto the support handle (3) of the “Steering” control panel module and the hydraulic control switch (8). Turn the travel selection switch (6) to change travel speed and direction.
6
Diagonal travel Diagonal travel is possible (simultaneous travelling and lifting / lowering) when both control switches (6 and 8) are pressed simultaneously).
28
Tracking is completed once the truck has been set to the guidance wire. The display (28) changes to “guidance wire applied”. The tracking signal is no longer sounded. The track is now automatically guided.
8 2
Press the pressure switch (22) to quit the guidance wire. The display (23) goes out.
23
F
You can only change from automatic to manual steering once the truck has fully left the rack lane.
You can only change from automatic to manual steering once the truck has fully left the rack lane.
0206.GB
22
0206.GB
22
23
E 17
E 17
5.3
Lifting – Lowering – outside and inside the rack aisles
5.3
Lifting – Lowering – outside and inside the rack aisles
F
Risk of injury when the driver’s cab and the load lifting device are lowered. There must be nobody in the danger zone.
F
Risk of injury when the driver’s cab and the load lifting device are lowered. There must be nobody in the danger zone.
Lift – Lower (Main Lift)
Lift – Lower (Main Lift)
– Apply the foot switch. – Turn the hydraulic control button (8) simultaneously Clockwise = Lift Anti-clockwise = Lower
– Apply the foot switch. – Turn the hydraulic control button (8) simultaneously Clockwise = Lift Anti-clockwise = Lower
Z
The lift and lower speeds are proportional to the amount of turn of the hydraulic control switch.
Z
If the wire break safety device is applied, lift again and slowly lower.
8
Z
The lift and lower speeds are proportional to the amount of turn of the hydraulic control switch.
Z
If the wire break safety device is applied, lift again and slowly lower.
Lift – Lower (Aux. Lift)
Lift – Lower (Aux. Lift)
– Apply the foot switch. – Press the aux. lift pressure switch (4). – Turn the hydraulic control button (8) simultaneously Clockwise = Lift Anti-clockwise = Lower
– Apply the foot switch. – Press the aux. lift pressure switch (4). – Turn the hydraulic control button (8) simultaneously Clockwise = Lift Anti-clockwise = Lower
4
8
The lift and lower speeds proportional to the amount of turn.
E 18
4
8
are
0206.GB
are
0206.GB
The lift and lower speeds proportional to the amount of turn.
8
E 18
5.4
Order picking and stacking
5.4
Picking up, transporting and placing load units
M
Picking up, transporting and placing load units
M
Before picking up a load unit the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Observe the load diagram. – Check the fork distance for the pallet and adjust if necessary.
Before picking up a load unit the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Observe the load diagram. – Check the fork distance for the pallet and adjust if necessary.
o Adjusting the forks To pick up the load securely, the forks must be as far apart as possible and centrally positioned with respect to the fork carriage. The load centre of gravity must be centrally aligned between the forks.
Order picking and stacking
o Adjusting the forks 30
To pick up the load securely, the forks must be as far apart as possible and centrally positioned with respect to the fork carriage. The load centre of gravity must be centrally aligned between the forks.
29
31
29
31
0206.GB
– Swivel the locking lever (29) up. – Push the forks (30) into the correct position on the fork carriage (31). – Swivel the locking lever (29) down and move the forks until the locking pin engages in a notch.
0206.GB
– Swivel the locking lever (29) up. – Push the forks (30) into the correct position on the fork carriage (31). – Swivel the locking lever (29) down and move the forks until the locking pin engages in a notch.
30
E 19
E 19
M
M
Picking up a load from the front
Picking up a load from the front
– Drive the truck at creep speed. – Slowly insert the forks into the pallet until the fork back touches the load or the pallet. – Raise the load slightly and reverse the truck slowly (creep speed).
– Drive the truck at creep speed. – Slowly insert the forks into the pallet until the fork back touches the load or the pallet. – Raise the load slightly and reverse the truck slowly (creep speed).
M
The ground surface must be in good condition to ensure this works correctly. Transporting loads
Transporting loads
– Always transport a load outside the rack aisle as low as possible, allowing for ground clearance. – Always transport loads with both forks. When transporting heavy loads always ensure that both forks carry the same weight. – Gradually accelerate the truck. – Travel at a constant speed. – Always be prepared to brake. Only stop suddenly in dangerous situations. – Reduce speed accordingly on narrow bends.
– Always transport a load outside the rack aisle as low as possible, allowing for ground clearance. – Always transport loads with both forks. When transporting heavy loads always ensure that both forks carry the same weight. – Gradually accelerate the truck. – Travel at a constant speed. – Always be prepared to brake. Only stop suddenly in dangerous situations. – Reduce speed accordingly on narrow bends.
Placing loads
Placing loads
– Drive the truck carefully up to the storage location
– Drive the truck carefully up to the storage location
M
Before a load can be placed, the driver must ensure that the storage location is suitable for storing the load (size and capacity). – Raise the load lifting device so that the load can be taken to the storage location without striking any objects. – Carefully set the load into its storage location. – Carefully lower the load lifting device so that the forks are clear of the load.
M
Before a load can be placed, the driver must ensure that the storage location is suitable for storing the load (size and capacity). – Raise the load lifting device so that the load can be taken to the storage location without striking any objects. – Carefully set the load into its storage location. – Carefully lower the load lifting device so that the forks are clear of the load.
M
Avoid placing the load down suddenly to avoid damaging the load and the load lifting device.Carefully remove the load lifting device from the load.
Avoid placing the load down suddenly to avoid damaging the load and the load lifting device.Carefully remove the load lifting device from the load.
0206.GB
– Fully lower the load lifting device.
0206.GB
– Fully lower the load lifting device.
E 20
The ground surface must be in good condition to ensure this works correctly.
E 20
5.5
Park the truck securely
5.5
When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
Park the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
F
Do not park the truck on an incline. In special cases the truck may need to be secured with wedges.
F
Do not park the truck on an incline. In special cases the truck may need to be secured with wedges.
Z
Select a parking place where nobody will collide with the forks.
Z
Select a parking place where nobody will collide with the forks. – Always park the truck with the mast completely lowered. – Lower the forks to the ground. – Set the keyswitch to “0” and remove the safety key.
0206.GB
0206.GB
– Always park the truck with the mast completely lowered. – Lower the forks to the ground. – Set the keyswitch to “0” and remove the safety key.
E 21
E 21
Troubleshooting
6
This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table.
This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table.
Fault Truck does not start.
Fault Truck does not start.
