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ERE 224

Jungheinrich ERE 224 Operating Instructions Manual

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Page 1
Operating instructions
50468220
ERE 224
G
09.05-
01.06
Page 2
0108.GB
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following graphics:
F
Used before safety instructions which must be observed to avoid danger to personnel.
M
Used before notices which must be observed to avoid material damage.
Z
Used before notices and explanations.
t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
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Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assemblies .......................................................................................... B 2
3 Technical data ..................................................................................... B 3
3.1 Performance data ................................................................................ B 3
3.2 Dimensions ......................................................................................... B 4
3.3 EN standards ...................................................................................... B 5
3.4 Conditions for application .................................................................... B 5
4 Location of instruction labels and identification plates ........................ B 6
4.1 Truck identification plate ..................................................................... B 7
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 2
3 Moving the truck with the drive unit inoperative .................................. C 3
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
3.1 Standard version ................................................................................. D 2
3.2 Battery removal from the side (o) ....................................................... D 3
4 Charging the battery ............................................................................ D 4
5 Removing and installing the battery .................................................... D 5
5.1 Removal - standard version ................................................................ D 5
5.2 Removal “Battery removal from the side” (o) ..................................... D 6
5.3 Installation of the battery ..................................................................... D 6
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E Operation
1 Safety regulations governing the operation of the fork-lift truck .......... E 1
2 Description of the operating controls and displays .............................. E 2
3 Starting up the truck ............................................................................ E 6
3.1 Truck variants ...................................................................................... E 6
3.2 Switching on the truck ......................................................................... E 6
4 Operation of the fork-lift truck .............................................................. E 7
4.1 Safety regulations applicable when operating the truck ...................... E 7
4.2 Driving, steering, braking .................................................................... E 8
4.3 Picking up and setting down loads ...................................................... E 14
4.4 Safe parking of the truck ..................................................................... E 15
5 Keyboard (CANCODE) (o) ................................................................. E 16
5.1 Code lock ............................................................................................ E 16
5.2 Drive programme ................................................................................ E 18
5.3 Parameters .......................................................................................... E 18
5.4 Parameter settings .............................................................................. E 19
5.5 Travel parameters ............................................................................... E 23
6 Display instrument (CANDIS) (o) ....................................................... E 25
6.1 Discharge monitor function ................................................................. E 26
6.2 Operating hours display ...................................................................... E 26
6.3 Switch-on test ...................................................................................... E 26
7 Fault location ....................................................................................... E 27
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F Maintenance of the fork-lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist ........................................................................ F 4
5 Lubrication schedule ........................................................................... F 6
5.1 Consumption-type materials ............................................................... F 7
6 Description of the servicing and maintenance operations ................... F 8
6.1 Preparing the truck for the performance of the servicing and
maintenance operations ...................................................................... F 8
6.2 Opening the front hood ....................................................................... F 8
6.3 Opening the front hood ....................................................................... F 8
6.4 Checking the mounting and the attachment of the drive wheel .......... F 9
6.5 Checking the hydraulic oil level ........................................................... F 9
6.6 Checking the electric fuses ................................................................. F 10
6.7 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork-lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and following any
untoward incidents (D: Accident prevention check according
to BGV D27) ........................................................................................ F 12
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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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A 1
0600.GB
A Correct use and application of the truck
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these oper- ating instructions and must always be heeded. National regulations are fully applica- ble.
The fork lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these oper- ating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail.
Duties of the user: A “user” within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid- ered the person, who, in accordance with existing contractual agreements between the owner and the user of the fork lift truck, is charged with the observance of the op- erating duties. The user must ensure that the truck is not abused and only used within its design lim- its and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and mainte- nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions.
M
If these operating instructions are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary.
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B Truck description
1 Application
The truck is an electric control shaft lift truck with hinged driver's platform and safety frames. A fixed driver standing platform is available as an option. The truck has been designed for lifting operations and transportation on level ground and is able to pick up, outside the load-bearing wheel range, pallets with open bases or lateral boards, as well as trolleys. The rated capacity of the truck is shown on the identification plate or can be seen on the capacity label Qmax.
