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EKS 308

Jungheinrich EKS 308 Operating Instructions Manual

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Page 1
Operating instructions
51009741
EKS 308
G
03.06 -
07.08
Page 2
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
F
Used before safety instructions which must be observed to avoid danger to personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
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Index
A Correct Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ................................................................................................... B 3
3 Standard Version Specifications ......................................................... B 5
3.1 Performance Data ............................................................................... B 5
3.2 Dimensions (as per data plate) ........................................................... B 7
3.3 Mast version ........................................................................................ B 7
3.4 EN norms ............................................................................................ B 8
3.5 Conditions of use ................................................................................ B 8
4 Identification points, warning decals and data plates .......................... B 9
4.1 Truck data plate .................................................................................. B 11
4.2 Capacity .............................................................................................. B 11
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by crane .................................................................................... C 1
2.1 Crane points / Strap points .................................................................. C 3
2.2 Lifting the battery by crane .................................................................. C 3
3 Securing the truck during transport ..................................................... C 3
3.1 Basic truck transport safety ................................................................. C 4
3.2 Mast transport safety ........................................................................... C 5
3.3 Mast assembled .................................................................................. C 5
4 Using the truck for the first time .......................................................... C 6
4.1 Moving the truck without a battery ...................................................... C 6
4.2 Installing/removing or erecting/folding the mast .................................. C 6
5 Commissioning .................................................................................... C 7
D Battery Maintenance, Re-Charging, Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Charging the Battery ........................................................................... D 3
4 Battery removal and installation .......................................................... D 4
5 Check the battery condition, the acid level and acid density ............... D 6
6 Battery discharge indicator .................................................................. D 6
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E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
2.1 Operating and display equipment on control panel ............................. E 2
2.2 Display unit controls and displays ....................................................... E 3
2.3 Truck operational status symbols ........................................................ E 7
3 Starting up the truck ............................................................................ E 8
3.1 Checks and operations to be performed before starting daily work .... E 8
3.2 Truck entry and exit ............................................................................. E 8
3.3 o Attaching the safety restraint belt .................................................... E 9
3.4 t Preparing the truck for operation .................................................... E 10
3.5 o Preparing the truck for operation with an additional access code ... E 11
3.6 Setting the time ................................................................................... E 12
3.7 Operator specific settings .................................................................... E 13
4 Industrial truck operation ..................................................................... E 14
4.1 Safety regulations for truck operation ................................................. E 14
4.2 Travelling, Steering, Braking ............................................................... E 15
4.3 Negotiating narrow aisles .................................................................... E 17
4.4 Lifting – Lowering – outside and inside narrow aisles ......................... E 21
4.5 Diagonal travel .................................................................................... E 21
4.6 Order picking and stacking .................................................................. E 22
4.7 Parking the truck securely ................................................................... E 24
5 Troubleshooting .................................................................................. E 25
5.1 Emergency stop device ....................................................................... E 27
5.2 Driver's cab emergency lowering ........................................................ E 27
5.3 Exiting the driver's cab with the emergency abseil device .................. E 28
5.4 Slack chain safety device override ...................................................... E 29
5.5 Travel cutout override (o) ................................................................... E 29
5.6 Lift limit override (o) ........................................................................... E 29
5.7 Aisle end safety device (o) ................................................................. E 30
5.8 Wire guidance emergency mode (IF) (Error 144) ............................... E 31
5.9 Recovering the truck from a narrow aisle / Moving the truck
without a battery .................................................................................. E 32
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F Maintenance of the forklift truck
1 Operational safety and environmental protection ................................ F 1
2 Maintenance Safety Regulations ........................................................ F 1
3 Servicing and inspection ..................................................................... F 3
4 EKS 308 maintenance checklist .......................................................... F 4
5 Lubrication Schedule .......................................................................... F 7
5.1 Consumables ...................................................................................... F 8
6 Maintenance and Repairs ................................................................... F 9
6.1 Prepare the truck for maintenance and repairs ................................... F 9
6.2 Securing the driver’s position carriage and mast ................................ F 10
6.3 Lift Chain Servicing ............................................................................. F 10
6.4 Inspecting the lift chains ...................................................................... F 10
6.5 Hydraulic oil ......................................................................................... F 11
6.6 Hydraulic hoses ................................................................................... F 11
6.7 Checking electrical fuses .................................................................... F 12
6.8 Recommissioning the truck after cleaning or maintenance work ........ F 13
7 Decommissioning the industrial truck .................................................. F 13
7.1 Action to be taken before decommissioning ....................................... F 13
7.2 Action to be taken during decommissioning: ....................................... F 14
7.3 Recommissioning the truck after decommissioning ............................ F 14
8 Safety checks to be performed at regular intervals and following
any unusual incidents .......................................................................... F 15
9 Final de-commissioning, disposal ....................................................... F 15
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1
0506.GB
Appendix
JH Traction Battery Operating Instructions
Z
These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.
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2
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0306.GB
A Correct Application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads. It must be applied, operated and serviced in accordance with the instructions contained in the present manual. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load chart are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust. Furthermore, the truck must not be operated in the vicinity of unprotected active components of electrical systems.
Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the industrial truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual.
M
Failure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required. Approval of the local authorities however does not constitute the manufacturer’s approval.
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B Truck Description
1 Application
The EKS 308 is an electric stockpicker. It is designed to transport and pick goods on level surfaces in accordance with DIN 15185.
The truck can lift open bottom or diagonal board pallets as well as roll cages outside the load wheel area. Loads can be stacked and unstacked and transported over long distances.
The driver's cab is raised together with the load handler to provide excellent visibility and easy access to the rack heights to be operated.
The racks must be suitable for the EKS 308. The safety distances stipulated by the manufacturer (e. g. EN 1726-2 item 7.3.2) must be observed.
– For trucks guided in the aisle (rail guidance) a minimum safety distance of 100 mm
must be maintained between the rack and the truck.
– For wire guidance trucks a minimum safety distance of 125 mm is recommended.
The ground surface must comply with DIN 15185. Guide rails must be provided in the narrow aisles for the rail guidance system. Vulkollan guide wheels attached to the truck chassis guide the truck between the guide rails. A guidance wire must be routed in the ground for the wire guidance system. The signals from the wire are received on the chassis and processed by the on-board computer.
The capacity can be found on the data plate, for example:
Travel Direction, Definition:
The following references apply to travel direction specifications.
Type Capacity Load centre of gravity
EKS 308 1,360 kg 600 mm
Left
Right
Drive Direction
Load
Direction
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B 2
2 Assemblies and Functional Description
Item Description
1 t Mast
2 t Overhead guard
3 o Safety gates in load direction
4 t Side safety gates
5 o Handle for two-hand operation in narrow aisles
6 t Control panel
7 t Safety belt
8 t Height-adjustable driver’s position
9 t Chassis 10 t Foot button / deadman button 11 o Pallet sensing device 12 o Pallet clamp
t = Standard equipment o = Optional Equipment
1
2
3
10
12
7
8
9
65
4
11
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2.1 Truck
Safety mechanisms:
Safey gates positioned in load direction (option) and laterally (3,4). The overhead guard (2) protects the driver from falling objects. The driver can be optionally secured by a safety belt (7). The Emergency Disconnect immediately disconnects all truck movement in hazardous situations. Safety gates (3,4) in load direction (option) and on both sides of the cabin disconnect all truck movement as soon as they open. Travelling, lifting and lowering can only be activated when the foot button (10) is applied.
When the truck is operating in narrow aisles and the pallet sensing device (11) is not applied and/or the pallet clamp (12) is not closed, the driver’s platform (8) on trucks without safety gates (3) in the load direction can only be raised to a height of
1.2 metres. If the lift height is more than 1.2m and one of the above conditions is not met, only lowering is possible (travel is inhibited).
When the truck is operating outside narrow aisles the driver’s platform (8) on trucks without safety gates (3) in the load direction can only be raised to a height of 1.2 m.
Drive: Vertical, heavy-duty threephase motor (asynchronous), hence easy and rapid maintenance. The motor is mounted directly onto the single-wheel driving gear.
Brake system:
The truck brakes gently and with no wear by pulling back the travel control knob or steering in the opposite direction. This feeds energy into the battery (service brake).
The electromagnetic spring pressure brake acting on the drive motor serves as a parking brake and handbrake.
Steering:
Particularly smooth steering with threephase drive system. The handy steering wheel is integrated within the control panel. The position of the steered drive wheel is shown in the display unit. The steering angle is +/- 90°, offering maximum manoeuvrability in narrow aisles.
With the mechanical rail guidance system the drive wheel is set to the forward position at the press of a button.
In wire guidance mode, steering is automatically assumed by the truck controller when it detects the guidance wire, and manual steering is deactivated.
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B 4
Controls and Displays
The functions are activated via ergonomic thumb and finger movement to ensure fatigue-free operation without straining the wrists; sensitive application of travel and hydraulic movements to spare and position the goods exactly. The display unit shows all the important driver information such as steer wheel position, overall lift, truck status reports (e. g. faults), service hours, battery capacity, time and wire guidance status etc.
Hydraulic system:
All hydraulic movements are controlled by a maintenance-free AC motor with a flanged low emission gear pump. Oil is distributed via magnetic switch valves. The varying oil requirements are controlled by the speed of the motor. During a lowering operation the hydraulic pump drives the motor which then acts as a generator (regenerative lowering). The energy produced is then fed back to the battery.
