Transcript
ESE 220 Operating instructions 50453554 07.08
01.05-
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
Table of contents
Table of contents
Foreword
Foreword A
Correct use and application of the truck
B
Description of the truck
B
Description of the truck
1 2 2.1 2.2 2.3 2.4 2.5 3 3.1
Design and application...................................................................... B 1 Assemblies ....................................................................................... B 2 Technical data - standard version ..................................................... B 3 Performance data.............................................................................. B 3 Dimensions ....................................................................................... B 4 EN standards .................................................................................... B 6 Conditions for application.................................................................. B 6 Labels................................................................................................ B 7 Truck identification plate ................................................................... B 8
1 2 2.1 2.2 2.3 2.4 2.5 3 3.1
Design and application...................................................................... B 1 Assemblies ....................................................................................... B 2 Technical data - standard version ..................................................... B 3 Performance data.............................................................................. B 3 Dimensions ....................................................................................... B 4 EN standards .................................................................................... B 6 Conditions for application.................................................................. B 6 Labels................................................................................................ B 7 Truck identification plate ................................................................... B 8
C
Transportation and commissioning
C
Transportation and commissioning
1 2 3
Transportation by crane .................................................................... C 1 Commissioning.................................................................................. C 1 Moving the truck with the drive unit inoperative ................................ C 2
1 2 3
Transportation by crane .................................................................... C 1 Commissioning.................................................................................. C 1 Moving the truck with the drive unit inoperative ................................ C 2
D
Battery servicing, recharging and replacement
D
Battery servicing, recharging and replacement
1 2 3 4 5 6
Safety regulations governing the handling of lead-acid batteries...... D 1 Battery types ..................................................................................... D 2 Exposing the battery ......................................................................... D 2 Charging the battery.......................................................................... D 3 Removing and installing the battery .................................................. D 4 Battery discharge indicator, battery discharge monitor, operating hour meter......................................................................... D 5
1 2 3 4 5 6
Safety regulations governing the handling of lead-acid batteries...... D 1 Battery types ..................................................................................... D 2 Exposing the battery ......................................................................... D 2 Charging the battery.......................................................................... D 3 Removing and installing the battery .................................................. D 4 Battery discharge indicator, battery discharge monitor, operating hour meter......................................................................... D 5
0708.GB
Correct use and application of the truck
0708.GB
A
I3
I3
E
Operation
E
Operation
1 2 3 4 4.1 4.2 4.3 4.4 5 5.1 5.2 5.3 5.4 6
Safety regulations governing the operation of the fork-lift truck ........ E 1 Description of the operating controls and indicators ......................... E 2 Starting up the truck .......................................................................... E 4 Operation of the fork-lift truck ............................................................ E 7 Safety regulations applicable when operating the truck .................... E 7 Driving, steering, braking .................................................................. E 8 Picking up and setting down loads .................................................. E 11 Safe parking of the truck ................................................................. E 12 Information and service indicator (LISA) ......................................... E 13 LED indicators................................................................................. E 13 Keyboard assignment ..................................................................... E 13 Indicators......................................................................................... E 14 Changing driving parameters .......................................................... E 15 Fault location................................................................................... E 16
1 2 3 4 4.1 4.2 4.3 4.4 5 5.1 5.2 5.3 5.4 6
Safety regulations governing the operation of the fork-lift truck ........ E 1 Description of the operating controls and indicators ......................... E 2 Starting up the truck .......................................................................... E 4 Operation of the fork-lift truck............................................................ E 7 Safety regulations applicable when operating the truck .................... E 7 Driving, steering, braking .................................................................. E 8 Picking up and setting down loads.................................................. E 11 Safe parking of the truck ................................................................. E 12 Information and service indicator (LISA) ......................................... E 13 LED indicators................................................................................. E 13 Keyboard assignment ..................................................................... E 13 Indicators......................................................................................... E 14 Changing driving parameters .......................................................... E 15 Fault location................................................................................... E 16
F
Maintenance of the fork-lift truck
F
Maintenance of the fork-lift truck
1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 7.3 8
Operational safety and environmental protection...............................F 1 Safety regulations applicable to truck maintenance ...........................F 1 Servicing and inspection ....................................................................F 3 Maintenance checklist........................................................................F 4 Lubrication schedule ..........................................................................F 6 Fuels, coolants and lubricants............................................................F 7 Instructions for the servicing operations.............................................F 8 Preparing the truck for servicing and maintenance operations ..........F 8 Tilting up the armrest .........................................................................F 8 Opening the battery door and the seat hood......................................F 8 Opening the hood...............................................................................F 9 Tightening the wheel screws ............................................................F 10 Checking the electric fuses ..............................................................F 11 Recommissioning the truck ..............................................................F 12 Decommissioning the fork lift truck ..................................................F 12 Operations to be performed prior to decommissioning ....................F 12 Measures to be taken during decommissioning...............................F 12 Recommissioning the truck ..............................................................F 13 Safety checks to be performed at regular intervals and following any unusual incidents.......................................................................F 14 Final de-commissioning, disposal ....................................................F 14
1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 7.3 8
Operational safety and environmental protection...............................F 1 Safety regulations applicable to truck maintenance ...........................F 1 Servicing and inspection ....................................................................F 3 Maintenance checklist........................................................................F 4 Lubrication schedule ..........................................................................F 6 Fuels, coolants and lubricants............................................................F 7 Instructions for the servicing operations.............................................F 8 Preparing the truck for servicing and maintenance operations ..........F 8 Tilting up the armrest .........................................................................F 8 Opening the battery door and the seat hood......................................F 8 Opening the hood...............................................................................F 9 Tightening the wheel screws............................................................F 10 Checking the electric fuses ..............................................................F 11 Recommissioning the truck ..............................................................F 12 Decommissioning the fork lift truck ..................................................F 12 Operations to be performed prior to decommissioning ....................F 12 Measures to be taken during decommissioning...............................F 12 Recommissioning the truck ..............................................................F 13 Safety checks to be performed at regular intervals and following any unusual incidents.......................................................................F 14 Final de-commissioning, disposal ....................................................F 14
I4
0708.GB
9
0708.GB
9
I4
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 included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable.
The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.
The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.
Duties of the user: A “user” within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties. The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
Duties of the user: A “user” within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties. The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
M
If these Operating Instruction are not observed the warranty becomes void. The same applies if improper work is carried out on the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
0105.GB
0105.GB
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
If these Operating Instruction are not observed the warranty becomes void. The same applies if improper work is carried out on the device by the customer and/or third parties without permission of our Customer Service.
A1
A1
A2 A2 0105.GB
0105.GB
B Description of the truck
B Description of the truck
1
1
Design and application
The ESE 220 is an electric pallet truck with lateral seat in four-wheel design. It is provided with a driver's seat with electric steering wheel control. The ESE 220 is designed for transport and order-picking operations on level ground. Pallets with open ground support or pallets fitted with lateral boards (provided that the boards are outside the range of the load-bearing wheels) can be picked up. The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax.
0708.GB
0708.GB
The ESE 220 is an electric pallet truck with lateral seat in four-wheel design. It is provided with a driver's seat with electric steering wheel control. The ESE 220 is designed for transport and order-picking operations on level ground. Pallets with open ground support or pallets fitted with lateral boards (provided that the boards are outside the range of the load-bearing wheels) can be picked up. The rated capacity of the truck is shown on the identification plate or on the capacity label Qmax.
Design and application
B1
B1
Assemblies
2
1
2
3
Assemblies
4
1
11
2
3
4
11
5
5
10
10
6
6
7
7
9
9
8
Designation
Designation Battery door
1t
Information and service indicator
6t 7t
Seat hood
2t
Travelling direction handle
8t
3t
Master switch (emerg. stop)
9t
4t
Hood
5t
Lifting device t = Standard equipment
B2
Item
Item
Designation
Item
Designation
1t
Information and service indicator
6t
Battery door
7t
Seat hood
Drive wheel
2t
Travelling direction handle
8t
Drive wheel
Supporting wheel
3t
Master switch (emerg. stop)
9t
Supporting wheel
10 t
Dead man's switch
4t
Hood
10 t
Dead man's switch
11 t
Parking brake
5t
Lifting device
11 t
Parking brake
o = Optional equipment
t = Standard equipment
0708.GB
Item
8
B2
o = Optional equipment
0708.GB
2
2.1
Technical data - standard version
2.1
Technical data - standard version
Z
Indication of technical data according to VDI 2398, subject to modification and supplementing.
Z
Indication of technical data according to VDI 2398, subject to modification and supplementing.
