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EJC M10

Jungheinrich EJC M10 Operating Instructions Manual

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Page 1
Operating instructions
51145321
EJC M10
G
05.09 -
05.09
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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0108.GB
Page 4
I 1
0509.GB
Table of contents
A Correct Use and Application BDescription
1 Application ...........................................................................................B 1
2 Assemblies ..........................................................................................B 2
3 Technical Specifications ...................................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions .........................................................................................B 3
3.3 EN norms ............................................................................................B 5
3.4 Conditions of use ................................................................................B 5
4 Identification points and data plates ....................................................B 6
4.2 Capacity ..............................................................................................B 7
C Transport and Commissioning
1 Lifting by crane ....................................................................................C 1
2 Securing the Truck for Transport ........................................................C 1
3 Using the truck for the first time ..........................................................C 2
4 Operating the truck without its own drive system
(emergency operation) ........................................................................ C 3
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
5 Charging the battery with a stationary charger (o) .............................D 5
6 Battery removal and installation ..........................................................D 6
7 Battery charge / discharge indicator (t) .............................................D 7
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 4
4 Industrial Truck Operation ...................................................................E 5
4.1 Safety regulations for truck operation .................................................E 5
4.2 Travel, steering, braking ...................................................................... E 6
4.3 Lifting and depositing load units ..........................................................E 9
5 Emergency lowering ............................................................................ E 10
5.1 Parking the truck securely ...................................................................E 10
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0509.GB
I 2
6 Travel parameters ............................................................................... E 11
7 Display instrument (CanDis) (o) .........................................................E 12
7.1 Service hours display .......................................................................... E 13
7.2 Power up test ...................................................................................... E 13
7.3 Troubleshooting ..................................................................................E 14
F Industrial 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 Lubrication 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 Removing the front panel .................................................................... F 8
6.3 Removing the drive panel ...................................................................F 8
6.4 Checking the hydraulic oil level ...........................................................F 9
6.5 Checking electrical fuses ....................................................................F 10
6.6 Recommissioning ................................................................................F 11
7 Decommissioning the industrial truck ..................................................F 11
7.1 Prior to decommissioning ....................................................................F 11
7.2 During decommissioning .....................................................................F 11
7.3 Returning the truck to operation after decommissioning ..................... F 12
8 Safety tests to be performed at intervals and after unusual
incidents ..............................................................................................F 12
9 Final de-commissioning, disposal .......................................................F 12
Page 6
1
0506.GB
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
Page 8
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 operating instructions is an industrial truck designed for lifting and transporting loads. 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 industrial 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 chart 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 industrial 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 users have read and understood these operating instructions.
M
Failure to comply with the operating instructions 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 enhances 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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0509.GB
B Description
1 Application
The EJC M10 is a four wheel, electric pedestrian stacker 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
Item EJC M10 Description
1 t Key switch
2
t Battery charge / discharge indicator o CANDIS display instrument
3 t Tiller and tiller arm
4 t “Shunt” button
5 t Controller
6 t Collision safety switch
7 t Mast
8 t Mast guard / auxiliary mast guard
9 t Battery cover 10 t Battery connector (Emergency Disconnect) 11 t Lift mechanism 12 t Front panel 13 t Castor wheel 14 t Traction controller and charger 15 t Drive wheel
t = Standard equipment o= Optional equipment
1
15
2
3
4
55
6
10
9
12
1314
11
7
8
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3 Technical Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
3.1 Performance data
3.2 Dimensions
Description EJC M10
Q Rated capacity 1000 kg C Load centre distance
Standard fork length 600 mm Travel speed
w. rated load / w.o. load 4.2 / 5.0 km/h Raise lift speed
w. rated load / w.o. load 8.5 / 12 cm/sec Lowering speed
w. rated load / w.o. load 11 / 11 cm/sec Max. gradeability (5 min rating)
w / w.o. load 8 %
Description EJC M10
h1 Height 1950 mm
h2 Free lift 100 mm
h3 Lift 2900 mm
h4 Mast height extended 3373 mm
h13 Load fork lowered 90 mm h14 Tiller height in min./max. travel position 820/1310 mm
y Wheelbase 1171 mm l1 Overall length 1787 mm l2 Headlength 637 mm BWidth 800 mm
b5 Outside straddle 560 mm m2 Ground clearance 30 mm Ast Working aisle width 800 x 1200 longit. 2096 mm Ast Aisle width 800 x 1200 longit.