Load cannot be lifted
Rapid travel disabled
Possible cause Action – Battery not connected – Check battery plug and plug in if necessary. – Safety gates open – Close the safety gates – EMERGENCY – Unlatch EMERGENCY DISCONNECT switch DISCONNECT switch pressed – Keyswitch in “0” – Set key switch to “I” position – Battery charge too low – Check battery charge, charge battery if necessary – Foot switch not – Press foot switch pressed – Fuse blown – Check fuses – Travel cutout activated – Press travel cutout bypass switch (charge battery) – Travel cutout activated – Switch off automatic traction via aisle end safety controller and re-align truck with device guidance wire. – Chains slack – Bypass chain slack safety device – Truck not operational – Carry out all measures listed under “Truck does not start” – Battery charge too low, – Check battery charge, charge battery lift cutout if necessary – Insufficient hydraulic – Check hydraulic oil level and if oil necessary replenish – Fuse blown – Check fuses – Main Lift / Aux. Lift – Lower Main Lift / Aux. Lift below 0.5m raised above 0.5m – WG search mode – Align truck or turn off WG mode activated – No test run performed – Perform lifting and lowering – Truck not operational – Carry out all measures listed under “Truck does not start” – Narrow aisle mode – Switch off narrow aisle travel function switch pressed
Load cannot be lifted
Rapid travel disabled
Truck cannot be steered
0206.GB
Truck cannot be steered
E 22
Troubleshooting
Possible cause Action – Battery not connected – Check battery plug and plug in if necessary. – Safety gates open – Close the safety gates – EMERGENCY – Unlatch EMERGENCY DISCONNECT switch DISCONNECT switch pressed – Keyswitch in “0” – Set key switch to “I” position – Battery charge too low – Check battery charge, charge battery if necessary – Foot switch not – Press foot switch pressed – Fuse blown – Check fuses – Travel cutout activated – Press travel cutout bypass switch (charge battery) – Travel cutout activated – Switch off automatic traction via aisle end safety controller and re-align truck with device guidance wire. – Chains slack – Bypass chain slack safety device – Truck not operational – Carry out all measures listed under “Truck does not start” – Battery charge too low, – Check battery charge, charge battery lift cutout if necessary – Insufficient hydraulic – Check hydraulic oil level and if oil necessary replenish – Fuse blown – Check fuses – Main Lift / Aux. Lift – Lower Main Lift / Aux. Lift below 0.5m raised above 0.5m – WG search mode – Align truck or turn off WG mode activated – No test run performed – Perform lifting and lowering – Truck not operational – Carry out all measures listed under “Truck does not start” – Narrow aisle mode – Switch off narrow aisle travel function switch pressed
0206.GB
6
E 22
Fault Error 144 Error 330 Error 334 Error 331 Error 335 Error 332 Error 336
Error 338 Error 339 Error 344
Action – Restore wire guidance
Fault Error 144
– Do not press travel control button, switch truck off and on again
Error 330 Error 334
– Do not press hydraulic control button, switch truck off and on again
Error 331 Error 335
– Do not press function preselect key, switch truck off and on again
Error 332 Error 336
– Do not press foot switch, switch truck off and on again – Do not press key, switch truck off and on again
Error 338
– PSA scanner contaminated, clean
Error 344
Error 339
Z
Possible cause – Truck has quit guidance wire – Travel control button pressed during powerup test – Hydraulic control button pressed during power-up test – During the power up test a function preselect key was pressed on the control panel – Foot switch pressed during power-up test – During the power-up test a key was pressed below the display unit – Personal safety system
Action – Restore wire guidance – Do not press travel control button, switch truck off and on again – Do not press hydraulic control button, switch truck off and on again – Do not press function preselect key, switch truck off and on again
– Do not press foot switch, switch truck off and on again – Do not press key, switch truck off and on again – PSA scanner contaminated, clean
If, after carrying out the remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department. Additional troubleshooting must only be performed by the manufacturer’s specialist service engineers. The manufacturer has a customer service department specially trained for these tasks. To provide targeted and rapid response to faults, the following details are useful and important to provide for the customer service department: - Truck serial number - Display unit error number (if present) - Error description - Current location of truck.
0206.GB
If, after carrying out the remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department. Additional troubleshooting must only be performed by the manufacturer’s specialist service engineers. The manufacturer has a customer service department specially trained for these tasks. To provide targeted and rapid response to faults, the following details are useful and important to provide for the customer service department: - Truck serial number - Display unit error number (if present) - Error description - Current location of truck.
0206.GB
Z
Possible cause – Truck has quit guidance wire – Travel control button pressed during powerup test – Hydraulic control button pressed during power-up test – During the power up test a function preselect key was pressed on the control panel – Foot switch pressed during power-up test – During the power-up test a key was pressed below the display unit – Personal safety system
E 23
E 23
6.1
Emergency stop device
6.1
When the automatic emergency stop device is applied (e.g. if the wire guidance is lost, or the electrical steering fails) the truck automatically comes to a halt. Before starting again, the cause of the error must be identified and corrected. When starting the truck again, follow the manufacturer’s instructions as laid down in the present operator manual. Driver’s cab / Aux. Lift emergency lowering
6.2
F
When using emergency lowering, make sure that nobody is present in the danger zone. If a second person is used to lower the load lifting device via the emergency lowering device, this person must consult with the driver. Both people must be in a safe area to avoid danger. The truck may only be started again once the error has been localised and rectified.
E 24
Driver’s cab / Aux. Lift emergency lowering When using emergency lowering, make sure that nobody is present in the danger zone. If a second person is used to lower the load lifting device via the emergency lowering device, this person must consult with the driver. Both people must be in a safe area to avoid danger. The truck may only be started again once the error has been localised and rectified.
If necessary, a second person can be deployed to lower the cabin from the ground.
If necessary, a second person can be deployed to lower the cabin from the ground.
– – – –
– – – –
Remove the Allen key from the bracket above the beacon. Insert the Allen key into the hole (33). Slowly open the drain valve (32) using the Allen key. The cabin lowers.
Remove the Allen key from the bracket above the beacon. Insert the Allen key into the hole (33). Slowly open the drain valve (32) using the Allen key. The cabin lowers.
42 32
42 32
33 43
33 43
0206.GB
F
When the automatic emergency stop device is applied (e.g. if the wire guidance is lost, or the electrical steering fails) the truck automatically comes to a halt. Before starting again, the cause of the error must be identified and corrected. When starting the truck again, follow the manufacturer’s instructions as laid down in the present operator manual.
0206.GB
6.2
Emergency stop device
E 24
6.3
Exiting the driver's cab with the emergency abseil device
6.3
Industrial trucks with a height-adjustable operator position which can exceed 3m from the ground, have an emergency lowering mechanism and an emergency abseil device for the driver which he can use if the operator position ever becomes stuck.
Z
Exiting the driver's cab with the emergency abseil device Industrial trucks with a height-adjustable operator position which can exceed 3m from the ground, have an emergency lowering mechanism and an emergency abseil device for the driver which he can use if the operator position ever becomes stuck.
