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EJC 212-220

Jungheinrich EJC 212-220 Operating Instructions Manual

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Page 1
Operating Instructions
50460011
EJC 212-220
G
12.05 -
03.07
Page 2
0108.GB
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 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:
F
Used before safety instructions which must be observed to avoid danger to personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard 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.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
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I 1
0306.GB
Index:
A Correct use and application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies .......................................................................................... B 2
3 Standard Version Specifications ......................................................... B 3
3.1 Performance data for standard trucks ................................................. B 3
3.2 Dimensions EJC 212/214 .................................................................... B 3
3.3 Dimensions EJC 216/220 .................................................................... B 4
3.4 EN norms ............................................................................................ B 6
3.5 Conditions of use ................................................................................ B 6
4 Identification points and data plates .................................................... B 7
4.1 Truck data plate .................................................................................. B 8
4.2 Capacity .............................................................................................. B 8
4.3 Plate, order, inventory and service nos. (o) ...................................... B 9
C Transport and Commissioning
1 Lifting by crane .................................................................................... C 1
2 Securing the truck during transport ..................................................... C 2
3 Using the truck for the first time .......................................................... C 3
4 Operating the truck without its own drive system ................................ C 4
D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
4.1 Charging the battery with an on-board charger (o) ............................ D 3
4.2 Charging the battery with a stationary charger (o) ............................. D 6
5 Battery removal and installation .......................................................... D 8
5.1 Lifting the battery out from the top ...................................................... D 8
5.2 Lateral battery replacement (o) ......................................................... D 9
6 Battery discharge indicator .................................................................. D 10
6.1 Battery Discharge Indicator (t) .......................................................... D 10
6.2 Candis display instrument (o) ............................................................ D 11
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I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
3 Starting up the truck ............................................................................ E 6
4 Using the industrial truck ..................................................................... E 8
4.1 Safety regulations for truck operation ................................................. E 8
4.2 Travelling, Steering, Braking ............................................................... E 9
4.3 Collecting and depositing loads .......................................................... E 12
5 Emergency lowering ............................................................................ E 13
5.1 Park the truck securely ........................................................................ E 14
6 CANCODE keypad (o) ....................................................................... E 14
6.1 Code Lock ........................................................................................... E 14
6.2 Travel programs .................................................................................. E 16
6.3 Parameters .......................................................................................... E 16
6.4 Parameter Settings ............................................................................. E 17
6.5 Travel parameters ............................................................................... E 21
7 Display instrument (CANDIS) (o) ....................................................... E 24
7.1 Discharge monitor function ................................................................. E 25
7.2 Operating hours display ...................................................................... E 25
7.3 Power up test ...................................................................................... E 25
7.4 Troubleshooting .................................................................................. E 26
F Forklift Truck Maintenance
1 Operational safety and environmental protection ................................ F 1
2 Maintenance Safety Regulations ........................................................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance Checklist ........................................................................ F 4
5 EJC 212 – 220 Maintenance Schedule ............................................... F 6
5.1 Consumables ...................................................................................... F 7
6 Maintenance Instructions .................................................................... F 8
6.1 Preparing the truck for maintenance and repairs ................................ F 8
6.2 Remove the front panel ....................................................................... F 8
6.3 Remove the drive panel ...................................................................... F 8
6.4 Checking the hydraulic oil level ........................................................... F 9
6.5 Flushing the gauze filter, Replacing the gauze filter ........................... F 10
6.6 Replace the filter cartridge .................................................................. F 10
6.7 Checking electrical fuses .................................................................... F 11
6.8 Recommissioning ................................................................................ F 12
7 Decommissioning the industrial truck .................................................. F 12
7.1 Prior to decommissioning: ................................................................... F 12
7.2 During decommissioning: .................................................................... F 12
7.3 Restoring the truck to operation after decommissioning ..................... F 13
8 Safety tests to be performed at intervals and after unusual events
(D: Accident prevention check according to BGV D27 .................... F 13
9 Final de-commissioning, disposal ....................................................... F 13
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Appendix
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.
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2
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A 1
1004.GB
A Correct use and application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.
The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual.
M
Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer’s approval.
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A 2
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0306.GB
B Truck Description
1 Application
The EJC is a four wheel, tiller guided electric truck with a steered drive wheel. It is designed for use on level floors to lift and transport palletised goods. Open bottom pallets or roll cages can be lifted. The capacity can be obtained from the data plate. The capacity with respect to lift height and load centre of gravity is indicated on the capacity plate.
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B 2
2 Assemblies
M
1)
The truck must not be operated without the emergency disconnect (see chapter C).
Item EJC 212-220 Description
1 o Charge display 2 t Key switch 3 o CANCODE keypad
o ISM Access Module 4 t Battery discharge indicator /hourmeter
o CANDIS display instrument 5 t Tiller and grip 6 t Crawl button 7 t Travel switch 8 t Collision safety switch 9 t Mast
10 t Mast guard; optional protective frame 11 t Battery panel 12 t Battery connector (emergency disconnect)
1)
13 t Lift mechanism 14 o Charger 15 t Front panel 16 t Caster wheel 17 o Document pocket 18 t Drive wheel
t = Standard equipment o = Optional Equipment
1
2
3
4
5
7
8
7
6
9
10
11
12
13
14
15
16
18
17
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3 Standard Version Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
3.1 Performance data for standard trucks
3.2 Dimensions EJC 212/214
1)
for 100 mm free lift (h2)
2)
DZ + 35 mm
Description EJC 212 EJC 214 EJC 216 EJC 220
Q Rated capacity 1200 1400 1600 2000 kg
c Load centre distance