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B 2
2 Assemblies
Item Designation Item Designation
1 t Controller 8 t Hinged driver standing platform 2 t Control shaft 9 t Collision guard 3 o Display instrument
(CANDIS)
10 t Safety extension
4 t Key switch 11 t Master switch 5 o Keyboard
(CANCODE)
12 o Fixed driver standing platform
6 t Supporting wheel 13 o Deadman key 7 t Driven wheel
t = Standard equipment o = Optional equipment
1 2
3 4
5
66
9
10
11
8
7
12
13
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3 Technical data
Z
Indication of technical data according to VDI 2198. Subject to modification and supplements.
3.1 Performance data
* approx. 465 mm with fixed driver standing platform ** Chassis height
Designation
Q Capacity 2.400 kg
c Load centre distance 600 mm
Travelling speed, pedestrian-controlled operation with/without load
4,5 km/h
Travelling speed, stand-on operating mode with/without load
8,5 / 10 km/h
Lift speed with/without load 0,04 / 0,05 m/s Lowering speed with/without load 0,065 / 0,04 m/s Max. climbing capacity (5 min.) with/without load 8,0 / 15,0 %
**
*
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B 4
3.2 Dimensions
(all dimensions in mm)
Length including fork back I2 = 788 mm (pedestrian-controlled operation)
1)Lifted: - 90 mm
2)Stand-on operating mode: +388 mm
3)Short version (I2=723 mm):- 65 mm
Designation
h
13
Height of fork when lowered 85 h2Lift 125 b5Distance between forks, outside 510 / 540 / 670 b3Distance between forks, inside 170 / 200 / 330
e Fork width 170
b
11
Track width 340 / 370 / 500
a Safety distance 200
Dead weight: Refer to truck identification label
lI
1
3
)y
1
1)3
)x
1
)I6b
12
W
a
1)2)3
)A
st
2)3
)
1.000 1.723 1.509 814 1.000 800 1.619 2.005
1.150 1.873 1.659 964 1.200 800 1.768 2.204
1.200 1.923 1.709 1.014 1.200 800 1.817 2.203
1.400 2.193 1.979 1.214 1.400 700 2.016 2.402
1.600 2.393 2.179 1.414 1.600 1.200 2.215 2.601
1.950 2.743 2.529 1.392 2.000 800 2.193 3.001
2.150 2.943 2.729 1.592 2.100 700 2.392 3.100
2.400 3.193 2.979 1.840 2.400 1.200 2.639 3.399
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3.3 EN standards
Continuous sound level: 68 dB(A)
according to EN 12053 as stipulated in ISO 4871
Z
The continuous sound level is a value averaged according to standard regulations, taking the sound pressure level into account when driving, lifting and idling. The sound pressure level is measured at the ear.
Vibration: 0.67 m/s
2
according to EN 13059
Z
The swinging acceleration acting on the body in its operating position is, according to standard regulations, the linear integrated, weighted acceleration in the vertical plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit val- ues for electromagnetic emission and interference immu- nity as well as testing of static electricity discharge ac- cording to EN 12895 and the references to other standards contained therein.
Z
Electrical or electronic components and their arrangement may only be modified after written approval by the manufacturer has been obtained.
3.4 Conditions for application
Ambient temperature
- during operation: 5 °C to 40 °C
Z
Industrial trucks must be specially equipped and approved for continuous use in en- vironments with temperatures below 5 °C or in cold stores respectively with extreme temperatures or humidity changes.
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B 6
4 Location of instruction labels and identification plates
Z
The truck identification plate (14) is visible after the front hood has been opened (refer to chapter F).
The battery identification plate (18) is visible after the battery hood has been opened (refer to chapter D).
Item Designation
14 Truck identification plate 15 Caution: Heed the operating instructions! (see chapter C) 16 Rated capacity 17 Attachment point of hooks for transportation by crane 18 Battery identification plate 19 Accident prevention inspection label
1615
17
18
14
19
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4.1 Truck identification plate
Z
In the event of queries relating to the truck or spare part orders, please give the serial No. (21) of the truck.
Item Designation Item Designation
20 Type 26 Manufacturer logo
21 Serial No. 27 Min./max. battery weight in kg
22 Rated capacity in kg 28 Drive power in kW
23 Battery voltage 29 Load centre distance in mm
24 Empty weight without battery in kg 30 Year of manufacture
25 Manufacturer 31 Option
31 30 29 28 27
26
20 21 22 23 24
25
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C Transportation and commissioning
1 Transportation by crane
F
Only lifting gear of adequate capacity must be used (for the weight of the truck, refer to the truck identification plate - see chapter B).