(in accordance with VDI)
2234 mm
Wa Turning radius for shunting
(tiller upright)
1383 mm
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B 4
h
1
h
14
h
2
h
3
h
4
l
1
l
l
2
h
13
m
2
y
c
Q
b
5
A
st
W
a
B
s
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3.3 EN norms
Noise emission: 70 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 level of the driver's ear.
Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein.
Z
No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.
3.4 Conditions of use
Ambient temperature
- operating at 5 °C to 40 °C
Z
Special equipment and authorisation is required if the truck is to operate constantly below 5 °C or in a cold store or in extreme temperatures or conditions of fluctuating air humidity.
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B 6
4 Identification points and data plates
Item Description
16 Capacity 17 Data plate 18 Strap point for crane lifting 19 "Do not reach through the mast" warning 20 “Do not step under the load handler” warning 21 Battery data plate 22 Serial number 23 Truck description 24 “No riding” warning 25 Test plaque (o)
16
16
24
20
19
21
17
25
18
18
18
22
23
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4.1 Data Plate
Z
For truck-related queries or when ordering spare parts always quote the truck serial number (26).
4.2 Capacity
F
The capacity data with respect to lift height and load centre of gravity distance can be found on the capacity plate (16).
Depending on the mast fitted, the truck will have one of the following two capacity plates (16a / 16b): (illustrations for reference purposes only)
The capacity plate to the right (16a) shows the capacity (Q in kg) for different load centres of gravity (D in mm) in diagram form.
The lower plate (16b) 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.
The arrow shape markings (38 and 39) 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 (16).
Item Description Item Description
26 Type 32 Manufacturer’s logo
27 Serial no. 33 Min./max. battery weight (kg)
28 Rated capacity (kg) 34 Output (kW)
29 Battery voltage (V) 35 Load centre of gravity (mm)
30 Net weight excl. battery 36 Year of manufacture
31 Manufacturer 37 Option
25
26
27
28
29
30
35
34
31
33
32
36
16a
-Nr.
Serien-Nr.
Dmm
Hmm
Q
kg
16b
38 39
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B 8
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C 1
0509.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 attachment points (1) are provided for lifting the truck with crane lifting gear (in the middle on the ZZ mast).
– Park the truck securely (see Chapter E). – Strap the lifting gear onto the attachment
points (1) (in the middle on the ZZ mast).
M
Attach the crane slings to the strap points so that the truck cannot slip. Crane slings should be fastened in such a way that they do not come into contact with any parts of the truck when it is being raised.
2 Securing the Truck for Transport
F
The truck must be securely fastened when transported on a lorry or a trailer. The lorry / trailer must have fastening rings.
– To fasten the truck strap the tensioning
belt to the truck and attach it to the fastening rings.
– Tighten the tensioning belt with the
tensioner.
Z
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 must be made and appropriate safety measures adopted.
1
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0509.GB
C 2
3 Using the truck for the first time
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
Do not lift 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: – Make sure the truck's equipment is complete and in a satisfactory condition.
– Install battery (where required). Do not damage battery cable.
(see Chapter D). – Charge the battery (see Chapter D). – If necessary, adjust the display instrument and the battery parameter 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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0509.GB
4 Operating the truck without its own drive system (emergency operation)
F
This operating mode is not permitted when negotiating inclines and gradients. If the truck has to be moved after a fault has made it non-operational, proceed
as follows: – Set the main switch/isolator “OFF”.