Standard fork length
600 600 600 600 mm
Travel speed w. nominal load / w.o. load
6,0 / 6,0 6,0 / 6,0 6,0 / 6,0 6,0 / 6,0 km/h
Raise lift speed w. nominal load / w.o. load
15 / 26 15 / 26 14 / 26 10 / 18 cm/s
Lowering speed w. nominal load / w.o. load
40 / 40 40 / 40 40 / 40 40 / 40 cm/s
Max. gradeability (5 min rating) w / w.o. load
8 / 16 8 / 16 7 / 16 7 / 16 %
Description EJC 212 EJC 214
h1 Height (retracted) ZT
1)
1750 – 2650 1750 – 2650 mm
h1 Height (retracted) ZZ
1)
1700 – 2600 1700 – 2600 mm
h1 Height (retracted) DZ
1)
1830 – 2250 1830 – 2250 mm h2 Free lift ZT 100 100 mm h2 Free lift ZZ 1223 – 2123 1223 – 2123 mm h2 Free lift DZ 1356 – 1776 1356 – 1776 h3 Lift (mast-dependent) ZT 2500 – 4300 2500 – 4300 mm h3 Lift (mast-dependent) ZZ 2500 – 4300 2500 – 4300 mm h3 Lift (mast-dependent) DZ 4090 – 5350 4090 – 5350 mm h4 Extended mast height ZT 2977 – 4777 2977 – 4777 mm h4 Extended mast height ZZ 2977– 4777 2977– 4777 mm h4 Extended mast height DZ 4565 – 5825 4565 – 5825 mm
h13 Load fork lowered 90 90 mm h14 Tiller height in min/max travel
position
768/1298 768/1298 mm
y Wheelbase 1277/1357 1277/1357 mm l1 Overall length 1896/1976 1896/1976 mm l2 Headlength 746/826 746/826 mm
b1 Truck width 802 802 mm
b5 Width across forks 570 570 mm m2 Ground clearance 30 30 mm Ast Working aisle width
1000 x 1200 crosswise
2364/2443
2)
2364/2443
2)
mm
Ast Working aisle width
800 x 1200 longit. (in accordance with VDI)
2337/2416
2)
2337/2416
2)
mm
Wa Turning radius in crawl mode
(tiller vertical)
1488/1567 1488/1567 mm
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B 4
3.3 Dimensions EJC 216/220
1)
for 100 mm free lift (h2)
2)
DZ + 35 mm
Description EJC 216 EJC 220
h1 Height (retracted) ZT
1)
1750 – 2650 1750 – 2650 mm
h1 Height (retracted) ZZ
1)
1700 – 2600 1700 – 2600 mm
h1 Height (retracted) DZ
1)
1830 – 2250 1830 – 2250 mm h2 Free lift ZT 100 100 mm h2 Free lift ZZ 1173 – 2073 1223 – 2123 mm h2 Free lift DZ 1306 – 1726 1356 – 1776 h3 Lift (mast-dependent) ZT 2400 – 4200 2500 – 4300 mm h3 Lift (mast-dependent) ZZ 2400 – 4200 2500 – 4300 mm h3 Lift (mast-dependent) DZ 3990 – 5250 4090 – 5350 mm h4 Extended mast height ZT 2927 – 4727 2977 – 4777 mm h4 Extended mast height ZZ 2927– 4727 2977– 4777 mm h4 Extended mast height DZ 4515 – 5775 4565 – 5825 mm
h13 Load fork lowered 90 90 mm h14 Tiller height in min/max travel
position
768/1298 768/1298 mm
y Wheelbase 1277/1357 1277/1357 mm l1 Overall length 1896/1976 1896/1976 mm l2 Headlength 746/826 826 mm
b1 Truck width 802 802 mm
b5 Width across forks 570 570 mm m2 Ground clearance 30 20 mm Ast Working aisle width
1000 x 1200 crosswise
2364/2443
2)
2364/2443
2)
mm
Ast Working aisle width
800 x 1200 longit. (in accordance with VDI)
2337/2416
2)
2337/2416
2)
mm
Wa Turning radius in crawl mode
(tiller vertical)
1488/1567 1488/1567 mm
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0306.GB
h
4
h
3
h
2
h
13
s
h
14
h
14
c
Q
y
l
l
2
l
1
m
2
b
5
A
st
W
a
x
max.
min.
h
1
b
11
(b12)
e
(l
6
)
b
10
a/2 a/2
b
1
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B 6
3.4 EN norms
Noise emission: 65 dB(A)
in accordance with EN 12053 as harmonised with ISO
4871.
Z
The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear.
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.
Z
No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.
3.5 Conditions of use
Ambient temperature
- during operation -5 °C to 40 °C
Z
Special equipment and authorisation is required if the truck is to operate constantly below -5 °C to -25 °C or in a cold store or in extreme temperatures or conditions of fluctuating air humidity.
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0306.GB
4 Identification points and data plates
Item Description
18 Capacity 19 "Do not reach through the mast" warning 20 Truck data plate 21 Attachment point for lifting by crane (with ZZ mast in the middle) 22 “Do not step under the load handler” warning 23 Serial number 24 Battery data plate 25 “No passengers” warning 26 UVV test label
24
22
21
20
19
18
21
23
26
25
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B 8
4.1 Truck data plate
Z
For queries regarding the truck or ordering spare parts always quote the truck serial number (30).
4.2 Capacity
F
The stated capacities apply only for battery weights as indicated on the data plate.
The lower plate (18) gives the capacity (Q in kg) of the truck as a function of the load centre of gravity distance (D in mm) and lift height (H in mm) in tabular form (illustration as example only).
Item Description Item Description
29 Type 35 Manufacturer’s logo 30 Serial no. 36 Min./max. battery weight (kg) 31 Rated capacity (kg) 37 Output (kW) 32 Battery voltage (V) 38 Load centre of gravity (mm) 33 Net weight w.o. battery (kg) 39 Year of manufacture 34 Manufacturer 40 Option
34
33
32
31
30
39
40
38
37
36
35
29
-Nr.
Serien-Nr.
Dmm
Hmm
Qkg
18
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The arrow shape markings (42 and 43) on the inner mast and bottom and outer tie bar indicate to the driver when he has exceeded the height limits specified by the capacity plate (18).
4.3 Plate, order, inventory and service nos. (o)
Z
The capacity plate with the full service number is only issued when a service agreement has been reached.
Item Description
44 Order no.
45 Inventory no.
46 Full service no.
42
43
44
45
46
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B 10
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0606.GB
C Transport and Commissioning
1 Lifting by crane
F
Only use lifting gear with sufficient capacity (for transport weight see truck data plate).
Z
The strap points (1) on the mast are for loading the truck with crane lifting gear.
– Park the truck securely (see Chapter E). – Secure the lifting slings to the attachment
points (1).
M
Attach the crane slings to the strap points so that the truck cannot slip. Lifting slings should be fastened to the harness in such a way that they do not come into contact with any parts of the truck when it is being raised..
1
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C 2
2 Securing the truck during transport
F
The truck must be securely fastened when transported on a lorry or a trailer. The lorry / trailer must have fastening rings.
– To secure the truck attach the tensioning belt to the strap points (1) and secure
them to the fastening rings.
– Tighten the tensioning belt with the tensioner.
M
Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case correct measurements shall be determined and appropriate safety measures adopted.
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3 Using the truck for the first time
F
In order to disconnect the power supply immediately in an emergency, the battery connector (not supplied) must be connected to the truck’s emergency disconnect.
The truck must not be operated without the emergency disconnect.
M
Only operate the truck with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6m long.
F
It is forbidden to raise loads if the truck is operated via a tow lead with an external battery.
To prepare the truck after delivery or after transport, proceed as follows:
– Check the truck for completeness and satisfactory condition of the equipment. – Install battery (where required). Do not damage battery cable.
(see chapter D).
Z
Set the characteristic curve (charging curve) on the charger (see Chapter D).
– Charge the battery (see Chapter D). – If necessary, adjust the combination instrument to match the battery type (see
Chapter D).
– Start up the truck as indicated.
(see Chapter E).
Z
When the truck is parked, the surface of the tyres will flatten. The flattening will disappear after a short period of operation.
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C 4
4 Operating the truck without its own drive system
F
This operating mode is not permitted when negotiating inclines and gradients.
To operate the truck in emergency conditions, the electromagnetically applied brake must be released.
– Remove the front panel (see Chapter F). – Raise the anchor plate by screwing two off M4x20 screws in as far as the stop. – The truck can now be moved.
M
Remove the screws again when you have parked the truck. Braking is now restored again.
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0606.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.
Fire protection: Smoking and naked flames must be avoided when working with batteries Wherever a truck is parked for charging there shall be no inflammable material or operating fluids capable of creating sparks within 2 metres around the truck. The area must be well ventilated. Fire protection equipment must be provided.
Battery maintenance: The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease. Batteries with non insulated terminals must be covered with a non slip insulation mat.
Battery Disposal: Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore, always wear protective clothing and eye protection when carrying out work on batteries. Above all avoid any contact with battery acid. Nevertheless, should clothing, skin or eyes come in contact with acid the affected parts should be rinsed with plenty of clean water - where the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.