Electrical System:
Service laptop connection interface:
– To configure all the key truck data (limit position damping, lift cutout, retardation
and acceleration patterns, cut-outs etc.) rapidly and reliably. – To read off the error log to analyse fault causes. – To simulate and analyse program operations. – Simple functional extension by releasing code numbers.
The controller is fitted with a CAN Bus and a continually measuring sensor system.
The controller provide smooth start-up and braking of the load in all limit positions through limit position and intermediate cushioning.
Highly efficient threephase technology with energy retention for the drive and lift motors provides high travel and lift speeds and better use of energy.
The MOSFET threephase controller provides smooth starting for all movements.
For drive battery options see “Battery Type” section in Chapter D.
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3 Standard Version Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved.
3.1 Performance Data
RG: Rail guidance WG: Wire guidance FR: Free ranging
Description EKS 308
Q Capacity (where D = 600 mm) 1,360 kg D Load centre of gravity 600 mm
Travel speed without load (RG) 10.5 km/h Travel speed with load (RG) 10.5 km/h Travel speed without load (WG) 7.5 km/h Travel speed with load (WG) 7.5 km/h Travel speed without load (free ranging) 9.0 km/h Travel speed with load (free ranging) 9.0 km/h Lift speed without load 0.37 m/s Lift speed with load 0.37 m/s Lower speed with load 0.34 m/s Lower speed without load 0.34 m/s
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B 6
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3.2 Dimensions (as per data plate)
1)
DZ mast - performance data measured for 500 DZ
RG: Rail guidance WG: Wire guidance
3.3 Mast version
Description EKS 308
h
1
Mast height (retracted)
1)
2,510 mm
h
3
Lift
1)
5,000 mm
h
4
Mast height (extended)
1)
7440 mm
h
6
Cabin height 2,440 mm
h
7
Truck height retracted 320 mm
h
12
Truck height raised
1)
5,320 mm
h
15
Picking height
1)
6,920 mm
Ast Aisle width for pallets 1000 x 1200 mm
traverse
1400 mm (RG)
1450 mm (WG)
b
1
Drive width 1,000 mm
b
2
Load axle width 1200 - 1400 mm
b
5
Width across forks approx. 750 mm
Width across guide wheels before load wheels
Width across guide wheels behind load wheels
min. 1310 min. 1320
l
1
Overall length 4,030 mm
l
2
Length incl. fork shank 2015 mm
s/e/l Fork dimensions 120 mm/150mm/2,015 mm
WaTurning radius 1865 mm
m1Mast ground clearance 50 mm
m2Ground clearance from centre of wheelbase 70 mm
x Load distance 153 mm
y Wheelbase 1,630 mm
Net weight incl. battery, w.o. load
1)
4,120 kg
Description EKS 308 (DZ) EKS 308 (ZT)
h1Mast height (retracted) 2510 - 3950 mm 3310 - 4870 mm
h3Lift 5000 - 9250 mm 5000 - 8000 mm
h4Mast height (extended) 7440 - 11690 mm 7440 - 10440 mm
h6Cabin height 2440 mm 2440 mm
h12Truck height raised 5320 - 9570 mm 5320 - 8320 mm
h15Stockpicking height 6920 - 11170 mm 6920 - 9920 mm
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B 8
3.4 EN norms
Noise level: 64 dB(A)
in accordance with EN 12053 as harmonized with ISO
4871.
Z
The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear on a level surface in accordance with DIN 15185.
Vibration: 1.37 m/s2 in accordance with EN 13059
Z
The vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated when travelling over bumps at constant speed.
Electromagnetic Compatibility (
The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein.
Z
No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.
3.5 Conditions of use
Ambient temperature
during operation 5°C to 40 °C
Z
Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations.
The truck is not authorised for use in cold stores.
The truck may only be used in closed indoor rooms. The following applies:
– Ambient temperature in 24-hour mode: max. 25 °C – max. air humidity (inside) 70%, non-condensing.
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4 Identification points, warning decals and data plates
F
Warnings and notices such as load charts, strap points and data plates must be legible at all times. Replace if necessary.
Item Description
15 “Read operating instructions" notice 16 Truck data plate
17 Capacity plate
18 “Wear safety belt” decal (option) 19 “Abseil device” decal
20 “No passengers” decal 21 Test sticker (o) 22 “Do not lean out” notice
23 Jack contact points
24 Serial number (engraved in chassis underneath the battery cover)
25
mV
1,5 V
26
D (mm)
h3 (mm) Q (kg)
22
21
20
18
17
15
30
16
25
27
28
29
19
19
23
23
24
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B 10
Item Description
25 Strap points for crane lifting
26 “Add hydraulic oil” notice
27 “Emergency drain” decal 28 “Caution: Low voltage electronics system" decal
29 “Emergency drain key” decal
30 “Do not step onto or beneath the load, risk of trapping” decal
25
mV
1,5 V
26
D (mm)
h3 (mm) Q (kg)
22
21
20
18
17
15
30
16
25
27
28
29
19
19
23
23
24
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4.1 Truck data plate
For queries relating to the truck or spare parts orders, please state the truck serial no. (31).
4.2 Capacity
The capacity plate (17) gives the capacity (Q in kg) of the truck as a function of the load centre of gravity distance (D in mm) and lift height (H in mm) in tabular form.
Item Description Item Description
35 Type 41 Manufacturer
36 Serial no. 42 Min./max. battery weight (kg)
37 Rated capacity (kg) 43 Drive output (kW)
38 Battery voltage (V) 44 Load centre of gravity (mm)
39 Net weight w.o. battery (kg) 45 Year of Manufacture
40 Manufacturer’s logo 46 Option
35
36
37
38
39
40
41
42
43
44
45
46
D (mm)
h3 (mm) Q (kg)
17
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B 12
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C 1
0306.GB
C Transport and Commissioning
1 Transport
Depending on the height of the mast and local conditions, the truck can be transported in three different ways:
– Vertically, with mast and load handler assembled (for low heights) – Vertically, with mast and load handler disassembled (for large heights) – Vertically, with the mast folded.
M
Only personnel trained by the manufacturer may assemble the truck on site, commission it and instruct the driver.
2 Lifting by crane
M
Only use lifting gear with sufficient capacity (for truck weight see “Truck data plate”, chapter B).
F
The truck must only be lifted by crane with the battery removed.
– Park the truck securely
(see “Parking the Truck Securely” in Chapter E).
Loading by crane with mast assembled
– With the mast assembled, attach the crane slings to the mast cross member (1) and
to the side of the chassis (2).
M
Attach the crane slings to the strap points (1,2) so that the truck cannot slip.
1
2
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0306.GB
C 2
Loading by crane with the mast folded
– With a folded mast attach the
crane slings to the cross member
at the top of the mast and the one
at the bottom of the mast. – When lifting a truck with a folded
mast by crane, always attach the
transportation components.
M
Attach the crane slings to the strap points (3) so that the truck cannot slip.
Loading by crane with the mast disassembled
– With the mast disassembled, attach the crane slings to the side of the chassis (5)
and to the top mast bearing (4).
M
Attach the crane slings to the strap points (4, 5) so that the truck cannot slip.
3
3
5
4
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C 3
0306.GB
2.1 Crane points / Strap points
The crane points (1) are the eyes in the mast.
The crane points (5) are located on the side of the chassis and crane points (4) are located on the top mast bearing respectively. Suitable ring screws must be screwed in at this point.
When lifting by crane, use the following crane points:
– Crane points for complete truck with mast assembled:
points (1) and (2) (for weight see data plate) – Crane points for basic truck:
points (4) and (5) (weight 1500 kg) – Mast crane points including driver’s cab and load handler:
points (3). Depending on the lift height the weight with the:
- DZ mast is between 2200 kg and 2625 kg
- ZT mast between 2100 kg and 2400 kg.
2.2 Lifting the battery by crane
When lifting the battery with a crane attach suitable lifting gear to the four eyes of the battery container (for weight see battery data plate).
Z
For battery removal see “Battery removal and installation” in Chapter D.
3 Securing the truck during transport
F
The truck must be securely fastened when transported on a lorry or a trailer. The lorry / trailer must have fastening rings.
M
Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case correct measurements shall be determined and appropriate safety measures adopted.
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C 4
3.1 Basic truck transport safety
M
The mast must only be disassembled by the manufacturer’s authorised service department.
To ensure secure transport of a disassembled EKS 308, use the attachment points for fastening/quick release belts.
Z
Only use fastening / quick release belts with a rated capacity of >5 tonnes.
M
When transporting, always relieve the drive wheel by placing the entire surface of a wooden beam (8) underneath the counterweight (minimum chassis width). In addition, secure the load wheels with wedges (10).
M
If the truck’s battery is supplied in the chassis, disconnect the battery.
Fastening/quick release belts (9, 11) should be attached to at least 4 different lorry/ truck eyes (7).
Fastening/quick release belts placed over “sharp” edges must be protected by a suitable support material , e. g. foam.
To ensure secure transport of an EKS 308, use the following prescribed attachment points for fastening/quick release belts.
– The fastening/quick release belt (9) is tensioned above the battery compartment.
To do this, remove the side parts and pack them separately.