2.2
Performance data
2.2
Performance data
Designation
Standard
Rapid drive
t
o
Designation
Standard
Rapid drive
t
o
Q
Rated capacity
2000
2000
kg
Q
Rated capacity
2000
2000
kg
C
Load centre distance
600
600
mm
C
Load centre distance
600
600
mm
Travelling speed with / without rated load
8,4 / 10,7
9,5 / 12,5
km/h
Travelling speed with / without rated load
8,4 / 10,7
9,5 / 12,5
km/h
Lifting speed with / without rated load
3,0 / 2,6
3,0 / 2,6
cm/s
Lifting speed with / without rated load
3,0 / 2,6
3,0 / 2,6
cm/s
Lowering speed with / without rated load
6,5 / 4,0
6,5 / 4,0
cm/s
Lowering speed with / without rated load
6,5 / 4,0
6,5 / 4,0
cm/s
6 / 13
7 / 14
%
6 / 13
7 / 14
%
Max. climbing capacity (5 min.) with / without rated load
Max. climbing capacity (5 min.) with / without rated load
h7
c
l2
30
70
95
y
95
y
155
l
l2
l1
l l1
l6
l6
a _ 2 Ast3
B3
a _ 2
Wa
b12
b5
b11
b1
b5
b12
0708.GB
Wa
b3
b11
b1
0708.GB
a _ 2
e
x
e
x
b3
155
h13
30
70
h3
Q
h3
Q
h13
h7
c
a _ 2 Ast3
B3
2.3
Dimensions
2.3
(all dimensions in mm)
Dimensions (all dimensions in mm)
Designation
Designation
l2
Design length of front
880
l2
Design length of front
h13 h3
Height of fork when lowered
86
h13
Height of fork when lowered
86
Lift
125
h3
Lift
125
h7
Seat height
900
h7
Seat height
900
b1
Truck width
830
b1
Truck width
b5
Distance between forks, outside
510 / 540 / 670
b5
Distance between forks, outside
510 / 540 / 670
b11
Track
340 / 370 / 500
b11
Track
340 / 370 / 500
b3
Distance between forks, inside
170 / 200 / 330
b3
Distance between forks, inside
170 / 200 / 330
e
Fork width
170
e
Fork width
170
a
Safety distance
200
a
Safety distance
200
Dead weight
Refer to truck identification label
830
Dead weight
Working aisle widths
Working aisle widths
(all dimensions in mm)
(all dimensions in mm)
Refer to truck identification label
l
l1
y1)
x1)
l6
b12
Wa1)
Ast3
l
l1
y1)
x1)
l6
b12
Wa1)
Ast3
1000
1880
1539
814
1000
800
1721
2107
1000
1880
1539
814
1000
800
1721
2107
1150
2030
1689
964
1200
800
1869
2305
1150
2030
1689
964
1200
800
1869
2305
1200
2080
1739
1014
1200
800
1918
2304
1200
2080
1739
1014
1200
800
1918
2304
1400
2280
1939
1214
1400
700
2116
2502
1400
2280
1939
1214
1400
700
2116
2502
1600
2480
2139
1414
1600
1200
2314
2700
1600
2480
2139
1414
1600
1200
2314
2700
1750
2630
1917
1192
2000
800
2094
3102
1750
2630
1917
1192
2000
800
2094
3102
1950
2830
2117
1392
2000
800
2292
3100
1950
2830
2117
1392
2000
800
2292
3100
2150
3030
2317
1592
2100
700
2491
3199
2150
3030
2317
1592
2100
700
2491
3199
2400
3280
2565
1840
2400
1200
2737
3497
2400
3280
2565
1840
2400
1200
2737
3497
1)With
the load part lifted, the values are reduced by 90mm.
0708.GB
the load part lifted, the values are reduced by 90mm.
0708.GB
1)With
B4
880
B4
a _ 2 Wa
a _ 2 a _ 2
Ast3
B5
l1
x
Wa
l2
l6 h13
95
b12
y
b5
e
155
b3
l 30
70
30
70
h3
h3
h7
h7
Q
b11
b1
b12
l2 h13
95
b5
e
y
b3
b11
b1
155
0708.GB
0708.GB
c c
Q
l1 l
x l6
a _ 2
Ast3
B5
2.4
EN standards Continuous sound level:
2.4 68 dB(A)
EN standards Continuous sound level:
according to EN 12053 as stipulated in ISO 4871
Z
according to EN 12053 as stipulated in ISO 4871
Z
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration:
0.36 m/s2
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration:
according to EN 13059
Z
68 dB(A)
0.36 m/s2 according to EN 13059
Z
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed. Electromagnetic compatibility (EMC)
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed. Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other standards contained therein.
The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other standards contained therein.
Z
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
Z
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
2.5
Conditions for application
2.5
Conditions for application
Ambient temperature:
Ambient temperature: - during operation: 5 °C to 40 °C
B6
Special equipment and a special approval are required if fork-lifttrucks are operated under continued extreme temperature or humidity fluctuations.
0708.GB
Z
Special equipment and a special approval are required if fork-lifttrucks are operated under continued extreme temperature or humidity fluctuations.
0708.GB
Z
- during operation: 5 °C to 40 °C
B6
Labels
3
mV
Qmax 2000kg 12
Labels
13
18
12 14
Kundendienst
Kundendienst Regelmäßige Prüfung nach UVV VBG 12 a/ 12 b §20 durch Sachkundigen
12
1
2 1
3
11
1
3
9 8 7
9 8 7
2 1
11
0
0
0 200
6
4
5
4
Nächste Prüfung
Nächste Prüfung
Ihr Kundendienst-Partner
Ihr Kundendienst-Partner
16
16 16
Item
16
Designation
Item
Designation
12
Capacity Qmax
12
Capacity Qmax
13
Travelling direction handle
13
Travelling direction handle
14
Label “CAUTION: Low-voltage electronics”
14
Label “CAUTION: Low-voltage electronics”
15
Battery identification plate
15
Battery identification plate
16
Attachment point of hooks for transportation by crane
16
Attachment point of hooks for transportation by crane
17
Test sticker (o)
17
Test sticker (o)
18
Truck identification plate
18
Truck identification plate
The capacity label (12) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded. The "Caution electronics and low voltage“ warning signs (14) are visible after opening the corresponding hood. The battery identification plate (15) is visible after opening the battery hood and door (refer to chapter D, section 5).
B7
Z 0708.GB
0708.GB
Z
14
17
nach UVV VBG 12 a/ 12 b §20 durch Sachkundigen
5
13
15
Regelmäßige Prüfung
0 200
1,5 V
18
15
17
6
mV
Qmax 2000kg
1,5 V
12
3
The capacity label (12) indicates the maximum capacity of the truck as Qmax. The rated capacity as shown must not be exceeded. The "Caution electronics and low voltage“ warning signs (14) are visible after opening the corresponding hood. The battery identification plate (15) is visible after opening the battery hood and door (refer to chapter D, section 5).
B7
3.1
Truck identification plate
3.1
Truck identification plate
18
29
18
29
19
28
19
28
20
27
20
27
21
26
21
26
22
25
22
25
Item Designation 18
24
23
23
Item Designation 24
Item Designation
Manufacturer
18
B8
Type
Item Designation 24
Manufacturer
19
Serial No.
25
Min./max. battery weight in kg
19
Serial No.
25
Min./max. battery weight in kg
20
Rated capacity in kg
26
Drive power in kW
20
Rated capacity in kg
26
Drive power in kW
21
Battery: Voltage V
27
Load centre distance in mm
21
Battery: Voltage V
27
Load centre distance in mm
22
Empty weight without battery in kg
28
Year of manufacture
22
Empty weight without battery in kg
28
Year of manufacture
23
Manufacturer logo
29
Option
23
Manufacturer logo
29
Option
In the event of queries relating to the truck or spare part orders, please state the serial No. (21) of the truck.
0708.GB
Z
In the event of queries relating to the truck or spare part orders, please state the serial No. (21) of the truck.
0708.GB
Z
Type
24
B8
C Transportation and commissioning
C Transportation and commissioning
1
Transportation by crane
1
Transportation by crane
F
Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).
F
Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).
Z
Bore holes for lifting screws (1) and hoisting points at the chassis (2) can be used if hoisting gear is to be used for transporting the truck.
Z
Bore holes for lifting screws (1) and hoisting points at the chassis (2) can be used if hoisting gear is to be used for transporting the truck.
F
1
- Park the truck and render it safe (refer to chapter E, section 4.4).
- Park the truck and render it safe (refer to chapter E, section 4.4).
- Screw the transportation screws (1) into the bore holes of the single mast.
- Screw the transportation screws (1) into the bore holes of the single mast.
F
Only M16 DIN 580 lifting screws may be used as transportation screws. - Attach the hoisting gear to the stop points (2) and the lifting screws (1). The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip and cannot come into contact with any attachments of the truck when the truck is lifted.
Only M16 DIN 580 lifting screws may be used as transportation screws. - Attach the hoisting gear to the stop points (2) and the lifting screws (1).
M 2
The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip and cannot come into contact with any attachments of the truck when the truck is lifted.
2
2
Commissioning
2
Commissioning
M
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
M
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
Z
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
- Check the truck for completeness and satisfactory condition of the equipment.
- Check the truck for completeness and satisfactory condition of the equipment.
- If necessary, install the battery. Do not damage the battery cable (refer to chapter D, section 5.)
- If necessary, install the battery. Do not damage the battery cable (refer to chapter D, section 5.)
- Charge the battery (refer to chapter D, section 4).
- Charge the battery (refer to chapter D, section 4).
- Check whether the information and service indicator setting corresponds to the used battery type (refer to chapter D, section 6).
- Check whether the information and service indicator setting corresponds to the used battery type (refer to chapter D, section 6).
- Commission the truck as detailed in chapter E, section 3.
- Commission the truck as detailed in chapter E, section 3.
When the truck is parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
C1
0105.GB
0105.GB
M
1
Z
When the truck is parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
C1
3
Moving the truck with the drive unit inoperative
3
Moving the truck with the drive unit inoperative
F
This operating mode is not permitted when negotiating inclines and gradients.
F
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failure has rendered it immobile, proceed as follows: - Set the master switch to position “OFF”.
- Set the master switch to position “OFF”.
- Set the key switch to position “OFF” (“0”) and remove the key.
- Set the key switch to position “OFF” (“0”) and remove the key.
- Ensure that the truck cannot accidentally move. - Open the seat hood (refer to chapter F, section 6.3).
- Ensure that the truck cannot accidentally move.
3
- Open the seat hood (refer to chapter F, section 6.3).
- Slacken the lock nuts (4) and tighten the screws (3). The brake has now been released and the truck can be moved.
C2
3
- Slacken the lock nuts (4) and tighten the screws (3). The brake has now been released and the truck can be moved.
4
F
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition.
4
After arriving at the repair bay, ensure that the brake is put back to its initial state. The truck must on no account be parked with the brake in the released condition. - Loosen the screws (3) by approx. 5 mm and lock by tightening the lock nuts (4).
The brake is now applied again.
The brake is now applied again.
- Close the seat hood.
- Close the seat hood.
0105.GB
- Loosen the screws (3) by approx. 5 mm and lock by tightening the lock nuts (4).
0105.GB
F
If the truck has to be moved after a failure has rendered it immobile, proceed as follows:
C2
D Battery servicing, recharging and replacement
D Battery servicing, recharging and replacement
1
Safety regulations governing the handling of lead-acid batteries
1
Safety regulations governing the handling of lead-acid batteries
F
Before undertaking any operations on the batteries, park the truck and render it safe (refer to chapter E, section 4.4).
F
Before undertaking any operations on the batteries, park the truck and render it safe (refer to chapter E, section 4.4).
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual and the instructions as prepared by the battery supplier and as available at the battery recharging station must be observed when performing the above operations.
Servicing staff: Recharging, servicing and replacing of batteries must only be performed by qualified personnel. The instructions contained in this operating manual and the instructions as prepared by the battery supplier and as available at the battery recharging station must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 metres of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.