– Set the key switch “OFF” (“0”) and remove the key. – Prevent the truck from rolling away. – Remove the front panel (2) (see Chapter F). – Remove the right-hand drive panel (3) (see Chapter F). – Pull up the anchor plate by screwing in two M5 screws (4, at least 35 mm long)
as far as the stop. The brake has now been released and the truck can be moved.
F
On reaching your destination, ensure that the brake is restored to its initial state. The truck must not be parked with the brakes released.
– Remove the screws (4). The brake is now applied again.
2
3
4
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C 4
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D 1
0509.GB
D Battery Maintenance, Charging &
Replacement
1 Safety regulations for handling acid batteries
Park the industrial 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. This operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.
Fire protection: Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there must be no inflammable material or lubricants capable of creating sparks within 2 metres of 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 insulating 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 panel 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. Neutralise any spilled battery acid immediately.
M
Only batteries with a sealed battery container may be used.
F
The weight and dimensions of the battery have a considerable effect on the operational safety of the industrial truck. Battery equipment may only be replaced with the agreement of the manufacturer.
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D 2
2Battery 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:
3 Exposing the battery
– Park the truck securely (see Chapter E). – Remove the battery connector (1). – Lift up the battery panel (2).
F
When you lift up the battery panel, make sure the panel lock engages.
Z
Remove the panel when replacing the battery.
Battery
EJC M10 2 PzB 110 Ah
2
1
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0509.GB
4 Charging the battery
F
The on-board charger must not be opened. The mains cable must not be damaged.
F
It is essential to follow the safety regulations of the battery and charging station manufacturers.
Z
The mains cable of the charger is located in the mains cable holder in the battery compartment.
M
The battery temperature rises by approx. 10°C during charging. Battery charging should only start when the battery temperature is below 35°C. The battery temperature before charging should be at least 15°C as otherwise it will affect the charge.
To charge the battery, the truck must be parked in a closed and properly ventilated room.
– Lift up the battery panel (2). – Where necessary remove the
insulating mat from the battery. – Remove the mains connector (3)
from its receptacle and insert it in a
suitable mains socket. The LED (4)
flashes green or a permanent
yellow to indicate that the charger
is connected to the mains.
Z
When the mains connector (3) is connected to the mains, all the truck’s electrical functions are interrupted (electrical start-up protection). The truck cannot be operated.
– Charge the batteries until the
LED (4) produces a permanent
green light. Remove the mains
connector (3) from the mains
socket and insert it in its receptacle
on the truck.
Z
Charging continues automatically after a mains failure. Charging can be interrupted by removing the mains connector and continued as partial charging.
Z
When the battery connector is removed the batteries are disconnected from the charger and cannot be charged.
On-Board Charger Mains Connection
Mains supply: 110-230 V ±10% Mains frequency: 50/60 Hz ±4%
The on-board charger identifies the mains voltage and adapts itself automatically.
3
4
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D 4
LED display (4)
Red LED (fault)
Float charge
When the green LED (4) is permanently lit, the battery is fully charged. The charger changes to compensation charge. The compensation charge lasts until the mains connector is removed from the mains socket.
Z
The 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.
A red flashing LED (4) means that the battery is faulty or the charge current circuit has been interrupted.
Lit Charging complete,
battery fully charged. (charge interval, float or 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 restart.
Rapid flash Invalid characteristic curve
setting.
4
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0509.GB
5 Charging the battery with a stationary charger (o)
Park the truck securely (see Chapter E).
M
The battery connector and socket may only be attached or disconnected when the main switch and the charger are switched off.
– Expose the battery (see section 3).
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.
– Where necessary remove the insulating mat from the battery. – Connect the charging cable of the battery charging station to the battery
connector (1) and switch on the charger.
M
Charge the battery in accordance with the battery and charging station manufacturers’ instructions.
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0509.GB
D 6
6 Battery removal and installation
– Undo the spring elements of the battery panel and remove the battery panel.
F
The truck must be level. 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 identification plate at the battery trough). The lifting gear must exert a vertical pull so that the battery container is not compressed. The hooks must be attached to the eyes (5) 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 (5) 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, 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
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7 Battery charge / discharge indicator (t)
After the truck has been released via the key switch or CanCode, the battery charge status is displayed.