M
Only batteries with a sealed battery container may be used.
F
The weight and dimensions of the battery have considerable affect on the operational safety of the truck. Battery equipment may only be replaced with the agreement of the manufacturer.
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0606.GB
D 2
2Battery types
Depending on the model, the EJC comes with different battery types. The battery weights can be taken from the battery data plate.
M
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
The following table shows which combinations are included as standard:
Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.
F
The battery weight and size will affect the capacity of the truck. A truck will only have the capacity stated on the capacity data plate if the battery weight is as indicated on the data plate.
3 Exposing the battery
– Park the truck securely (see Chapter E). – Lift up the battery panel (1). – Remove the battery connector (2).
Chassis version Truck type 24V - Pz... battery
l2 = 746 mm
short
EJC 212 – 216
24 V 3 EPzB 195 Ah
24 V 3 EPzB 300 Ah
24 V 3 EPzV-BS 255 Ah
l2 = 826 mm
long
EJC 212 – 220
24 V 3 EPzS 270 Ah 24 V 3 EPzV 240 Ah 24 V 3 EPzS 345 Ah 24 V 3 EPzS 375 Ah 24 V 3 EPzV 300 Ah
24 V 3 PzW 300 Ah
1
2
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4 Charging the battery
The EJC 212-220 is fitted as standard with an onboard charger (for charging: see section 4.1).
The EJC 212-220 can be optionally fitted with a stationary charger (for charging: see section 4.2).
M
To charge the battery, the truck must be dry and parked in closed and properly ventilated rooms.
4.1 Charging the battery with an on-board charger (o)
The charger must not be opened. If damaged, it must be replaced.
Z
The switch (3) of trucks supplied without a battery is factory-set to the “0” position. The red LED (4) flashes to indicate the battery cannot be charged.
3
4
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0606.GB
D 4
Selecting the charging curve for the onboard charger
Use the switch (3) on the charger to adapt the charge curves to the particular battery used, in accordance with the following table.
M
Remove the battery and mains connectors before setting the appropriate curve.
Z
All other switch (3) positions block the charger, and the battery is not charged.
Setting the charging characteristics
Set the characteristics as follows:
Switch (3) Position Selected charge curves (characteristics)
1 Wet cell batteries: 100 - 300 Ah
2 Maintenance-free: 100 -149 Ah
3 Maintenance-free: 150 -199 Ah
4 Maintenance-free: 200 - 300 Ah
5 Wet cell batteries: 200 - 400 Ah pulse
characteristic
6 Wet cell batteries: Jungheinrich 100 - 300 Ah
Connect the battery This allows you to adjust via the
charger
Turn the setting switch to the right to select the desired characteristic curve
If the characteristic curve is valid, the green LED flashes according to the set position.
If invalid, the red LED flashes.
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0606.GB
Starting to charge with the onboard charger
– Park the truck securely (see Chapter E).
F
When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. It is essential to follow the safety regulations of the battery and charger station manufacturers.
Mains connection
Mains supply: 230 V (± 6%) Mains frequency: 50/60 Hz (± 1%)
The mains cable of the charger (5) is located in the mains cable holder in the battery compartment.
– Lift up the battery panel (1). – Where necessary remove the insulating mat from the battery. – Attach the mains connector (5) to a mains socket.
5
1
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0606.GB
D 6
The flashing LED indicates the charge status or a fault (for flashing codes see “LED Display” table).
Z
If the mains connector (5) is connected to the mains, all the truck’s electrical functions will be interrupted (electrical start block). The truck cannot be operated.
– Remove the connector (5) from the socket and store it in the battery compartment.
Z
Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging.
M
The mains cable must not be opened.
F
Before starting the truck, the battery panel must be firmly closed.
Charging times
The duration of charge depends on the battery capacity.
LED display
Compensation charge
Compensation charge starts automatically when charging is complete.
Partial charging
The charger is designed to automatically adapt to partially charged batteries. This keeps battery wear to a minimum.
4.2 Charging the battery with a stationary charger (o)
– Park the truck securely (see Chapter E).
M
Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.
– Expose the battery (see Section 3).
LED green
(charge status)
LED red
(fault)
Display
Lit --- Charging complete, battery full. (Charging interval,
compensation charge)
Flashes slowly --- Charging
Rapid flash --- Display at beginning of charge or after setting a new
characteristic curve. Number of flash pulses corresponds to the characteristic curve set.
--- Lit Overtemperature. Charging is interrupted.
--- Flashes slowly Safety charging time exceeded. Charging is cancelled. Mains must be disconnected for charging to recommence.
--- Rapid flash Invalid characteristic curve setting.
--- --- Mains failure and/or no battery connected.
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F
When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
– Remove the battery plug (7) from the socket. – Where necessary remove the insulating mat from the battery. – Connect the charging cable of the battery charging station (6) to the battery
connector (7) and switch on the charger.
M
Charge the battery in accordance with the battery and charging station manufacturers’ instructions.
7
6
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0606.GB
D 8
5 Battery removal and installation
– Expose the battery (see Section 3).
F
The truck must be parked on level ground. To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or the battery cable in such a way that they will not get caught on the truck when the battery is removed.
Z
When transporting batteries using a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery data plate on the battery container). The lifting gear must exert a vertical pull so that the battery container is not compressed. The hooks must be attached to the eyes of the battery in such a way that they cannot fall onto the battery cells when the lifting gear is discharged.
– Attach the lifting gear to the attachment eyes and lift out the battery.
F
When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position.
– Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly.
M
After installing the battery again, check all cables and plug connections for visible signs of damage.
F
Before starting the truck, the battery panel must be firmly closed. Close the battery panel carefully and slowly. Do not reach between the battery panel and the chassis.
5.1 Lifting the battery out from the top
– Open the battery panel. – Disconnect the battery. – Attach the crane lifting gear to the attachment eyes (8). – Lift out the battery.
Installation is in the reverse order of removal. When reinstalling the battery, note the required installation position and make sure the battery is connected correctly.
8
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5.2 Lateral battery replacement (o)
– Open the battery panel. – Disconnect the battery. – Pull the battery panel lock (9) up while holding onto the battery panel (11). – Lift out the battery panel and keep it in a safe place. – Position the battery trolley by the truck. – Carefully push the battery from the truck onto the trolley or batterychangingstation.
F
Do not put your fingers between the truck frame and the battery. Observe the operating instructions of the battery changing station manufacturer!
When installing the battery note the following:
Installation is in the reverse order of removal. When reinstalling the battery, note the required installation position and make sure the battery is connected correctly.
– Push the battery in as far as the battery stop. – Apply the battery stop lever (10) and hold it securely. – Pull the battery into the truck.
9
11
10
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D 10
6 Battery discharge indicator
6.1 Battery Discharge Indicator (t)
When the truck has been released via the key switch or CANCODE, the battery charge status is displayed.
The colours of the LEDs (12) represent the following conditions:
Z
If the LED is red, load units can no longer be lifted. Lifting is only released when the battery connected is at least 70 % charged.
If the charge status calculated when the truck is switched on is at least 70% of that of a fully charged battery, the display is reset to 100%. The display reduces in increments of 10% depending on the charge status. The displayed status is reduced to a maximum of 10% within 3 minutes.
The displayed status cannot rise again during the present operation.
The status display is reset to 100% when the battery type is adjusted.