Fire protection measures: Smoking and naked flames are not permitted when handling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 metres of the truck parked for battery recharging. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with non-isolated poles must be covered with a non-slip isolation mat.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with non-isolated poles must be covered with a non-slip isolation mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for disposal must be heeded.
Disposal of the battery: Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions. The manufacturer’s specifications for disposal must be heeded.
M
Before closing the battery hood, make sure that the battery cable cannot be damaged.
M
Before closing the battery hood, make sure that the battery cable cannot be damaged.
F
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.
F
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must be immediately neutralized.
M F
Only batteries with closed battery trough may be used.
M F
Only batteries with closed battery trough may be used. The battery weight and dimensions have a considerable effect on the operational safety of the truck. For this reason, battery type changes are only permitted with the manufacturer’s approval.
0105.GB
0105.GB
The battery weight and dimensions have a considerable effect on the operational safety of the truck. For this reason, battery type changes are only permitted with the manufacturer’s approval.
D1
D1
2
Battery types
2
Depending on the truck version, the truck will be supplied with different battery types.
Battery types Depending on the truck version, the truck will be supplied with different battery types.
24V - PzS - Battery
3 PzS 330L (with weights)
24V - PzS - Battery
3 PzS 330L (with weights)
24V - PzS - Battery
3 PzS 420L
24V - PzS - Battery
3 PzS 420L
24V - PzS - Battery performance-enhanced 3 PzS 450HX
24V - PzS - Battery performance-enhanced 3 PzS 450HX
The battery weights can be seen on the battery identification plate.
The battery weights can be seen on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.
Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.
M
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
M
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
3
Exposing the battery
3
Exposing the battery
F
Park the truck and render it safe (refer to chapter E, section 4.4).
1
F
Park the truck and render it safe (refer to chapter E, section 4.4).
1
- Pull the unlocking lever (3) for the battery hood (1).
2
- Pull the unlocking lever (3) for the battery hood (1).
2
Swivel the hood (1) upwards.
- Installation is in the reverse order.
F
Carefully open or close the battery hood.
F
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
3
All covers and connections must be restored to the normal operating condition before the truck is started up for work.
0105.GB
F
Carefully open or close the battery hood.
D2
- Installation is in the reverse order.
3
0105.GB
F
Swivel the hood (1) upwards.
D2
4
Charging the battery
4
Charging the battery
F
To charge the battery, the truck must be parked in a closed and properly ventilated room.
F
To charge the battery, the truck must be parked in a closed and properly ventilated room.
- Expose the battery (refer to chapter D, section 3).
- Expose the battery (refer to chapter D, section 3).
M
The battery connector (2) and the charging cable (4) must only be connected or disconnected with the truck and the battery charger switched off. The master switch must also only be actuated with the truck and the battery charger switched off.
M
The battery connector (2) and the charging cable (4) must only be connected or disconnected with the truck and the battery charger switched off. The master switch must also only be actuated with the truck and the battery charger switched off.
F
During the recharging operation, the tops of the battery cells must be exposed to ensure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
F
During the recharging operation, the tops of the battery cells must be exposed to ensure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connections for visible damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed. - Withdraw the battery connector (2).
- Remove any insulating mats from the battery.
- Remove any insulating mats from the battery.
- Connect the charging cable (4) of the battery charger to the battery connector (2) and switch on the charger.
- Connect the charging cable (4) of the battery charger to the battery connector (2) and switch on the charger.
M
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
2
4
4
0105.GB
2
0105.GB
M
- Withdraw the battery connector (2).
D3
D3
5
Removing and installing the battery
5
Removing and installing the battery
F
The truck must be parked on level ground. To prevent short-circuits, batteries with exposed poles or cell connectors must be covered using a rubber mat. Place the battery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
F
The truck must be parked on level ground. To prevent short-circuits, batteries with exposed poles or cell connectors must be covered using a rubber mat. Place the battery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
M
When transporting batteries with the aid of a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points in such a way that the lifting gear, when slack, cannot collapse on the battery cells.
M
When transporting batteries with the aid of a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points in such a way that the lifting gear, when slack, cannot collapse on the battery cells. - Expose the battery (refer to chapter D, section 3).
- Withdraw the battery connector (2) (refer to chapter D, section 4).
- Withdraw the battery connector (2) (refer to chapter D, section 4).
- Open the battery door (6) using a square key.
- Open the battery door (6) using a square key.
Z
The square key is located under the armrest (refer to chapter F, section 6.2). - Remove the red battery lock (8).
- Remove the red battery lock (8).
- Pull the battery (7) laterally onto the battery change station.
- Pull the battery (7) laterally onto the battery change station.
F
Heed the operating instructions of the manufacturer of the battery exchange trolley!
F
After reinstallation of the battery, visually check all leads and connectors for damage. Ensure that the battery is firmly secured in the truck to prevent any damage caused by sudden movements of the truck. Make sure that the red battery lock (8) is properly attached. The battery hood and door must be properly closed.
Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.
F
Heed the operating instructions of the manufacturer of the battery exchange trolley!
F
After reinstallation of the battery, visually check all leads and connectors for damage. Ensure that the battery is firmly secured in the truck to prevent any damage caused by sudden movements of the truck. Make sure that the red battery lock (8) is properly attached. The battery hood and door must be properly closed.
5
2
6
7
Installation is in the reverse order of operations. When reinstalling the battery, heed the required installation position and make sure the battery is connected correctly.
5
2
6
8
0105.GB
8
D4
The square key is located under the armrest (refer to chapter F, section 6.2).
7
0105.GB
Z
- Expose the battery (refer to chapter D, section 3).
D4
6
Battery discharge indicator, battery discharge monitor, operating hour meter
6
Battery discharge indicator: The loading status of the battery (9) is indicated in steps of 10% on the information and service indicator.
M
Z
The manufacturer setting of the battery discharge indicator / discharge monitor is standard batteries. If maintenance-free batteries are used, the indicator must be adjusted in such a way that the "T" symbol (10) appears behind the percent specification. If this setting is not selected the battery may be damaged due to a complete discharge. Contact the customer service for setting the instrument.
9
10
BAT T : 0 4 0 % T
Battery discharge indicator, battery discharge monitor, operating hour meter Battery discharge indicator: The loading status of the battery (9) is indicated in steps of 10% on the information and service indicator.
M
11
4 71 h
The manufacturer setting of the battery discharge indicator / discharge monitor is standard batteries. If maintenance-free batteries are used, the indicator must be adjusted in such a way that the "T" symbol (10) appears behind the percent specification. If this setting is not selected the battery may be damaged due to a complete discharge. Contact the customer service for setting the instrument.
9
10
BAT T : 0 4 0 % T
11
4 71 h
If the remaining battery capacity falls below 30%, it is required to recharge the battery.
If the remaining battery capacity falls below 30%, it is required to recharge the battery.
Battery discharge monitor: If the residual capacity falls below the specified minimum value, the lifting function is switched off. A corresponding message is displayed in the information and service indicator.
Battery discharge monitor: If the residual capacity falls below the specified minimum value, the lifting function is switched off. A corresponding message is displayed in the information and service indicator.
Z
The lifting function will only then be released, if the connected battery is reloaded by min. 70%.
Operating hour meter: The operating hours (11) are indicated next to the loading status of the battery. The operating hour meter indicates the total time of all riding and lifting movements.
0105.GB
0105.GB
Operating hour meter: The operating hours (11) are indicated next to the loading status of the battery. The operating hour meter indicates the total time of all riding and lifting movements.
The lifting function will only then be released, if the connected battery is reloaded by min. 70%.
D5
D5
D6 D6 0105.GB
0105.GB
E Operation
E Operation
1
1
F
Safety regulations governing the operation of the fork-lift truck
Safety regulations governing the operation of the fork-lift truck
Driving permission: The fork-lift truck must only be operated by persons who have been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Driving permission: The fork-lift truck must only be operated by persons who have been trained in the operation of trucks, who have demonstrated to the user or his representative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork-lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork-lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork-lift truck during working time. He must forbid unauthorised persons to drive or operate the forklift truck. The transport or lifting of persons is forbidden.
Prohibition of unauthorised use: The driver is responsible for the fork-lift truck during working time. He must forbid unauthorised persons to drive or operate the forklift truck. The transport or lifting of persons is forbidden.
Damage and defects: Damage or defects noted on the fork-lift truck or on the attachments must immediately be brought to the notice of the person in charge. Fork-lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Damage and defects: Damage or defects noted on the fork-lift truck or on the attachments must immediately be brought to the notice of the person in charge. Fork-lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork-lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork-lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork-lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling/lowering truck attachments.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork-lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also includes the area within reach of falling loads or falling/lowering truck attachments.
F
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork-lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
0105.GB
0105.GB
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork-lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
E1
E1
Description of the operating controls and indicators Item Operating control or display
2
Function
Item Operating control or display
Function
1 Key switch
t Switches the control current on and off. When the key is removed from the key switch, the truck cannot be operated by unauthorised persons.
1 Key switch
t Switches the control current on and off. When the key is removed from the key switch, the truck cannot be operated by unauthorised persons.
2 Control lamp driver seat heating
o Shows, when alight, that the driver seat heating is ON.
2 Control lamp driver seat heating
o Shows, when alight, that the driver seat heating is ON.
3 Lamp indicating that the truck is operational
t Shows, when alight, that the control current in ON.
3 Lamp indicating that the truck is operational
t Shows, when alight, that the control current in ON.
4 Operating key “Horn”
t Gives an audible warning signal.
4 Operating key “Horn”
t Gives an audible warning signal.
5 Operating key “Lowering”
t Lowers the lifting device.
5 Operating key “Lowering”
t Lowers the lifting device.
6 Operating key “Lifting”
t Lifts the lifting device.
6 Operating key “Lifting”
t Lifts the lifting device.
7 Travelling direction handle
t Sets the desired travelling direction.
7 Travelling direction handle
t Sets the desired travelling direction.
8 Switch - driver seat heating
o Switches the driver seat heating ON and OFF.
8 Switch - driver seat heating
o Switches the driver seat heating ON and OFF.
9 Master switch (emergency stop)
t The circuit is interrupted, all electrical functions are switched off and the truck is automatically braked.
