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Jungheinrich
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EJE 222

Jungheinrich EJE 222, EJE 220, EJE 230, EJE 220r, EJE 222r Operating Instructions Manual

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Page 1
Operating instructions
50425892
EJE 220/222/225/230/220r/222r
G
10.03 -
06.06
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
Page 3
0108.GB
Page 4
I 1
0606.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assembly groups ................................................................................. B 2
3 Technical data - standard version ....................................................... B 3
3.1 Performance data for standard trucks ................................................. B 3
3.2 Dimensions ......................................................................................... B 3
3.3 EN standards ...................................................................................... B 6
3.4 Conditions for application .................................................................... B 6
4 Location of instruction labels and identification plates ........................ B 7
4.1 Truck identification plate ..................................................................... B 8
4.2 Label: order no., inventory no., full service no. ................................... B 8
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Moving an incapacitated truck (emergency operation) ....................... C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery .................................................... D 4
6 Combined instrument (o) ................................................................... D 5
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0606.GB
I 2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Description of controls and indicating instruments .............................. E 2
3 Putting vehicle in operation ................................................................. E 4
4 Using the industrial truck ..................................................................... E 5
4.1 Safety regulations for truck operation ................................................. E 5
4.2 Driving, steering, braking .................................................................... E 6
4.3 Picking up or lowering load units ......................................................... E 9
4.4 Safe parking of the truck ..................................................................... E 11
5 CANCODE keypad ............................................................................. E 12
5.1 Code Lock ........................................................................................... E 12
5.2 Travel programs .................................................................................. E 14
5.3 Parameters .......................................................................................... E 14
5.4 Parameter Settings ............................................................................. E 15
5.5 Travel parameters ............................................................................... E 19
6 Display instrument (CANDIS) .............................................................. E 22
6.1 Discharge monitor function ................................................................. E 23
6.2 Operating hours display ...................................................................... E 23
6.3 Power up test ...................................................................................... E 23
6.4 Fault location ....................................................................................... E 24
F Maintenance of the truck
1 Operational safety and protection of the environment ........................ F 1
2 Safety regulations for repair ................................................................ F 1
3 Maintenance and service .................................................................... F 3
4 Maintenance checklist EJE 220 / 222 / 225 / 230 / EJE 220r / 222r. .. F 4
5 Lubrication chart EJE 220 / 222 / 225 / 230 / EJE 220r / 222r ........... F 6
5.1 Operating material ............................................................................... F 7
6 Notes on maintenance ........................................................................ F 8
6.1 Preparation of the truck for servicing and maintenance operation ...... F 8
6.2 Open the battery hood ........................................................................ F 8
6.3 Open the front hood ............................................................................ F 8
6.4 Checking the electric fuses ................................................................. F 9
6.5 Recommissioning the truck ................................................................. F 10
7 Decommissioning the fork lift truck ..................................................... F 10
7.1 Operations to be performed prior to decommissioning ....................... F 10
7.2 Measures to be taken during decommissioning .................................. F 10
7.3 Recommissioning the truck ................................................................. F 11
8 Safety checks to be performed at regular intervals and following
any untoward incidents (D: Accident prevention check according
to BGV D27) ........................................................................................ F 11
9 Final de-commissioning, disposal ....................................................... F 11
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.
Page 7
2
Page 8
A 1
0600.GB
A Correct use and application of the truck
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these oper- ating instructions and must always be heeded. National regulations are fully applica- ble.
The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these oper- ating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A “user” within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid- ered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the op- erating duties. The user must ensure that the truck is not abused and only used within its design lim- its and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
M
If these operating instructions are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
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0600.GB
A 2
Page 10
B 1
0606.GB
B Truck description
1 Application
The trucks of the EJE series are of a three-wheeled design equipped with a steered drive wheel and two spring-loaded, swivellable supporting wheels arranged within the enclosed truck envelope. The EJE truck is designed for operation on level ground and is intended for the handling of loads. The EJE can pick up pallets of open ground sup- port, or pallets provided with lateral boards arranged outside the range of the load- bearing wheels, as well as trolleys. The capacity of the truck is shown on the identifi- cation plate, or can be seen from the capacity label Qmax.
Truck types, capacities and motor output:
Type Capacity Motor output EJE 220 2000 kg 1.3 kW EJE 222 2,200 kg 1.5 kW EJE 225 2,500 kg 1.5 kW EJE 230 3,000 kg 1.5 kW
EJE 220r 2,000 kg 1.3 kW EJE 222r 2,200 kg 1.5 kW
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0606.GB
B 2
2 Assembly groups
Item EJE 220/222/225/
230/220r/222r
Designation
1 t Key switch 2 t Discharge indicator
o Display instrument (CANDIS) 3 o CANCODE keypad 4 t Master switch (emergency stop) 5 t Control shaft with control shaft head 6 t Safety key 7 t Driving regulator 8 t Battery hood 9 t Lifting device
10 t Front hood 11 t Supporting wheel 12 t Drive wheel 13 t Button-creep speed
1
3
2
4
5
6
8
10
1211 11
9
13
7
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B 3
0606.GB
3 Technical data - standard version
Z
Technical data to VDI 2198. Technical data are subject to alteration and extension in scope.
3.1 Performance data for standard trucks
*)In the case of longer fork versions, the load centre of gravity is at the fork centre.