If the LED flashes red and the truck is not ready for operation, inform the manufacturer's service department. Red flashing is a fault code of the truck controller. The flashing sequence indicates the type of fault.
LED colour Rating
Green Standard battery residual capacity 40 - 100 %
Maintenance free battery residual capacity 60 - 100 %
Orange Standard battery residual capacity 30 - 40 %
Maintenance free battery residual capacity 50 - 60 %
Green/orange Flashing. 1Hz
Standard battery residual capacity 20 - 30 %
Maintenance free battery residual capacity 40 - 50 %
Red Standard battery residual capacity 0 - 20 %
Maintenance free battery residual capacity 0 - 40 %
12
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6.2 Candis display instrument (o)
Battery Discharge Indicator: Shows the battery
discharge status in 10% increments through 10 bars on the battery symbol (13).
The bars go out from top to bottom as the battery continues to discharge.
M
When using maintenance free batteries the instrument must be set so that that the symbol (T) (15) appears next to the hourmeter display. If this setting is not made the battery may become damaged through excessive depletion. This instrument should only be adjusted by the manufacturer’s service department.
If there is a battery residual capacity of
- 30% for standard batteries
- 50% for maintenance-free batteries a “warning” symbol appears (14). A battery charge is recommended.
If there is a battery residual capacity of
-20% for standard batteries
-40% for maintenance-free batteries the “warning” symbol goes out and a flashing “STOP” symbol (16) appears. After 5 minutes the "STOP" symbol is permanently lit. The battery must be charged.
Battery Discharge Monitor: When the "STOP" symbol is permanently lit, lifting is inhibited.
Z
Lifting is only released when the battery connected is at least 70% charged.
Hourmeter: The hourmeter (15) incorporated in the battery discharge indicator shows the overall travel and lifting times.
Z
When active, the figure flashes after the comma.
14
13
15
16
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E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation The forklift truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Driver’s rights, obligations and responsibilities: The driver must be informed of his duties and responsibilities and be instructed in the operation of the truck and shall be familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn with pedestrian operated trucks. Travel with a raised load is prohibited (max. height above ground = 500 mm).
Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. The drive must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.
Damage and Faults:The supervisor must be immediately informed of any damage or faults to the forklift truck. Trucks which are unsafe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the industrial truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches.
Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
F
Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions shall be strictly observed.
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2 Controls and Displays
Item Control /
Display
EJC
212-220
Function
1 Battery connector
(Emergency Stop)
t Interrupts the circuit, all electrical functions are
cut out. The truck automatically brakes.
2 Charging display
on charger
o Indicate the charge status (see Chapter D).
3 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched on by unauthorised personnel.
4Keypad
(CANCODE)
o Switches control current on and off.
Code settings. Release and select the travel programs. Enter travel parameters.
ISM access module o Code settings.
Release and select the travel programs. Enter travel parameters.
5 Battery discharge
indicator
t Battery charge status.
Display instrument (CANDIS)
o Operating hours meter.
Battery charge status. Displays service messages and travel
parameters in combination with CANCODE.
6 Tiller t Used to steer and brake the truck. 7 Crawl button t If the tiller is in the upper braking zone, braking
can be overriden by pressing the switch, and the truck can move at reduced speed (crawl speed) .
8 Travel switch t Controls travel direction and speed.
t = Standard equipment o = Optional Equipment
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1
2
3
4
5
6
7
8
9
8
10
11
12
13
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E 4
Item Control /
Display
EJC
212-220
Function
9 Collision safety
switch
t Truck moves away from the operator and
stops.
10 Load fork raise
switch
t Raises load forks.
The lift speed can be infinitely controlled via the switch stroke (8 mm).
11 Load fork lower
switch
t Lowers the load forks.
The lowering speed can be infinitely controlled via the switch stroke (8 mm).
12 Warning signal
(horn) button
t Activates a warning signal.
13 Integrated charger o Used to charge the battery (see Chapter D).
t = Standard equipment o = Optional Equipment
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1
2
3
4
5
6
7
8
9
8
10
11
12
13
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E 6
3 Starting up the truck
F
Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.
The electronic traction and steering controllers monitor their own operation. They inhibit travel in the event of an error.
Checks and operations to be performed before starting daily work
– Visually inspect the entire truck (in particular wheels and load handler) for obvious
damage.
– Visually inspect the battery attachment and cable connections
Switching on the truck
– Make sure the battery is connected (1). – Insert the key in the key switch (3) and turn it to the right as far as it will go (position
“I”) or for CANCODE (4, o) enter the activation code. (see Section 6).
– Test the warning button (12).
The truck is now operational.
o The battery discharge indicator (5) indicates the current battery charge status.
– Test the braking operation of the tiller (6) (see section 4.2).
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1
3
4
5
6
12
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E 8
4 Using the industrial truck
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Travel visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. Loads that affect visibility must be positioned at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
Negotiating slopes and inclines: Slopes or inclines may only be negotiated if they are designated traffic routes, are clean and have a non-slip surface and providing they can be safely negotiated in accordance with the technical specifications of the truck. The truck must always be driven with the load unit facing uphill. The industrial truck must not be turned, operated at an angle or parked on inclines or slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient capacity, are suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a halt and must leave the lift before the truck.
Type of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or falling down.
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4.2 Travelling, Steering, Braking
F
Never carry passengers.
Emergency Disconnect
– Remove the battery connector (1).
All electrical functions are deactivated.
Automatic braking
Automatic braking occurs when the tiller is released – the tiller automatically sets itself to the upper brake zone (B).
F
If the tiller moves slowly to the upper brake zone, the cause of this fault must be rectified. If necessary, replace the gas pressure spring.
Travel
M
Travel with raised forks / raised load beyond 500 mm above the ground is prohibited.
M
Do not drive the truck unless the panels are closed and properly locked.
– Start up the truck (refer to section 3).
The travel speed is governed by the travel switch (8).
– Set the tiller (6) to the travel range (F) and press the controller (8) in the desired
direction (fwd. or rev.).
R
V
B
F
B
6
8
R
V
7
1
0
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E 10
Crawl speed
F
The driver must be particularly careful when applying the “Crawl speed” switch (7).
The truck can be operated with a vertical tiller (6) (e.g. in congested areas / travel seat).
– Press the crawl speed button (7). – Set the controller (8) to the required direction (fwd. or rev.).
The brake is released. The truck travels at slow speed.
M
The brake is only activated with the crawl speed button is released; with crawl speed you can only brake by plugging (controller (8)).
F
In hazardous situations brake the truck by immediately releasing the crawl button (7).
When you apply the crawl button in the travel range (F) the truck travels with reduced speed and acceleration.
Steering (t)
– Move the tiller (6) to the left or right.
Electric steering (o)
The electric steering system is self-monitoring.
The steering controller permanently monitors the entire steering system. If an error is detected the traction controller interrupts travel, brakes regeneratively and the magnetic brake is applied.
F
As the steering system is a safety-critical component, the fault must be rectified by the manufacturer's service department. Improper maintenance or repair work by untrained personnel can result in random steering movements.
Braking
F
The brake pattern of the truck depends largely on the ground conditions. The driver must take this into account when operating the truck.
Braking with the operating brake:
– Set the tiller (6) up or down to one of the brake
zones (B).
M
The service brake is the generator brake. The mechanical brake is only applied when this brake fails to achieve the necessary braking force.
Plugging:
– You can set the travel switch (8) to the opposite
direction when traveling.