9 Master switch (emergency stop)
t The circuit is interrupted, all electrical functions are switched off and the truck is automatically braked.
10 Deadman key
t released: Driving function blocked or truck is slowing down operated: Driving function released
11
10 Deadman key
t released: Driving function blocked or truck is slowing down operated: Driving function released t Braking of the truck.
t Braking of the truck.
11
12 Driver seat locking mechanism
t Horizontal adjustment of the driver seat.
12 Driver seat locking mechanism
t Horizontal adjustment of the driver seat.
13 Backrest adjusting mechanism
t Adjustment of the driver seat backrest.
13 Backrest adjusting mechanism
t Adjustment of the driver seat backrest.
14 Adjusting wheel for seat damping
t Sets the driver weight for optimum damping effect. The set weight is indicated.
14 Adjusting wheel for seat damping
t Sets the driver weight for optimum damping effect. The set weight is indicated.
15 Foot space height adjustment
t Height adjustment of the foot space in relation to the driver seat.
15 Foot space height adjustment
t Height adjustment of the foot space in relation to the driver seat.
16 Switch - parking brake
t Applies or releases the parking brake.
16 Switch - parking brake
t Applies or releases the parking brake.
17 Control lamp - parking brake
t Shows, when alight, that the parking brake is applied.
17 Control lamp - parking brake
t Shows, when alight, that the parking brake is applied.
18 Information and service indicator
t Indicates important driving and lifting parameters, warning messages, notes on operation faults and service information (refer to chapter E, section 5).
18 Information and service indicator
t Indicates important driving and lifting parameters, warning messages, notes on operation faults and service information (refer to chapter E, section 5).
Brake pedal
o = Optional equipment
Brake pedal
t = Standard equipment
0105.GB
t = Standard equipment
E2
Description of the operating controls and indicators
o = Optional equipment
0105.GB
2
E2
1 2 3 4
5
6
7
8
1 2 3 4
9
17
16
16
15
15
14
14
13
13
12
12
11
11
10
10
6
7
8
9
0105.GB
18
17
0105.GB
18
5
E3
E3
3
Starting up the truck
3
Starting up the truck
F
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
F
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
The electronic driving and steering systems automatically control their functions. If an error or fault occurs, the driving and steering functions are stopped.
F
F
The electronic driving and steering systems automatically control their functions. If an error or fault occurs, the driving and steering functions are stopped.
F
Before the truck is restarted, it is required to perform the relevant troubleshooting actions. Checks and operations to be performed before starting daily work
Checks and operations to be performed before starting daily work
- Visually check the entire truck (especially the wheels and the lifting device) for visible damage.
- Visually check the entire truck (especially the wheels and the lifting device) for visible damage.
- Visually check the battery attachment and the cable connections.
- Visually check the battery attachment and the cable connections.
F
Do not operate the travelling direction lever when climbing on the truck. Adjusting the driver seat Do not reach into the rear wall of the truck when adjusting the driver’s seat.
Adjusting the driver seat
F
19
Do not reach into the rear wall of the truck when adjusting the driver’s seat.
- Sit down on the seat.
- Sit down on the seat.
- Release the driver seat locking mechanism (12) and slide the seat (19) forward or backward to the desired position.
- Release the driver seat locking mechanism (12) and slide the seat (19) forward or backward to the desired position.
- Allow the locking mechanism (12) to reengage.
- Allow the locking mechanism (12) to reengage.
- Using the adjusting wheel (14), adjust the seat damping system to the driver weight.
19
- Using the adjusting wheel (14), adjust the seat damping system to the driver weight.
13 12 14
- Adjust the backrest by means of the backrest adjusting mechanism (13).
0105.GB
- Adjust the backrest by means of the backrest adjusting mechanism (13).
E4
Do not operate the travelling direction lever when climbing on the truck.
13 12 14
0105.GB
F
Before the truck is restarted, it is required to perform the relevant troubleshooting actions.
E4
Adjusting the height of the foot space
Adjusting the height of the foot space
- Sit down on the seat.
- Sit down on the seat.
- Operate the foot space height adjustment key (15) to raise the floor.
- Operate the foot space height adjustment key (15) to raise the floor.
- Operate the foot space height adjustment key (15) and step on the floor. This will lower the floor plate.
Z
- Operate the foot space height adjustment key (15) and step on the floor. This will lower the floor plate.
15
Adjusting the tilting angle
Adjusting the tilting angle
- Tilt the floor plate (20) towards the driver.
- Tilt the floor plate (20) towards the driver.
- The tilting angle of the floor plate can be adjusted by means of a bolt (21) and a choice of three holes.
- The tilting angle of the floor plate can be adjusted by means of a bolt (21) and a choice of three holes.
Whenever making any adjustments, ensure that the operating elements remain within comfortable reach.
21
Z
20
o Retaining system (D only)
F
If the vehicle is delivered with the retaining system option, the driver must fasten the three-point seat belt before starting and operating the vehicle. The belt must be adjusted to the body size and must not be loose.
21 20
o Retaining system (D only)
F
23 22
- Adjust the belt (22) to your body size using the belt height adjustment (23).
If the vehicle is delivered with the retaining system option, the driver must fasten the three-point seat belt before starting and operating the vehicle. The belt must be adjusted to the body size and must not be loose.
23 22
- Adjust the belt (22) to your body size using the belt height adjustment (23).
F
Belt system and seat hood must be chekked by the service personnel after an accident and replaced if necessary.
0105.GB
Belt system and seat hood must be chekked by the service personnel after an accident and replaced if necessary.
0105.GB
F
Whenever making any adjustments, ensure that the operating elements remain within comfortable reach.
15
E5
E5
Switching on the truck
- Step on to the standing platform.
- Step on to the standing platform.
- Pull up the master switch (9).
- Pull up the master switch (9).
- Insert the key in the key switch (1) and turn the key clockwise towards the ”I” position until reaching the stop.
- Insert the key in the key switch (1) and turn the key clockwise towards the ”I” position until reaching the stop.
- Check the horn (4) for correct functioning.
- Check the horn (4) for correct functioning.
- Check whether the deadman key (10), brake pedal (11), "Parking brake“ switch (16) and travelling direction lever (7) are properly functioning (refer to chapter E, section 4.2).
- Check whether the deadman key (10), brake pedal (11), "Parking brake“ switch (16) and travelling direction lever (7) are properly functioning (refer to chapter E, section 4.2).
The truck is now ready for operation.
The truck is now ready for operation.
The information and service indicator (5) briefly displays the vehicle code, followed by the current steering position of the drive wheel, the available battery capacity and the hours of operation.
18
1
4
7
JUNGHEINRICH ESE
BATT: 100%
Z 20h
9
18
16
16
11
11
10
10
0105.GB
E6
The information and service indicator (5) briefly displays the vehicle code, followed by the current steering position of the drive wheel, the available battery capacity and the hours of operation.
1
4
7
JUNGHEINRICH ESE
BATT: 100%
20h
9
0105.GB
Z
Switching on the truck
E6
4
Operation of the fork-lift truck
4
Operation of the fork-lift truck
4.1
Safety regulations applicable when operating the truck
4.1
Safety regulations applicable when operating the truck
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork-lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Driving conduct: The travelling speed must be adapted to the prevailing local conditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the fork-lift truck and the vehicle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork-lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork-lift truck to give suitable warnings.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork-lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork-lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork-lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating slopes and inclines: Negotiating of slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking of the fork-lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork-lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. 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 together with the fork-lift truck must only enter the lift after the fork-lift truck has come safely to a standstill, and must leave the lift before the fork-lift truck.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork-lift truck driver has to satisfy himself accordingly before driving into lifts or on to loading platforms. 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 together with the fork-lift truck must only enter the lift after the fork-lift truck has come safely to a standstill, and must leave the lift before the fork-lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork carriage, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork-lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork-lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
0105.GB
Driving lanes and work areas: Only such lanes and routes that are specially allocated for truck traffic must be used. Unauthorised persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
0105.GB
Driving lanes and work areas: Only such lanes and routes that are specially allocated for truck traffic must be used. Unauthorised persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
E7
E7
4.2
Driving, steering, braking
4.2
Driving, steering, braking
F
Increased attention has to be paid during driving and steering the truck. Control the steering position of the drive wheel on the information and service indicator (18).
F
Increased attention has to be paid during driving and steering the truck. Control the steering position of the drive wheel on the information and service indicator (18).
F
F
The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switsching the truck off and on again. This method prevents the cancelletion of a fault without eliminating the fault.
The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switsching the truck off and on again. This method prevents the cancelletion of a fault without eliminating the fault.
F
As the steering system is a safety-relevant component, the fault must be elininated by trained service personnel.
E8
As the steering system is a safety-relevant component, the fault must be elininated by trained service personnel.
Emergency stop
Emergency stop
- Depress the master switch (9).
- Depress the master switch (9).
This will switch off all electric functions.
This will switch off all electric functions.
Deadman key
Deadman key
The deadman key (10) must be operated for all operating functions. If it is not applied, all functions (exception: the information and service indicator (18)) are deactivated and the brake is operated.
The deadman key (10) must be operated for all operating functions. If it is not applied, all functions (exception: the information and service indicator (18)) are deactivated and the brake is operated.
Driving
Driving
F
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
- Start up the truck (refer to chapter E, section 3).
- Start up the truck (refer to chapter E, section 3).
- Operate the deadman key (10).
- Operate the deadman key (10).
- Release the parking brake by depressing the parking brake switch (16).
- Release the parking brake by depressing the parking brake switch (16).
F
Control the steering position of the drive wheel on the information and service indicator (18).
Control the steering position of the drive wheel on the information and service indicator (18).
- Set the travelling direction handle (7) to the desired travelling direction (V) or( R).
- Set the travelling direction handle (7) to the desired travelling direction (V) or( R).
The truck will move in the selected direction.
The truck will move in the selected direction.
Z
The travelling speed is controlled by means of the travelling direction handle (7).
0105.GB
Z
The electric steering system is self-monitoring.
The travelling speed is controlled by means of the travelling direction handle (7).
0105.GB
F
The electric steering system is self-monitoring.
E8
Driving up an incline
Driving up an incline
M
The load must be transported facing the incline!
M
When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.