M
Note the cable routing and cover sharp edges with a suitable material.
– The fastening/quick release belt (11) above the upper chassis section is routed
behind the two mast attachment bars (6).
6
11
710 98 7
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0306.GB
3.2 Mast transport safety
M
Use a transport retaining device (12) to prevent the driver’s position carriage (13) from sliding.
If the mast is stored on a pallet(s), fasten them securely to the mast (18).
Use the lower attachment latch (17) as the "mast bottom" strap point for attaching to the lorry eyes (15).
Route the fastening/quick release belt (16) over the lift cylinder/chains to act as the "mast top” strap point.
M
Protect the fastening/quick release belt placed over the lift chains with a suitable material (14).
Any supplied parts (forks (15), guide rollers etc.) can be attached to a pallet, which can then be fastened to the mast.
3.3 Mast assembled
Safely transporting the truck with the mast assembled
M
If the truck’s battery is supplied in the chassis, disconnect the battery.
Z
Only use fastening / quick release belts with a rated capacity of >5 tonnes.
M
When transporting, always relieve the drive wheel by placing the entire surface of a wooden beam (22) underneath the counterweight (minimum chassis width). In addition, secure the load wheels with wedges (23).
At least 4 fastening/quick release belts, 2 on the left and 2 on the right (20,21) must be attached to the mast.
13 14
15
161718171917
12
20
21
23 22
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C 6
Safely transporting the truck with the mast folded
M
If the truck’s battery is supplied in the chassis, disconnect the battery.
Z
Only use fastening / quick release belts with a rated capacity of >5 tonnes.
The fastening/quick release belts (24) should be attached to at least 4 different lorry / truck eyes.
F
Warning! Risk of tipover through high centre of gravity.
The fastening/quick release belts are tensioned over the battery compartment. To do this, remove the side parts and pack them separately.
Z
Using wooden beams (25), make sure the system is a positive fit from the load wheels to the front of the transporter.
Z
Place the entire surface area of a wooden beam (26) underneath the counterweight, the chassis width as minimum, to discharge the drive wheel.
4 Using the truck for the first time
4.1 Moving the truck without a battery
M
This work must only be performed by suitably trained maintenance personnel. This operating mode is forbidden on slopes and inclines (no brakes).
See also chapter E, “Recovering the truck from a narrow aisle / Moving the truck without a battery”.
4.2 Installing/removing or erecting/folding the mast
M
This operation must only be performed by the manufacturer or a customer service team authorised by the manufacturer.
2625
24
24
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0306.GB
5 Commissioning
M
Only operate the truck with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6m long.
To prepare the truck after delivery or after transport, proceed as follows:
– If necessary install and charge the battery (see chapter D, “Battery removal and
installation” and “Charging the battery”). – Commission the truck as per instructions (See chapter E, “Starting up the truck”).
F
Before commissioning, check the truck to ensure the tilt safety device (27) is present.
Z
The tilt safety device (27) must be 12-14 mm off the ground.
F
Attach the seat belt and secure it to the front of the overhead guide through the safety cord as soon as you step on the platform and before starting other work (see "Attaching the Seat Belt" in chapter E).
Z
Check that all safety devices are present and operational.
27
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C 8
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D 1
0306.GB
D Battery Maintenance, Re-Charging,
Replacement
1 Safety regulations for handling acid batteries
Park the industrial truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.
Fire protection: Smoking and naked flames must be avoided when working with batteries Wherever an industrial truck is parked for charging there shall be no inflammable material or lubricants capable of creating sparks within 2 metres around the truck. The area must be well ventilated. Fire protection equipment must be provided.
Battery maintenance: The battery cell covers must be kept dry and clean. The terminals and cable shoes must be clean, secure and have a light coating of dielectric grease.
Battery Disposal: Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.
M
Before closing the battery cover make sure that the battery lead cannot be damaged.
F
Batteries contain an acid solution which is poisonous and corrosive. Therefore, always wear protective clothing and eye protection when carrying out work on batteries. Avoid all contact with battery acide. Should however clothing, skin or eyes come in contact with acid the affected parts should be rinsed with plenty of clean water - where the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.
M
Only batteries with a sealed battery container may be used.
F
The weight and dimensions of the battery have a considerable effect on the operational safety of the industrial truck. Battery equipment may only be replaced with the agreement of the manufacturer.
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D 2
2Battery types
The EKS 308 can be fitted with a variety of battery types. All battery types comply with DIN 43531-A. The following table shows which combinations can be included as standard:
*) A compensating weight is required when using one of these batteries.
The battery weights can be taken from the battery data plate.
F
The weight and dimensions of the battery have a considerable affect on the operational safety of the truck. Changing the battery features requires the manufacturer’s approval, as compensating weights are required if smaller batteries are fitted.
Battery type Truck type
48 V 2 PzS 160 L - A *
)
EKS 308
48 V 3 PzS 240 L - A *
)
EKS 308
48 V 3 PzS 330 L - A *
)
EKS 308
48 V 3 PzS 420 L - A *
)
EKS 308
48 V 4 PzS 320 L - A *
)
EKS 308
48 V 4 PzS 360 L - A *
)
EKS 308
48 V 4 PzS 412 L *
)
EKS 308
48 V 4 PzS 440 L - A *
)
EKS 308
48 V 4 PzS 560 L - A EKS 308
48 V 4 PzS 600 LD - A EKS 308
Page 34
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3 Charging the Battery
F
Park the truck securely (see “Parking the Truck Securely” in Chapter E).
– Turn key switch (1) to "0" (zero). – Lift up the battery panels (3) (see arrow direction).
F
Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.
– Pull out the battery connector (2). – If necessary, remove the insulating mat from the battery.
F
When charging, the tops of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage.
Z
The charger must be adapted to the battery in terms of voltage and charge capacity.
– Connect the charger lead of the battery charger station with the battery connector. – Switch on the charger. – Charge the battery in accordance with the battery and charging station
manufacturers’ instructions.
F
It is essential to follow the safety regulations of the battery and charger station manufacturers.
1
2
3
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D 4
4 Battery removal and installation
F
Only batteries with insulated cells and terminal connectors may be used. When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position.
F
The truck must be horizontal in order to prevent the battery from falling out when the battery retainer is removed.
F
Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.
– Turn key switch (1) to "0" (zero). – Lift up the battery panels (3) (see arrow direction) and lift them out. – Remove the battery connector (2).
1
2
3
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– Undo the battery retainer (4) by moving the lever (5) and remove the retainer. – Pull the battery (6) onto the side of the prepared battery trolley.
F
Make sure the battery trolley is properly secured.
F
After replacing/fitting the battery (6), make sure that the battery (6) is well secured in the battery compartment.
Z
The battery retainers (4, 7) can swap positions. This means that they can both be fitted in either the left or right side of the truck’s chassis.
Installation is the reverse order of removal.
M
To avoid pushing the battery (6) through on assembly, the battery retainer (7) must first be plugged in on the opposite side.
F
After installing again, check all cables and connectors for signs of visible damage and before using the truck again check that:
– the battery retainers (4,7) are fitted and the battery retainer (4) is secured by the
lever (5), – the battery panels (4) are inserted and properly closed.
4
5
7
6
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D 6
5 Check the battery condition, the acid level and acid density
– The battery manufacturer’s maintenance instructions apply. – Check the battery housing for cracks and any spilled acid. – Remove any oxydation remains from the battery terminals and apply an acid-free
grease to the battery terminals. – Unscrew the stops and check the acid level.
The acid level should be at least 10-15 mm above the top of the plates. Now close
the stops. – If necessary, re-charge the battery.
6 Battery discharge indicator
When you turn the EMERGENCY DISCONNECT to activate it and turn the key in the key switch clockwise, the battery discharge indicator will show the residual capacity available. The display flashes at a residual capacity of 30%. Lift cut-out occurs at a 20% capacity display.
For maintenance-free and special batteries the display and cutout points can be adjusted by authorised personnel by assigning parameters.
+-
50%
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0306.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.
Unauthorised Use of Truck: The driver is responsible for the truck during the time it is in use. The drive must prevent unauthorised persons from driving or operating the truck. Do not carry passengers or lift other people.
Damage and Faults: The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authorisation to do so. The driver must never disable or adjust safety mechanisms or switches.
Hazardous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.
F
Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning instructions in the present operating instructions shall be strictly observed.
F
Warnings and notices such as load diagrams, strap points and data plates must at all times be legible. Replace if necessary.
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E 2
2 Controls and Displays
2.1 Operating and display equipment on control panel
Item Control / Display Function
1 Travel control knob t Controls the travel direction and speed of the
truck
2 Hydraulic control knob t Lifting and lowering of main lift. 3 Key switch t Switches control current on and off. Removing
the key prevents the truck from being switched on by unauthorised personnel.
4 “Warning” button t Activates a warning 5 EMERGENCY
DISCONNECT
t Interrupts the main supply, all truck movement
is disabled
6 Keys (F1 - F5) t Activate or confirm the function related to the
symbol displayed above it
7 Display unit t Operating information and warning message
display
8 “Cancel sub-menu” key
(F0)
t Sets the menu to the basic display
9
“Palletclamp” button
o Fixes (clamps) and loosens the pallet.