Z
Attachment points (1) are provided on the chassis and the fork for transport- ing the truck with lifting gear.
– Park the truck and render it safe (re-
fer to chapter E).
– Secure the lifting gear to the attach-
ment points (1).
M
The lifting gear must be attached to the attachment points in such a manner that it cannot slip and does not come into contact with any attachments!
M
If the battery hood is marked according to the figure, proceed as follows.
– Lift up battery hood (2) by means
of handle recess and fold over (t).
– Unlock hood lock by pushing down, fold battery hood forward, unlock hood safety
lock, and fold down battery hood and place on the load fork (o) (refer to chapter D).
Z
The battery compartment contains a spanner (19 SW ring/open-end) and the disas- sembly and assembly instructions for the transport plugs.
11
2
1
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C 2
2 Commissioning
M
The truck must only be operated on battery current! Rectified alternate current will damage the electronic components. Cables connected to the battery (trailing cables) must be less than 6 meters in length.
Z
For trucks starting from February 2001, transport plugs have been introduced.
F
When there is no battery in the truck, the truck cannot be braked with counter-current brake and service brake.
In the front hood area there is a warning sign for the transport plugs (3), which must be removed after installing the battery.
– Fold down the foldable standing platform. – Open front hood (see chapter F). – Loosen nut M12 (19 SW) and remove transport plugs. – Leave the transport plugs at the truck for later transports of the battery.
3
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In order to prepare the truck for work following delivery or transportation, the following operations must be performed:
– Check the truck for completeness and satisfactory condition of the equipment. – If necessary, install the battery. Do not damage the battery cable. – Charge the battery (refer to chapter D). – If necessary, check whether the setting of the combined instrument matches the
type of battery (refer to chapter D)
– Start the truck as described (refer to chapter E).
Z
When parked, the running surface of the tyres will flatten. The flattening will disappear after a short operating time of the truck.
3 Moving the truck with the drive unit inoperative
F
This operating mode is not permitted when negotiating inclines and gradients.
If the truck has to be moved after a failu- re affecting proper operation has rende- red it immobile, proceed as follows:
– Set the master switch to position
“OFF”.
– Set the key switch to position “OFF”
and withdraw the key.
– Immobilise the truck, ensuring that it
cannot move.
– Open the front hood and remove it (re-
fer to chapter F).
– Loosen the lock nuts (5) and tighten
the screws (4).
This releases the brake so that the truck can now be moved.
F
After arriving at the destination, ensure that the brake system is restored to its initial state. The truck must on no ac- count be parked with the brake in the re- leased condition.
– Turn out the screws (4) by approx. 5
mm again and secure them with the lock nuts (5).
The brake is now applied again.
5
4
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C 4
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D Battery - Servicing, recharging, replace-
ment
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per- formed by qualified personnel. The instructions contained in this operating manual, and the instructions of the manufacturer of the battery and of the battery recharging station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when han- dling batteries. No inflammable substances or spark-generating materials must be present or stored within a distance of 2 meters of the truck parked for battery recharg- ing. The location must be well ventilated and fire fighting equipment must be kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter- minals and cable shoes must be clean, lightly greased with pole grease and must be securely tightened. Batteries with bare terminal posts must be covered using a non- skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na- tional environmental protection regulations or waste disposal provisions. The manu- facturer’s specifications for the disposal must be heeded.
M
Before closing the battery hood, make sure that the battery cable cannot be dam- aged.
F
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective clothing and goggles must be worn whenever work is undertaken on batteries. Avoid physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into con- tact with battery acid. Spilled battery acid must be immediately neutralized.
M
Only batteries with closed tray may be used.
F
Battery weight and dimensions have considerable influence on operational safety of the truck. Changing the battery equipment is not permitted without prior approval by the manufacturer.
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D 2
2Battery types
The battery types meet the EN 60254-2 standards. The following table shows the battery combinations and battery capacities:
The battery weight is indicated on the battery identification plate.
Depending on the type of battery used, it is also possible to use models with en- hanced performance or maintenance-free batteries.
F
When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.
3 Exposing the battery
F
Park the truck and render it safe (refer to chapter E).
3.1 Standard version
– Set the master switch (1) to position “OFF”. – Lift up and swing forward the battery hood (2) using the handle (3).