Safety measures against "rolling down" of the truck: With the travelling direction handle (7) set to neutral, the service brake is automatically applied after a brief jolt (the controller detects the truck’s rolling down on an incline). The travelling direction handle (7) is used to release the service brake; the speed and driving direction are set as desired.
7
18 V
M
The load must be transported facing the incline!
M
When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.
Safety measures against "rolling down" of the truck: With the travelling direction handle (7) set to neutral, the service brake is automatically applied after a brief jolt (the controller detects the truck’s rolling down on an incline). The travelling direction handle (7) is used to release the service brake; the speed and driving direction are set as desired.
9
7
18
R
V
9 R
R 16
R 16
V
10
10
Steering
Steering
- Turn the steering wheel to the left or to the right.
- Turn the steering wheel to the left or to the right.
Z
The position of the steered wheel is displayed on the information and service indicator (18).
0105.GB
The position of the steered wheel is displayed on the information and service indicator (18).
0105.GB
Z
V
E9
E9
Braking
F
Braking
F
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
The truck may be braked in three ways:
The truck may be braked in three ways:
- using the service brake (break pedal (11))
- using the service brake (break pedal (11))
- using the generator brake (coasting)
- using the generator brake (coasting)
- by counter-current braking (travelling direction handle (7))
- by counter-current braking (travelling direction handle (7))
F
In case of emergencies, the truck must only be braked using the service brake (break pedal (11)).
F
In case of emergencies, the truck must only be braked using the service brake (break pedal (11)).
Z
During normal operation, the generator brake and counter-current braking should be applied. These methods of braking reduce wear and require less energy (energy recovery.
Z
During normal operation, the generator brake and counter-current braking should be applied. These methods of braking reduce wear and require less energy (energy recovery.
Braking by means of the service brake:
Braking by means of the service brake:
- Depress the brake pedal (11).
- Depress the brake pedal (11).
The truck is braked at the maximum possible deceleration rate until it stands still.
The truck is braked at the maximum possible deceleration rate until it stands still.
7
7
11
11
10
10
E 10
0105.GB
16
0105.GB
16
E 10
Z M
Braking by means of the generator brake (coasting)
Braking by means of the generator brake (coasting)
- Release the travelling direction lever (7) - travelling direction lever in home position ("0").
- Release the travelling direction lever (7) - travelling direction lever in home position ("0").
Depending on the setting, the truck is braked by the generator braked, coasting to a stop.
Depending on the setting, the truck is braked by the generator braked, coasting to a stop.
Z M
The degree of speed reduction can be set by the manufacturer service. When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.
The degree of speed reduction can be set by the manufacturer service. When the service personnel has switched off the coast-down brake, only the service and/or the counter-current brake can be used.
Counter-current braking
Counter-current braking
- Setting the travelling direction lever (7) to the opposite drive direction while travelling.
- Setting the travelling direction lever (7) to the opposite drive direction while travelling.
The truck is braked by counter-current until it starts moving into the opposite direction.
The truck is braked by counter-current until it starts moving into the opposite direction.
Z
The braking effect depends on the setting of the travelling direction handle.
Z
The braking effect depends on the setting of the travelling direction handle.
4.3
Picking up and setting down loads
4.3
Picking up and setting down loads
M
Before picking up a load, the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded.
M
Before picking up a load, the driver has to make sure that it is correctly palletised and that the capacity of the truck is not exceeded.
- Pass the lifting device as far as possible under the load. Picking up long loads crosswise is not permitted.
Lifting and lowering
5
Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm). Lifting and lowering
6
Z
When operating the keys “Lifting” or “Lowering”, the lifting or lowering movement will be at a fixed speed. The deadman key (10) must be operated.
5
6
When operating the keys “Lifting” or “Lowering”, the lifting or lowering movement will be at a fixed speed. The deadman key (10) must be operated.
Lifting
Lifting
- Depress operating key “Lifting” (6) until the required lifting height has been reached.
- Depress operating key “Lifting” (6) until the required lifting height has been reached.
Lowering
Lowering
- Depress operating key “Lowering” (5); the fork is lowered.
- Depress operating key “Lowering” (5); the fork is lowered.
0105.GB
Z
M
Pick up the load, ensuring that it does not project excessively from the tips of the lifting device (less than 50 mm).
0105.GB
M
- Pass the lifting device as far as possible under the load. Picking up long loads crosswise is not permitted.
E 11
E 11
4.4
Safe parking of the truck
4.4
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
F
Z
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
F
Never park the truck on a slope or incline. The lifting device must always be completely lowered.
Never park the truck on a slope or incline. The lifting device must always be completely lowered.
- Operate the parking brake switch (16).
- Operate the parking brake switch (16).
- Lower the lifting device.
- Lower the lifting device.
- Set the drive wheel to the "straight ahead position". Turn the steering wheel until the drive wheel is set to its straight ahead position.
- Set the drive wheel to the "straight ahead position". Turn the steering wheel until the drive wheel is set to its straight ahead position.
Z
Control the displayed steering angle on the information and service indicator (18). - Switch the key switch (1) to position “OFF” (“0”) and remove the key. - Depress the master switch (emergency cut-out) (9) to the “OFF” position.
18
1
Control the displayed steering angle on the information and service indicator (18). - Switch the key switch (1) to position “OFF” (“0”) and remove the key. - Depress the master switch (emergency cut-out) (9) to the “OFF” position.
9
18
1
9
0105.GB
16
0105.GB
16
E 12
Safe parking of the truck
E 12
5
Information and service indicator (LISA)
5
The LCD display (25) of the LISA 25 26 information and service indicator indicates the battery charge status (24), 27 the operating hours (27) and the posi- 24 tion of the steered wheel (26). The BA T T : 1 0 0 % 20 h operating data is shown in the service and diagnosis mode (refer to chapter E, section 5.3). Two light-emitting diodes (LED (28) (29)) below the display are used as 28 29 30 31 32 33 indicators. The keyboard, four keys, (30) to (33), is needed to select, read or modify truck parameters.
The LCD display (25) of the LISA 25 26 information and service indicator indicates the battery charge status (24), 27 the operating hours (27) and the posi- 24 tion of the steered wheel (26). The BA T T : 1 0 0 % 20 h operating data is shown in the service and diagnosis mode (refer to chapter E, section 5.3). Two light-emitting diodes (LED (28) (29)) below the display are used as 28 29 30 31 32 33 indicators. The keyboard, four keys, (30) to (33), is needed to select, read or modify truck parameters.
M
In the service mode, only authorised personnel of the manufacturer service may perform modifications!
M
In the service mode, only authorised personnel of the manufacturer service may perform modifications!
5.1
LED indicators
5.1
LED indicators
Two lit LED indicators show the following states: Pos.
Two lit LED indicators show the following states:
Function
Pos.
Function
28
Driving direction forward (direction of the drive) (green LED)
28
Driving direction forward (direction of the drive) (green LED)
29
Driving direction backwards (direction of the load) (green LED)
29
Driving direction backwards (direction of the load) (green LED)
Keyboard assignment Pos.
5.2
Function
Keyboard assignment Pos.
Function
30
Double function - increase of the selected parameter in steps - Selection of the individual menu items in upward direction
30
Double function - increase of the selected parameter in steps - Selection of the individual menu items in upward direction
31
Double function - decrease of the selected parameter in steps - Selection of the individual menu items in downward direction
31
Double function - decrease of the selected parameter in steps - Selection of the individual menu items in downward direction
32
Double function - Release of a selection menu from the main menu - Confirmation of a question with "NO" -> "x"
32
Double function - Release of a selection menu from the main menu - Confirmation of a question with "NO" -> "x"
33
Quadruple function - Quitting a selected menu item - Saving a modified parameter - Confirmation of a question with "YES" -> "q" - Change between "operating hours" and "time" indication
33
Quadruple function - Quitting a selected menu item - Saving a modified parameter - Confirmation of a question with "YES" -> "q" - Change between "operating hours" and "time" indication
0105.GB
5.2
0105.GB
Information and service indicator (LISA)
E 13
E 13
Indicators Operating data and error messages are displayed on the indicator. The operator menu can be used to set the following truck parameters: Here, the interval between maximum controller actuation SPEED DRIVE L and 100% adjustment of the electronics is set.
5.3
Indicators Operating data and error messages are displayed on the indicator. The operator menu can be used to set the following truck parameters: Here, the interval between maximum controller actuation SPEED DRIVE L and 100% adjustment of the electronics is set.
This driving parameter may only be adjusted by the custom service.
DYNAMIC BRAKE (ROLLL
This driving parameter may only be adjusted by the custom service.
DYNAMIC BRAKE (ROLLL
This driving parameter has no function.
REVERSING BRAKE
This driving parameter has no function.
REVERSING BRAKE
L
This driving parameter may only be adjusted by the custom service.
SPEED DRIVE
This driving parameter has no function.
LOW-SPEED DRIVE.
L
L
This driving parameter may only be adjusted by the custom service.
SPEED DRIVE
This driving parameter has no function.
LOW-SPEED DRIVE.
L
L
This driving parameter may only be adjusted by the custom service.
SPEED OF FORK
This driving parameter has no function.
SLOW FORK
L
L
This driving parameter may only be adjusted by the custom service.
SPEED OF FORK
This driving parameter has no function.
SLOW FORK
L
L
Issues an audible alarm in case of an operating fault.
This setting has no function.
BUZZER ON/OFF O F F
L
Issues an audible alarm in case of an operating fault. L
This setting has no function.
BASIC SETTING L
E 14
SETTING THE TIME 1 2 : 2 2 L
L
BASIC SETTING L
Setting the time: Select the required hours and minutes with key (32). Use keys (30) and (31) to correct the entered values.
0105.GB
Setting the time: Select the required hours and minutes with key (32). Use keys (30) and (31) to correct the entered values.
BUZZER ON/OFF O F F
E 14
SETTING THE TIME 1 2 : 2 2 L
0105.GB
5.3
5.4
Changing driving parameters
5.4
Changing driving parameters
F
The driving behaviour of the truck is changed if the truck parameters are modified. This is to be taken into consideration during start-up! Parameters may only be modified with the truck parked and while it is not performing any lifting movements.
F
The driving behaviour of the truck is changed if the truck parameters are modified. This is to be taken into consideration during start-up! Parameters may only be modified with the truck parked and while it is not performing any lifting movements.