3.2 Dimensions
*)Load section lowered + 75 mm (EJE 230 + 100 mm)
**) Ast diagonally, acc. to VDI +196 mm
Ast at shunt driving - 230 mm
Model EJE 220
EJE 220r
EJE 222
EJE 222r
EJE 225 EJE 230
Q Capacity 2000 2200 2500 3000 kg
C Load centre distance for
standard fork length *)
600 600 600 600 mm
Travel speed with rated load / w.o. load
6.0 / 6.0 6.0 / 6.0 6.0 / 6.0 5.0 / 6.0 km/h
Lift speed (lift) with rated load / w.o. load
5.1 / 6.7 4.9 / 6.7 4.7 / 6.7 4.2 / 6.1 cm/s
Max. gradeability (5 min) w / w.o. load
10 / 20 9 / 20 8 / 20 5 / 20 %
Model EJE 220
EJE 220r
EJE 222
EJE 222r
EJE 225 EJE 230
h2Lift 130 130 130 130 mm
h Load fork lowered 85 85 85 90 mm
y Wheel base *
)
L
XL
1340
-
1340 1410
1340 1410
1570 1640
mm
L Truck length (= L2 + l) L
XL
1760
-
1760 1830
1760 1830
1920 1990
mm
L
2
Headlength L
XL
610
-
610 680
610 680
770 840
mm
l Standard fork length 1150 1150 1150 1150 mm
b
1
Truck width 690 690 690 790 mm
Wa Turning radius *
)
L
XL
1620
-
1620 1690
1620 1690
2000 2080
mm
Wa Turning radius*)
in shunt mode (tiller vertical)
L
XL
1390
-
1390 1460
1390 1460
1770 1850
mm
Ast Aisle width **
)
800 x 1200 longit.
L
XL
2130
-
2130 2200
2130 2200
2250 2320
mm
Page 13
0606.GB
B 4
EJE 220/222/225/220r/222r
hh
2
b
1
Ast
Wa
850
y
L
2
l
L
1305
C
Q
Page 14
B 5
0606.GB
EJE 230
1270
L
2
L
h
h
2
Page 15
0606.GB
B 6
3.3 EN standards
Continuous sound level: 64 dB(A)
according to EN 12053 as stipulated in ISO 4871
Z
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0.77 m/s
2
according to EN 13059
Z
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit val- ues for electromagnetic emission and interference immu- nity as well as testing of static electricity discharge ac- cording to EN 12895 and the references to other standards contained therein.
Z
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature:
- during operation 5 °C to 40 °C
Z
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.
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B 7
0606.GB
4 Location of instruction labels and identification plates
Item Designation
14 Prohibition sign “Do not ride on truck” 15 Load capacity Qmax. 16 Truck identification label 17 Label: order no., inventory no., full service no. 18 Limit-stop for crane loading 19 UVV control label
15
16
17
18
Qmax xx00kg
19
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
1996
Ihr Kundendienst-Partner
14
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0606.GB
B 8
4.1 Truck identification plate
Z
In the event of queries relating to the truck or spare part orders, please state the serial no. (21) of the truck.
4.2 Label: order no., inventory no., full service no.
The full service no. will only be assigned if a servicing agreement has been conclud- ed.
Item Designation Item Designation
20 Type 26 Manufacturer 21 Serial no. 27 Min./max. battery weight in kg 22 Rated capacity in kg 28 Drive power in kW 23 System Voltage V 29 Load centre distance in mm 24 Empty weight without battery in kg 30 Year of manufacture 25 Manufacturer logo 31 Option
Item Designation
32 Order no. 33 Inventory no. 34 Full service no.
26
25
2724
2823
2922
3021
3120
32
33
34
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C 1
0606.GB
C Transportation and commissioning
1 Transportation by crane
M
Only lifting gear of adequate capacity must be used (for the transport weight, refer to the truck identification label).
Z
Lifting gear attachment points (1) are provided at the chassis and at the fork in case the truck is to be lifted or transported by crane.
– Park the truck and render it safe (refer
to chapter E).
– Secure the lifting gear to the attach-
ment points (1).
M
The lifting gear must be attached to the attachment points in such a manner that it absolutely cannot slip. If necessary, pull it through the openings! The lifting gear must be fitted in such a way that it will not come into contact with any at- tachments of the truck when the truck is lifted.
2 Commissioning
M
The truck must only be operated on battery current. Rectified alternate current will damage the electronics. Cables connected to the battery (trailing cable) must be less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check the truck for completeness and satisfactory condition of the equipment. – If necessary, install the battery. Do not damage the battery cable. – Charge battery (refer to chapter D). – If necessary, check whether the setting of the combined instrument matches the
type of battery (see chapter D).
– Commission the truck as detailed in chapter E.
Z
When parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
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0606.GB
C 2
3 Moving an incapacitated truck (emergency operation)
In order to be able to move the truck in emergency operation, the electromagnetically operated brake must be released.
– Open and remove the front hood (2) (see chapter F). – Screw on 2 off M4x20 bolts (3) to loosen the armature plate.
The truck can now be moved.
M
Remove the screws again when you have parked the truck. Braking is now restored again.