Z
If the driver’s cab cannot be lowered due to a fault, not even manually, the operator must exit the driver's cab via the emergency abseil device. The driver must be instructed in how to use the emergency abseil device. To exit the cabin with the emergency abseil device, proceed as follows: – – – –
Turn the keyswitch to “0”. Press the EMERGENCY DISCONNECT switch. Take the emergency abseil device (35) out of its compartment. Attach the karabiner hook (38) of the abseil device (left or right) to the eye (34) of the overhead guard. – Throw out the rope without knots, the rope must pass over fixed objects. Do not pass the rope over sharp edges. – Fit the safety belt or slings in accordance with the accompanying operating instructions or as instructed. – Attach the safety belt to the abseil device (39).
If the driver’s cab cannot be lowered due to a fault, not even manually, the operator must exit the driver's cab via the emergency abseil device. The driver must be instructed in how to use the emergency abseil device. To exit the cabin with the emergency abseil device, proceed as follows: – – – –
Turn the keyswitch to “0”. Press the EMERGENCY DISCONNECT switch. Take the emergency abseil device (35) out of its compartment. Attach the karabiner hook (38) of the abseil device (left or right) to the eye (34) of the overhead guard. – Throw out the rope without knots, the rope must pass over fixed objects. Do not pass the rope over sharp edges. – Fit the safety belt or slings in accordance with the accompanying operating instructions or as instructed. – Attach the safety belt to the abseil device (39).
34
34
37
35
38
39
0206.GB
39
36
36
37
38
0206.GB
35
E 25
E 25
Abseiling
F
Do not drop into loose rope. Watch out for obstacles when abseiling.
6.4
Bypassing the chain slack safety device
M 6.5
– – – –
Abseiling
Make the rope (37) taut. Exit with your face towards the truck. To abseil, press the lever (36) on the abseil device down. To stop abseiling, release the brake lever (36).
F
Do not drop into loose rope. Watch out for obstacles when abseiling.
6.4
Bypassing the chain slack safety device
Make the rope (37) taut. Exit with your face towards the truck. To abseil, press the lever (36) on the abseil device down. To stop abseiling, release the brake lever (36).
If the chain slack safety device applies, e. g. when assembling the fork carriage, loosening or rupturing the lift chain. It is possible to “Raise” the Main Lift if the override switch is held down. “Travel” and “Lower” are no longer possible.
If the chain slack safety device applies, e. g. when assembling the fork carriage, loosening or rupturing the lift chain. It is possible to “Raise” the Main Lift if the override switch is held down. “Travel” and “Lower” are no longer possible.
Before starting again, rectify the damage.
Before starting again, rectify the damage.
M
The truck can only be started again when the damage has been rectified. Bypassing the travel cutout (o)
6.5
If travel is inhibited from a certain lift height, but the position of the truck relative to the rack must be adjusted to load or unload goods, press the “unlock travel” switch and apply the travel lever as described in “Travelling”. This allows you to travel in creep mode. 6.6
– – – –
The truck can only be started again when the damage has been rectified. Bypassing the travel cutout (o) If travel is inhibited from a certain lift height, but the position of the truck relative to the rack must be adjusted to load or unload goods, press the “unlock travel” switch and apply the travel lever as described in “Travelling”. This allows you to travel in creep mode.
Lift cutout (o)
6.6
If local conditions require, an automatic lift cutout to apply from a given lift height can be fitted for safety reasons.
Lift cutout (o) If local conditions require, an automatic lift cutout to apply from a given lift height can be fitted for safety reasons.
M
Lift cutout only becomes effective after a test run has been carried out. You can tell when this is the case, because the actual height is shown in the display unit.
M
Lift cutout only becomes effective after a test run has been carried out. You can tell when this is the case, because the actual height is shown in the display unit.
F
When disabling the lift cutout the driver must look out for obstacles when the mast is extended.
F
When disabling the lift cutout the driver must look out for obstacles when the mast is extended.
Pressing the “bypass lift cutout” switch disables the lift cutout mechanism.
The respective travel and lift limit keys are located in the control panel.
E 26
Lift cutout is re-activated each time the mast falls below the lift limit height. The respective travel and lift limit keys are located in the control panel.
0206.GB
Z
Lift cutout is re-activated each time the mast falls below the lift limit height.
0206.GB
Z
Pressing the “bypass lift cutout” switch disables the lift cutout mechanism.
E 26
M
F
6.7
Aisle end safety device (o)
Trucks with the aisle end safety device brake before the aisle exit or in the transfer aisle. There are two basic versions for this:
Trucks with the aisle end safety device brake before the aisle exit or in the transfer aisle. There are two basic versions for this:
1. Braking to a halt
1. Braking to a halt
2. Braking to 2.5 km/h
2. Braking to 2.5 km/h
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
1. Braking to a halt:
1. Braking to a halt:
When the truck passes over the aisle end safety magnets heading for the aisle end, it comes to a halt.
When the truck passes over the aisle end safety magnets heading for the aisle end, it comes to a halt.
To continue traveling:
To continue traveling:
– Briefly release the foot switch and then apply it again
– Briefly release the foot switch and then apply it again
The truck can be driven out of the narrow aisle at max. 2.5 km/h.
The truck can be driven out of the narrow aisle at max. 2.5 km/h.
2. Braking to 2.5 km/h
2. Braking to 2.5 km/h
When the truck passes over the aisle end safety magnets heading for the aisle end, it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.
When the truck passes over the aisle end safety magnets heading for the aisle end, it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.
M
In both cases the braking distance depends on the travel speed.
F
Aisle end safety braking is an additional function designed to support the operator, but which does not release him from any responsiblity, e.g. to monitor braking at the aisle end and if necessary to apply the brakes.
WG emergency operation
6.8
In both cases the braking distance depends on the travel speed.
Aisle end safety braking is an additional function designed to support the operator, but which does not release him from any responsiblity, e.g. to monitor braking at the aisle end and if necessary to apply the brakes.
WG emergency operation
If in a wire guidance system the guiding antenna goes beyond the pre-determined range of the guidance wire, an emergency stop is immediately carried out.
If in a wire guidance system the guiding antenna goes beyond the pre-determined range of the guidance wire, an emergency stop is immediately carried out.
If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The “tracking on” display and the audible tracking signal however remain permanently on and hence warn the driver.
If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The “tracking on” display and the audible tracking signal however remain permanently on and hence warn the driver.
Automatic EMERGENCY STOP
Automatic EMERGENCY STOP
If during operation one of the monitors for steering control, steering system, wire guidance or the safety cutout for the traction electronics or power electronics applies, the truck safety devices will cause the truck to stop.
If during operation one of the monitors for steering control, steering system, wire guidance or the safety cutout for the traction electronics or power electronics applies, the truck safety devices will cause the truck to stop.
0206.GB
6.8
Aisle end safety device (o)
0206.GB
6.7
E 27
E 27
To enable the truck to travel again after an EMERGENCY STOP, carry out the following:
– – – –
– – – –
Determine the possible cause of the EMERGENCY STOP. Press the EMERGENCY STOP switch and turn it again. Apply inductive automatic steering. Press the travel lever.