– The truck brakes regeneratively until it starts to
move in the opposite direction.
8 8
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Braking with the Coasting Brake:
If the travel switch is set to 0, the truck automatically brakes regeneratively.
F
In hazardous situations set the tiller to the brake position.
Z
The coasting brake is adjustable (controller parameter setting, see chapter E).
Parking brake:
The mechanical brake (handbrake) applies when the truck comes to rest.
Driving on inclines
M
Loads must always be carried on the end of the truck facing uphill.
Preventing the truck from “rolling downhill”:
– With the travel switch set to zero, the brake automatically applies after a short jerk
(the controller detects the truck is rolling back on the slope). The service brake is released again via the travel switch, which is also used to select the speed and the travel direction.
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4.3 Collecting and depositing loads
Z
Before lifting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded.
– Drive the truck with forks as far as possible underneath the load.
Z
With the two-stage Duplex mast (ZZ) a short, centre-mounted free lift cylinder initially lifts the load carriage (free lift) without changing the overall height of the truck.
Lifting
– Press the “Raise Load Forks” switch
(10) until the required lifting height has been reached.
Z
The lift speed can be infinitely controlled via the switch stroke (8 mm).
Short switch stroke= slow lift Long switch stroke= fast lift
Lowering
– Press the “Lower Load Forks” switch
(11) until the required lifting height has been reached.
Z
The lowering speed can be infinitely controlled via the switch stroke (8 mm).
Short switch stroke= slow lower Long switch stroke= fast lower
M
Avoid suddenly depositing the load.
Safety switch height
When lifting from approx. 1.8 m (depending on the mast type):
– Travel speed reduction above the safety switch height (to approx. 4 km/h).
– Backing roller lock (o). The lifting hydraulics act on the backing roller cylinder. This
results in an alignment of the truck.
10
11
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5 Emergency lowering
F
Keep all personnel out of the hazardous area when applying emergency lowering.
If the mast cannot be lowered any further due to a fault in the controller, manually activate the valve (14) on the hydraulic unit..
– Set key switch (3) to “0”. – Disconnect the battery (see chapter
D).
– Open the front panel (see Chapter F,
Section 6.2).
– Using a suitable object (pen, tool or
similar): gently press the valve slide inØ approx. 3 mm and hold it firm.
The lifting mechanism lowers.
F
Only operate the truck once the fault has been removed.
14
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E 14
5.1 Park the truck securely
When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
F
Do not park the truck on a slope. The load forks must always be lowered to the ground.
– Lower the load forks. – Set the key switch (3) to “0” and remove the key or press “o” for CANCODE.
6 CANCODE keypad (o)
The keypad consists of 10 number keys, a Set key and a o key. Activation of the travel programs via switches 1,2,3 is indicated by green LEDs. The o key indicates operating statuses via a red/ green LED.
It contains the following functions:
– Code lock function (commissioning the truck). – Travel program selection. – Setting the travel and battery parameters, only in conjunction with the display
instrument (CANDIS (o)).
The o switch has top priority and resets the truck from any condition to its default condition without modifying any settings.
6.1 Code Lock
When the correct code has been entered, the machine is ready for use. You can allocate an individual code to each truck, driver or group of drivers.
M
When supplied from the factory, the operator code (factory setting 2-5-8-0) is indicated on a removable sticker.
Z
When starting the truck for the first time, change the master and operating codes. (refer to section 6.4)
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Starting the truck for the first time
The LED (15) goes red when you connect the battery and if necessary switch on the key switch.
When you enter the correct operator code (factory setting 2-5-8-0) the LED (15) turns green.
If the wrong code is entered LED (15) flashes red for two seconds. The correct code can then be entered.
Z
The Set key (16) has no function in operating mode
Switching off
To switch the truck off, press the
o- switch (20).
Z
The truck can switch off automatically after a pre-determined time. To do this, you need to set the corresponding code lock parameter. (see Section 6.4).
1516
17
18
19
20
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6.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated programme is indicated by the green LEDs (17), (18), (19) in the corresponding key.
Z
The travel programs differ with respect to travel speed, acceleration and deceleration force.
Factory settings:
– Program 1: Soft operation – Program 2: Normal mode (pre-selected when using the truck for the first time) – Program 3: Power mode
Z
The travel programs can be individually adapted (see Section 6.5).
6.3 Parameters
In programming mode, the operator keypad enables you to set the code lock functions and adapt travel programs. In addition, the battery parameters can also be set.
Z
For trucks without a display instrument (CANDIS (o)) only the code lock parameters can be set.
Parameter Groups
The parameter number is composed of three digits. The first digit refers to the parameter group as shown in Table 1. The second and third digits are numbered in sequence from 00 to 99.
No. Parameter Group 0xx Code Lock Settings
(Codes, travel program release, automatic cutout, etc.)
1xx Travel program 1 parameters
(Acceleration, coasting brake, speed, etc.)
2xx Travel program 2 parameters
(Acceleration, coasting brake, speed, etc.)
3xx Travel program 3 parameters
(Acceleration, coasting brake, speed, etc.)
4xx Program-independent parameters
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6.4 Parameter Settings
To change the truck setting you must enter the master code.
Z
The factory setting for the master code is 7-2-9-5.
M
When starting the truck for the first time, change the master code.
F
Safety instructions for trucks with a display instrument (CANDIS (o))
– Parameter settings must be made carefully and only by special trained personnel.
If in doubt, consult the manufacturer's service department.
– Each setting must be monitored on the LC display of the display instrument
(CANDIS (o)). If in doubt, cancel the setting by pressing the o-key (20).
– Since changing any parameter will affect the truck's travel pattern, you must carry
out a test run in a specially designated work area.
To enter the master code:
– Press theo key – Enter master code
Code Lock Parameters
Setting procedure for trucks without a display instrument (CANDIS (o)):
– Enter the three digit parameter number, confirm with the Set key (16). – Enter the setting according to the parameter list or change and confirm with the Set
key (16).
Z
If the entry is incorrect, the LED (15) of the o key (20) turns red. If you enter the parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To finish entering, press the o key (20).
Display instrument
(CANDIS)
LED (15)
o key
LED (17)
Key 1
LED (18)
Key 2
LED (19)
Key 3
Service hours are indicated
284.0
Green
flashing
Off Off Off
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Setting procedure for trucks with and without display instrument (CANDIS (o)):
– Enter the three digit parameter number, confirm with the Set key (16). – The display instrument (CANDIS (o)) continues to display the operating hours. If
the display changes, cancel the setting with the o-key (20) and restart from the beginning.
– Enter the setting according to the parameter list or change and confirm with the Set
key (16).
Z
If the entry is incorrect, the LED (15) of the o key (20) turns red. If you enter the parameter number again the setting can be entered or changed.
To enter more parameters, repeat the procedure. To finish entering, press the o key (20).
The following parameters may be entered.