3
2
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D 1
0606.GB
D Battery - Servicing, recharging,
replacement
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe, before any operations on batteries are to be undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by qualified personnel. The instructions contained in this operating manual, and the instructions as prepared by the battery supplier and as available at the battery recharging station must be observed, when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when han- dling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharg- ing. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- minals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- tional environmental protection regulations or waste disposal provisions. The manu- facturer’s specifications for the disposal must be heeded.
M
Before closing the battery hood, make sure that the battery cable cannot be dam- aged.
F
Batteries contain dissolved acid, which is toxic and caustic. For this reason protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes have accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor, when skin or eyes have come into contact with battery acid. Spilled battery acid must be immediately neutral- ized.
M
Only batteries with closed battery trough may be used.
F
Battery weight and dimensions have considerable influence on the safety of truck op- eration. A change of battery equipment is only permitted with approval of the manu- facturer.
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0606.GB
D 2
2Battery types
The vehicle is equipped with different battery types depending on the type. The bat- tery weights can be seen from the battery identification plates. Batteries with non-iso- lated poles must be covered with a non-slip isolation mat.
M
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
The following table shows the standard battery combinations and battery capacities:
Depending on the type of battery used, it is also possible to use models with en- hanced performance or maintenance-free batteries.
M
Only batteries with closed battery trough may be used.
3 Exposing the battery
– Park the truck and render it safe (refer to chapter E). – Press the main switch (1) to “OFF”. – Lift up and swing forward the battery hood (2) using the handle (3).
Chassis version Truck type 24 V PzS battery
Long version L2 = 610 mm EJE 220 / 222 / 225
EJE 220r / 222r
2 PzS 200 Ah
XL - version L2 = 680 mm EJE 222 / 225
EJE 222r
2 PzS 300 Ah
Long version L2 = 770 mm EJE 230 2 EPzS 230 Ah
XL - version L2 = 840 mm EJE 230 3 EPzS 345 Ah
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D 3
0606.GB
4 Charging the battery
– Park the truck and render it safe (refer to chapter E).
F
The battery connector and the socket must only be connected and disconnected with the truck switched off.
– Expose the battery (refer to section 3).
F
During the recharging operation the, tops of the battery cells must be exposed to en- sure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed.
– Disconnect the battery connector (4). – If present, remove any insulating mats from the batteries. – Connect the charging cable (5) to the battery connector (4) and switch on the bat-
tery charger.
M
Recharge the battery observing the instructions provided by the battery supplier and by the battery charger supplier.
Page 23
0606.GB
D 4
5 Removing and installing the battery
– Expose the battery (see section 3).
F
The truck must be parked on level ground. To prevent short-circuits, batteries with ex- posed poles or cell connectors must be covered using rubber matting. Place the bat- tery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
Z
When transporting batteries with the aid of a crane, ensure that the crane is of ade- quate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points (8) in such a way that the lifting gear, when slack, cannot collaps on the battery cells.
– Loosen the screw (6) of the battery support (7). – Lift and pull out the battery support. – Disconnect the battery. – Fix the lifting gear to the attachment points (8) and lift out the battery.
Installation is in the reverse order of operations. Check for correct mounting position and correct connection of the battery.
F
Upon completion of the battery refitting operations, check all cable connections and plugged connections for any visible damage. Before starting the truck, fasten the bat- tery support (7) with the screw (6) and make sure that the battery hood is closed safe- ly with the hood lock !
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D 5
0606.GB
6 Combined instrument (o)
Battery discharge indicator: The
charging condition of the battery is indi- cated in 10% increments by means of ten bars shown on the battery symbol (9).
With progressive depletion of the bat- tery, the illuminated bars will go out from the top downwards.
M
When using maintenance-free batteries, the instrument must be set so that the “T” symbol (12) will appear next to the oper- ating hour display. When this setting is not performed, the battery might suffer damage caused by exhaustive dis- charge. For adjusting the instrument, it is recommended to consult the manufac- turer service.
An advance “CAUTION” symbol (10) will appear at a residual battery capacity of:
-30 percent in the case of standard batteries and
-50 percent in the case of maintenance:free batteries.
Battery recharging is now advisable.
The advance “CAUTION” symbol will go out and a flashing “STOP” symbol (11) will appear at a residual battery capacity of:
-20 percent in the case of standard bat-
teries and
-40 percent in the case of maintenance-
free batteries.
After a period of 5 minutes the “STOP” symbol will remain permanently alight. Battery recharging is now required.
Battery discharge monitor: As soon as the “STOP” symbol is permanently dis- played, the lifting function of the truck will be automatically switched off.
Z
Lifting will only become possible again after the battery has been recharged to at least 70 percent.
Hour meter: The hour meter (13) integrated into the battery discharge indicator shows the total operating time of the travelling and lifting movements.
Z
In the operative condition, the digit after the comma will flash.
h
h
h
STOP
T
T
T
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0606.GB
D 6
Page 26
E 1
0606.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 shoes must be worn with pedestrian operated trucks.
Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. He shall prevent unauthorised persons from driving or operating the truck. It is forbidden to carry passengers or lift personnel.
Damage and Faults: The supervisor must be immediately informed of any damage or faults to the forklift truck. Trucks not safe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authoristion to do so. On no account may the driver 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 in good time. 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.