- Commissioning the truck (refer to chapter E, section 3).
- Commissioning the truck (refer to chapter E, section 3).
- Put the key into the key switch and turn it right until stop.
- Put the key into the key switch and turn it right until stop.
The operator menu is displayed for approx. 3 sec., indicating the truck designation. Then, the current steering angle, the battery charging status and the operating hours are indicated.
The operator menu is displayed for approx. 3 sec., indicating the truck designation. Then, the current steering angle, the battery charging status and the operating hours are indicated.
- Key
- Key
Press selection menu key (32).
The indicator displays "acceleration" with the corresponding parameter.
The indicator displays "acceleration" with the corresponding parameter.
- Proceed as indicated in the following diagram, if you want to check or modify any truck parameters.
- Proceed as indicated in the following diagram, if you want to check or modify any truck parameters.
- Use the following keys to change between the adjustment parameters: and (31).
- Use the following keys to change between the adjustment parameters: and (31).
BATT xxx%
xx h4)
Acceleration Coasting brake Reverse brake
6)
Low-speed ride Load direction Buzzer on/off OFF
Coasting brake Reverse brake
L3) 7)
(30)
xx:xx5)
Acceleration
L1)
Speed Direction of the drive L1)
Speed Load direction
BATT xxx%
L1)
Low-speed ride Direction of the drive L1)
Speed Direction of the drive
S2)
S3)
L1) L1)
Low-speed ride Load direction
L1)
Buzzer on/off ON/OFF
xx h4)
Acceleration
Change?
Coasting brake
S2)
Reverse brake
yes
S2)
Low-speed ride Direction of the drive S3) Speed Load direction
BATT xxx%
6)
no
S2) S3)
Low-speed ride Load direction
S2 )
Buzzer on/off OFF
Coasting brake Reverse brake
L3) 7)
Speed Direction of the drive
S2)
S3)
L1)
Speed Load direction
S2)
L1)
Low-speed ride Load direction
S3)
L1)
Buzzer on/off ON/OFF
S2 )
Basic setting Default val. for "driving“ L3)
Basic setting Default val. for "driving“ S3)
Setting the time XX:XX
Setting the time XX:XX
Setting the time XX:XX
Setting the time XX:XX
1)
1)
2)
2)
L = Read operating parameters (Read mode). S = Change operating parameters (Write mode) using the keys . 3) no function 4 6) Indicator "Operating hours" Parameter selection indicator 5) 7) Indicator "Time" Parameter selection indicator
L1)
yes
S2)
Low-speed ride Direction of the drive S3)
Basic setting Default val. for "driving“ S3) S2)
Change?
S2)
Basic setting Default val. for "driving“ L3) L1)
(30)
xx:xx5)
Acceleration
L1)
Speed Direction of the drive L1)
Speed Load direction
BATT xxx%
L1)
Low-speed ride Direction of the drive L1)
no
S2)
L = Read operating parameters (Read mode). S = Change operating parameters (Write mode) using the keys . no function 4 6) Indicator "Operating hours" Parameter selection indicator 5) 7) Indicator "Time" Parameter selection indicator 3)
0105.GB
0105.GB
Press selection menu key (32).
E 15
E 15
Fault location
This chapter enables the operator to locate and rectify minor faults and malfunctions, or the effects of operating errors. When trying to locate a fault, proceed in the order shown in the table.
Fault
Remedial action
Fault
- Check the battery connector and connect if necessary. - Release the master switch.
Truck does - Battery connector not not move connected. - Master switch (emergency stop) depressed. - Key switch in position ”0”. - Battery exhausted. - The deadman’s key has not been pressed. - Fuse defective.
Load cannot be lifted
Possible cause
- Truck not operative. - Hydraulic oil level too low. - Battery discharge monitor has switched off the lifting function and indicates “STOP”. - Fuse defective. - Load is too heavy.
- Set the key switch to position ”I”. - Check the charging condition of the battery and recharge if necessary. - Press the deadman’s key - Check fuses F1, 1F1 and 3F9. - Perform all remedial actions listed under the fault “Truck does not move”. - Check the hydraulic oil level. - Recharge the battery.
Load cannot be lifted
Possible cause
- Truck not operative. - Hydraulic oil level too low. - Battery discharge monitor has switched off the lifting function and indicates “STOP”. - Fuse defective. - Load is too heavy.
- Check fuse 2F1. - Heed the maximum capacity (see the identification plate).
Z
If it is not possible to rectify the fault by performing the indicated remedial actions, please contact the customer service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
0105.GB
E 16
Fault location
This chapter enables the operator to locate and rectify minor faults and malfunctions, or the effects of operating errors. When trying to locate a fault, proceed in the order shown in the table.
Truck does - Battery connector not not move connected. - Master switch (emergency stop) depressed. - Key switch in position ”0”. - Battery exhausted. - The deadman’s key has not been pressed. - Fuse defective.
Z
6
Remedial action - Check the battery connector and connect if necessary. - Release the master switch. - Set the key switch to position ”I”. - Check the charging condition of the battery and recharge if necessary. - Press the deadman’s key - Check fuses F1, 1F1 and 3F9. - Perform all remedial actions listed under the fault “Truck does not move”. - Check the hydraulic oil level. - Recharge the battery.
- Check fuse 2F1. - Heed the maximum capacity (see the identification plate).
If it is not possible to rectify the fault by performing the indicated remedial actions, please contact the customer service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
0105.GB
6
E 16
F Maintenance of the fork-lift truck
F Maintenance of the fork-lift 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.
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
Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
F
Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
M
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork-lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
M
Only original spare parts have been certified by our quality assurance service. To ensure safe and reliable operation of the fork-lift truck, only spare parts of the manufacturer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F). 2
M
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
Safety regulations applicable to truck maintenance
2
Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Servicing and maintenance personnel: The fork-lift truck must only be serviced and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assignments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork-lift 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, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Lifting and jacking up: When a fork-lift 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, suitable measures must be taken to prevent the truck from slipping or tipping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the forklift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery-operated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
Cleaning operations: No inflammable liquids must be used when cleaning the forklift truck. Prior to commencing cleaning operations, all safety measures that are required to prevent sparking (e.g. by short-circuits) have to be taken. For battery-operated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak compressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
M
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed. 0708.GB
0708.GB
Upon completion of cleaning work, the operations detailed in the section “Recommissioning” must be performed.
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
F1
F1
Welding operations: To prevent any damage to electric or electronic com-ponents, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Welding operations: To prevent any damage to electric or electronic com-ponents, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic compo-nents or assemblies, all truck-specific settings have to be retained.
Settings: When repairing or replacing hydraulic, electric or electronic compo-nents or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. Changes must only be made following consultations with the manufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. Changes must only be made following consultations with the manufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubrication is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hydraulic components, also renew the hoses in this hydraulic system.
F2
0708.GB
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.
0708.GB
Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.
F2
3
Servicing and inspection
3
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork-lift truck. The neglect of regular servicing intervals can lead to fork-lift truck failure and constitutes a potential hazard to personnel and equipment.
M
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The indicated servicing intervals are based on single-shift operation under normal operating conditions. For applications in dusty environments, or involving large temperature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
The following servicing checklist indicates the operations to be performed and the respective intervals to be observed. The servicing intervals are defined as follows:
W A B C
W A B C
= every 50 operating hours, but at least once per week = every 500 operating hours = every 1000 operating hours, or at least annually = every 2000 operating hours, or at least annually
Z
W service intervals are to be performed by the customer. In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.
0708.GB
Z
Thorough and expert servicing is one of the most important preconditions for safe operation of the fork-lift truck. The neglect of regular servicing intervals can lead to fork-lift truck failure and constitutes a potential hazard to personnel and equipment.
= every 50 operating hours, but at least once per week = every 500 operating hours = every 1000 operating hours, or at least annually = every 2000 operating hours, or at least annually
W service intervals are to be performed by the customer. In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.
0708.GB
M
Servicing and inspection
F3
F3
Maintenance checklist
4 standard cold store
Chassis and superstruct. Drive unit
Wheels Steering
Brake system
Hydraulic system
Electrical system
Maintenance intervals = t W A = k
B
1.1
Check all load bearing elements for damage
t
1.2
Check all bolted connections
t
1.3
Check platform for correct functioning and damage
t
2.1
Check the transmission for noises and leakage
t
2.2
Check the transmission oil level
2.3
Change the transmission oil
C
standard cold store
Maintenance intervals = t W A = k
B
C
1.1
Check all load bearing elements for damage
t
1.2
Check all bolted connections
t
1.3
Check platform for correct functioning and damage
t
2.1
Check the transmission for noises and leakage
t
t
2.2
Check the transmission oil level
t
l t
2.3
Change the transmission oil
l t
3.1
Check for wear and damage
t
3.2
Check the wheel bearings for correct fastening
l
4.1
Check the steering wheel play
4.2
Check the steering chain and chain sprocket for wear, adjust and grease
4.3
Replacing the "actual value" steering-angle potentiometer (at the steering motor)
5.1
Performance and adjustment check
5.2
Check the brake linings for wear
t
5.3
Check reset function of the brake pedal
5.4
Check the brake linkage; adjust if necessary
6.1 6.2 6.3
Check hydraulic cylinders for leakage, damage and secure attachment
6.4
Clean filter
6.5
Check the oil level
6.6 6.7
Chassis and superstruct. Drive unit
3.1
Check for wear and damage
t
3.2
Check the wheel bearings for correct fastening
l
4.1
Check the steering wheel play
4.2
Check the steering chain and chain sprocket for wear, adjust and grease
4.3
Replacing the "actual value" steering-angle potentiometer (at the steering motor)
5.1
Performance and adjustment check
5.2
Check the brake linings for wear
t
5.3
Check reset function of the brake pedal
l
t
5.4
Check the brake linkage; adjust if necessary
l
t
Performance check
l
t
6.1
Performance check
l
t
Check all connections for leakage and damage
l
t
6.2
Check all connections for leakage and damage
l
t
l
t
6.3
Check hydraulic cylinders for leakage, damage and secure attachment
l
t
t
6.4
Clean filter
t
6.5
Check the oil level
l
t
Change hydraulic oil
l t
6.6
Change hydraulic oil
l t
Check the pressure relief valves for correct functioning
l t
6.7
Check the pressure relief valves for correct functioning
l t
7.1
Performance check
t
7.1
Performance check
t
7.2
Check all cables for secure connection and damage
t
7.2
Check all cables for secure connection and damage
t
7.3
Check the fuses for correct amperage
7.3
Check the fuses for correct amperage
7.4
Check switches and trip cams for secure attachment and correct functioning
t
7.4
Check switches and trip cams for secure attachment and correct functioning
7.5
Check the warning installation for correct functioning
t
7.5
Check the warning installation for correct functioning
7.6
Check contactors, replace wearing parts if necessary
t
7.6
Check contactors, replace wearing parts if necessary
Check the carbon brushes for wear
t
Electric motors 8.1
8.2
Check the motor for secure attachment
t
8.3
Clean motor housing by means of a vacuum cleaner and check the commutator l for wear
8.4
Check whether the cover of the steering-engine potentiometer is present.