10 Steering wheel t Steers the truck in the required direction. 11 Grip o Handle for two-hand operation in narrow aisles
t = Standard equipment o = Optional Equipment
11 10 9 8 7 6 5 4 3
21
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2.2 Display unit controls and displays
2.2.1 Upper range symbols
Item Symbol Control /
Display
Function
12 Displays possible
travel speeds: Turtle Rabbit
t
Crawl speed Max. travel speed
13 “Guidance wire
recognition” display
WG Sensors which have recognised the
guidance wire have a dark background
14 Steering angle display
changes with display – “Tracking in
progress”
– “Automatically
guided”
– “Deviation from
guidance wire”
t
RG
WG
WG
WG
WG
Indicates the current steering angle with reference to the middle position When “Rail guidance” is selected, the steering angle is permanently displayed at the middle position The steering angle display goes out and is replaced by guide wire symbols
– when the truck is tracked onto the
guidance wire (inductive guidance)
– when the truck is automatically guided
by the guidance wire
– when the truck deviates without
guidance from the guidance wire and automatic guidance
12
13
14
19
15
17
16
18
20
21
6
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15 “Time” display
“Operating hours” display
t Time display
Displays the number of service hours since the truck was commissioned
16 Battery
dischargeindicator
t Displays the battery charge status
(residual capacity as a percentage)
17
“Overall lift” display “Referencing
required” display: Main lift - raise
Main lift - lower
t Displays the height of the forks
Raise request
Lower request
19 Foot switch not
pressed
Gates open
EMERGENCY DISCONNECT pressed
t Requests activation of foot switch
Requests gate closure
Requests EMERGENCY DISCONNECT release
20 Pallet clamps
open
Pallet clamps closed
o Appears when the pallet clamp
is open
Appears when the pallet clamp is closed.
21 Option o
Item Symbol Control /
Display
Function
STO
P
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2.2.2 Lower range symbols and switches
Activate switch (6) under the respective symbols (18) displayed or confirm the related function. The symbol will be given a dark background.
Symbol Control or Display Function
Warning Labels
“Slack chain safety device” display
t Displayed when the slack chain safety
device engages
“Slack chain safety device override” switch
Overrides the slack chain safety device to lift the driver's position freely
“Fwd./Rev. travel only” display
t Displayed when lift cutout is actvated due to
low battery capacity and only forward or reverse travel is possible.
“Acknowledge lift cutout due to battery discharge” button
Confirms lift cutout due to low battery capacity and releases travel (the Fwd./Rev. Travel Only display has a dark background)
“Lift limit” display
o Displayed when the lift limit is activated
“Lift limit override”switch Overrides the lift limit (display has a dark
background). Observe the maximum passage heights
“Lower limit” display o Indicates that the automatic lowering limit
has been activated.
“Lowering limit override” switch
Overrides the lowering limit, controlled by hydraulic control knob
“Travel cutout” display o Indicates that automatic, height dependent
travel cutout has been activated
“Travel cutout override” switch
Overrides the automatic, height dependent travel cutout
“Aisle endsafety device” display (option)
o Indicates that the aisle end safety device has
been activated. The truck brakes.
Select “Warning sub- menu” display
o Indicates that several warnings (e.g. slack
chain safety device height dependent lift cutout) have been issued.
Quit “warnings” sub- menu.
Displays individual warnings
Quit “warnings” sub- menu.
o Indicates that the sub-menu can be quit.
“Cancel warnings sub- menu” switch
Sets the “warnings” sub-menu to the standard menu
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E 6
Guidance systems
“Guidance on” display not active
“Guidance on” display active
t
R
G
W G
Displays automatic guidance in the aisle:
Rail guidance display (drive wheel set to forward position)
Indicates that wire guidance is activated
“Guidance on” switch R
G
W G
Sets the drive wheel to forward position
Activates the aligning process (and frequency selection for multi- frequencies)
Displays “Select Frequency 1” (similar to other frequencies) (“Guidance on” sub- menu)
o
W G
Indicates that guidance is possible via frequency 1
“Select Frequency 1” switch (similar to other frequencies)
Activates guidance via frequency 1 (sub-menu is quit automatically after 1 sec.)
“Special attachment” display
o Indicates that the special attachment can be
controlled
“Special attachment”button
Activates control of the special attachment, controlled via the hydraulic control knob
t = Standard equipment o = Optional Equipment
RG = Rail guidance WG = Wire guidance
Symbol Control or Display Function
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2.3 Truck operational status symbols
The operational status of the truck when it is switched on is indicated by symbols in the display unit.
Safety gates open
Foot switch not pressed
When the following symbols are displayed you must carry out a reference movement in accordance with the display, i.e. the Main Lift must be raised approx. 10 cm and then lowered again. This is the only way for the controller to release all the truck movements at full speed.
Referencing: Main lift - raise
Referencing: Main lift - lower
Lift cutout for referencing
F
When disabling the lift cutout the driver must look out for obstacles when the mast is extended.
Pressing the “lift cutout override” switch disables the lift cutout.
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E 8
3 Starting up the truck
F
Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area.
3.1 Checks and operations to be performed before starting daily work
– Check the whole of the outside of the truck for signs of damage and leaks. – Check the battery attachment and wire connections for damage, make sure they
are secure. – Check the battery connector is secure. – Check the overhead guard for damage. – Check the load handler for visible damage such as cracks, bent or severely worn
load forks. – Test pallet clamp operation (option). – Check the load wheels for damage. – Make sure the load chains are evenly tensioned. – Make sure all safety mechanisms are correct and working. – Test the operating and parking brakes. – For rail guidance systems check the guide wheels are smooth and not damaged. – Check the safety restraint harness for damage and wear (option).
F
It is forbidden for more than one person to enter the driver’s cab at a time.
3.2 Truck entry and exit
When entering/exiting the truck the operator can hold on to either the cabin (25) of the chassis (26).
25
26
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3.3 o Attaching the safety restraint belt
F
Carry out a daily inspection of the safety restraint belt (32) and the eye (30), safety rope (29), karabiner hooks (28, 31) and attachment rail (27) at the front of the overhead guard, checking for wear and damage. Do not operate the truck under any circumstances if the safety restraint harness (28 - 32) and the attachment rail (27) at the front of the overhead guard are damaged. The safety restraint harness (28-32) must be immediately replaced after an accident (catching a person) or if it becomes damaged or worn. Any damage must be reported to a supervisor. All warnings on the safety restraint harness must be read and observed.
F
Put on the safety restraint belt (32) and secure it through the safety rope (29) to the front of the overhead guard as soon as you step onto the platform and before starting other work.
– Attach the safety restraint belt (32) to your body. – Insert the karabiner hook (28) of the safety rope (29) into the attachment rail (27)
at the front of the overhead guard. – Attach the karabiner hook (31) of the safety rope (29) to the eye (30) of the safety
restraint belt (32).
29
30
31
32
27
28
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3.4 t Preparing the truck for operation
– Put on the safety restraint harness, see “Attaching the safety restraint belt” in this
chapter (option). – Close all safety gates. – Undo the EMERGENCY DISCONNECT (5) by turning it. – Put the key in the key switch (3) and turn it clockwise. – Test the warning device (horn) (4). – Test the operating and parking brakes. – Carry out a test run of the mast to adjust the height display.
F
Press the EMERGENCY DISCONNECT (5) immediately if the truck starts to move or lift when it is switched on.
Z
Brief steering movements caused by steering referencing are permissible.
54 3
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3.5 o Preparing the truck for operation with an additional access code
– Put on the safety restraint harness, see “Attaching the safety restraint belt” in this
chapter (option). – Fully close all safety gates. – Undo the EMERGENCY DISCONNECT (5) by turning it. – Put the key in the key switch (3) and turn it clockwise. – In the display unit (7) you are required to enter a 5 digit code / pin with the five
function keys (6).
Z
Press function key F0 (8) to assign to the five function keys (6) the digits 0 - 4 or 5 -9 for entering the code / pin.
Z
Unless the correct code / pin is entered, none of the truck's functions will operate
Z
A maximum of 10 different code / pins can be set.
– Test the warning device (horn) (4). – Test the operating and parking brakes. – Carry out a test run of the mast to adjust the height display.
Z
After a factory-set interval, you will be required to enter in the display a 5 digit code /
pin using the five function keys (6).
F
Press the EMERGENCY DISCONNECT (5) immediately if the truck starts to move or lift when it is switched on.
Z
Brief steering movements caused by steering referencing are permissible.
54 3678
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3.6 Setting the time
Selecting the “Set Time” menu:
Press key 8, the display changes to the sub menu.
Z
Truck movements are inhibited in this truck menu.
Now press key 35 twice; the “Set Time” menu now appears in the display unit.
Setting the time:
Z
Truck movements are inhibited in this truck menu.
Simultaneously press key 35
– and 36: to set the time forward by an hour. – and 37: to set the time back by an hour. – and 38: to set the time forward by a minute. – and 39: to set the time back by a minute.
The set time (40) is then shown in the display unit.
Quitting the “Set Time” menu:
Press key 8, the display changes to the sub menu.
Now press key 39, the display changes to the “Truck Functions” sub menu.
v,a
8
35 39
13:22
8
35
36
37
38
39
40
v,a
8
35 39
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3.7 Operator specific settings
Selecting the “Operator Specific Settings” menu:
Press key 8, the display changes to the sub menu.