Battery type Battery compartment ap-
prox. 225 mm
Battery compartment ap-
prox. 295 mm 24 V batteries 3 EPzB 300 Ah 3 EPzS 345 Ah 24 V batteries
(performance-enhanced)
3 EPzS 375 Ah
3
2
1
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3.2 Battery removal from the side (o)
– Set the master switch (7) to position “OFF”. – Unlock the hood locking mechanism (4) by pressing it down,
tilt the battery hood (5) towards the front and unlock the hood catch (6)r.
– Fold the battery hood (5) down and place it onto the fork.
64
5
6
7
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D 4
4 Charging the battery
– Park the truck and render it safe (refer to chapter E).
F
Do not connect or disconnect the battery connector and the socket unless the truck is switched off.
– Expose the battery (refer to section 3).
F
During the recharging operation, the tops of the battery cells must be exposed to en- sure adequate ventilation. No metal objects must be placed on the battery. Prior to starting the recharging operation, check all cable connections and plugged connec- tions for visible damage. All safety instructions as provided by the supplier of the battery and the charging sta- tion must be strictly observed.
– Disconnect the battery connector (8). – If present, remove any insulating mats from the battery. – Connect the charging cable (9) to the battery connector (8) and switch on the bat-
tery charger.
M
Recharge the battery observing the instructions provided by the battery supplier and by the charging station supplier.
8
9
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5 Removing and installing the battery
F
The truck must be parked on level ground. To prevent short-circuits, batteries with ex- posed poles or cell connectors must be covered using rubber matting. Place the bat- tery connector or the battery cable, respectively, in such a way that they will not catch behind any truck protrusions when the battery is withdrawn.
Z
When transporting batteries with the aid of a crane, ensure that the crane is of ade- quate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must pull in a vertical direction to prevent damage to the battery trough. The lifting gear hooks must be secured to the attachment points (12) in such a way that the lifting gear, when slack, cannot collapse on the battery cells.
5.1 Removal - standard version
– Expose the battery (refer to section 3). – Loosen the screw (10) of the battery support (11). – Lift and pull out the battery support. – Disconnect the battery. – Fix the lifting gear to the attachment points (12) and lift out the battery.
10
11
12
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D 6
5.2 Removal “Battery removal from the side” (o)
– Expose the battery (refer to section 3). – Push the battery against the chassis in order to relieve the battery support (13). – Lift the battery support r, push it a short distance into the chassis p, lift r and with-
draw it u.
– Disconnect the battery. – Pull the battery laterally onto the battery exchange point.
F
Heed the operating instructions of the manufacturer of the battery exchange point!
Z
The battery can also be removed using crane gear.
5.3 Installation of the battery
Installation is in the reverse order of steps.
F
Following reinstallation of the battery, check all cable connections and plugged con- nections for any visible damage. Standard version: Before starting up the truck again, fasten the battery support (11) with the screw (10) and make sure that the battery hood is closed safely with the hood locking mechanism. Truck with battery removal from the side: Before starting up the truck again, check:
– that the battery support is installed and, – that the battery hood is safely locked.
13
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E Operation
1 Safety regulations governing the operation of the fork-lift truck
Driving permission: The fork-lift truck must only be operated by persons who have
been trained in the operation of trucks, who have demonstrated to the user or his rep- resentative their capability of moving and handling loads, and who have expressly been charged by the user or his representative with the operation of the truck.
Rights, duties and conduct of the driver: The driver must be: informed of his rights and duties; trained in the operation of the fork-lift truck; and familiar with the contents of these operating instructions. All necessary rights must be granted to him. If the fork-lift truck can be used in the pedestrian-controlled mode, the driver must wear safety boots when operating the truck.
Prohibition of unauthorised use: The driver is responsible for the fork-lift truck dur- ing working time. He must forbid unauthorised persons to drive or operate the fork-lift truck. It is forbidden to transport or lift persons.
Damage and defects: Damage or defects noted on the fork-lift truck or on the attach- ments must immediately be brought to the notice of the person in charge. Fork-lift trucks that cannot be safely operated (e.g. due to worn tyres or defective brakes) must not be used until they have been properly repaired.
Repairs: Without specific training and express authorisation, the driver is not allowed to perform any repairs or modifications on the fork-lift truck. Under no circumstances must the driver change the setting of switches or safety installations or render them ineffective.