The colours of the LEDs (6) represent the following conditions:
Z
If the LED is red, load units can no longer be lifted. Lifting is only enabled again when the battery connected is at least 70 % charged.
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 Capacitance 40 - 100 %
Orange Capacitance 30 - 40 %
Green/orange
Flashing. 1Hz
Capacitance 20 - 30 %
Red Capacitance 0 - 20 %
6
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D 8
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E 1
0509.GB
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 shows must be worn for 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 driver 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 truck or attachment. 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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E 2
2 Controls and Displays
Item Control /
display item
EJC M10 Function
1 Battery connector
(Emergency Disconnect)
t Disconnects the circuit, all electrical functions
are deactivated. The truck stops.
2 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel. 3 Battery charge /
discharge indicator
t Indicates the charge/discharge status of
the battery.
Display instrument (CanDis)
o Hourmeter.
Battery charge status.
Displays service messages and travel
parameters in combination with CanCode. 4 Tiller t Used for steering and braking. 5 “Shunt” button t If the tiller is in the upper braking zone, braking
can be overridden by pressing the switch,
and the truck can move with reduced speed
(shunting). 6 Controller t Controls travel direction and speed. 7 Collision safety
switch
t Truck moves away from the operator and
stops. 8 Load fork
raise switch
t Raises the forks.
9 Load fork
lower switch
t Lowers the forks.
The lowering speed can be controlled in
2 stages by the distance the button is moved
(8 mm).
10 Warning signal
(horn) button
t Activates a warning signal.
11 On-board charger t Charges the battery
(see Chapter D).
t = Standard equipment o= Optional equipment
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2
1
11
3
4
5
7
66
8
9
10
7
66
8
9
10
8
9
t
o
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E 4
3 Starting up the truck
F
Before the truck can be started, operated or a load lifted, the driver must ensure that there is nobody within the hazardous area.
Checks and operations to be performed before starting daily operation
– Visually inspect the entire truck (in particular wheels and load handler) for obvious
damage. – Check the battery attachment and cable connections and grease terminals
if required. – Check the battery connector for damage, test it and make sure it is secure. – Check the mains connector and mains cable for damage. – Check labels for legibility and completion (see chapter B). – Test warning indicators and safety devices. – Test hydraulic system. – Test the efficiency of the brakes (see page 6) – Check the hydraulic oil level weekly and adjust if necessary.
Switching on the truck
– Make sure the battery is connected (1). – Insert the key in the key switch (2) and turn it clockwise as far as it will go to
the “I” position. – Test the warning button (10).
The truck is now operational. The battery charge / discharge indicator (3) or the CanDis (o) shows the available
battery capacity. – Test the brake function of the tiller (4) (see section 4.2).
2
3
4
1
10
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4 Industrial Truck Operation
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.
Travel 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. Do not lean out 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.
Nature of loads to be carried: Only transport properly secured loads. Never transport loads stacked higher than the top of the fork carriage or the load guard.
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E 6
4.2 Travel, steering, braking
F
Never carry passengers.
Emergency Disconnect
– Remove the battery connector (1). All electrical functions are deactivated.
Automatic braking
The truck automatically brakes 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 (see section 3). The travel speed is governed by the travel switch (6). – Set the tiller (4) to the travel range (F) and press the controller (6) in the desired
direction (fwd. or rev.).
0
B
F
B
6
5
1
4
R
R
V
V
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0509.GB
Crawl speed
F
The driver must be particularly careful when applying the “Crawl speed” button (5). The truck can be operated with a vertical tiller (4) (e.g. in congested areas / travel
seat). – Press the crawl speed button (5).
– Set the controller (6) to the required direction (fwd. or rev.). The brake is released. The truck travels at slow speed.
M
The brake is only activated when the crawl speed button is released; with crawl speed you can only brake by plugging (travel switch (6)).