Wheels t t
Steering
l t
l
l
t
Brake system
Hydraulic system
Electrical system t
l
t t l t
l
t t t
t
t t l
t t
Check the carbon brushes for wear
t
8.2
Check the motor for secure attachment
t
t
8.3
Clean motor housing by means of a vacuum cleaner and check the commutator l for wear
t
t
8.4
Check whether the cover of the steering-engine potentiometer is present.
t
0708.GB
Electric motors 8.1
F4
Maintenance checklist
0708.GB
4
F4
standard cold store Battery
Lifting device
Maintenance intervals = t W A = k l
B
C
standard cold store
t
Battery
Maintenance intervals = t W A = k l
B t
9.1
Check acid density, acid level and cell voltage
9.1
Check acid density, acid level and cell voltage
9.2
Check the terminals for secure attachment and apply grease
l
t
9.2
Check the terminals for secure attachment and apply grease
l
t
9.3
Clean battery connections, check for tight seat
l
t
9.3
Clean battery connections, check for tight seat
l
t
9.4
Check the battery cables for damage, renew, if necessary
t
9.4
Check the battery cables for damage, renew, if necessary
t
9.5
Check whether the battery lock is fully functioning
t
9.5
Check whether the battery lock is fully functioning
t
t
10.1 Performance and adjustment check
Lifting device
C
t
10.1 Performance and adjustment check
10.2 Perform sight check of rollers, sliding elements, and stops
l
t
10.2 Perform sight check of rollers, sliding elements, and stops
l
t
10.3 Check fork tines and fork carrier for wear and damage
l
t
10.3 Check fork tines and fork carrier for wear and damage
l
t
Lubrication
11.1 Grease the vehicle in accordance with the lubrication schedule
l
t
Lubrication
11.1 Grease the vehicle in accordance with the lubrication schedule
l
t
General measurements
12.1 Check the electrical system for a grounding fault
t
12.1 Check the electrical system for a grounding fault
t
12.2 Check the driving speed and braking distance
t
General measurements
12.2 Check the driving speed and braking distance
t
12.3 Check the lifting and lowering speed
t
13.1 Perform a trial run under a nominal load
t
13.2 Upon completion of servicing operations, demonstrate the vehicle to the person l responsible
t
12.4 Check safety and shutdown devices Demonstration
0708.GB
Demonstration
t
t t
13.1 Perform a trial run under a nominal load
t
13.2 Upon completion of servicing operations, demonstrate the vehicle to the person l responsible
t
0708.GB
12.4 Check safety and shutdown devices
12.3 Check the lifting and lowering speed
F5
F5
5
Lubrication schedule
5
Lubrication schedule
G
G 0,7 l
1,25 - 1,3 l 1) B B+C
g s b a
A
1)
A+C
0,7 l E 1,25 - 1,3 l 1) B B+C
F
g s
Gliding surfaces Grease nipples Filler plug for hydraulic oil Filler plug for gear oil Drain plug for gear oil Cold store usage
1) Compound
b a
2) 1.25l
E F
for cold store usage 1:1
2) 1.25l
0708.GB
- 1.3l; depending on the drive type (always up to the lower edge of the filler neck).
0708.GB
- 1.3l; depending on the drive type (always up to the lower edge of the filler neck).
F6
1)
A+C
Gliding surfaces Grease nipples Filler plug for hydraulic oil Filler plug for gear oil Drain plug for gear oil Cold store usage
1) Compound
for cold store usage 1:1
A
F6
5.1
Fuels, coolants and lubricants
5.1
Handling consumption type material: Consumption type material must always be handled properly. Manufacturer's instructions are to be observed.
F
Fuels, coolants and lubricants Handling consumption type material: Consumption type material must always be handled properly. Manufacturer's instructions are to be observed.
F
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
Improper handling is injurious to health, life, and environment. Consumption type materials must be stored in adequate containers. They might be inflammable and, therefore, must not come into contact with hot components or open fire.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions.
When filling in consumption type materials use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Code
Order No.
Supply Qty
A
50 449 669
5.0 l
H-LP 46
5.0 l
B
50 380 904
Designation
Code
Order No.
Supply Qty
Hydraulic system
Used for:
A
50 449 669
5.0 l
H-LP 46
Fuchs Titan Cytrac HSY 75W-90
Transmission
B
5.0 l
Fuchs Titan Cytrac HSY 75W-90
Transmission
DIN 51524
50 380 904
Designation
Used for:
DIN 51524
Hydraulic system
C
29 200 810
5.0 l
H-LP 10
DIN 51524
Hydraulic system
C
29 200 810
5.0 l
H-LP 10
DIN 51524
Hydraulic system
E
29 201 430
1.0 kg
Grease
DIN 51825
Lubrication
E
29 201 430
1.0 kg
Grease
DIN 51825
Lubrication
F
29 200 100
1.0 kg
Grease
TTF52
Lubrication
F
29 200 100
1.0 kg
Grease
TTF52
Lubrication
Grease data
Grease data Dropp. point °C
E
Lithium
185
265 - 295
F
—
—
310 - 340
Service temperat. °C
Code
Saponification
Dropp. point °C
2
-35 / +120
E
Lithium
185
265 - 295
2
-35 / +120
1
-52 / +100
F
—
—
310 - 340
1
-52 / +100
NLG1 class
0708.GB
Saponification
Worked penetr. at 25 °C
NLG1 class
Service temperat. °C
0708.GB
Worked penetr. at 25 °C
Code
F7
F7
6
Instructions for the servicing operations
6
Instructions for the servicing operations
6.1
Preparing the truck for servicing and maintenance operations
6.1
Preparing the truck for servicing and maintenance operations
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
- Park the truck and render it safe (refer to chapter E, section 4.4).
- Park the truck and render it safe (refer to chapter E, section 4.4).
- Disconnect the battery plug to prevent accidental starting of the truck (refer to chapter D, section 4)
- Disconnect the battery plug to prevent accidental starting of the truck (refer to chapter D, section 4)
F
When work has to be performed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, the instructions contained in the chapter “Transportation and commissioning” have to be observed.
F
When work has to be performed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, the instructions contained in the chapter “Transportation and commissioning” have to be observed.
6.2
Tilting up the armrest
6.2
Tilting up the armrest
Z
- Pull up the release (1).
- Pull up the release (1).
The armrest (2) will swivel upwards.
The armrest (2) will swivel upwards.
Z
This will give access to the square key.
1
6.3
2
1
Opening the battery door and the seat hood
6.3
- Open the battery door (3) using the square key.
F8
Opening the battery door and the seat hood - Open the battery door (3) using the square key.
M
The seat hood (6) must only be opened after the battery door has been opened and swivelled aside. The hood (8) must be closed.
The seat hood (6) must only be opened after the battery door has been opened and swivelled aside. The hood (8) must be closed.
- Loosen the screw (5) with a square spanner.
- Loosen the screw (5) with a square spanner.
- Open the seat hood (6) using the square key (4).
- Open the seat hood (6) using the square key (4).
- Swivel the seat hood (6) back against the side of the truck.
- Swivel the seat hood (6) back against the side of the truck.
Z
Drive unit, steering motor, steering control and the hydraulic installation can be easily accessed for maintenance works. 0708.GB
Z
2
Drive unit, steering motor, steering control and the hydraulic installation can be easily accessed for maintenance works. 0708.GB
M
This will give access to the square key.
F8
3
3
6
6
5
6.4
Z
4
5
Opening the hood
6.4
- Using the service key (7), unlock the hood (8).
- Swivel the hood (8) upwards.
- Swivel the hood (8) upwards.
Z
- Closing the battery door (3) , seat hood (6) and hood (8) is performed in reverse order.
The drive current control system and the truck fuses are readily accessible for servicing purposes. 8 7
- Closing the battery door (3) , seat hood (6) and hood (8) is performed in reverse order.
F
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
0708.GB
Do not drive the truck unless the hoods are closed and locked in the stipulated manner.
0708.GB
F
Opening the hood
- Using the service key (7), unlock the hood (8).
The drive current control system and the truck fuses are readily accessible for servicing purposes. 8 7
4
F9
F9
6.5
M
Tightening the wheel screws
6.5
The wheel screws of the drive wheel must be retightened in accordance with the servicing intervals indicated in the servicing checklist.
The wheel screws of the drive wheel must be retightened in accordance with the servicing intervals indicated in the servicing checklist.
- Position the drive wheel (10) at right angles to the longitudinal axis of the truck.
- Position the drive wheel (10) at right angles to the longitudinal axis of the truck.
- Tighten all wheel-fixing bolts (9) using a wrench which is to be inserted through the opening (11) of the collision guard (tightening torque 105Nm).
- Tighten all wheel-fixing bolts (9) using a wrench which is to be inserted through the opening (11) of the collision guard (tightening torque 105Nm).
M
Remove the wrench after tightening the wheel-fixing bolts.
9
Remove the wrench after tightening the wheel-fixing bolts.
9
11
11
0708.GB
10
0708.GB
10
F 10
Tightening the wheel screws
F 10
Checking the electric fuses
6.6
- Prepare the truck for the servicing and maintenance operations (refer to chapter F, section 6.1).
- Open the hoods (refer to chapter F, section 6.3 and 6.4).
- Open the hoods (refer to chapter F, section 6.3 and 6.4).