Code Lock Parameter List
No. Function Range
Setting
Standard
Setting
Comments
Procedure
Code Lock
000 Change Master Code
The length (4-6 digits) of the master code also pre- determines the length of the operator code (4-6 digits). Provided the operator codes are programmed, only news codes of the same length can be entered. If the code length is to be changed, all operator codes must first be deleted.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 17 flashes)
Enter
current code
Confirm (Set)
(LED 18 flashes)
Enter
new code
Confirm (Set)
(LED 19 flashes)
Repeat new code
Confirm (Set)
001 Add operator code (max.
600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 18 flashes)
Enter
code
Confirm (Set)
(LED 19 flashes)
Repeat
code entry
Confirm (Set)
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LEDs 17-19 are located in key fields 1-3 (see Section 6)
No. Function Range
Setting
Standard
Setting
Comments
Procedure
Code Lock
002 Change user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 17 flashes)
Enter
current code
Confirm (Set)
(LED 18 flashes)
Enter
new code
Confirm (Set)
(LED 19 flashes)
Repeat
code entry
confirm
003 Delete user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 18 flashes)
Enter
code
Confirm (Set)
(LED 19 flashes)
Repeat
code entry
Confirm (Set)
004 Delete code memory
(Deletes all user codes )
3265 3265 = delete
other inputs= do not
delete
010 Automatic time cutout 00 - 31 00 00 = no
cutout
01 to 30 =
Cutout time in
minutes
31 = Cutout after 10
seconds
011
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*) only in conjunction with display instrument (CANDIS (o))
only block if not start travel program.
Error messages on keypad
LED (15) flashes red to indicate the following errors:
– New master code is already operator code. – New operator code is already master code. – Operator code to be changed does not exist. – Tried to change the operator code to another user code that already exists. – Operator code to be deleted does not exist. – Code memory full – Start program blocked. – Travel program to be blocked is the start travel program.
No. Function Range
Setting
Standard
Setting
Comments
Procedure
Code Lock
020 Start travel program 1 - 3 2 1 = Travel program 1
2 = Travel program 2 3 = Travel program 3
021 Travel program 1
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
022 Travel program 2
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
023 Travel program 3
Release
0 or 1 1 0 = Travel program
not enabled
1 = Travel program
enabled
030 Display of the number of
used operator codes*
)
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6.5 Travel parameters
Z
For trucks without a display instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service department.
The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101).
Acceleration example
– Enter the three digit parameter number (101) and confirm with the Set key (16). – Check the LC display of the display instrument (CANDIS (o)) (parameter number
and current parameter value are displayed).
Z
If there is no input for approx. 5 seconds, the display switches back to showing the operating hours.
F
If a parameter number other than the one desired is displayed, you must wait until the operating hours are displayed again.
– Enter the parameter according to the parameter list or change and confirm with the
Set key (16). – Check the LC display of the display instrument (CANDIS (o)), confirm with the Set
key (16). – The LED (15) of the o key (20) switches briefly to a steady light and starts flashing
again after approx. 2 seconds.
Z
If the entry is incorrect, the LED (15) of the o key (20) turns red. If you enter the parameter number again the setting can be entered or changed.
Repeat the process to enter more parameters as soon as the LED (15) of the o key (20) flashes. To finish entering, press the o key (20).
Z
Travel is disabled while the parameters are being entered. If the setting is to be checked in programming mode, follow this sequence:
– Select the edited travel program after entering the parameter, and confirm with the
Set key (16). – The truck is now in travel mode and can be checked. – To continue setting, confirm with the Set key (16) again.
Display instrument
(CANDIS)
LED (20)
o key
LED (17)
Key 1
LED (18)
Key 2
LED (19)
Key 3
Current Setting is displayed
101 6
Green
flashing
Off Off Off
Changed Setting is displayed
101 8
Green
flashing
Off Off Off
Parameter
number
Paramete
r setting
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The following parameters may be entered.
Travel programs
No. Function Range
Setting
Standard
Setting
Comments
Travel program 1
101 Acceleration 0 - 9
(0.2 – 2.0 m/s2)10.4 m/s2)
102 Coasting brake 0 - 9
(0.2 – 1.1 m/s2)
3
(0,5 m/s2)
104 Maximum speed in drive
direction using travel switch
0 - 9
(2.8 -6.2 km/h)4(4.4 km/h)
depending on
travel switch
108 Maximum speed in fork
direction using travel switch
0 - 9
(2.8 -6.2 km/h)3(4.0 km/h)
depending on
travel switch
No. Function Range
Setting
Standard
Setting
Comments
Travel program 2
201 Acceleration 0 - 9
(0.2 – 2.0 m/s)2(0.6 m/s)
202 Coasting brake 0 - 9
(0.2 – 2.0 m/s)4(0.6 m/s)
204 Maximum speed in tiller
direction using travel switch
0 - 9
(2.8 -6.2 km/h)7(5.6 km/h)
depending on
travel switch
208 Maximum speed in fork
direction using travel switch
0 - 9
(2.8 -6.2 km/h)7(5.6 km/h)
depending on
travel switch
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Battery parameters
Z
For trucks without a display instrument (CANDIS (o)) theCODE lock parameters can only be set by the manufacturer's service department.
The parameters are set in the same way as for the travel parameters.
The following parameters may be entered.
Setting 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Range
Setting
Standard
Setting
Comments
Travel program 3
301 Acceleration 0 - 9
(0.2 – 2.0 m/s2)4(1.0 m/s2)
302 Coasting brake 0 - 9
(0.2 – 2.0 m/s2)60.8 m/s2)
304 Maximum speed in tiller
direction using travel switch
0 - 9
(2.8 -6.2 km/h)8(6.0 km/h)
depending on
travel switch
308 Maximum speed in fork
direction using travel switch
0 - 9
(2.8 -6.2 km/h)8(6.0 km/h)
depending on
travel switch
No. Function Range
Setting
Standard
Setting
Comments
Battery parameters
411 Battery type (normal /
enhanced / dry)
0 - 2 0 0 = Normal (wet)
1 = Enhanced (wet)
2 = Dry (maintenance-free)
412 Discharge monitor
function
0 / 1 1
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7 Display instrument (CANDIS) (o)
The instrument indicates:
– battery residual charge status
(LED bars (22)), – Service hours
(LC display (24)).
In addition, service messages for the electronic components and parameter changes are displayed.
Discharge status display
Setting limits for the additional “Warning” (21) and “Stop” (23) displays will depend on the battery type.
Numb
er
of bars
Charge
status
Standard battery Maintenance-free battery
LED (yellow)
Warning
LED (red)
Stop
LED (yellow)
Warning
LED (red)
Stop
10 90,1- 100% Off Off Off Off
9 80,1 - 90% Off Off Off Off 8 70,1 - 80% Off Off Off Off 7 60,1 - 70% Off Off Off Off 6 50,1 - 60% Off Off Off Off 5 40,1 - 50% Off Off On Off 4 30,1 - 40% Off Off On On 3 20,1 - 30% On Off On On 2 10,1 - 20% On On On On
Avoid falling below the 20% limit for standard batteries or the 40% limit for maintenance-free batteries.
21
22
23
24
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7.1 Discharge monitor function
When the discharge monitor function is enabled, lifting is cut out when the discharge limit is reached (the Stop LED is lit). Travel and lowering are still possible. For standard batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. The batteries should be recharged when they reach 30% (for standard batteries) or 50% (for maintenance-free batteries). The yellow LED lights up as warning indicator.
7.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting are logged. This is a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours display (24).
Errormessages
The operating hours display is also used to display errors. The error is displayed in two parts, starting with a “C” for component and a three-digit component number, followed by an “E” for error with alternating three-digit error number. If several errors occur simultaneously, they are displayed one after the other. The errors are displayed as long as they are present (always in combination Cxxx / Exxx). Error messages overwrite the service hour display. Most errors cause the emergency stop to be triggered. Errors remain displayed until the control circuit is switched off (Code lock).