Page 27
0606.GB
E 2
2 Description of controls and indicating instruments
Item Control /
Display
EJE 220 /
222 / 225
/ 230
EJE 220r
/ 222r
Function
1 Key switch ttSwitches current on and off.
Removing the key prevents the truck from being switched on by unauthorised personnel.
2 CANCODE
keypad
ooCode settings.
Release and select the travel programs.
Enter travel parameters.
3 Discharge indicator ttBattery charge status.
Display instrument (CANDIS)
ooHourmeter.
Battery charge status. Displays service messages and
travel parameters in combination with CANCODE.
4 Tiller ttUsed to steer and brake the truck. 5 Main switch /
isolator (Emergency Disconnect)
ttDisconnects the circuit, all
electrical functions are deactivated.
6 Warning signal
(horn) button
ttTriggers a warning signal.
7 Fork lower button ttLowers the forks. 8 Fork raise button ttRaises the forks. 9 Controller ttControls travel direction and
speed.
10 Collision safety
switch
ttTruck moves away from the
operator at crawl speed and stops.
11 Raise button
Auxiliary lift Ramp mode
--- t Raises the fork heel while
simultaneously lowering the fork tips.
12 Shunt mode button ttIf the tiller is in the upper braking
zone, braking can be overriden by pressing the button, and the truck can travel in shunt mode.
t = Standard equipment o = Optional equipment
Page 28
E 3
0606.GB
3
4
5
6
7
7
8
99
10
12
11
Page 29
0606.GB
E 4
3 Putting vehicle in operation
F
Before starting or operating the truck, or before lifting any loads, the driver has to make sure that nobody is within the danger area.
Checks and actions before routine start-up
– Visual inspection for damages of the whole truck (especially tyres and load carrying
devices).
– Visual inspection of battery fixing and cable connections.
Starting up the truck
– Pull out master switch (5). – Put key into the key switch (1) and turn right until stop to position “I”. – Check function of horn (6).
The truck is now ready for operation. The battery discharge indicator (3) indicates the available battery capacity.
– Check control shaft (4) for braking function (see section 4.2).
3
4
5
6
Page 30
E 5
0606.GB
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 persons must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility when travelling: The driver must look in the direction of travel and must always have a clear view of the route ahead. When carrying loads which affect visibility, these must be stored at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
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 to prevent parts of the load from tipping or falling down.
Page 31
0606.GB
E 6
4.2 Driving, steering, braking
F
Increased attention has to be paid during driving and steering the truck, especially if movements outside of the truck contour are to be performed. It is not admissible to stay on the vehicle during driving.
EMERGENCY STOP
– Push master switch (5) down.
All electric functions are switched off. The truck is compulsory braked.
Emergency stop
When the control shaft is released, the truck is compulsory braked (emergency stop)
- the control shaft automatically swivels into the upper braking range (B).
F
If the control shaft swivels only slowly into the braking position, it is required to per- form troubleshooting measures. For example, the return spring must be exchanged!
Driving
F
Do not drive the truck unless the hoods are closed and locked in the stipulated man- ner. When driving through swinging doors, etc., make sure that the doors do not trig- ger the collision-guard button (10).
– Commissioning the truck (see section 3). – Push the control shaft (4) into the driving range (F) and set the driving switch (9) to
the desired driving direction (V or R).
The truck starts to drive into the selected direction.
Z
The driving speed can be continuously regulated with the driving switch (9).
5
10
4
9
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F
If the truck can only be moved with reduced driving speed, a defect has occurred which is influencing the safety of operation of the truck. It may be that the service brake can only be used after pressing the EMERGENCY-STOP switch (5). The truck needs to be taken out of service and must be repaired by expert personnel (see chapter F).
Driving on slopes
M
The load must be transported pointing towards the mountain!
Securing the truck against “rolling downhill”:
If the driving switch is set to zero, the service brake is automatically triggered when the truck starts to roll downhill (the control system detects the unintended movement of the truck). The driving switch can be used to release the service brake and to select the desired driving speed and direction.
F
If the roll-off brake was deactivated by the service, only service brake and counterflow brake are available.
Shunt driving
F
The driver must pay special attention if he uses the “Shunt driving” button (12).
The truck can be moved with its control shaft (4) in vertical position (e.g. in confined spaces / lifts):
– Press “Shunt driving” button (12). – Set the driving switch (9) to the desired driving di-
rection (V or R). The service brake is triggered. The truck changes to the slow-driving mode.
M
The service brake is only activated after releasing the “Shunt driving” button; in the Shunt driving mode, braking is only possible using the counterflow brake (driving switch (9)).
F
In case of danger, the truck can be immediately braked by releasing the “Shunt driv- ing” button (12).
Steering
– Swivelling the control shaft (4) to the left-hand or right-hand side.
4
9912
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Braking
F
The braking effect of the truck is mainly depending on the road surface. This must be taken into account by the driver for his driving behavior.
The truck may be braked in three ways:
– Using the service brake (control shaft (4)), – Using dynamic braking (roll-off brake can be adjusted by the service), – Control with regenerative brake via the drive control (9).
Braking with the service brake:
F
In case of danger, the truck must be braked with the service brake (control shaft (4)).
– Swivel control shaft (4) upwards or downwards into one of the braking ranges (B).
The drive motor is mechanically braked.