F
If the truck now starts, test that it works with manual steering and inductive automatic steering.
E 28
Determine the possible cause of the EMERGENCY STOP. Press the EMERGENCY STOP switch and turn it again. Apply inductive automatic steering. Press the travel lever.
If the truck now starts, test that it works with manual steering and inductive automatic steering.
Automatic and manual EMERGENCY STOP
Automatic and manual EMERGENCY STOP
If, after an automatic or manual EMERGENCY STOP and having rectified the problem, you cannot start the truck again, remove the keyswitch and put it back in. Now carry out a test run as follows: Raise and lower the Main Lift and Aux. Lift in accordance with the symbols until the respective display goes out.
If, after an automatic or manual EMERGENCY STOP and having rectified the problem, you cannot start the truck again, remove the keyswitch and put it back in. Now carry out a test run as follows: Raise and lower the Main Lift and Aux. Lift in accordance with the symbols until the respective display goes out. Carry out a test run:
- REF-Test run: Raise Main Lift
- REF-Test run: Raise Main Lift
- REF-Test run: Lower Main Lift
- REF-Test run: Lower Main Lift
- REF-Test run: Raise Main Lift
- REF-Test run: Raise Main Lift
- REF-Test run: Lower Aux. Lift
- REF-Test run: Lower Aux. Lift
0206.GB
Carry out a test run:
0206.GB
F
To enable the truck to travel again after an EMERGENCY STOP, carry out the following:
E 28
6.9
Recovering the truck from a narrow aisle / Moving the truck without a battery
6.9
Recovering the truck from a narrow aisle / Moving the truck without a battery
F
Before recovering the truck from a narrow aisle, disconnect the battery.
F
Before recovering the truck from a narrow aisle, disconnect the battery.
M
Z
M
This operation can only be performed by a specialist service engineer specially trained in operating the truck.
This operation can only be performed by a specialist service engineer specially trained in operating the truck.
When the brakes are de-activated the truck must be parked on an even ground as the brakes are no longer effective.
When the brakes are de-activated the truck must be parked on an even ground as the brakes are no longer effective.
– Fully lower the mast
– Fully lower the mast
Z
Obtain the help of another person. The other person must be trained and familiar with recovery operations.
Obtain the help of another person. The other person must be trained and familiar with recovery operations.
To recover the truck from the aisle, release the brakes.
To recover the truck from the aisle, release the brakes.
Release the magnetic brake
Release the magnetic brake
– Remove the electronic compartment cover at the back. – Screw in the setscrews (41) on the magnetic brake above the traction motor to release it. – Attach the tow rope to the service openings (40) and carefully pull the truck out of the narrow aisle. – When bring the truck back into operation: Check the brake retardation value.
– Remove the electronic compartment cover at the back. – Screw in the setscrews (41) on the magnetic brake above the traction motor to release it. – Attach the tow rope to the service openings (40) and carefully pull the truck out of the narrow aisle. – When bring the truck back into operation: Check the brake retardation value.
40
40
0206.GB
41
0206.GB
41
E 29
E 29
F
Dismantling the hydraulic brake
Dismantling the hydraulic brake
– Remove the electronic compartment cover at the back. – Remove the protective cap (43) from the discharge valve. – Push the hose (44) onto the vent connectino and insert the other end of the hose in the brake fluid container (45) above it.
– Remove the electronic compartment cover at the back. – Remove the protective cap (43) from the discharge valve. – Push the hose (44) onto the vent connectino and insert the other end of the hose in the brake fluid container (45) above it.
F
Brake fluid container is pressurised. Risk of scalding. – Open the discharge valve (42) and drain the brake fluid into the brake fluid container. – Close the discharge valve and brake fluid container.
Brake fluid container is pressurised. Risk of scalding. – Open the discharge valve (42) and drain the brake fluid into the brake fluid container. – Close the discharge valve and brake fluid container.
Z
Switch on the truck and press the foot switch several times to restore the functionality of the brake system.
M
Check the brake retardation.
M
Check the brake retardation.
E 30
0206.GB
Switch on the truck and press the foot switch several times to restore the functionality of the brake system.
0206.GB
Z
E 30
Adjust the steering angle
Using an Allen key set the steered wheel to the required direction via the screw in the steering motor (46).
The battery must be disconnected when adjusting the steering angle. Using an Allen key set the steered wheel to the required direction via the screw in the steering motor (46).
46
Z
It is advisable to discharge the wheel if setting an angle greater than 4 degrees.
0206.GB
Z
F
The battery must be disconnected when adjusting the steering angle.
46
It is advisable to discharge the wheel if setting an angle greater than 4 degrees.
0206.GB
F
Adjust the steering angle
E 31
E 31
E 32 E 32 0206.GB
0206.GB
F Maintenance of the forklift truck
F Maintenance of the forklift truck
1
1
Operational safety and environmental protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
F M
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
F
Modifications to the forklift truck, especially to the safety devices, are not permitted. The operational speeds of the truck must not be changed under any circumstances.
M
Only original spare parts come under the remit of our quality assurance service. To ensure safe and reliable operation of the forklift truck, only use the manufacturer’s spare parts. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, contact the manufacturer’s oil service department. Upon completion of inspection and servicing, carry out the tasks contained in the „Recommissioning“ section (see Chapter F).
2
Operational safety and environmental protection
Modifications to the forklift truck, especially to the safety devices, are not permitted. The operational speeds of the truck must not be changed under any circumstances. Only original spare parts come under the remit of our quality assurance service. To ensure safe and reliable operation of the forklift truck, only use the manufacturer’s spare parts. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, contact the manufacturer’s oil service department. Upon completion of inspection and servicing, carry out the tasks contained in the „Recommissioning“ section (see Chapter F).
Maintenance Safety Regulations
2
Maintenance Safety Regulations
Maintenance personnel: The forklift truck must only be serviced and maintained by trained personnel provided by the manufacturer. The manufacturer’s service department has specially trained field engineers for this work. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Maintenance personnel: The forklift truck must only be serviced and maintained by trained personnel provided by the manufacturer. The manufacturer’s service department has specially trained field engineers for this work. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When a forklift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). Only work under a raised load handler and cab if they are secured by a chain of sufficient capacity or by the retaining bolt (see “Securing the Driver's Position Carriage” in Chapter F).
Lifting and jacking up: When a forklift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). Only work under a raised load handler and cab if they are secured by a chain of sufficient capacity or by the retaining bolt (see “Securing the Driver's Position Carriage” in Chapter F).
Z
Jacking point see chapter B.
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 malfuntions. Do not clean with steam jets.
Cleaning: No inflammable liquids may be used to clean the forklift truck. Prior to cleaning, all safety measures required to prevent sparking (e.g. through short circuits) must be taken. 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 electrical or electronic assemblies.
Jacking point see chapter B.