Danger area: A “danger area” is considered to be the area within which persons are endangered by the travelling or lifting movements of the fork-lift truck or its load lifting devices (e.g. fork or attachments), or by the loads being transported. This also in- cludes the area within reach of falling loads or falling/lowering truck attachments.
F
Unauthorised persons must be asked to leave the danger area. The driver must give a warning signal whenever a situation presenting danger to persons might develop. The fork-lift truck must immediately be brought to a standstill if persons, although asked, do not leave the danger area.
Safety devices and warning labels: The safety devices, warning labels and warning notes described in the present operating instructions must always be heeded.
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E 2
2 Description of the operating controls and displays
Item Operating control or display Function
1 Hinged standing platform t Pedestrian-controlled operation:
– Driver standing platform in folded-up position:
Truck travelling speed is limited to 4.5 km/h.
Stand-on operating mode, standing platform serves as the deadman switch:
– Unweighted driver standing platform in folded-up
position: Travelling function blocked.
– Driver standing platform in folded-down position,
with driver standing on it: Travelling function released.
2 Hinged safety extensions t The travelling function is blocked if the safety ex-
tensions are not folded out when the standing plat- form is folded down: Truck travelling speed is limited to 4.5 km/h.
3Master switch
(emergency cut-out)
t The electric circuit is interrupted, all electrically
controlled functions are switched off and the truck is automatically braked.
4 Anti-collision key t Pedestrian-controlled operation:
Safety function which, when operated, will force the truck for approx. 5 seconds in the opposite trav- elling direction (R) and which will then switch off the travelling function until the controller has been briefly moved to its neutral position.
Stand-on operating mode: without function
5 Controller t Controls the direction of travel as well as the trav-
elling speed (refer to section 4.2).
6 Display instrument
(CANDIS)
o Operating hours meter
Battery capacity display Shows the residual capacity of the battery and the accumulated operating hours of the truck
7 Key switch t Switches the control current on and off. The truck
cannot be operated by unauthorised persons when the key has been removed from the switch.
8 Keyboard
(CANCODE)
o Code settings
Drive programme release
9 Control shaft t Movable control shaft.
Steering and braking: – Swivelling the control shaft into the braking
range (B): The truck is mechanically braked.
– Swivelling the control shaft into the driving range
(F): This releases the brake so that the truck can be moved.
t = Standard equipment o = Optional equipment
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Item Operating control or display Function
10 Operating key - Horn t Issues a warning signal. 11 Operating key “Lowering” t Lowers the fork. 12 Operating key “Lifting” t Lifts the fork. 13 Brake switch
(variant “Suspended standing platform”)
o Emergency stop and service brake
14 Control shaft
(electrical steering)
o Steering
15 Rigid safety barriers o Only stand-on operation is possible. 16 Deadman key
(The function depends on the control shaft variant.)
o Truck with moveable control shaft:
– Deadman key pressed:
Travelling function released. – Deadman key released:
Truck coasts to a stop. Truck with rigid control shaft: – Deadman key pressed:
Truck is ready for operation. – Deadman key released:
Truck is braked.
17 Fixed driver standing platform o Only stand-on operation is possible. 18 Rigid safety barriers
(variant “Suspended standing platform”)
o Only stand-on operation is possible.
19 Fixed driver standing platform
(suspended) (variant “Suspended standing platform”)
o Stand-on operation with weighted standing
platform.
t = Standard equipment o = Optional equipment
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E 6
3 Starting up the truck
F
The driver must make sure that nobody is within the danger area of the truck before the truck is switched on or operated, or before a load is lifted.
Checks and operations to be performed before starting daily work
– Perform a visual check of the entire truck (especially wheels and load lifting equip-
ment) for visible damage. – Check the steering wheel play. – Ensure through a visual inspection that the battery is securely locked in place and
that the cable connections are in order.
3.1 Truck variants
F
Commissioning and operation of the truck depend on the truck variant and truck con- figuration.
3.2 Switching on the truck
– Pull out the master switch (3). – Use the key to set the key switch (7) to
position “I”. – Check the horn (10) for proper func-
tioning.
F
When swivelling the hinged standing platform upwards (if available), do not reach between the standing platform and the truck’s side wall. Check the braking function (refer to section 4.2).
The truck is now ready for operation. The display instrument (CANDIS (6) (o)) shows the available battery capaci- ty.