Z
When the control shaft (4) is released, it swivels into the upper braking range (B). If the truck is parked, the service brake is used as parking brake
5
10
4
9
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Dynamic braking (roll-off brake):
– After releasing the driving switch (9) - driving switch set to zero - the truck is braked
with the help of the dynamic brake (roll-off brake), depending on the selected set- ting.
F
If the roll-off brake was deactivated by the service, only service brake and counterflow brake are available.
Braking with the counterflow brake:
M
If the control system or driving mechanism breaks down, the counterflow brake be- comes ineffective.
– Do not turn the drive control (9) into opposite driving direction.
Z
The braking effect depends on the position of the driving switch.
Z
For standard driving operations, only the dynamic brake and that counterflow brake are to be used, since these brake types are reduce wear and tear and help to save energy (energy return supply).
4.3 Picking up or lowering load units
F
Before a load unit is picked up, the driver has to make sure that it is properly palletised and does not exceed the permitted bearing capacity of the truck. Do not grab into the hoist frame during lifting and lowering.
– Drive the truck with the fork tines as far as possible below the load unit.
It is not permitted to pick up long goods with the truck driving transversally below the good.
Lifting
– Press the “Raise fork” button (8) until
the desired height has been reached.
Lowering
– Press the operating key “Lower fork”
(7) and the fork will descend.
Z
The fork lowering speed cannot be ad- justed as it was permanently set before leaving the works.
Z
Use the maximum possible lifting height when lifting heavy loads.
8
7
7
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Aux. lift for ramp operations (EJE-R 220/222 only)
Z
The fork will be automatically lowered before the fork lift function is changed over to the aux. lift function. The fork base will be automatically lowered before changing over from the aux. lift function to the fork lift function.
– Pallet resting on level ground, truck
on an incline.
Picking up a load
– Approach the pallet.
– Extend the aux. lift (11). – Insert the fork into the pallet.
– Lower the aux. liftv in steps by de-
pressing the operating key (7) while
at the same time continuing to insert
the fork into the pallet.
– Fully insert the fork into the pallet.
– Move the control shaft into the brak-
ing range. – Using the fork lift, lift the pallet clear. – Turn the controller by approx. a
third of the required movement into
the direction of travel. – Move the control shaft into the driv-
ing range - the truck will start with-
out rolling back.
11
7
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Setting down the load:
Set down the load and withdraw the fork from the pallet by proceeding in the reverse sequence of operations adopted when picking up the load.
4.4 Safe parking of the truck
If the truck is left unattended, even for only short periods of time, it must be rendered safe.
F
Do not park the truck on slopes! The lifting device must always be completely low- ered.
– Lowering the lifting device. – Set master switch to “OFF” position. – Set key switch to “0” position and remove the key.
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5 CANCODE keypad
The keypad consists of 10 digit keys, a Set key and a o-key. Activation of the travel programs is indicated through green LEDs on keys 1, 2 and 3. The o key indicates operational status through 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).
The o switch has top priority and resets the truck from any condition to its default condition without modifying any settings.
5.1 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.
Z
When supplied from the factory, the operator code (factory setting 2-5-8-0) is indicated on a removable sticker.
M
When starting the truck for the first time, change the master and operating codes (see section 5.4)
1 2 3
4 5 6
7 8 9
0
Set
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Commissioning
The LED (11) 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 (12) turns green.
If the wrong code is entered LED (12) flashes red for two seconds. The correct code can then be entered.
Z
The Set key (13) has no function in operating mode
Switching off
Press the o key (17) to switch off the truck.
Z
The truck can switch off automatically after a pre-determined time. To do this, the corresponding code lock parameter must be set(see section 5.4).
1 2 3
4 5 6
7 8 9
0
Set
14
13
12
17
1615
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5.2 Travel programs
Press the digit keys 1, 2, and 3 to select any of three travel programs. The activated program is indicated by the green LEDs (14), (15), (16) in the corresponding key.
Z
The travel programs differ with respect to travel speed, acceleration and deceleration force.
Factory settings:
– Program 1: Gentle operation – Program 2: Normal operation – Program 3: High performance mode (preset on commissioning)
Z
The travel programs can be individually adapted (see Section 5.5).
5.3 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 authorisation, 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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5.4 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 (see Section 5.1).
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 (17). – 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 (13). – Enter the setting according to the parameter list or change and confirm with the Set
key (13).
Z
If the entry is incorrect, the LED (12) of the o key (17) goes 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 (17).
Display instrument
(CANDIS)
LED (12)
o key
LED (14)
Key 1
LED (15)
Key 2
LED (16)
Key 3
Service hours are displayed
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 (13). – The display instrument (CANDIS (o)) continues to display the operating hours. If
the display changes, cancel the setting procedure with the o key (17) and restart
from the beginning. – Enter the setting according to the parameter list or change and confirm with the Set
key (13).
Z
If the entry is incorrect, the LED (12) of the o key (17) goes 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 (17).
The following parameters may be entered.