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 malfuntions. Do not clean with steam jets.
Cleaning: No inflammable liquids may be used to clean the forklift truck. Prior to cleaning, all safety measures required to prevent sparking (e.g. through short circuits) must be taken. 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 electrical or electronic assemblies.
0708.GB
After cleaning, carry out the tasks detailed in the „Recommissioning“ section.
0708.GB
After cleaning, carry out the tasks detailed in the „Recommissioning“ section.
Z
F1
F1
Welding: To avoid damaging electrical or electronic components, remove them from the truck before performing welding operations.
Welding: To avoid damaging electrical or electronic components, remove them from the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always keep the truck-specific settings.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always keep the truck-specific settings.
Wheels: The quality of wheels affects the stability and performance of the truck. When replacing wheels fitted at the factory, only use manufacturer’s original spare parts. Otherwise the truck's rated performance cannot be ensured. When replacing wheels, ensure that the truck does not slew (e.g. always replace left and right wheels at the same time)
Wheels: The quality of wheels affects the stability and performance of the truck. When replacing wheels fitted at the factory, only use manufacturer’s original spare parts. Otherwise the truck's rated performance cannot be ensured. When replacing wheels, ensure that the truck does not slew (e.g. always replace left and right wheels at the same time)
Lift chains: Lift chains wear rapidly if not properly lubricated. The intervals given in the service checklist apply to normal duty. 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 properly lubricated. The intervals given in the service checklist apply to normal duty. 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.
Hydraulic hoses: The hoses must be replaced every six years.
F2
0708.GB
Electrical System: Work on the electrical system may only be performed by trained personnel. Before commencing work 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.
0708.GB
Electrical System: Work on the electrical system may only be performed by trained personnel. Before commencing work 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 preconditions for safe operation of the forklift truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck considerably affect the wear levels of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage caused by wear. The service intervals listed 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 heavy dust, temperature fluctuations or multiple shifts.
The application conditions of an industrial truck considerably affect the wear levels of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage caused by wear. The service intervals listed 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 heavy dust, temperature fluctuations or multiple shifts.
The following service checklist indicates the tasks to be performed and the respective intervals to be observed. The service intervals are defined as follows:
The following service checklist indicates the tasks to be performed and the respective intervals to be observed. The service intervals are defined as follows:
W A B C
W A B C
= = = =
Every 50 Every 500 Every 1000 Every 2000
service hours, at least weekly operating hours operating hours, or at least annually operating hours, or at least annually
Z
W service intervals are to be performed by the customer.
0708.GB
Z
Thorough and expert servicing is one of the most important preconditions for safe operation of the forklift truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.
= = = =
Every 50 Every 500 Every 1000 Every 2000
service hours, at least weekly operating hours operating hours, or at least annually operating hours, or at least annually
W service intervals are to be performed by the customer.
0708.GB
M
Servicing and inspection
F3
F3
4
EKS 310 maintenance checklist
4
EKS 310 maintenance checklist
Maintenance intervals Standard = t W A B C 1.1 1.2 1.3 1.4
Drive:
2.1
Wheels: Steering:
Brake system:
2.2 2.3 3.1 3.2 4.1 4.2
5.1 5.2 5.3
t t t
Chassis/ Superstructure:
1.1 1.2 1.3 1.4
t
Drive:
2.1
t t Wheels: t t t
Steering:
t t t
Brake system:
F4
2.2 2.3 3.1 3.2 4.1 4.2
5.1 5.2 5.3 5.4 5.5 5.6
t t
0708.GB
5.4 5.5 5.6
Check all load bearing items for damage Check screw connections Test the operator’s platform and check for damage Check that identification points, data plates and t warnings are legible and replace if necessary Lubricate the bearing between traction motor and transmission Check transmission for noise and leakage Change transmission oil Check wheels for wear and damage t Check bearings and attachment Test operation and setting of wheel setting display Check the distance between the guide rollers and the rail guidance over the entire length of the rails. The play between the two guide rollers and the rails (measured over the axle) should be 0-5 mm. The rollers should not jam. Test operation and settings Check the brake lining wear Check brake mechanism, adjust and lubricate if necessary Check brake lines, connections and brake fluid level t Check brake fluid Replace brake fluide
Check all load bearing items for damage Check screw connections Test the operator’s platform and check for damage Check that identification points, data plates and t warnings are legible and replace if necessary Lubricate the bearing between traction motor and transmission Check transmission for noise and leakage Change transmission oil Check wheels for wear and damage t Check bearings and attachment Test operation and setting of wheel setting display Check the distance between the guide rollers and the rail guidance over the entire length of the rails. The play between the two guide rollers and the rails (measured over the axle) should be 0-5 mm. The rollers should not jam. Test operation and settings Check the brake lining wear Check brake mechanism, adjust and lubricate if necessary Check brake lines, connections and brake fluid level t Check brake fluid Replace brake fluide
t t t
t t t t t t
t t t
t t
0708.GB
Chassis/ Superstructure:
Maintenance intervals Standard = t W A B C
F4
Maintenance intervals Standard = t W A B C Hydraulic System:
Electrical System:
Electric motors: Battery:
6.1 Test operation 6.2 Check connections and ports for leaks and damage 6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure 6.4 Check oil level 6.5 Test the hoses and check for damage 6.6 Check ventilation and discharge filter on hydraulic reservoir 6.7 Replace ventilation and discharge filter on hydraulic reservoir 6.8 Replace hydraulic oil and filter cartridge 6.9 Test pressure relief valves 6.10 Make sure hydraulic hoses are sealed and check for damage. p) 6.11 Test line brake safety device 7.1 Test static charge eliminator t 7.2 Test operation 7.3 Make sure wire connections are secure and check for wire damage 7.4 Test cable guide operation and check for damage 7.5 Test operation of warning devices and safety switches. 7.6 Make sure sensors are fixed, not damaged, clean and operational 7.7 Test operation of controls and displays. 7.8 Check contactors and relays; if necessary replace worn parts 7.9 Check fuse rating 8.2 Check motor attachment 9.1 Check acid density, acid level and cell voltage 9.2 Check terminals are securely attached, and apply grease 9.3 Clean battery plug connections, make sure they are firmly secured 9.4 Check battery cables for damage, replace if necessary.