Z
Truck movements are inhibited in this truck menu.
Now press key 38; the “Operator Specific Settings” menu now appears in the display unit.
Settings in the “Operator Specific Settings” menu:
Z
Truck movements are inhibited in this truck menu.
The operator can adjust the settings in:
– Acceleration Travel
– Apron speed
– Aisle Speed
– Steering Wheel Transmission
between 1 (weak) and 8 (strong).
Key 36 weakens the chosen function and key 38 intensifies it.
The setting is transferred to the program with key 37.
When the next function is to be set, you can use key 35 (back) or key 39 (forward) to do this.
Quitting the “Operator Specific Settings” menu:
Press key 8, the display changes to the sub menu.
Now press key 39, the display changes to the “Truck Functions” sub menu.
v,a
8
353938
a
v
v
v
OK
+
-
8
3536373839
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4 Industrial truck operation
4.1 Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
Travel conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area.
Visibility when travelling outside the narrow aisle: The driver must look in the direction of travel and must always have a clear view of the route ahead. Loads that affect visibility must be positioned at the rear of the truck. If this is not possible, a second person must walk in front of the truck as a lookout.
Operating with a walk-on pallet: If the truck is equipped for operation with a walk- on pallet without side gates or railing, the opeator must wear a restraint belt in accordance with EN 361 and a harness (2.0m) in accordance with EN 355 (see chapter 3.1).
F
It is prohibited to stop and operate racks without a base even on just one side of the rack aisle. Keep a maximum distance of 0.2m to the rack.
M
Negotiating slopes and inclines: It is forbidden to negotiate slopes and inclines.
M
Negotiating docks: It is forbidden to negotiate docks.
Negotiating lifts: Lifts may only be negotiated if they have sufficient capacity, are
suitable for driving on and authorised for truck traffic by the owner. The driver must satisfy himself of the above before entering these areas. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift with the forklift truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck.
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.
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4.2 Travelling, Steering, Braking
– Press the EMERGENCY
DISCONNECT (5) down.
All truck movement is disabled.
The operation of the switch must not
be affected by any objects placed in
the way.
4.2.1 Travel
The truck can be operated in 3 modes: Free ranging, wire guidance (WG) or rail guidance (RG). The applicable mode depends on the guidance system of the racking system being operated.
M
Do not drive the truck unless the panels are closed and properly locked.
The foot switch (45) must be kept depressed for travel.
Travelling in apron field
– Close the safety gates. – Turn the EMERGENCY
DISCONNECT (5) to undo it. – Put the key in the key switch (3) and
turn it anti-clockwise; the “operational”
display lamp will be lit. – Apply the foot switch (45). – Carry out a test run, see Seite E7. – Raise the Main lift with the hydraulic
control knob (2) until the forks are
clear of the ground. – Slowly turn the travel control knob (1)
with your right thumb.
Turn in drive direction (F)
= Forward travel
Turn in load direction (R)
= Reverse travel – You can control the travel speed by
continuing to turn or by retracting the
travel control knob. – Use the steering wheel (10) to steer
the truck in the required direction.
F
R
510 3
1
2
F
R
45
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4.2.2 Steering
The truck is steered outside of narrow aisles with the steering wheel. The drive wheel position is shown in the display unit (14).
4.2.3 Braking
Z
The truck’s brake pattern depends largely on the ground conditions. The driver must take this into consideration when handling the truck.
The truck can brake in one of three ways:
- with the service brake
- with the foot switch
- with the EMERGENCY DISCONNECT.
Braking with the service brake
While travelling, set the travel direction switch to the zero position or the opposite travel direction; the traction controller will cause the truck to brake.
Braking with the foot switch
Releasing the foot switch causes the truck to brake.
Braking with the EMERGENCY DISCONNECT
Applying the EMERGENCY DISCONNECT will cause the truck to brake to a halt.
M
The EMERGENCY DISCONNECT must only be used in dangerous situations.
14
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4.3 Negotiating narrow aisles
M
It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm) or for personnel to cross through them. These work areas must be marked and identified accordingly. Carry out a daily inspection of the safety mechanisms on the truck or the racking sysem to avoid hazards and protect personnel. These must not be rendered ineffective, misused, adjusted or removed. Immediately report and rectify any faulty safety devices.
M
Observe the instructions of DIN 15185 Part 2.
Z
Before entering a narrow aisle, the driver must look for people or other trucks in the aisle. Never enter a narrow aisle where there are people or other trucks. If there are people in the aisle, stop the truck immediately.
Z
Only enter narrow aisles in trucks which are designated for this purpose If a narrow aisle is equipped with a guidance wire for wire guidance and the system is faulty or switched off, the truck may only be removed from the narrow aisle at crawl speed.
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4.3.1 Rail guidance truck
Rail guidance trucks are equipped with sensors which activate aisle sensing when they enter narrow aisles.
– Approach the aisle at reduced speed so that the truck is aligned with the narrow
aisle and is within the demarcation.
Z
Observe the notices attached along the route.
Z
Travel and hydraulic operations can only be activated in the narrow aisle with two- handed operation.
– Slowly enter the narrow aisle.
Ensure that the truck guide rollers enter the narrow aisle guidance rails.
– Press the “guidance on” (37) switch. – The “guidance on” display light (46) changes to
active mode. – The drive wheel is automatically set forward. The
steering angle display (14) shows the steering
angle permanently in the centre position after
alignment. Manual steering is disabled.
– Grab the handle (11) with the hand rest and
with the other hand operate the travel
control knob (1) and/or the hydraulic control
knob (2) (two-hand operation). – The travel control knob (1) affects travel
speed and direction. – Continue to travel along the narrow aisle at
your required speed.
M
Press the push button (37) to leave the rail guidance. The display (46) changes to non-active mode. The truck is now also free to move.
F
You can only change from automatic to manual steering once the truck has completely left the narrow aisle.
37
14 46
1
11
2
14
37
46
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4.3.2 Wire guidance trucks
F
When starting or continuing the truck after the wire guidance has been deactivated, note the position of the drive wheel as manual steering is now activated again.
F
If an automatically guided truck is switched off, the wire guidance is no longer active when it is switched on again. Risk of accident! When you continue to travel a warning is sounded and the speed is reduced. Apply push button (37) to re-activate the wire guidance (“Wire guidance active” light (46) goes on) and re-align the truck.
F
During alignment, the rear part may veer out when it reaches the guidance wire (49).
– Approach the guidance wire (49) at an angle
and at reduced speed.
When aligning, the truck should not be parallel to the guidance wire. The optimum approach angle is between 10° and 50°.
Tracking should preferably be in the load direction, as this involves less time and distance.
– When the truck is close to the guidance wire,
switch on the wire guidance with push button
(37).
The “guidance on” display light (46) changes to active mode.
When the guidance wire has been reached the truck is automatically guided.
When the guidance wire is reached tracking automatically ensues at reduced speed. The steering angle display (14) changes to “Tracking On” (50). The audible trackingsignal is sounded.
Inductive automatic steering takes over the steering of the truck and applies it to the guidance wire.
Tracking is complete once the truck has been led precisely to the guidance wire (49). “Tracking on” (50) changes to “guidance wire applied” (51). The tracking signal no longer sounds. The track is now automatically guided.
Z
Travel and hydraulic operations can only be activated in the narrow aisle with two-handed operation.
49
48
47
37
14 46
37
50 46
37
4651
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Grab the handle (11) with the hand rest and with the other hand operate the travel control knob (1) and/or the hydraulic control knob (2) (two-hand operation).
Turn the travel control knob (1) to change travel speed and direction. Continue to travel along the narrow aisle at your required speed.
M
Press the push button (37) to quit the guidance wire. The display (46) changes to non-active mode. In addition, the ”guidance wire applied” (51) display changes to the steering angle display (14). The truck is now free to move again.
F
You can only change from automatic to manual steering once the truck has completely left the narrow aisle.
1
11
2
37
14 46
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4.4 Lifting – Lowering – outside and inside narrow aisles
F
Risk of injury when lowering the driver’s cab and the load handler. Do not allow anyone to stay in the hazardous area.
Z
Lifting and lowering inside the narrow aisle requires two-handed operation.
4.4.1 Lift – Lower (Main Lift)
– Apply the foot switch (45). – At the same time turn the hydraulic control knob (2) “up”
- in drive direction (L) = Lower
- in load direction (R) = raise or at the same time turn the hydraulic control knob (2) “down”
- in drive direction (R) = Lift
- in load direction (L) = Lower
Z
The lift and lower speeds are proportional to the degree of turn of the hydraulic control knob.
Z
If the line break safety devices applies for an unauthorised lowering speed (error: E287), determine the cause and if there no leakage in the hydraulic system, briefly raise the Main Lift and then lower it again.
4.5 Diagonal travel
M
Diagonal travel (simultaneous travel and lifting/lowering) is possible when you press the hydraulic control knob (2) while simultaneously depressing the travel control knob (1).
Lower (L)
Raise (R)
L
R
2 “up”
2 “down”
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4.6 Order picking and stacking
Collecting, transporting and depositing loads
M
Before picking up a load unit the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Observe the load chart.
– Check the fork distance for the pallet and adjust if necessary.
o Adjusting the forks
To lift the load securely, the forks must be as far apart as possible and centrally positioned with respect to the fork carriage. The load centre of gravity must be centrally aligned between the forks.