Code Lock Parameter List
No. Function Setting
range
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 13 flashes)
Enter
current code
Confirm (Set)
(LED 14 flashes)
Enter a
new code
Confirm (Set)
(LED 15 flashes)
Repeat new code
Confirm (Set)
001 Add operator code (max.
600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 14 flashes)
Enter a
code
Confirm (Set)
(LED 15 flashes)
Repeat code
entry
Confirm (Set)
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LEDs 14-16 are located in key fields 1-3 (see Section 5.2)
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
002 Change user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 14 flashes)
Enter
current code
Confirm (Set)
(LED 15 flashes)
Enter a
new code
Confirm (Set)
(LED 16 flashes)
Repeat code
entry
Confirm
003 Delete user code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 15 flashes)
Enter a
code
Confirm (Set)
(LED 16 flashes)
Repeat
code entry
Confirm (Set)
004 Delete code log
(Deletes all user codes )
3265 3265 = delete
other inputs= do not
delete
010 Automatic timeout 00 - 31 00 00 = No
cutout
01 to 30 =
Cutout time in
minutes
31 = cutout in 10
seconds
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*) only in conjunction with display instrument (CANDIS (o))
Error messages on keypad
LED (12) 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
No. Function Setting
range
Standard
setting
Comments
Procedure
Code Lock
021 Travel program 1*
)
release
0 or 1 1 0 = Travel program
not released
1 = travel program
released
022 Travel program 2*
)
release
0 or 1 1 0 = Travel program
not released
1 = travel program
released
023 Travel program 3*
)
release
0 or 1 1 0 = Travel program
not released
1 = travel program
released
030 Display of the number of
used operator codes*
)
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5.5 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 (13). – 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 or change the parameter value according to the parameter list. – Check the LC display of the display instrument (CANDIS (o)), confirm with the Set
key (12). – The LED (12) of the o key (17) switches briefly to a steady light and starts flashing
again after approx. 2 seconds.
Z
If the entry is incorrect, the LED (12) of the o key (17) goes 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 (12) of the o key (17) flashes. To finish entering, press the o key (17).
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 (13). – The truck is now in travel mode and can be checked. – To continue setting, confirm with the Set key (13) again.
The following parameters may be entered.
Display instrument
(CANDIS)
LED (17)
o key
LED (14)
Key 1
LED (15)
Key 2
LED (16)
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
Parameter
setting
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Travel programs
No. Function Setting
range
Standard
setting
Comments
Travel program 1
101 Acceleration 0 - 9
(0.2 – 2.0 m/s2)30.8 m/s2)
102 Coasting brake 0 - 9
(0.2 – 1.1 m/s2)
3
(0.5 m/s2)
104 Maximum speed in drive
direction via controller
0 - 9
(2.8 -6.2 km/h)3(4.8 km/h)
depending on
travel switch
108 Maximum speed in fork
direction via controller
0 - 9
(2.8 -6.2 km/h)3(4.8 km/h)
depending on
travel switch
No. Function Setting
range
Standard
setting
Comments
Travel program 2
201 Acceleration 0 - 9
(0.2 – 2.0 m/s)6(1.4 m/s)
202 Coasting brake 0 - 9
(0.2 – 2.0 m/s)6(0.8 m/s)
204 Maximum speed in tiller
direction via travel switch
0 - 9
(2.8 -6.2 km/h)8(6.0 km/h)
depending on
travel switch
208 Maximum speed in fork
direction via controller
0 - 9
(2.8 -6.2 km/h)8(6.0 km/h)
depending on
travel switch
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Battery parameters
Z
For trucks without a display instrument (CANDIS (o)) theBATTERY 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 Setting
range
Standard
setting
Comments
Travel program 3
301 Acceleration 0 - 9
(0.2 – 2.0 m/s2)9(2.0 m/s2)
302 Coasting brake 0 - 9
(0.2 – 2.0 m/s2)91.1 m/s2)
304 Maximum speed in tiller
direction via 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 via controller
0 - 9
(2.8 -6.2 km/h)8(6.0 km/h)
depending on
travel switch
No. Function Setting
range
Standard
setting
Comments
Battery parameters
411 Battery type (normal /
high performance / dry)
0 - 2 0 0 = Normal (wet)
1 = high performance (wet)
2 = Dry (maintenance-free)
412 Discharge monitor
function
0 / 1 1
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6 Display instrument (CANDIS)
The instrument indicates:
– Residual battery charge
((LED bars (19)), – Service hours
(LCD display (21)).
In addition, service messages for the electronic components and parameter changes are displayed.
Discharge status display
Setting limits for the additional “Warning” (18) and “Stop” (20) displays will depend on the battery type.
Number
of bars
Charge
Level
Wet 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 wet batteries or the 40% limit for maintenance- free batteries.
18
19
20
21
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6.1 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 wet batteries the residual capacity is 20%, for maintenance-free batteries it is 40%. The batteries should be recharged when they reach 30% (for wet batteries) or 50% (for maintenance-free batteries). The yellow LED lights up as warning indicator.
6.2 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 (21).
Error messages
The operating hours display is also used for indicating 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 occurs at the same time, they are displayed one after the other. The errors are displayed for as long as they remain (always in combination Cxxx / Exx). 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 (21) 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.
6.3 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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6.4 Fault location
This chapter helps the operator to locate and fix simple malfunctions or the results of operating errors him- or herself. The order of the work stated in the table must be ob- served for fault location.
Z
If it is not possible to rectify the fault by performing the indicated “remedial actions”, please contact the Customer Service, as more intricate faults can only be rectified by specially trained and qualified service personnel.