Maintenance intervals Standard = t W A B C
t t t
Hydraulic System:
t t t t t t t t Electrical System:
t t t t t t t t t
Electric motors: Battery:
t t t t
9.1 Check acid density, acid level and cell voltage 9.2 Check terminals are securely attached, and apply grease 9.3 Clean battery plug connections, make sure they are firmly secured 9.4 Check battery cables for damage, replace if necessary.
t t t t t t t t t t t t t t t t t t t t t t t t
0708.GB
p) Replace hydraulic hoses after 6 years' operation
0708.GB
p) Replace hydraulic hoses after 6 years' operation
6.1 Test operation 6.2 Check connections and ports for leaks and damage 6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure 6.4 Check oil level 6.5 Test the hoses and check for damage 6.6 Check ventilation and discharge filter on hydraulic reservoir 6.7 Replace ventilation and discharge filter on hydraulic reservoir 6.8 Replace hydraulic oil and filter cartridge 6.9 Test pressure relief valves 6.10 Make sure hydraulic hoses are sealed and check for damage. p) 6.11 Test line brake safety device 7.1 Test static charge eliminator t 7.2 Test operation 7.3 Make sure wire connections are secure and check for wire damage 7.4 Test cable guide operation and check for damage 7.5 Test operation of warning devices and safety switches. 7.6 Make sure sensors are fixed, not damaged, clean and operational 7.7 Test operation of controls and displays. 7.8 Check contactors and relays; if necessary replace worn parts 7.9 Check fuse rating 8.2 Check motor attachment
F5
F5
Maintenance intervals Standard = t W A B C 10.1 Clean rollers, guide rollers and contact surfaces in the mast sections and apply grease.
M
t
Lift mechanism:
M
Warning: Danger of crashing!
10.2 Check mast attachments (bearings and retaining screws) 10.3 Check lift chains and chain guide for wear, adjust and lubricate 10.4 Lubricate lift chains t 10.5 Visually inspect rollers, slide pieces and stops Attachments: 11.1 Test operation and settings 11.2 Check attachment on truck and load bearing items 11.3 Check forks and fork carriage for wear and damage 11.4 Lubricate fork carriage rollers Lubrication: 12.1 Lubricate the truck according to the lubrication schedule General mea- 13.1 Check electrical system for accidental earth surements: 13.2 Check travel speed and braking distance 13.3 Check lift and lowering speeds 13.4 Check safety devices and cutouts 13.5 IG: Measure the current in the guidance wire, adjust if necessary e) 13.6 Check travel on the IG wire, check maximum deviation and adjust if necessary e) 13.7 Check tracking mode on the IG wire for aisle tracking . e) 13.8 Check IG EMERGENCY STOP operation e) Demons14.1 Test run with rated load tration: 14.2 When maintenance is completed, present the truck to the responsible person.
t
t
Warning: Danger of crashing!
10.2 Check mast attachments (bearings and retaining screws) 10.3 Check lift chains and chain guide for wear, adjust and lubricate 10.4 Lubricate lift chains t 10.5 Visually inspect rollers, slide pieces and stops Attachments: 11.1 Test operation and settings 11.2 Check attachment on truck and load bearing items 11.3 Check forks and fork carriage for wear and damage 11.4 Lubricate fork carriage rollers Lubrication: 12.1 Lubricate the truck according to the lubrication schedule General mea- 13.1 Check electrical system for accidental earth surements: 13.2 Check travel speed and braking distance 13.3 Check lift and lowering speeds 13.4 Check safety devices and cutouts 13.5 IG: Measure the current in the guidance wire, adjust if necessary e) 13.6 Check travel on the IG wire, check maximum deviation and adjust if necessary e) 13.7 Check tracking mode on the IG wire for aisle tracking . e) 13.8 Check IG EMERGENCY STOP operation e) Demons14.1 Test run with rated load tration: 14.2 When maintenance is completed, present the truck to the responsible person.
t
t t t t t t t t t t t t t t t t
t t
t t t t t t t t t t t t t t t t
e) IG: inductive guidance trucks
0708.GB
e) IG: inductive guidance trucks
F6
10.1 Clean rollers, guide rollers and contact surfaces in the mast sections and apply grease.
0708.GB
Lift mechanism:
Maintenance intervals Standard = t W A B C
F6
Lubrication Schedule
Lubrication Schedule
G
G
G
G
E
G
E
H
H
E
E
B
g
G
E
Slide surfaces
A
B
a Transmission oil drain plug
g
s Grease nipple
E
Slide surfaces
A
a Transmission oil drain plug
s Grease nipple
c Hydraulic oil drain plug
c Hydraulic oil drain plug 0708.GB
Hydraulic oil filler neck
0708.GB
Hydraulic oil filler neck
F7
F7
4.1
Fuels, coolants and lubricants
4.1
Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions.
F
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.
Consumables must always be stored in clean containers only. The mixing of different grade consumables is forbidden. The only exception to this is when mixing is expressly stipulated in the operator manual.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be dispoed of according to regulations.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be dispoed of according to regulations.
A
B D
Order No.
Quantity Filling delivered quantity
51037497 51037494
5l 1l
51085361*
5l
50022968
5l
ca. 33 l
Designation HLP D22 + 2% of 68 ID additive Plantohyd 22 S (BIO hydraulic oil)
Used for
Code
Hydraulic system
A
Order No.
Quantity Filling delivered quantity
51037497 51037494
5l 1l
51085361*
5l
ca. 33 l
Designation HLP D22 + 2% of 68 ID additive Plantohyd 22 S (BIO hydraulic oil)
Used for
Hydraulic system
2.5 l
SAE 80 EP API GL4 Transmission
B
50022968
5l
2.5 l
SAE 80 EP API GL4 Transmission
Brake fluid SAE DOT 4
Hydraulic brake system
D
29201580
5l
0.18 l
Brake fluid SAE DOT 4
Hydraulic brake system
Lithium-saponified grease KP2K-30 (DIN 51825)
General
E
14038650
400 g cartridge
---
General
29201430
1 kg
Lithium-saponified grease KP2K-30 (DIN 51825)
Chain spray Tunfluid LT 220
Lifting mast sliding track, lifting chains
G
29201280
400 ml
---
Chain spray Tunfluid LT 220
Lifting mast sliding track, lifting chains
Lithium-saponified grease K3K-20 (DIN 51825)
Front wheel bearings
H
50157382
1 kg
400 g
Lithium-saponified grease K3K-20 (DIN 51825)
Front wheel bearings
29201580
5l
0.18 l
14038650
400 g cartridge
---
29201430
1 kg
G
29201280
400 ml
---
H
50157382
1 kg
400 g
E
* Plus 2% additive 68 ID (order no. 50307735)
* Plus 2% additive 68 ID (order no. 50307735) The trucks are supplied from the factory with “HLP D22” hydraulic oil or the “Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive. You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
0708.GB
F
The trucks are supplied from the factory with “HLP D22” hydraulic oil or the “Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive. You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
0708.GB
F8
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.
Consumables must always be stored in clean containers only. The mixing of different grade consumables is forbidden. The only exception to this is when mixing is expressly stipulated in the operator manual.
Code
F
Fuels, coolants and lubricants
F8
5
Maintenance and Repairs
5
Maintenance and Repairs
M
Load bearing parts of the truck, e. g. chassis and mast, may only be welded after consultation with the manufacturer.
M
Load bearing parts of the truck, e. g. chassis and mast, may only be welded after consultation with the manufacturer.