If no CANDIS is present, the error code is displayed by the flashing of the discharge monitor LED.
Z
The manufacturer’s service department has detailed component descriptions with error codes.
Display for parameter changes (travel programs)
The LC display (24) is used in conjunction with the operator keypad (CANCODE (o)) to display the setting parameters. The first three digits of the display show the parameter numbers, the last three digits indicate the parameter value.
Z
Settings of parameter group 0XX (code lock) are not displayed.
7.3 Power up test
On power up the display shows:
– the software version of the display instrument (briefly), – the operating hours – the charge status
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7.4 Troubleshooting
This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table.
Z
If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service department, as any further troubleshooting can only be performed by specially trained and qualified service personnel.
Fault Possible cause Action
Truck does not start.
– Battery plug not connected. – Check the battery connector
and connect if necessary. – Key switch in "0" position – Set key switch to "I" – Incorrect CANCODE code – Check code – Battery charge too low – Check battery charge, charge
battery if necessary – Tiller not set to travel range (F) – Set tiller to travel range (F) – Faulty fuse – Check fuses F1 and F15 – On board charger connected – Disconnect on board charger
from mains
Load cannot be lifted
– Truck not operational – Carry out all remedial actions
listed under “Truck does not
start”. – Hydraulic oil level too low – Checking the hydraulic oil level – Faulty fuse – Check fuse F15 – Load is too heavy – Note maximum capacity (see
data plate) – Charge capacity below
20 / 40%
– Charging the battery
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F Forklift Truck Maintenance
1 Operational safety and environmental protection
The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the maintenance checklists.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.
M
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the forklift truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.
Upon completion of inspection and servicing, the tasks contained in the “Recommissioning” section must be performed (see chapter F).
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). You may only work underneath a raised load handler if it is supported by a sufficiently strong chain.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, implement all necessary safety measures to prevent sparking (e.g. through short circuits). For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical and electronic components must be carefully covered beforehand as moisture can cause malfunctions. Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.
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Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.
Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.
Tyres: The quality of tyres affects the stability and performance of the truck. When replacing factory fitted tyres only used original manufacturer’s spare parts, as otherwise the data plate specifications will not be kept. When changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing wheels always left and right simultaneously).
Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.
Hydraulic hoses: The hoses must be replaced every six years. When replacing hy- draulic components, also replace the hoses in the hydraulic system.
o Electric Steering: As the steering system is a safety-critical component, the fault must be rectified by the manufacturer's service department. Improper maintenance or repair work by untrained personnel can result in random steering movements.
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3 Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend that a Jungheinrich customer adviser carries out an application analysis on site to determine specific service intervals to prevent damage caused by wear. The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as:
W= Every 50 service hours, at least weekly A = Every 500 operating hours B = Every 1000 operating hours, or at least annually C = 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.
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4 Maintenance Checklist
Maintenance intervals
Standard = t WAB C Cold store= k
Brakes 1.1 Check effectiveness of operating and parking brakes,
adjust where necessary and measure braking distance.
kt
1.2 Check the brake lining wear k
Electrics 2.1 Test operation of instruments, displays and control
switches
t
2.2 Test warning and safety device kt
2.3 Check fuse ratings t
2.4 Make sure wire connections are secure and check for damage
t
2.5 Test micro switch setting t
2.6 Check contactors and relays t
2.7 Test safety switch t
2.8 Test cable and motor attachments t
2.9 Check carbon brush wear, replace if necessary t
Energy supply
4.1 Battery visual inspection kt
4.2 Check battery connections are secure, grease terminals if necessary.
kt
4.3 Check acid density, acid level and battery voltage kt
Travel 5.1 Check transmission for noise and leakage t
5.2 Test travel mechanisms, adjust and lubricate if necessary, carry out tiller recuperation test.
kt
5.3 Check wheels for wear and damage kt
5.4 Check wheel suspension and attachments kt
Truck structure
6.1 Check mast attachment t
6.2 Check chassis for damage. t
6.3 Check labels t
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Maintenance intervals
Standard = t WAB C Cold store= k
Hydraulic operation
7.1 Check mast bearings t
7.2 Check setting of slide pieces and stops, and adjust if necessary
t
7.3 Visually inspect the mast rollers and check contact surface wear level
kt
7.4 Check lateral clearance of mast connections and of fork carriage
t
7.5 Check load chain setting and tighten if necessary t
7.6 Check forks and fork carriage for wear and damage kt
7.7 Check mast tilt angle t
7.8 Test hydraulic system operation kt
7.9 Check that hose and pipe lines and their connections are secure, check for leaks and damage, and tighten connections if necessary.
kt
7.10 Check cylinders and piston rods for damage and leaks, and make sure they are secure
kt
7.11 Check the hydraulic oil level kt
7.12 Replace hydraulic oil (this may have to be performed using a special environmental service truck)
tt
7.13 Replace the hydraulic oil filter t
7.14 Test tie rods (EJC-Z only) t
Agreed performance levels
8.1 Lubricate truck in accordance with Lubrication Schedule.
kt
8.2 Test run t
8.3 Demonstration after servicing kt
Steering system
9.1 Test electric steering t
9.2 Test steering play and steering chain t
Fitting times 10.1 Enable servicing and inspection by removing/
assembling panels and covers.
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F 6
5 EJC 212 – 220 Maintenance Schedule
g Contact surfaces
Hydraulic oil filler plug
c Hydraulic oil drain plug
1)
Compound ratio for cold store usage 1:1
E
A
G
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5.1 Consumables
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
F
Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Instructions.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent / consumable mixture must be disposed of in accordance with regulations.
Code Order no. Quantity Description Used for
A 50449669 5.0 l H-LP 46, DIN 51524 Hydraulic system
B 50380904 5.0 l Fuchs Titan Cytrac
HSY 75W-90
Transmission
C 029 200 810 5.0 l H-LP 10, DIN 51524 Hydraulic system
E 29 201 430 1.0 kg Grease, DIN 51825 Lubrication
G 29 201 280 0.4 l Chain spray Chains
Code Saponification Dew point°CWorked penetr.
at 25 °C
NLG1-
class
Application
temperature °C
E Lithium >220 280 - 310 2 -35 / +120
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6 Maintenance Instructions
6.1 Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:
– Park the truck securely (see Chapter E). – Disconnect the battery (1) to prevent the truck from accidentally starting.
F
When working under a raised lift truck, secure it to prevent it from tipping or sliding away. When raising the truck also refer to the instructions in the “Transport and Commissioning” section.
6.2 Remove the front panel
– Open the battery panel. – Remove the three screws (6). – Carefully lift off the front panel (2).
6.3 Remove the drive panel
The drive panel consists of two halves (3 and 4).
– Set the tiller 45° to the right in the travel direction. – Unscrew the 2 screws (5) respectively for the LH and RH cover halves using the
size 5 Allen key (in accordance with DIN 911).
– Carefully remove both cover halves (3 and 4).
1
2
3
4
5
6
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6.4 Checking the hydraulic oil level
– Prepare the truck for maintenance and repairs (see Chapter 6.1). – Remove the front panel (see Section 6.2). – Check hydraulic oil level in hydraulic reservoir.
M
There are markings on the hydraulic reservoir. The oil level must be checked when the load forks are lowered.
– If necessary add hydraulic oil of the correct grade (see Section 5.1) – see table.
M
Assembly is the reverse order.