Fault Possible cause Remedy
Truck does not move
– Battery connector
not connected
– Check the battery connector
and reconnect it, if necessary – Master switch (EMERGENCY
STOP) pressed
– Release master switch
(EMERGENCY STOP) – Incorrect CANCODE code – Check code – Key switch set to “0” position – Set the key switch to position “I” – Battery voltage too low – Check the charging status of
the battery and recharge, if ne-
cessary – Faulty fuse – Check
fuses F1 and 1F1
Load cannot be lifted
– Truck not ready for operation – Perform all troubleshooting
measures that are mentioned
under “truck does not drive” – hydraulic oil level too low – check hydraulic oil level – Faulty fuse – Check fuse 2F1
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0606.GB
F Maintenance of the truck
1 Operational safety and protection of the environment
The checks and maintenance work listed in this chapter have to be performed accord- ing to the intervals of the maintenance checklists.
F
Modifications of truck assemblies, especially of the safety installations, are not per- mitted. On no account must the operational speeds of the truck be changed.
M
Only original spare parts have been passed by our quality assurance service. In order to ensure safe and reliable operation only original spare parts of the manufacturer must be used. Old parts and changed consumption type materials must be disposed of in accordance with the applicable environmental protection regulations. The Oil Change Service of the manufacturer is available for oil changes.
Upon completion of any checks and servicing activities, the operations contained in the section "Recommissioning" must be performed (see chapter F).
2 Safety regulations for repair
Servicing and maintenance personnel: Maintenance and repair of the floor con-
veyors may only be performed by expert personnel of the manufacturer. The Service Organisation of the manufacturer has service engineers available that have been specifically trained for these tasks. We therefore advise to conclude a maintenance contract with the manufacturer’s Service Base responsible for the area.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tip- ping over (use of chocks, wooden blocks). Work underneath raised forks must only be carried out, when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the in- dustrial truck. Prior to performing cleaning operations all appropriate safety measures must be taken to avoid sparking (e.g. due to short circuits). The battery connector must be disconnected. Electric and electronic components must be cleaned with low- pressure air or suction air and a non-conducting, antistatic brush.
M
If the truck is to be cleaned using water or a steam jet, all electric and electronic as- semblies have to be carefully covered beforehand, as humidity will cause malfunc- tions. Steam-cleaning is not permitted.
Upon the completion of cleaning work the operations detailed in section “Recommis- sioning” have to be performed.
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Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depowered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.
Tire equipment: The quality of the tires greatly affects the stability and the driving behaviour of the fork-lift truck. Modifications must only be carried out after discussion with the manufacturer. When replacing wheels or tires, it must be ensured that the truck remains level (tires and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply for use in normal environment. For applications in aggravated conditions (dust, temperature), frequent re-lubrication must be performed. The specified chain spray must be used as specified. Applying grease to the outside and heavy external dirt accumulation prevent the lubricant to penetrate into the joints.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy- draulic components, you should also replace the hydraulic hose lines in the corre- sponding hydraulic system.
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3 Maintenance and service
Thorough and expert servicing is one of the most important preconditions for safe op- eration of the fork-lift truck. The neglect of regular servicing intervals can lead to fork- lift failure and constitutes a potential hazard to personnel and operation.
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 service adviser carries out an applica- tion analysis on site to establish specific service intervals to prevent damage caused by wear. The indicated servicing intervals are based on single-shift operation under normal op- erating conditions. For applications in dusty environments, or involving large temper- ature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the re- spective intervals to be observed. The following maintenance intervals are defined:
W = Every 50 operating hours, at least, however, once a week A = Every 500 operating hours, or at least every six months B = Every 1000 operating hours, or at least annually C = Every 2000 operating hours, or at least annually
Z
The W maintenance intervals must be carried out by the operator / 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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F 4