5.1
Preparing the truck for maintenance and repairs
5.1
Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents during maintenance and repair work. The following preparations must be made:
– Park the truck securely (See Chapter E). – Disconnect the battery to prevent the truck from being switched on accidentally – When working under a raised lift truck, secure it to prevent it from lowering, tipping or sliding away.
– Park the truck securely (See Chapter E). – Disconnect the battery to prevent the truck from being switched on accidentally – When working under a raised lift truck, secure it to prevent it from lowering, tipping or sliding 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 parking brake, prevent the truck from rolling away.
0708.GB
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 parking brake, prevent the truck from rolling away.
0708.GB
F
All necessary safety measures must be taken to avoid accidents during maintenance and repair work. The following preparations must be made:
F9
F9
5.2
Securing the driver’s position carriage The driver’s position carriage can be secured in the raised position. – Raise the driver’s position carriage until the inner mast (1) is above the carriage (2) of the load lifting safety device. – Unscrew the attachment screw (4) and remove the retaining bolt (3) from the carriage (2) on the mast. – Place the retaining bolt (3) on the vertical hole of the carriage (2) and secure them. – Very slowly lower the driver’s position carriage until the inner mast (1) is positioned on the retaining bolt.
5.2
1
Securing the driver’s position carriage The driver’s position carriage can be secured in the raised position. – Raise the driver’s position carriage until the inner mast (1) is above the carriage (2) of the load lifting safety device. – Unscrew the attachment screw (4) and remove the retaining bolt (3) from the carriage (2) on the mast. – Place the retaining bolt (3) on the vertical hole of the carriage (2) and secure them. – Very slowly lower the driver’s position carriage until the inner mast (1) is positioned on the retaining bolt.
2
4 3
1
2
4 3
5.3
Maintaining the lift chains
5.3
Maintaining the lift chains
M
It is important that all lift chains and pivots are at all times kept clean and well lubricated. Only lubricate discharged chains. A chain must be lubricated with particular care where it passes over a deflection pulley. Lift chains are safety-critical parts. Chains should not have any major contamination. They should only be cleaned with parafin derivatives e. g. petroleum or diesel fuels. Never clean chains with steam jet high pressure cleaners, cold or chemical cleaning agents.
M
It is important that all lift chains and pivots are at all times kept clean and well lubricated. Only lubricate discharged chains. A chain must be lubricated with particular care where it passes over a deflection pulley. Lift chains are safety-critical parts. Chains should not have any major contamination. They should only be cleaned with parafin derivatives e. g. petroleum or diesel fuels. Never clean chains with steam jet high pressure cleaners, cold or chemical cleaning agents.
5.4
Inspecting the lift chains
5.4
Inspecting the lift chains Unauthorised wear and external damage:
In accordance with official regualtions, a chain is considered to be worn if it has extended in length by 3% in the section which passes over the deflection pulley. For safety reasons, we advise replacing chains when they elongate by 2%. Chains should also be replaced immediately when visible damage is noted, as such damage leads to permanent breakage after a certain time.
In accordance with official regualtions, a chain is considered to be worn if it has extended in length by 3% in the section which passes over the deflection pulley. For safety reasons, we advise replacing chains when they elongate by 2%. Chains should also be replaced immediately when visible damage is noted, as such damage leads to permanent breakage after a certain time.
F 10
If the truck is fitted with two lift chains, both chains must always be replaced. This is the only way to ensure even load distribution over the two chains. When replacing chains the connecting bolts between the chain anchor and the chain must be replaced. Only new original parts may be used.
0708.GB
M
If the truck is fitted with two lift chains, both chains must always be replaced. This is the only way to ensure even load distribution over the two chains. When replacing chains the connecting bolts between the chain anchor and the chain must be replaced. Only new original parts may be used.
0708.GB
M
Unauthorised wear and external damage:
F 10
5.5
Cleaning the discharge filter
5.5
Unscrew the discharge filter and the oil dipstick (5) and clean with compressed air or a cleaning agent.
M
Cleaning the discharge filter Unscrew the discharge filter and the oil dipstick (5) and clean with compressed air or a cleaning agent.
M
Dispose of used filters in the correct manner.
Dispose of used filters in the correct manner.
5
5.6
5
Replacing the hydraulic oil filter
5.6
– Unscrew the hydraulic oil filter sealing cap (6). – Replace filter insert and O ring. Apply a thin layer of oil to the O-ring on installation. – Screw the sealing cap back on.
Replacing the hydraulic oil filter – Unscrew the hydraulic oil filter sealing cap (6). – Replace filter insert and O ring. Apply a thin layer of oil to the O-ring on installation. – Screw the sealing cap back on.
0708.GB
6
0708.GB
6
F 11
F 11
5.7
Hydraulic oil
5.7
– Preparing the truck for maintenance and repairs
M
Hydraulic oil – Preparing the truck for maintenance and repairs
M
Oil must never be allowed to enter the drainage system or the soil. Used oil must be preserved until it can be disposed of in the correct manner.
Oil must never be allowed to enter the drainage system or the soil. Used oil must be preserved until it can be disposed of in the correct manner.
Draining oil:
Draining oil:
Suction off the hydraulic oil with the discharge filter removed (5). If this is not possible, the hydraulic oil can be drained from the bottom of the hydraulic reservoir after the oil drain screw (8a) has been unscrewed.
Suction off the hydraulic oil with the discharge filter removed (5). If this is not possible, the hydraulic oil can be drained from the bottom of the hydraulic reservoir after the oil drain screw (8a) has been unscrewed.
Adding oil: Screw in the oil drain screw (8a). Replenish with new hydraulic oil up to the Max. mark on the dipstick (7). Screw the discharge filter backon.
Adding oil:
7
Screw in the oil drain screw (8a). Replenish with new hydraulic oil up to the Max. mark on the dipstick (7). Screw the discharge filter backon.
5 8a
8a
F
8b
F
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
F 12
Check which hydraulic oil is being added. If Plantohyd 22 S BIO hydraulic oil is being used, the warning: “Only add BIO hydraulic oil” (8b) will be on the hydraulic reservoir. In this case you may only use Hydrauliköl „Plantohyd 22 S BIO hydraulic oil to fill the hydraulic reservoir.
8b
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIO hydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 S BIO hydraulic oil.
Checking the hydraulic oil level
Checking the hydraulic oil level
When the mast is fully lowered, check that the hydraulic oil level is between the min. and max. markings on the dipstick (7). If this is not the case, add new hydraulic oil.
When the mast is fully lowered, check that the hydraulic oil level is between the min. and max. markings on the dipstick (7). If this is not the case, add new hydraulic oil.
0708.GB
F
Check which hydraulic oil is being added. If Plantohyd 22 S BIO hydraulic oil is being used, the warning: “Only add BIO hydraulic oil” (8b) will be on the hydraulic reservoir. In this case you may only use Hydrauliköl „Plantohyd 22 S BIO hydraulic oil to fill the hydraulic reservoir.