Tank capacity level
1
(5.7 litres)
2
(6.6 litres)3(7.4 litres)
Max
(7.9 litres) ZT All ZZ up to 280 over 280
DZ All
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6.5 Flushing the gauze filter, Replacing the gauze filter
– Preparing the truck for maintenance and repairs
(see Section 6.1). – Remove the front panel (see Section 6.2). – Undo the union (8). – Remove connection and take out the gauze filter – insert a clean / new filter
M
Assembly is the reverse order.
6.6 Replace the filter cartridge
– Preparing the truck for maintenance and repairs
(see Section 6.1). – Remove the front panel (see Section 6.2). – Unscrew the reservoir lid (7) and remove filter cartridge from the filter cone.
M
Assembly is the reverse order.
7
8
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6.7 Checking electrical fuses
– Preparing the truck for maintenance and repairs
(see Section 6.1).
– Remove the front panel
(see Section 6.2).
– Check the fuse rating and condition in accordance with the table; replace if
necessary.
Item Description To protect: Rating
9 F1 Overall control fuse 10 A 10 6F1 Discharge indicator / hourmeter 2 A 11 4F1 Horn 3 A 12 3F1 Steering controller (o) 30 A 13 1F1 Traction controller 300 A
9 10 11 12
13
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6.8 Recommissioning
The truck may only be restored to service after cleaning or repair work, once the following operations have been performed.
– Test horn. – Test EMERGENCY DISCONNECT switch. – Test brakes. – Lubricate the truck in accordance with the maintenance schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.
If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.
7.1 Prior to decommissioning:
– Thoroughly clean the truck. – Check the brakes. – Check the hydraulic oil level and replenish as necessary (see Chapter F). – Apply a thin layer of oil or grease to any non-painted mechanical components. – Lubricate the truck in accordance with the maintenance schedule (see Chapter F). – Charge the battery (see Chapter D). – Disconnect the battery, clean it and apply grease to the terminals.
Z
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2 During decommissioning:
Every 2 months:
– Charge the battery (see Chapter D).
M
Battery powered trucks: The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.
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7.3 Restoring the truck to operation after decommissioning
– Thoroughly clean the truck. – Lubricate the truck in accordance with the maintenance schedule (see Chapter F). – Clean the battery, grease the terminals and connect the battery. – Charge the battery (see Chapter D). – Check transmission oil for condensed water and replace if necessary. – Check hydraulic oil for condensed water and replace if necessary. – Start up the truck (see Chapter E).
Z
Battery powered trucks: If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8 Safety tests to be performed at intervals and after unusual events
(D: Accident prevention check according to BGV D27
The truck must be inspected at least annually 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 inspection must include a comprehensive check of the technical condition of the truck in respect to accident safety. 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 manufacturer has a safety department with trained personnel to carry out inspec- tions. A test plate is attached to the truck as proof that it has passed the safety inspec- tion. This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
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.
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0506.GB
Instructions for use
Jungheinrich traction battery
Table of contents
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB.......................................... 2-6
Type plate Jungheinrich traction battery............................................ 7
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
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
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2
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte* Type EPzS: 1,29 kg/l Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C
6. Nominal electrolyte level: 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!
•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!
•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!
•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.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other me- tal objects on the battery!
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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).
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 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 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 electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap- plies to the operation traction batteries in industrial trucks.
2.1 Discharging
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.
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 di- scharge. Discharged batteries must be recharged immediately and must not be left discharged. This also applies to partially discharged batteries.
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.
In the gassing stage the current limits given in DIN EN 50272-3 must not be excee- ded. 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.
steel
M 10 23 ± 1 Nm
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Battery container lids and the covers of battery compartments must be opened or re- moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor- rect. (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 batte- ries 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 po- tentially explosive areas). During charging and subsequent gassing the container lids must be removed or opened so that the explosive mixture of gases loses its flamma- bility 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
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 follo- wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca- pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem- peratures shorten the life of the battery, lower temperatures reduce the capacity avai- lable. 55°C is the upper temperature limit and is not acceptable as an operating tem- perature.
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 tempe- ratures 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.
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3. Maintenance
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.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the bat- tery is charged regularly with a IU characteristic curve an equalising charge must be carried out (see point 2.3).
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 re- corded.
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
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 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.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea- ning 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 man- ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call in our service department for this.
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6
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:
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.
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 fin- ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
We reserve the right make technical modification.
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7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin/material 3 Battery type 10 Nominal battery voltage 4 Battery number 11 Nominal battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5 11 13
1
14
4
10 12
7
8
9
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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
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
These are cells with the positive plate 60Ah. The type designation of a cell is e.g. 2 EPzS 120.
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 in- structions on maintaining the respective protection class during operation (see asso- ciated certification).
Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (yellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm 2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm – 2/110 – 12/ 660 50,5 mm 51,0 mm – 2/130 – 12/ 780 50,5 mm 51,0 mm – 2/150 – 12/ 900 50,5 mm 51,0 mm – 2/172 – 12/1032 50,5 mm 51,0 mm – 2/200 – 12/1200 56,0 mm 56,0 mm – 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm 2/210 – 10/1050 – 61,0 mm 61,0 mm 2/230 – 10/1150 – 61,0 mm 61,0 mm 2/250 – 10/1250 – 61,0 mm 61,0 mm 2/280 – 10/1400 – 72,0 mm 66,0 mm 2/310 – 10/1550 – 72,0 mm 66,0 mm
stroke
length
stroke
length
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
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Diagrammatic view
Equipment for the water refilling system
1. Water tank
2. Level switch
3. Discharge point with ball valve
4. Discharge point with sole- noid valve
5. Charger
6. Sealing coupler
7. Closing nipple
8. Ion exchange cartridge with conductance meter and solenoid valve
9. Connection for untreated water
10. Charging lead
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjus- ting 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 den- sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua- matic/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
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 con- nections for the individual plugs. The hose ends are put onto the hose connection sleeves located on the T or < pieces.
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 sys- tem, 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.
at least 3 m
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4. Filling (manual/automatic)
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
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 fil- ling.
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.
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.
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.
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 wa- ter feed pipe must be separated from the battery after filling.
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.
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8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made.
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 tempe- rature 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).
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling sys- tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
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.
10. Accessories
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).
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug sys- tems (plug lifter). The greatest of care must be employed when prising out the plug to prevent any damage to the plug systems.
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10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres- sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- ry'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
The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen- tral 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
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
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2 Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h
4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe- re 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.
• 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!
• 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.
• 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.
• 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!
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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).
1. Commissioning
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.
Otherwise battery, vehicle or charger could be destroyed.
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:
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap- plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
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).
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 dischar- ged.
This also applies to partially discharged batteries.
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 modifica- tions. 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 re- moved.
steel
M 10 23 ± 1 Nm
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With the charger switched off connect up the battery, ensuring that the polarity is cor- rect (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 tem- peratures a longer time higher than +40° C or lower than +15° C, so the chargers need a temperatures regulated voltage.
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.
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
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 char- gers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher tempera- tures 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 tempera- ture.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
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3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
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 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.
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.
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.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea- ning 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 man- ner.
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
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 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.
The storage time should be taken into account when considering the life of the batte- ry.
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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 fin- ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
We reserve the right make technical modification.
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin/material 3 Battery type 10 Nominal battery voltage 4 Battery number 11 Nominal battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5 11 13
1
14
4
10 12
7
8
9
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