– Raise the forks (52) slightly at the front. – Push the forks (52) into the correct position on the fork carriage (24)
.
52
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4.6.1 Lifting a load from the front.
M
Before collecting the load the driver must ensure that the pallet clamp is open (see Chapter E, section 3.2).
– Apply the foot switch (45). – Drive the truck slowly. – Slowly insert the forks into the pallet until
the fork shank/driver’s platform touches the load or the pallet.
– Raise the load slightly. – Clamp the load by pressing the “Pallet
Clamp” switch (9) (option).
– Check on the display (7) in the control
panel that the pallet clamp is closed (option).
– Slowly reverse the truck.
M
The ground surface must be in good condition to ensure this works correctly.
4.6.2 Transporting a load
– Apply the foot switch (45). – Always transport a load outside the narrow aisle as low as possible, allowing for
ground clearance.
– Always transport loads with both forks. When transporting heavy loads always
ensure that both forks carry an equal weight.
– Gradually accelerate. – Drive at constant speed. – Always be prepared to brake. Only stop suddenly in dangerous situations. – Reduce speed accordingly at narrow bends.
97
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4.6.3 Depositing a load
– Drive the truck carefully up to the storage location
M
Before a load can be deposited, the driver must ensure that the storage location is suitable for storing the load (size and capacity).
– Apply the foot switch (45). – Raise the load handler so that the load
can be taken to the storage location without striking any objects.
– Carefully push the load into its storage
location.
– Open the pallet clamp by pressing the
“Pallet Clamp” switch (9) (option).
– Check on the display (7) in the control
panel that the pallet clamp is open (option).
– Carefully lower the load handler so
that the forks are clear of the load.
M
Avoid placing the load down suddenly to avoid damaging the load and the load handler.
– Carefully remove the load handler
from the load.
– Fully lower the load handler.
4.7 Parking the truck securely
When you leave the truck it must be securely parked even if you only intend to leave it for a short time.
F
Do not park the truck on an incline. In special cases the truck may need to be secured with wedges.
Z
Select a parking place where nobody will collide with the forks.
– Always park the truck with the mast completely lowered. – Lower the forks to the ground. – Set the key switch to “0” and remove the key.
97
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5 Troubleshooting
This chapter enables the user to identify and rectify basic faults and the results of incorrect operation. When locating a fault, proceed in the order shown in the table.
Fault Probable Cause Action
Truck does not start.
– Battery connector not
plugged in
– Check the battery connector and
connect if necessary.
– Safety gates
open
– Close the safety gates
–EMERGENCY
DISCONNECT pressed
– Unlock EMERGENCY
DISCONNECT
– Key switch in “0”
position
– Set key switch to “I”
– Battery charge too low – Check battery charge, charge battery
if necessary
– Foot switch not
pressed
– Press foot switch
– Faulty fuse – Check fuses
– Travel cutout activated – Press travel cutout override switch
(charge battery)
– Travel cutout activated
via aisle end safety device
– Set foot switch or travel
control knob to neutral and press it again.
– Chains slack – See “Slack Chain Safety Device
Override” section in Chapter E Load cannot be lifted
– Truck not operational – Carry out all measures listed under
“Truck does not start”
– Battery charge too
low, lift cutout
– Check battery charge, charge battery
if necessary
– Insufficient hydraulic
oil
– Check hydraulic oil, if necessary top
up
– Chains slack – See “Slack Chain Safety Device
Override” section in Chapter E
– Faulty fuse – Check fuses Rapid travel disabled
– Main lift raised above
0.5m
– Lower Main lift to below 0.5 m
– WG search mode
activated
– Align truck or turn off WG
mode
– No test run performed – Perform lifting and lowering Truck cannot be steered
– Truck not operational – Carry out all measures listed under
“Truck does not start”
– Narrow aisle mode
switch pressed
– Switch off narrow aisle travel function
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Z
If, after carrying out the remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department. Additional troubleshooting must only be performed by the manufacturer’s specialist service engineers. The manufacturer has a customer service department specially trained for these tasks. To provide targeted and rapid response to faults, the following details are useful and important to provide for the customer service department:
- Truck serial number
- Display unit error number (if present)
- Error description
- Current location of truck.
Error 144 – Truck has quit
guidance wire
– Restore wire guidance
Error 330 – Travel control button
pressed during power up test
– Do not press travel control button,
switch truck off and on again
Error 331 – Hydraulic control
button pressed during power-up test
– Do not press hydraulic control button,
switch truck off and on again
Error 338 – Foot switch pressed
during power-up test
– Do not press foot switch, switch truck
off and on again
Error 339 – During the power-up
test a key was pressed below the display unit
– Do not press key, switch truck off and
on again
Fault Probable Cause Action
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5.1 Emergency stop device
When the automatic emergency stop mechanism applies (e.g. if the wire guidance is lost, electric steering fails) the truck brakes to a halt. Before starting again, the cause of the error must be identified and corrected. Start the truck again in accordance with manufacturer’s instructions contained in these operating instructions (see “Starting up the Truck” in Chapter E).
5.2 Driver's cab emergency lowering
F
When using emergency lowering, make sure that nobody is present in the danger zone. If a second person is used to lower the load handler via the emergency lowering device, this person must consult with the driver. Both people must be in a safe area to avoid danger. The driver’s cab must not be lowered when the load handler is in the rack. The truck may only be started again once the error has been localised and rectified.
If necessary, a second person can be deployed to lower the cabin from the ground.
– Remove the Allen key from the bracket above the strobe. – Insert the Allen key into the hole (56). – Slowly open the drain valve (55) using the Allen key. – The cabin will lower.
55
56
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5.3 Exiting the driver's cab with the emergency abseil device
Industrial trucks with a height-adjustable operator position which can exceed 3m from the ground, have an emergency lowering mechanism and an emergency abseil device for the driver which he can use if the operator position ever becomes stuck.
Z
If the driver’s cab cannot be lowered due to a fault, not even with the emergency lowering (see “Driver’s Cab Emergency Lowering” section), the operator must exit the driver's cab via the emergency abseil device. The driver must undergo annual instruction in how to use the emergency abseil device. To exit the cabin with the emergency abseil device, proceed as follows:
– Turn the key switch (3) to “0”. – Press the EMERGENCY DISCONNECT switch (5). – Take the abseil device (58) out of its compartment below the control panel. – Insert the karabiner hook (61) of the safety rope (60) into the attachment rail (57)
at the front of the overhead guard.
– Throw out the rope (60) without knots, the rope (60) must pass over fixed objects.
Do not pass the rope over sharp edges.
– Fit the safety harness or slings in accordance with the accompanying operating
instructions or as instructed.
– Attach the eye of the safety harness to the karabiner hook (62) of the abseil device
(58).
Abseiling
F
Always use the safety harness to abseil.
– Remove the safety rope (29) from the safety harness (option).
F
Do not drop into the loose rope (60). Watch out for obstacles when abseiling.
– Make the rope (60) taut. – Exit facing the truck. – To abseil, press the lever (59) on the abseil device down. – To stop abseiling, release the brake lever (59).
58
59
60
61
62
57
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5.4 Slack chain safety device override
If the slack chain safety device has applied, e. g. when positioning the load handler, loosening or braking the lift chain, the “slack chain safety device” symbol (63) illuminates in the display unit. It is possible to raise the Main Lift if the slack chain safety device override switch (39) is depressed and held down while pressing the hydraulic control knob. Travelling and lowering are now inhibited.
Before starting again, rectify the damage.
M
The truck may only be started again once the damage has been removed.
5.5 Travel cutout override (o)
KIf travel is inhibited from a certain lift height (the “Travel cutout override” symbol (65) appears in the display), but the position of the truck relative to the rack must be adjusted to load or unload goods, press the “unlock travel” switch (39) and apply the travel control knob as described in “Travelling”. This allows you to travel at crawl speed.
5.6 Lift limit override (o)
If local conditions require, an automatic lift cutout to apply from a given lift height can be fitted for safety reasons. The display unit shows the "Lift Cutout Override" symbol (67).
M
Lift cutout only becomes effective after a test run has been carried out. You can tell when this is the case because the actual height is shown in the display unit. Pressing the “lift cutout override” switch (39) disables the lift cutout.
F
When disabling the lift cutout the driver must look out for obstacles when the mast is extended.
Z
Lift cutout is re-activated each time the mast falls below the lift limit height.
The respective travel and lift limit switches are located in the control panel.
63
39
65
39
67
39
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5.7 Aisle end safety device (o)
Trucks with the aisle end safety device brake before the aisle exit or in the transfer aisle. There are two basic versions for this:
1. Braking to a halt
2. Braking to 2.5 km/h
Other variants (affecting the subsequent travel speed, lift height etc.) are available.
1. Braking to a halt:
When the truck passes over the aisle end safety magnets heading for the aisle end, it comes to a halt.
To continue traveling:
– Briefly release the foot switch and then apply it again
The truck can be driven out of the narrow aisle at max. 2.5 km/h.
2. Braking to 2.5 km/h
When the truck passes over the aisle end safety magnets heading for the aisle end, it brakes to 2.5 km/h and can be driven out of the narrow aisle at this speed.
M
In both cases the braking distance depends on the travel speed.