F
In hazardous situations brake by immediately releasing the crawl speed button (5). When you apply the crawl speed button in the travel range (F) the truck travels at
reduced speed and acceleration.
Steering
– Move the tiller (4) to the left or right.
0
B
F
B
6
5
1
4
R
R
V
V
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E 8
Braking
F
The brake pattern of the truck depends largely on the track conditions. The driver must take this into account.
Braking with the service brake:
– Set the tiller (4) up or down to one of the brake
zones (B).
M
The service brake is the regenerative brake. Only when this brake fails to achieve the necessary brake force is the mechanical brake applied.
Inversion braking:
– You can set the travel switch (6) to the opposite direction when travelling. – The truck brakes regeneratively until it starts to move in the opposite direction.
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.
Travelling on inclines
M
Loads must always be carried at that end of the truck facing uphill. Preventing the truck from “rolling downhill”: – With the controller set to zero, the brake automatically engages after a short jerk
(the controller detects the truck is rolling back on the slope). The service brake is
released again via the controller, which is also used to select the speed and the
travel direction.
66
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4.3 Lifting and depositing load units
Z
Before lifting a load the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity.
– Travel with the forks as far as possible underneath the load.
Lifting
– Press the “raise load handler” button (8)
until you reach the required lifting height.
Z
The lift speed cannot be changed. When you reach the the load handler limit position, immediately release the button.
Lowering
– Press the “lower load handler” button (9)
until you reach the required lifting height.
M
Avoid depositing the load suddenly.
Slow lowering
M
The lowering speed can be infinitely controlled through the button stroke (ca. 8 mm). A short stroke results in lowering at a reduced speed. A long stroke results in lowering at full speed.
Two-hand operation (o)
The control unit is optionally fitted with a second rocker switch with the "raise load handler" (12) and "lower load handler" (13) buttons.
9
8
9
8
13
12
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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, apply emergency lowering on
the hydraulic unit. – Set key switch (2) to “0”.
– Disconnect the battery (see chapter D). – Open the front panel (see Chapter F). – Remove the screw gradually (14).
The lift mechanism lowers. – Insert the screw (14) as far as the stop.
F
Only operate the truck once the fault has been removed.
5.1 Parking the truck securely
When you exit the truck it must be securely parked even if you only intend to leave it for a short time.
F
Do not park the truck on an incline. The forks must always be lowered to the ground. – Lower the forks.
– Set the key switch (2) to the "0" position and remove the key.
14
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6 Travel parameters
Z
This travel parameters can only be adjusted by the manufacturer’s service department.
The following example shows the parameter setting for the acceleration of travel program 1 (parameter 101).
Travel program 1
Function Setting
range
Standard
setting
Comments
Acceleration 0 - 9
(0.1 – 1.0 m/s2)3(0.4 m/s2)
Coasting brake 0 - 9
(0.1 – 1.0 m/s2)3(0.4 m/s2)
Maximum speed in tiller direction via controller
0 - 9
(2.6 - 5.3 km/h)5(4.1 km/h)
dependant on
travel switch
Maximum speed in fork direction via controller
0 - 9
(2.6 - 5.3 km/h)5(4.1 km/h)
dependant on
travel switch
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7 Display instrument (CanDis) (o)
The instrument shows:
In addition, service messages for the electronic components and parameter changes are displayed.
Discharge status display
Setting limits for the additional “Warning” (20) and “Stop” (17) displays will depend on the battery model set.
The available capacity is shown via 8 LED bars. The two bottom bars are always off. The current battery capacity is shown by the illuminated LED bars.
8 bars correspond to full battery capacity, 1 bar corresponds to the minimum available capacity.
If only one LED bar is lit, the battery capacity is almost depleted and the “Warning” indicator (20) is lit. The battery must be charged immediately.
If no more LED bars are illuminated, the “Stop” indicator (17) lights up. Lifting is now inhibited. The battery must be charged.