Truck variant
Truck configuration Hinged driver
standing platform
Fixed driver
standing
platform
Suspended
driver standing
platform
Control shaft – movable tt--
–rigid -- o t
Steering – mechanic tt--
– electric oot
Safety extension
–hinged t---- –rigid -- t t
Operating mode
– pedestrian oper. t---- – stand-on oper. ttt
3
8
7
10
6
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4 Operation of the fork-lift truck
4.1 Safety regulations applicable when operating the truck
Driving lanes and work areas: Only such lanes and routes that are specially allo-
cated for truck traffic must be used. Unauthorised persons must stay away from work areas. Loads must only be stored at places specially provided for this purpose.
Driving conduct: The travelling speed must be adapted to the prevailing local con- ditions. The truck must be driven at slow speed when negotiating bends or narrow passages, when passing through swing doors and at blind spots. The driver must al- ways observe an adequate braking distance between the fork-lift truck and the vehi- cle in front and he must be in control of his truck at all times. Sudden stopping (except in emergencies), rapid U-turns and overtaking at dangerous or blind spots is not per- mitted. It is forbidden to lean or reach out of or reach beyond the working and operat- ing area. It is forbidden to transport or lift persons.
Visibility: The driver must look in the direction of travel and must always have a clear view of the route ahead. When loads blocking the view are carried, the fork-lift truck must be driven with the load at the rear. If this is not possible, a second person must walk in front of the fork-lift truck to give suitable warnings.
Negotiating slopes and inclines: Negotiating slopes and inclines is permitted only when they are recognised lanes, when they are clean and non-slipping, and when the technical specification of the truck permits safe driving on such slopes or inclines. Loads must always be carried at that end of the truck facing uphill. U-turns, cutting obliquely over slopes or inclines and parking the fork-lift truck on slopes or inclines is not permitted. Inclines must only be negotiated at slow speed, with the driver ready to brake at any moment.
Use of lifts and driving on loading platforms: Lifts and loading platforms must only be used if they are of adequate load bearing capacity, if suitable for driving on, and if authorised by the user of the truck for truck traffic. The fork-lift truck driver has to sat- isfy himself accordingly before driving into lifts or onto loading platforms. The truck must enter lifts with the load in front and must take up a position which does not allow it to come into contact with the walls of the lift shaft. Persons riding in the lift together with the fork-lift truck must only enter the lift after the fork-lift truck has come safely to a standstill, and must leave the lift before the fork-lift truck.
Nature of the loads carried: Only loads that have been safely and correctly secured must be carried. Never transport loads stacked higher than the top of the fork car- riage, or stacked higher than the guard grille.
Towing trailers: The maximum trailer load given for the fork-lift truck for braked and/ or unbraked trailers must not be exceeded. The trailer load must be properly secured and must not exceed the dimensions permitted for the driving routes. After attaching the trailer but before starting driving, the driver must check that the trailer attachment is secured against detachment. Towing fork-lift trucks must be operated in such a manner that safe driving and braking of the truck and the trailer is guaranteed for all driving movements.
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4.2 Driving, steering, braking
F
Be extremely careful when driving and steering, especially when parts of the body protrude from the truck contour. Make sure to keep sufficient distance when the truck is operated with an accompany- ing person.
The electric steering system is self-monitoring.
The steering control systems monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering control reduces the driving speed of the truck to low speed. If such a fault occurs, the driving speed is not reset to normal speed by switching the truck off and on again. This method pre- vents the cancellation of a fault without eliminating the fault.
F
As the steering system is a safety-relevant component, the fault must be eliminated by trained service personnel.
Cut-out
Depress the master switch (3). This will switch off all electric functions.
Emergency stop
Depending on the truck variant, the emergency stop function can be triggered in dif- ferent ways.
Truck with movable control shaft (t):
When the control shaft (9) is released, the truck is automatically braked (emergency stop). The control shaft will automatically move into the upper braking range (B).
F
If the control shaft is sluggish in moving into the braking range, the cause must be established and eliminated. If necessary, the gas pressure spring must be replaced.
Truck with rigid control shaft (o):
The emergency stop function is triggered when the deadman switch (16) in the stand- ing platform is released.
Truck with rigid control shaft and suspended standing platform (variant “Suspended standing platform”) (o):
The emergency stop function is released when:
– the brake switch (13) on the control shaft is pressed. – the standing platform (17) is no longer weighted.