F
Aisle end safety braking is an additional function designed to support the operator, but which does not release him from his responsiblities, e.g. to monitor braking at the aisle end and if necessary to apply the brakes.
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5.8 Wire guidance emergency mode (IF) (Error 144)
If in a wire guidance system the guiding antenna extends beyond the pre-determined range of the guidance wire, an emergency stop is immediately performed.
If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The “tracking on” display and the audible tracking signal however remain permanently on and hence warn the driver.
Automatic EMERGENCY STOP
If during operation one of the monitors for steering control, steering system, wire guidance or the safety cutout for the traction electronic system or power electronic system applies, the truck safety devices will cause the truck to stop.
To enable the truck to travel again after an EMERGENCY STOP, carry out the following:
– Determine the possible cause of the EMERGENCY STOP. – Press the EMERGENCY STOP switch and turn it again to release it. – Error E144 is displayed. – Apply inductive automatic steering. – Apply the travel control knob and carefully align the truck with the guidance wire. – Error E144 goes out.
F
If the truck now starts, test that it works with manual steering and inductive automatic steering.
Automatic EMERGENCY STOP
If, after an automatic EMERGENCY STOP and having rectified the problem, you cannot start the truck again, turn the key switch off and on again. Now perform a referencing operation, see “Truck Operational Status Symbols” section in Chapter E. The truck is now operational again.
Manual EMERGENCY STOP
Manual EMERGENCY STOPS occur when the EMERGENCY STOP button is pressed. The truck is operational again once the EMERGENCY STOP has been released.
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5.9 Recovering the truck from a narrow aisle / Moving the truck without a battery
F
Before recovering the truck from a narrow aisle, disconnect the battery.
M
This operation must only be performed by suitably trained maintenance personnel.
When the brakes are de-activated the truck must be parked on an even ground as the brakes are no longer effective.
– Fully lower the mast.
Z
Obtain assistance from another person. The other person must be trained and familiar with recovery operations.
To recover the truck from the aisle, release the brakes.
5.9.1 Release the magnetic brake
– Remove the electronic compartment cover at the back. – Screw in the setscrews (70) on the magnetic brake above the drive motor (71) to
release it.
Z
The setscrews (70) are located in the strobe bracket (69).
M
When using the truck again, check the braking deceleration.
70
69
71
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5.9.2 Adjusting the steering angle
F
The battery must be disconnected when adjusting the steering angle.
– Remove the electronic compartment
cover at the back.
Using an Allen switch set the steered wheel to the required direction via the screw in the steering motor (72).
Z
When setting an angle greater than 4 degrees it is advisable to discharge the wheel by raising/jacking up the truck.
5.9.3 Emergency recovery in drive direction:
– Remove the electronic compartment cover at the back. – Lower the operator position carriage and release the magnetic brake. – Guide the tow rope (75), tow force > 5 tonnes, around the counterweight (73) by the
left or right sides of the antenna (74).
M
Note the wire routing in the drive compartment and the antenna (74)!
– Carefully and slowly pull the truck out of the narrow aisle.
F
After recovery, prevent the truck from accidentally moving. To do this, unscrew the setscrews on the magnetic brake above the drive motor. If the brake is not working, place wedges underneath the wheels of the truck to prevent it from moving.
72
73
74
75
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5.9.4 Emergency recovery in load direction
– Remove the electronic compartment cover at the back. – Lower the operator position carriage and release the magnetic brake. – Insert the abseil rope (78), tow force > 5 tonnes, to the two mast suspensions (76,
77).
– Guide the tow rope (78) around the side of the driver’s position carriage above the
safety gates at the front in the load direction.
– Carefully and slowly pull the truck out of the narrow aisle.
F
After recovery, prevent the truck from accidentally moving. To do this, unscrew the setscrews on the magnetic brake above the drive motor. If the brake is not working, place wedges underneath the wheels of the truck to prevent it from moving.
78
77
76
78
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F Maintenance of the forklift truck
1 Operational safety and environmental protection
The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the maintenance checklists.
F
Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited. The operating speeds of the truck must not be increased under any circumstances.
F
Only original spare parts have been certified by our quality assurance department. To ensure safe and reliable operation of the forklift truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.
Upon completion of inspection and servicing, the tasks contained in the “Recommissioning” section must be performed (see chapter F).
2 Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend a maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When jacking up the truck, take appropriate measures to prevent the truck from slipping or tipping over (e.g. wedges, wooden blocks). Only work under a raised load handler and cab if they are secured by a chain of sufficient capacity or by the retaining bolt (see “Securing the driver’s position carriage and mast” in Chapter F).
Z
Jacking point see chapter B.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning, implement all necessary safety measures to prevent sparking (e.g. through short circuits). For battery-operated trucks, the battery connector must be removed. Only weak suction or compressed air and non-conductive antistatic brushes may be used for cleaning electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical and electronic components must be carefully covered beforehand as moisture can cause malfunctions. Do not clean with pressurised water.
After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.
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F 2
Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector.
Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, always note the truck-specific settings.
Wheels: The quality of wheels affects the stability and performance of the truck. When replacing factory fitted wheels, only use manufacturer’s original spare parts. Otherwise the truck's rated performance cannot be ensured. When replacing wheels, ensure that the truck does not slew (e.g. always replace left and right wheels at the same time).
Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.
Hydraulic hoses: The hoses must be replaced every six years.
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3 Servicing and inspection
Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck. Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck considerably affect the wear levels of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage caused by wear. The service intervals stated are based on single shift operation under normal operating conditions. They must be reduced accordingly if the truck is to be used in conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they should be carried out. Maintenance intervals are defined as:
W = Every 50 service hours or at least weekly A = Every 500 service hours B = Every 1000 service hours, or at least annually C = Every 2000 service hours, or at least annually
Z
W service intervals are to be performed by the customer.
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F 4
4 EKS 308 maintenance checklist
Maintenance intervals
Standard = t WA B C
Chassis/ Super- structure:
1.1 Check all load bearing components for damage t
1.2 Check screw connections t
1.3 Test the operator platform and check for damage t
1.4 Check that identification points, data plates and warnings are legible and replace if necessary
t
1.5 Check tilt safety devices are present and secure t
1.7 Make sure decals are present, legible and valid t
1.8 Check battery panel and sides are secure t
1.9 Test the operation of the battery panel attachment and check for damage
t
Drive: 2.1 Lubricate the bearing point between the drive
motor and transmission
t
2.2 Check transmission for noise and leakage t
2.3 Change transmission oil t
Wheels: 3.1 Check wheels for wear and damage t
3.2 Check and lubricate suspension and attachment t
Steering: 4.1 Test wheel position indicator t
4.2 Check the distance between the guide rollers and the rail guidance over the entire length of the rails. The play between the two guide rollers and the rails (measured over the axle) should be 0-5 mm. The rollers should not jam.
t
Brake system:
5.1 Test operation and settings t
5.2 Check the brake lining wear t
5.3 Check brake mechanism, adjust and lubricate if necessary
t
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p) Replace hydraulic hoses after 6 years' operation
Maintenance intervals
Standard = t WA B C
Hydraulic System
6.1 Test operation t
6.2 Check connections and ports for leaks and damage
t
6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure
t
6.4 Check oil level t
6.5 Test hose guide and check for damage
t
6.6 Check ventilation and discharge filter on hydraulic reservoir
t
6.7 Replace ventilation and discharge filter on hydraulic reservoir
t
6.8 Replace hydraulic oil and filter cartridge t
6.9 Test pressure relief valves t
6.10 Check hydraulic hoses for leaks and damage p)
t
6.11 Test line brake safety device t
Electrical System
7.1 Test static charge eliminator t
7.2 Test operation t
7.3 Make sure wire connections are secure and check for damage
t
7.4 Test the operation of the cable guides and check for damage
t
7.5 Test operation of warning devices and safety switches. t
7.6 Make sure sensors are fixed, not damaged, clean and operational
t
7.7 Test operation of instruments and displays t
7.8 Check contactors and relays; if necessary replace any worn parts
t
7.9 Check fuse ratings t
Electric motors:
8.1 Check motor attachment t
Battery: 9.1 Check acid density, acid level and cell voltage t
9.2 Check terminals are securely attached, and apply grease
t
9.3 Clean battery connections, make sure they are tight t
9.4 Check battery cables for damage, replace if necessary. t
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e) WG: wire guidance trucks
Maintenance intervals
Standard = t WA B C
Lift mechanism:
10.1 Clean rollers, guide rollers and contact surfaces in the mast sections and apply grease.
M
Warning: Danger of crashing!
t
10.2 Check mast attachments (bearings and retaining screws)
t
10.3 Check lift chains and chain guide for wear, adjust and lubricate
t
10.4 Lubricate lift chains t
10.5 Visually inspect rollers, slide pieces and stops t
10.6 Check forks and fork carriage for wear and damage t
10.7 Check pallet clamp for wear and damage
t
Safety Devices:
12.1 Check safety restraint harness for damage and wear, and test operation
t
12.2 Check receptacle eye on overhead guard for damage and wear, and test operation
t
12.3 Check legibility of notices on safety restraint belt. t
Lubrication: 13.1 Lubricate the truck according to the lubrication schedule t General
Measure- ments:
14.1 Check electrical system for frame leakage t
14.2 Test travel speed and braking distance t
14.3 Test lift and lowering speeds t
14.4 Test safety devices and cutouts t
14.5 WG: Measure the current in the guidance wire, adjust if necessary e)
t
14.6 Test travel on the guidance wire, check maximum deviation and adjust if necessary e)
t
14.7 Check tracking mode on the guidance wire for aisle tracking e)
t
14.8 Check wire guidance EMERGENCY STOP operatione) t
Demon- stration:
15.1 Test run with rated load t
15.2 When maintenance is complete, present the truck to the responsible person.
t
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5 Lubrication Schedule
g
Contact surfaces a Transmission oil drain plug
s
Grease nipple c Hydraulic oil drain plug
Hydraulic oil filler neck
G
E
B
EG
H
A
E
G
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F 8
5.1 Consumables
Handling Consumables:
Consumables must always be handled correctly. Follow the manufacturer’s instructions.