4 Maintenance checklist EJE 220 / 222 / 225 / 230 / EJE 220r / 222r.
Maintenance intervals
Standard = t WA B C Cold-storage depot = k
Chassis/ Design:
1.1 Check all load bearing elements for damage t
1.2 Check all bolted connections t
Drive unit: 2.1 Check the transmission for noises and leakage t
2.2 Check the transmission oil level t
2.3 Change the gear oil kt
Wheels: 3.1 Check for wear and damage t
3.2 Check seating and attachment kt
Steering: 4.1 Check the steering clearance t Brake system:
5.1 Check function and adjustment kt
5.2 Check the return spring for repositioning function and damage
t
5.3 Check the brake linings for wear t
5.4 Check the brake linkage and adjust, if necessary kt
Lifting device: 6.1 Check function, wear and tear and adjustment t
6.2 Visual check of rollers, slide pieces and stops kt
6.3 Check fork tines and fork carrier for wear and damage kt
Hydr. system: 7.1 Check function kt
7.2 Check all connections for leakage and damage kt
7.3 Check hydraulic cylinders for leakage, damage and secure attachment
kt
7.4 Check hydraulic oil level kt
7.5 Replace the hydraulic oil and the filter cartridge kt
7.6 Check the pressure relief valves for correct functioning kt
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Maintenance intervals
Standard = t WA BC Cold-storage depot = k
Electr. system:
8.1 Check function t
8.2 Check all cables for secure connection and damage t
8.3 Check the fuses for correct amperage t
8.4 Check switches and trip cams for proper functioning and seating
t
8.5 Check contactors and relays, replace wearing parts, if necessary
t
8.6 Check functioning of warning devices and safety circuits kt
Electric motors:
9.1 Check wear of carbon brushes t
9.2 Check the motor for secure attachment t
9.3 Suck out engine block, check wear of collector kt
Battery: 10.1 Check acid density, acid level and cell voltage kt
10.2 Check the terminals for secure attachment and apply pole grease
kt
10.3 Clean battery connections, check for tight fit kt
10.4 Check the battery cables for damage and replace, if ne- cessary
t
Lubrication service:
11.1 Grease truck according to lubrication schedule kt
General mea- surements:
12.1 Check electrical system for short to ground t
12.2 Check driving speed and braking distance t
12.3 Check lifting and lowering speed t
12.4 Check safety facilities and switch-off devices t
Demon- stration:
13.1 Perform a trial run under a nominal load t
13.2 Demonstrate the truck to a person charged with inspec- tion upon completion of the maintenance of the truck
kt
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F 6
5 Lubrication chart EJE 220 / 222 / 225 / 230 / EJE 220r / 222r
g Slide faces
s Grease nipple
Filler neck for hydraulic oil
b Filler neck Gear oil a Drain plug Gear oil
Cold store usage
1) Mixing proportion for application in cold-storage depots 1:1
2) For twin load wheel
2
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5.1 Operating material
Handling operating material: Consumption type material must always be handled
properly. Manufacturer's instructions to be observed.
F
Improper handling endangers health, life and environment. Operating material must only be stored in containers conforming to specification. They might be inflammable and must not come into contact with hot components or open fire.
When filling in consumption type materials, use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions. -This instruction may only be ignored, if another mixing ratio is explicitly prescribed in this manual.
Avoid any spilling. Spilled liquid must be removed immediately using a suitable bind- ing agent, and the mixture of consumption type material and binding agent is to be disposed of according to the regulations.
Code Order-no. Supplied
quantity
Description Used for:
A 50 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic system B 50 380 904 5.0 l Fuchs Titan Cytrac
HSY 75W-90
Transmission
C 29 200 810 5.0 l H-LP 10, DIN 51524 Hydraulic system E 29 202 050 1.0 kg Grease, Polylub
GA352P
Lubrication
Grease standard values
Code Type of
Saponification
Dropping
point °C
Worked penetration
at 25 °C
NLG1
Class
Service
temperature °C
E Lithium >220 280 - 310 2 -35 / +120
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6 Notes on maintenance
6.1 Preparation of the truck for servicing and maintenance operation
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
– Park the truck and render it safe (refer to chapter E). – Disconnect the battery connector to prevent accidental or unauthorised truck ope-
ration.
F
When work has to be performed under the jacked-up truck, suitable measures must be taken to prevent any dropping, tilting or slipping of the truck. When lifting the truck, the instructions included in chapter “Transportation and Commissioning” have to be observed.
6.2 Open the battery hood
See chapter D.
6.3 Open the front hood
– Remove the screws (1). – Raise the hood (2) and place it next to the truck.
Z
Mounting is performed in reverse order.
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6.4 Checking the electric fuses
– Preparation of the truck for servicing and maintenance operations
(refer to section 6.1). – Open the front hood (see section 6.3). – Referring to the table, check all fuses for correct rating and replace, where required.
Description Protection of: EJE 220 / 222 / 225 / 230
EJE 220r / 222r
F1 Total control fuse 10 A
1F1 Drive motor (in parallel to 1F10) 150 A
1F10 Drive motor (in parallel to 1F1) 40 A
2F1 Pump motor 150 A
6F1 Discharge indicator/operating hour meter 10 A
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6.5 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
– Check the horn for proper functioning. – Check the master switch for correct functioning. – Check the brake for correct functioning. – Lubricate truck according to lubrication schedule.
7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
M
During decommissioning, the fork lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional meas- ures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck. – Check the brakes for correct function. – Check the hydraulic oil level and top up if required (refer to chapter F). – Apply a thin film of oil or grease to all parts not protected by a paint coating. – Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F). – Recharge the battery (refer to chapter D). – Disconnect and clean the battery. Apply pole grease to the battery poles.
Z
In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
M
Battery-operated fork lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
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7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck. – Lubricate the fork lift truck according to the lubrication chart (refer to chapter F). – Clean the battery. Grease the pole screws using pole grease and reconnect the
battery. – Recharge the battery (refer to chapter D). – Check if the gear oil contains condensed water and change if required. – Check if the hydraulic oil contains condensed water and change if required. – Start up the fork lift truck (refer to chapter E).
Z
Battery-operated fork lift trucks: If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
F
Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to BGV D27)
At least once yearly, or after any untoward incident, the fork lift truck has to be chek- ked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experi- enced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the in- spection of fork lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork lift truck with regard to accident prevention aspects. Apart from this, the fork lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
Z
The manufacturer has set up a special safety service with specially qualified staff. As visual proof that the fork lift truck has passed the safety inspection, a plaque is affixed to it. This plaque indicates in which month of which year the next test will be due.
9 Final de-commissioning, disposal
Z
Final de-commissioning or disposal of the truck must be performed correctly 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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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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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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