5
0708.GB
F
7
F 12
5.8
Hydraulic hoses
5.8
Hose lines must be replaced every six years, see Safety Regulations for Hydraulic Hose Lines ZH 1/74. 5.9
F M
Hose lines must be replaced every six years, see Safety Regulations for Hydraulic Hose Lines ZH 1/74.
Check brake fluid
5.9
F
The brake fluid is poisonous and should therefore only be kept in sealed original containers. Also note that brake fluid will attack the truck’s paint. Brake fluid is added in the factory and must be replaced after 12 months at the latest, as it changes over time and loses its original qualities.
Hydraulic hoses
M
9
The brake fluid is poisonous and should therefore only be kept in sealed original containers. Also note that brake fluid will attack the truck’s paint. Brake fluid is added in the factory and must be replaced after 12 months at the latest, as it changes over time and loses its original qualities.
9
0708.GB
The brake fluid storage container (9) is located at the rear of the truck and can be accessed by removing the panel. The storage container should also be filled up to 2 cm below the lid. Only use the prescribed brake fluid. Make sure the entire brake system is fully sealed.
0708.GB
The brake fluid storage container (9) is located at the rear of the truck and can be accessed by removing the panel. The storage container should also be filled up to 2 cm below the lid. Only use the prescribed brake fluid. Make sure the entire brake system is fully sealed.
Check brake fluid
F 13
F 13
5.10
Checking electrical fuses
5.10
Checking electrical fuses
F
Electric fuses must only be checked and replaced by authorized personnel.
F
Electric fuses must only be checked and replaced by authorized personnel.
F
Only use the rating indicated on the controller. DIN and EN standardised fuses must not be used for UL standardised fuses. The opposite also applies.
F
– Prepare the truck for maintenance and repairs (see Chapter F). – Check all fuse ratings in accordance with the table; replace if necessary. Only use the rating indicated on the controller. DIN and EN standardised fuses must not be used for UL standardised fuses. The opposite also applies.
13
– Prepare the truck for maintenance and repairs (see Chapter F). – Check all fuse ratings in accordance with the table; replace if necessary.
13
14
12
12
18 17 16 15
18 17 16 15
10
To protect: Rating Travel 160A (DIN, EN) 250A (UL) Steering 35A (DIN, EN) 35A (UL) Hydraulics 250A (DIN, EN) 400A (UL) DC/DC converter U1 input 48 V 48V / 10A (UL) Lighting and special equipment 48 V 48V / 10A (UL) DC/DC converter U1 output 24 V 24V / 10A (UL) DC/DC converter U16 input 48 V 48V / 4A (UL) DC/DC converter U16 output 24 V 24V / 6,3A (UL) Drive controller 1A (UL)
Item 10 11 12 13 14 15 16 17 18 0708.GB
Description 1F11 3F10 2F15 F2.1 5F1 F3.1 F1.2 5F2 1F3
11
F 14
10
Description 1F11 3F10 2F15 F2.1 5F1 F3.1 F1.2 5F2 1F3
To protect: Rating Travel 160A (DIN, EN) 250A (UL) Steering 35A (DIN, EN) 35A (UL) Hydraulics 250A (DIN, EN) 400A (UL) DC/DC converter U1 input 48 V 48V / 10A (UL) Lighting and special equipment 48 V 48V / 10A (UL) DC/DC converter U1 output 24 V 24V / 10A (UL) DC/DC converter U16 input 48 V 48V / 4A (UL) DC/DC converter U16 output 24 V 24V / 6,3A (UL) Drive controller 1A (UL) 0708.GB
11
Item 10 11 12 13 14 15 16 17 18
14
F 14
5.11
6
Recommissioning
5.11
Recommissioning after cleaning or repair work is permitted only after the following operations have been performed.
Recommissioning after cleaning or repair work is permitted only after the following operations have been performed.
– – – –
– – – –
Test horn operation. Test EMERGENCY DISCONNECT switch. Test brake operation. Lubricate the truck in accordance with the lubrication chart.
Decommissioning the forklift truck
6
If the forklift truck is to be decommissioned for more than one month, 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
During 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.
6.1
Thoroughly clean the truck. Check the brakes. Check the hydraulic oil level and replenish as necessary (see Chapter F). Apply a think film of oil or grease to all parts not protected by a coating of paint. Lubricate the truck in accordance with the lubrication schedule (see Chapter F). Charge the battery (see Chapter D). Disconnect the battery, clean it and apply grease to the terminals.
During 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: – – – – – – –
Z
In addition, observe the battery manufacturer’s instructions.
Thoroughly clean the truck. Check the brakes. Check the hydraulic oil level and replenish as necessary (see Chapter F). Apply a think film of oil or grease to all parts not protected by a coating of paint. Lubricate the truck in accordance with the lubrication schedule (see Chapter F). Charge the battery (see Chapter D). Disconnect the battery, clean it and apply grease to the terminals.
In addition, observe the battery manufacturer’s instructions. – Apply a suitable contact spray to all exposed electrical contacts.
0708.GB
– Apply a suitable contact spray to all exposed electrical contacts.
0708.GB
Z
Decommissioning the forklift 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.
Prior to decommissioning: – – – – – – –
Test horn operation. Test EMERGENCY DISCONNECT switch. Test brake operation. Lubricate the truck in accordance with the lubrication chart.
If the forklift truck is to be decommissioned for more than one month, 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. 6.1
Recommissioning
F 15
F 15
6.2
During decommissioning:
6.2
During decommissioning:
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.
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.
6.3
Recommissioning
6.3
Recommissioning
Z
– – – – – – –
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 starting the truck again.
0708.GB
F
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).
F 16
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).
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. Perform several brake tests immediately after starting the truck again.
0708.GB
– – – – – – –
F 16
7
Safety checks to be performed at regular intervals and following any unusual incidents
7
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.
8
Final de-commissioning, disposal
8
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 17
F 17
F 18 F 18 0708.GB
0708.GB
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
0506.GB
2
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
2
Jungheinrich traction battery
0506.GB
1
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.
3
0506.GB
0506.GB
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.
4
0506.GB
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.
0506.GB
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.
4
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.
0506.GB
3. Maintenance
0506.GB
3. Maintenance
5
5
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!
6
0506.GB
We reserve the right make technical modification.
0506.GB
We reserve the right make technical modification.
6
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
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
0506.GB
* 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
7
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.
0506.GB
8
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
8
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.
9
0506.GB
0506.GB
5. Charger
at least 3 m
Diagrammatic view
at least 3 m
Diagrammatic view
9
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.
10
0506.GB
4. Filling (manual/automatic)
0506.GB
4. Filling (manual/automatic)
10
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.
0506.GB
8. Battery hose connections
0506.GB
8. Battery hose connections
11
11
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
0506.GB
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.
0506.GB
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.
12
- rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
12