- Referring to the table, check all fuses for correct rating and damage; replace fuses where required.
- Referring to the table, check all fuses for correct rating and damage; replace fuses where required.
12
Item.
13
14
15
16
17
Designation Protection of:
12
13
14
15
Value
Item.
30 A
12
3F9
t Steering motor
16
17
Designation Protection of:
Value
12
3F9
t Steering motor
13
2F1
t Pump motor
150 A
13
2F1
t Pump motor
150 A
14
1F1
t Drive motor
150 A
14
1F1
t Drive motor
150 A
15
1F10
t Field “Driving”
40 A
15
1F10
t Field “Driving”
40 A
16
6F2
t Battery discharge indicator / operating hour meter
10 A
16
6F2
t Battery discharge indicator / operating hour meter
10 A
17
F1
t Entire control circuit
10 A
17
F1
t Entire control circuit
10 A
t = Standard equipment 0708.GB
Checking the electric fuses
- Prepare the truck for the servicing and maintenance operations (refer to chapter F, section 6.1).
o = Optional equipment
t = Standard equipment
- Reclose the hoods (refer to chapter F, section 6.3 and 6.4).
0708.GB
6.6
F 11
30 A
o = Optional equipment
- Reclose the hoods (refer to chapter F, section 6.3 and 6.4). F 11
6.7
7
Recommissioning the truck
6.7
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
- Check the horn for proper functioning.
- Check the horn for proper functioning.
- Check the master switch for correct functioning.
- Check the master switch for correct functioning.
- Check the brake for correct functioning.
- Check the brake for correct functioning.
- Lubricate truck according to lubrication schedule.
- Lubricate truck according to lubrication schedule.
Decommissioning the fork lift truck
7
If the fork lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
M
M
During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
7.1
Operations to be performed prior to decommissioning
- Thoroughly clean the fork lift truck.
- Thoroughly clean the fork lift truck.
- Check the brakes for correct function.
- Check the brakes for correct function.
- Check the hydraulic oil level and top up if required (refer to chapter F).
- Check the hydraulic oil level and top up if required (refer to chapter F).
- Apply a thin film of oil or grease to all parts not protected by a paint coating.
- Apply a thin film of oil or grease to all parts not protected by a paint coating.
- Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
- Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
- Recharge the battery (refer to chapter D).
- Recharge the battery (refer to chapter D).
- Disconnect and clean the battery. Apply pole grease to the battery poles.
- Disconnect and clean the battery. Apply pole grease to the battery poles.
In addition to this, all instructions given by the battery supplier must be observed.
7.2
Measures to be taken during decommissioning
- Spray all exposed electrical contacts with a suitable contact spray.
Z
In addition to this, all instructions given by the battery supplier must be observed.
7.2
Measures to be taken during decommissioning
- Spray all exposed electrical contacts with a suitable contact spray.
Every 2 months:
Every 2 months:
- Recharge the battery (refer to chapter D).
- Recharge the battery (refer to chapter D). Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery. 0708.GB
M
Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery. 0708.GB
F 12
During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage. If the fork lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer.
Operations to be performed prior to decommissioning
Z
M
Decommissioning the fork lift truck If the fork lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
If the fork lift truck is to be decommissioned for more than 6 months, additional measures must be discussed with the Service Department of the manufacturer. 7.1
Recommissioning the truck
F 12
7.3
Recommissioning the truck
7.3
Recommissioning the truck
- Thoroughly clean the fork lift truck.
- Thoroughly clean the fork lift truck.
- Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
- Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
- Clean the battery. Grease the pole screws using pole grease and reconnect the battery.
- Clean the battery. Grease the pole screws using pole grease and reconnect the battery.
- Recharge the battery (refer to chapter D).
- Recharge the battery (refer to chapter D).
- Check if the gear oil contains condensed water and change if required.
- Check if the gear oil contains condensed water and change if required.
- Check if the hydraulic oil contains condensed water and change if required.
- Check if the hydraulic oil contains condensed water and change if required.
- Start up the fork lift truck (refer to chapter E).
- Start up the fork lift truck (refer to chapter E).
Z
Battery-operated fork lift trucks: If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
F
Perform several brake tests immediately after recommissioning the truck.
F
Perform several brake tests immediately after recommissioning the truck.
0708.GB
Battery-operated fork lift trucks: If switching troubles are experienced in the electric system, spray the exposed contacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
0708.GB
Z
F 13
F 13
8
Safety checks to be performed at regular intervals and following any unusual incidents
8
Safety checks to be performed at regular intervals and following any unusual incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.
Z
Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.
The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.
A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
The owner is responsible for ensuring that faults are immediately rectified.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.
9
Final de-commissioning, disposal
9
Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
Z
Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
F 14
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 14
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
Jungheinrich traction batterie
2
Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS
Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS
Rating Data
Rating Data
1. Nominal capacity C5:
See type plate
1. Nominal capacity C5:
See type plate
2. Nominal voltage:
2,0 Volt x No of cells
2. Nominal voltage:
2,0 Volt x No of cells
3. Discharge current:
C5/5h
3. Discharge current:
C5/5h
4. Rated temperature:
30° C
4. Rated temperature:
30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as for vented cells apply to protect against hazards from electric current, from explosion of electrolytic gas and in case of the cell container is damaged, from the corrosive electrolyte.
When operating valve-regulated lead-acid batteries the same safety requirements as for vented cells apply to protect against hazards from electric current, from explosion of electrolytic gas and in case of the cell container is damaged, from the corrosive electrolyte.
• 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, 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, 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! • In the normal operation of this batteries a contact with acid isn´t possible. If the cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid) is corrosive like the liquid electrolyte.
• Electrolyte is highly corrosive! • In the normal operation of this batteries a contact with acid isn´t possible. If the cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid) is corrosive like the liquid electrolyte.
• 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
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and where a water refilling isn’t permitted during the whole battery life. Instead of a vent plug there are valves used, who will be destroyed when they are opened.
0506.GB
2
13
13
Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void.
Ignoring the operation instructions, repair with non-original parts and non authorised interventions 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
1. Commissioning
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 battery end cables must have a good contact to terminals, check that the polarity is correct.
The battery end cables must have a good contact to terminals, check that the polarity is correct.
Otherwise battery, vehicle or charger could be destroyed.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors are:
The specified torque loading for the pole screws of the end cables and connectors are:
14
steel 23 ± 1 Nm
M 10
steel 23 ± 1 Nm
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
Ventilation openings must not be sealed or covered.
Ventilation openings must not be 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 60% of the rated capacity should be avoided (deep discharge).
To achieve the optimum life for the battery, operating discharges of more than 60% of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only the battery manufacturer recommended discharge indicators.
They reduce the battery life considerable. To measure the state of discharge use only the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left discharged.
Discharged batteries must be recharged immediately and must not be left discharged.
This also applies to partially discharged batteries.
This also applies to partially discharged batteries.
2.2 Charging
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN 41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. 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 and unacceptable gassing of the cells. EPzV batteries have a low gas emission.
Only direct current must be used for charging. Charging procedures according to DIN 41773 and DIN 41774 must only be applied in the manufacturer approved modifications. Therefore only battery manufacturer approved chargers must be used. 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 and unacceptable gassing of the cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases. Battery container lids and the covers of battery compartments must be opened or removed.
When charging, proper provision must be made for venting of the charging gases. Battery container lids and the covers of battery compartments must be opened or removed.
0506.GB
2. Operation
14
0506.GB
M 10
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170 / 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). The attention pictograms has to be respected.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170 / 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). The attention pictograms has to be respected.
2.3 Equalising charge
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its capacity. Equalising charges are carried out following normal charging.
Equalising charges are used to safeguard the life of the battery and to maintain its capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For the equalising charges has to be used only the battery manufacturer prescribed chargers.
They are necessary after deep discharges and repeated incomplete recharges. For the equalising charges has to be used only the battery manufacturer prescribed chargers.
Watch the temperature!
Watch the temperature!
2.4 Temperature
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity. 45° C is the upper temperature limit and is not acceptable as an operating temperature.
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures shorten the life of the battery, lower temperatures reduce the available capacity. 45° C is the upper temperature limit and is not acceptable as an operating temperature.
2.5 Electrolyte
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be measured.
The electrolyte is immobilised in a gel. The density of the electrolyte can not be measured.
3. Maintenance
3. Maintenance
Don’t refill water!
Don’t refill water!
3.1 Daily
3.1 Daily
Charge the battery immediately after every discharge.
Charge the battery immediately after every discharge.
0506.GB
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 battery rises by about 15° C, so charging should only begin if the battery temperature is below 35° C. The battery temperature should be at least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers need a temperatures regulated voltage.
0506.GB
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 battery rises by about 15° C, so charging should only begin if the battery temperature is below 35° C. The battery temperature should be at least +15°C before charging otherwise a full charge will not be achieved. Are the temperatures a longer time higher than +40° C or lower than +15° C, so the chargers need a temperatures regulated voltage.
15
15
16
Visual inspection after recharging for signs of dirt and mechanical damage.
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and recorded:
After the end of the charge and a rest time of 5 h following should be measured and recorded:
• the voltages of the battery
• the voltages of the battery
• the voltages of every cells
• the voltages of every cells
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 43539-1.
The tests on the insulation resistance of the battery must be conducted in accordance with DIN 43539-1.
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.
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 with DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call our service department for this.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call our service department for this.
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.
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:
To ensure the battery is always ready for use a choice of charging methods can be made:
1. a quarterly full charging like charge as in point 2.2. If any consumer is connected with, e.g. measure or controlling systems, it can be, that this charging is necessary every 14 days.
1. a quarterly full charging like charge as in point 2.2. If any consumer is connected with, e.g. measure or controlling systems, it can be, that this charging is necessary every 14 days.
2. float charging at a charging voltage of 2.25 V x the number of cells.
2. float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the battery.
The storage time should be taken into account when considering the life of the battery. 16
0506.GB
3.2 Weekly
0506.GB
3.2 Weekly
6. Malfunctions
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should be called 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 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!
We reserve the right make technical modification.
We reserve the right make technical modification.
7. Type plate, Jungheinrich traction battery
2/3 4 10 12 7 8
1
2
6 5 11 13
Baujahr Year of manufacture
Typ Type 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.
17
17
18 18 0506.GB
0506.GB