F
Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames.
Only use clean containers for adding consumables. Do not mix consumables of different grades. The only exception to this is when mixing is expressly stipulated in the Operating Instructions.
Avoid spilling any fluids. Spilled fluids must be removed immediately with an appropriate bonding agent. The bonding agent / consumable mixture must be disposed of in accordance with regulations.
* Plus 2% additive 68 ID (order no. 50307735)
F
The trucks are supplied from the factory with “HLP D22” hydraulic oil or the “Plantohyd 22 S” BIO hydraulic oil + 2 % 68 ID additive. You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 SBIO hydraulic oil.
Code Order no. Package
quantity
Capacity
Description Used for
A
51037497 51037494
5 l 1 l
33 l
HLP D22 including 2% share of additive 68 ID
Hydraulic system
51085361* 5 l 33 l
Plantohyd 22 S (BIO hydraulic oil)
B 50022968 5 l 2.5 l SAE 80 EP API GL4 Transmission
E
14038650
400 g
cartridge
---
Lithium lubricating grease KP2K-30 (DIN 51825)
General
29201430 1 kg
G 29201280 400 ml ---
Chain spray Tunfluid LT 220
Mast track, lift chains
H 50157382 1 kg 400 g
Lithium lubricating grease K3K-20 (DIN 51825)
Front wheel bearings
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6 Maintenance and Repairs
F
Load bearing parts of the truck, e. g. chassis and mast, may only be welded after consultation with the manufacturer.
6.1 Prepare the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made:
– Park the truck securely
(see “Parking the Truck Securely” in Chapter E). – Disconnect the battery to prevent the truck from being switched on accidentally – When working under a raised lift truck, secure it to prevent it from lowering, tipping
or sliding away. – Remove the electronic compartment cover at the back.
F
When working under a raised load handler/operator position carriage or a raised truck, secure them to prevent the truck from from lowering, tipping or sliding away. When raising the industrial truck, observe the instructions in the “Transport and Commissioning” chapter. When working on the parking brake, always secure the truck to prevent it from accidentally rolling away.
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6.2 Securing the driver’s position carriage and mast
The driver’s position carriage can be secured in the raised position.
– Raise the driver’s position carriage
until the threads (1,2) for the retaining bolts are free.
– Unscrew the retaining bolts from the
attachment (3).
– Plug retaining bolts in vertical holes
(1,2) and tighten. Make sure that one of the flat sides of the retaining bolts is facing up.
– Very slowly lower the driver’s
position carriage/mast until it is positioned on the retaining bolts.
Z
The thread (1) for the retaining bolt only exists for the DZ mast.
6.3 Lift Chain Servicing
M
It is important that all lift chains and pivots are at all times kept clean and well lubricated. Only lubricate discharged chains. A chain must be lubricated with particular care at the points where it passes over a pulley. Lift chains are safety critical components. Chains should not have any significant contamination. They should only be cleaned with paraffin derivatives e. g. petroleum or diesel fuels. Never clean chains with steam jet high pressure cleaners, cold or chemical cleaning agents.
6.4 Inspecting the lift chains
Unauthorised wear and external damage:
In accordance with official regulations, a chain is considered to be worn if it has extended in length by 3% in the section which passes over the deflection pulley. For safety reasons, we advise replacing chains when they elongate by 2%. Chains should also be replaced immediately when visible damage is noted, as such damage leads to permanent breakage after a certain time.
M
If the truck is fitted with two lift chains, both chains must always be replaced. This is the only way to ensure even load distribution over the two chains. When replacing chains the connecting bolts between the chain anchor and the chain must be replaced. Only new original parts may be used.
1
2
3
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6.5 Hydraulic oil
– Prepare the truck for maintenance and repairs
M
Oil must never be allowed to enter the drainage system or the soil. Used oil must be preserved until it can be disposed of in the correct manner.
M
Only fill or drain hydraulic oil when the mast is completely lowered.
Remove the electronic compartment cover at the back.
Draining oil:
Suction off the hydraulic oil with the discharge filter removed (4). If this is not possible, the hydraulic oil can be drained from the bottom of the hydraulic reservoir after the oil drain screw (6) has been unscrewed.
Adding oil:
Screw in the oil drain screw (6). Replenish with new hydraulic oil up to the Max. mark on the dipstick (7). Screw the discharge filter backon.
F
Check which hydraulic oil is being added. If Plantohyd 22 SBIOhydraulic oil is being used, the warning: “Only add BIO hydraulic oil” (8) will be on the hydraulic reservoir. In this case you may only use Hydrauliköl „Plantohyd 22 S BIOhydraulic oil to fill the hydraulic reservoir.
F
You cannot change from the Plantohyd 22 S BIO hydraulic oil to HLP D22. The same applies to changing from HLP D22 hydraulic oil to Plantohyd 22 S BIOhydraulic oil. Furthermore, you cannot mix HLP D22 hydraulic oilt Plantohyd 22 SBIO hydraulic oil.
Checking the hydraulic oil level
When the mast is fully lowered, check that the hydraulic oil level is between the min. and max. markings on the dipstick (7). If not, add new hydraulic oil.
6.6 Hydraulic hoses
Hose lines must be replaced every six years, see Safety Regulations for Hydraulic Hose Lines ZH 1/74.
4
6
7
8
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6.7 Checking electrical fuses
F
Electric fuses must only be checked and replaced by authorized personnel.
– Prepare the truck for maintenance and repairs
(see Chapter F). – Remove the electronic compartment cover at the back. – Check the fuse rating and condition in accordance with the table; replace if
necessary.
Item Description Current circuit Rating / type
10 1F11
Travel threephase controller AC-3 Power Control (U8)
250 A
11 3F10
Steering threephase controller AC-3 Power Control (U8)
35 A
12 2F15
Hydraulic threephase controller AC-3 Power Control (U8)
400 A
13 F2.1 DC/DC converter U1 input 48 V 48 V 10 A 14 5F1 Lighting and special equipment 48 V 48 V 10 A 15 F3.1 DC/DC converter U1 output 24 V 24 V 10 A 16 F1.2 DC/DC converter U16 input 48 V 48 V 4 A 17 5F2 DC/DC converter U16 output 24 V 24 V 6.3 A 18 1F3 Impulse controller / Drive controller 1 A
1011
12
13 14
15161718
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6.8 Recommissioning the truck after cleaning or maintenance work
The truck can only be re-commissioned after cleaning or maintenance once the following procedures have been carried out:
– Test the horn. – Test the MAIN SWITCH or the EMERGENCY DISCONNECT to make sure they
are operating correctly. – Test the brakes. – Lubricate the truck in accordance with the lubrication schedule.
7 Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than one month, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.
M
During decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of preventing damage to the wheels and wheel bearings.
If the truck is to be out of service for more than 6 months, determine in conjunction with the manufacturer’s customer service department if any additional measures need to be taken.
7.1 Action to be taken before decommissioning
– Throroughly clean the truck. – Test the brakes. – Check the hydraulic oil level and replenish if necessary
(see Section F). – Apply a thin coating of oil or lubrication to all non-painted parts. – Lubricate the truck in accordance with the lubrication
(schedule (see Section F). – Charge up the battery (see “Charging the Battery” in chapter D). – Disconnect the battery and clean it. Apply dielectric grease to the battery terminals.
Z
In addition, observe all the instructions of the battery manufacturer.
– Spray all exposed electrical contacts with a suitable contact spray.
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7.2 Action to be taken during decommissioning:
Every 2 months:
– Charge up the battery (see “Charging the Battery” in chapter D).
M
Battery powered trucks: It is important to regularly charge the battery as otherwise automatic discharge will result in battery depletion. This will destroy the battery as a result of sulphurisation.
7.3 Recommissioning the truck after decommissioning
– Throroughly clean the truck. – Lubricate the truck in accordance with the lubrication
(schedule (see Section F). – Clean the battery. Grease the terminal screws with delectric grease and re-connect
the battery. – Charge up the battery (see “Charging the Battery” in chapter D). – Check if the transmission oil contains condensate water and replace if necessary. – Check if the hydraulic oil contains condensate water and replace if necessary. – Start up the truck
(see “Starting up the truck” in chapter E).
M
Battery powered trucks: If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
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8 Safety checks to be performed at regular intervals and following any unusual
incidents
Z
Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The inspector shall assess the condition of the truck from purely a safety viewpoint, without regard to operational or economic circumstances. The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition from a safety aspect. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z
A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z
Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.
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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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