16 Capacity display bars
Battery residual charge status
17 Stop symbol; lift cutout,
Battery charge required
18 6 digit LCD display;
hourmeter, input display, error display
19 T symbol appears during operation
when the discharge indicator is set to maintenance-free battery
20 Warning - pre-warning symbol,
Battery charge recommended
21 Battery charge display
(on-board charger only)
20
19
21
16 17
18
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7.1 Service hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting operations are logged. This is a backlit display. For maintenance-free batteries a “T” symbol is shown in the service hours display (19).
Eventmessages
The service hours display is also used to display events. The event display starts with an "E" for error and a three digit error number. If several events occur simultaneously, they are displayed one after the other. The events are displayed until they are rectified. Event messages overwrite the service hour display. Most events cause the emergency stop to be activated. The event display remains until the control circuit is switched off (key switch).
If no CanDis is present, the event code is displayed by the flashing of the charge/ discharge indicator LED.
Z
The manufacturer’s service department has detailed component descriptions with event codes.
7.2 Power up test
On power up the display shows: – the software version of the display instrument (briefly),
– the service hours, – the charge status.
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7.3 Troubleshooting
This chapter allows the user to identify and rectify basic faults or the effects of incorrect operation. When trying to locate 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 organisation, as any further troubleshooting can only be performed by specially trained and qualified service personnel.
Fault Possible Cause Action
Truck does not start
– Battery connector not plugged in– Check battery connector
and insert if necessary. – Key switch in "0" position – Set key switch to "I" – Battery charge too low – Check battery charge,
charge battery if necessary – Control handle not set to travel
zone (F)
– Set control handle to travel
zone (F) – Faulty fuse – Check fuse 1F1 – On board charger connected – Disconnect on board charger
from mains
Load cannot be lifted
– Truck not operational – Carry out all measures listed
under “Truck does not start”. – Hydraulic oil level too low – Check the hydraulic oil level – Faulty fuse – Check fuse 2F1. – Load is too heavy – Note maximum capacity
(see data plate) – Battery charge too low – Charging the battery
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F Industrial 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. Do not alter the truck's operating speeds under any circumstances.
M
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the 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 that you enter into 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 operations detailed in the “Recommissioning” section.
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F 2
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. Battery-operated trucks must also be de- energised by disconnecting the battery.
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 truck will not comply with the data plate specifications. 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 hydraulic components, also replace the hoses in the hydraulic system.
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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 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 service hours B = Every 1000 service hours, or at least annually C = Every 2000 service hours, or at least annually
Z
W maintenance interval operations are performed by the proprietor. During the run-in period – after approx. 100 service hours – the owner must check
the wheel nuts/bolts and re-tighten if necessary.
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4 Maintenance Checklist
Maintenance Intervals
Standard = t WABC
Brakes 1.1 Test service and/or parking brakes. t
1.2 Check magnetic brake air gap, adjust if necessary t
Electrical sys- tem
2.1 Test warning indicators and safety devices. t
2.2 Test cable and motor attachments t
2.3 Test instruments, displays and control switches. t
2.4 Check micro switch setting t
2.5 Check contactors and relays. t
2.6 Check fuse ratings. t
2.7 Carry out a frame leakage test. t
2.8 Make sure wire connections are secure and check for damage.
t
2.9 Check the controller readings, check settings and adjust if necessary
t
2.10 Read the logbook and then clear it t
Power supply 3.1 Visually inspect battery and battery components. t
3.2 Check battery cable connections are secure, grease terminals if necessary.
t
3.3 Check acid density, acid level and battery voltage t
3.4 Check the battery connector for damage, test it and make sure it is secure.
t
Travel 4.1 INFORMATION: Replace gear oil if service
life exceeded [10000 h]
t
4.2 Check the transmission for noise and leakage t
4.3 Check wheel suspension and attachment. t
4.4 Check wheels for wear and damage. t
Chassis and superstruc- ture
5.1 Check chassis and screw connections for damage t
5.2 Check doors and covers t
5.3 Check labels are present and complete. t
5.4 Check mast attachment. t
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Maintenance Intervals
Standard = t WABC
Hydraulic oper- ations
6.1 Check cylinders and piston rods for damage and leaks, and make sure they are secure.
t
6.2 Check settings and wear levels of slide pieces and stops, and adjust if necessary
t
6.3 Check load chain setting and tension if necessary t
6.4 Visually inspect mast rollers and check contact surface wear level
t
6.5 Check lateral clearance of mast connections and of fork carriage
t
6.6 Test the hydraulic system. t
6.7 Replace the hydraulic oil filter t
6.8 Check that hose and pipe lines and their connections are secure, check for leaks and damage
t
6.9 Test the emergency lowering t
6.10 Check hydraulic oil level and top up if necessary. t
6.11 Replace the hydraulic oil after 2000 service hours / bi- annually
t
6.12 Check forks, load handler [e.g. mandrel] for wear and damage
t
Agreed per- formance levels
7.1 Carry out a test run with rated load t
7.2 Demonstration after servicing t
7.3 Lubricate truck in accordance with Lubrication Schedule.
t
Steering 8.1 Test tiller recuperating function t
Charger 9.1 Check mains connector and mains cable. t
9.2 Check the start-up protection system for trucks with an on-board charger.
t
9.3 Potential measurement on chassis while charging is in progress.
t
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F 6
5 Lubrication Schedule
g Contact surfaces h Hydraulic oil filler neck
b Transmission oil filler neck
Gear oil overflow and dipstick
a Transmission oil drain plug
0,55 l
4,5 l
min
max
G
B
A (C)
E / F
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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.
M
*The trucks are factory-equipped with a special hydraulic oil (the Jungheinrich hydraulic oil with a blue colouration) and the cold store hydraulic oil (red colouration). The Jungheinrich hydraulic oil can only be obtained from the Jungheinrich service department. The use of named alternative hydraulic oils is not prohibited but may lead to a decline in functionality. The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils.
Code Order no. Package
quantity
Description Used for
A
51132827* 5.0 l J ungheinrich
Hydraulic oil
Hydraulic system51132826* 1.0 l
50449669 5.0 l H-LP 46, DIN 51524
B 50380904 5.0 l Titan Cytra
HSY 75W-90
Transmission
C 51081875 5.0 l Renolin MR 310 Hydraulic system E 14038650 400g
Cartridge
Standard grease, DIN 51825
Lubrication
F 50006713 400g
Cartridge
Cold store grease, DIN 51825
G 29201280 0.4 l Chain spray Chains
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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). – Remove the battery connector (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 industrial truck also refer to the instructions in the “Transport and Commissioning” section.
6.2 Removing the front panel
– Open the battery panel. – Remove the two screws (6). – Carefully lift off the front panel (2).
6.3 Removing the drive panel
The drive panel consists of two halves (3 and 4). – Turn the tiller to the left limit position.
– Remove the two screws (5). – Carefully remove the first panel half (3). – Turn the tiller to the right limit position. – Unscrew the second panel half (4) and carefully remove it.
1
234
5
6
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6.4 Checking the hydraulic oil level
– Prepare the truck for maintenance and repairs (see section 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 transmission oil of the
correct specification (see section 5.1).
M
Assembly is the reverse order.
min
max
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6.5 Checking electrical fuses
– Prepare 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
7 2F1 Pump motor fuse 100 A 8 1F1 Drive motor fuse 60 A 9 1F9 Traction / lift electronics control fuse 10 A
10 F13 Solenoid / magnetic brake control fuse 10 A
87910
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6.6 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. – Test brakes. – Lubricate according to 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. – Spray 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 Returning 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 incidents
Z
Perform a safety check in accordance with national regulations. Jungheinrich recommends the truck be checked to FEM guideline 4.004. Jungheinrich has a safety department with trained personnel, able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified inspector (be sure to comply with national regulations). The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z
Final, correct de-commissioning or disposal of the truck must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
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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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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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8
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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10
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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14
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
Page 73
0506.GB
18
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