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5
15
14
9
16
19
1
B
B
B
F
R
V
0
4
9
2.1
2.2
R
V
3
13
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Driving
Truck with hinged standing platform and movable control shaft:
There are two different travelling modes:
F
When swivelling the standing platform upwards, do not reach between the standing platform and the truck’s side wall.
– Pedestrian-controlled operation: Starting with safety extension (2.2), swivel the
safety extensions (2.1 and 2.2) inwards and then fold up the standing platform (1).
The truck can only be operated at a reduced travelling speed. – Stand-on operating mode: Swivel the safety extensions (2.1 and 2.2) outwards and
then fold down the standing platform (1). The truck can be operated at the maxi-
mum travelling speed.
General:
– Swivel the control shaft (9) into the driving range (F). – Set the controller (5) to the required travelling direction (V or R).
Z
The travelling function is blocked if the driver is not standing on the platform and the safety extensions are not folded out. The truck can only be operated at a reduced travelling speed when the standing plat- form is weighted and the safety extensions are not folded out.
o Truck with rigid standing platform and movable control shaft:
– Step on the standing platform (19). – Press the deadman switch (16). – Swivel the control shaft (14) into the driving range (F). – Set the controller (5) to the required travelling direction (V or R).
Truck with rigid standing platform and rigid control shaft (o):
– Step on the standing platform (19). – Press the deadman switch (16). – Set the controller (5) to the required travelling direction (V or R).
Truck with rigid, lowered and suspended standing platform (variant “Suspended standing platform”) (o):
– Step on the suspended standing platform (19). – Set the controller (5) to the required travelling direction (V or R).
F
Do not drive the truck unless the hoods are closed and locked in the stipulated man- ner. When passing through swing doors or similar, take care that the anti-collision key (13) is not inadvertently operated.
– Start up the truck (refer to section 3).
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5
15
14
9
16
19
1
B
B
B
F
R
V
0
4
9
2.1
2.2
R
V
3
13
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Steering
F
In narrow bends, the driver will be positioned at the outer contours of the truck.
– Swivel the control shaft (9, 14) to the left or right.
Braking
F
The braking behaviour of the truck strongly depends on the state of the floor. This must be taken into account by the driver for his driving behaviour.
There are two ways to brake the truck:
– by means of the counter-current brake – by means of the service brake
Braking by means of the counter-current brake:
Truck with movable control shaft (t):
– Turn the controller (5) into the opposite travelling direction until the truck has come
to a standstill.
The truck is braked with the counter-current brake.
Braking by means of the service brake:
– Swivel the control shaft (9, 14) into one of the braking ranges (B) or release the con-
trol shaft.
The drive motor is mechanically braked by means of the motor brake. When the truck is parked, the service brake acts as a parking brake.
Z
When the control shaft is released, it automatically swivels into the upper braking range (B).
Truck with rigid control shaft (o) :
– Release the foot switch (17) in the standing platform.
Variant “Suspended standing platform”(o):
– Press the brake key (13) in the control shaft head.
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5
15
14
9
16
19
1
B
B
B
F
R
V
0
4
9
2.1
2.2
R
V
3
13
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4.3 Picking up and setting down loads
M
Before picking up a load, the driver has to check that the load rests properly on its pallet and that it does not exceed the capacity of his truck.
– Pass the fork tines as far as possible
under the load. It is not permitted to
pick up long loads crosswise.
M
When picking up the load, ensure that it does not project excessively from the tips of the tines (less than 50 mm).
Lifting and lowering
Z
When operating the keys “Lifting” or “Lowering”, the lifting or lowering move- ment will be at a fixed speed.
Lifting
– Press the operating key “Lifting” (12). Keep the key depressed until the required lift-
ing height is reached.
Lowering
– Depress operating key “Lowering” (11); the fork is lowered.
111211 12
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4.4 Safe parking of the truck
When the truck is parked and left unat- tended, it must be rendered safe even if it is left unattended for only a short peri- od of time.
– Never park the truck on a slope or in-
cline. – Completely lower the fork. – Switch the key switch (7) to position
“0” and remove the key from the key
switch. – Set the master switch (3) to position
“OFF”. – Swing in the hinged safety extensions
(if available).
F
When swivelling the hinged standing platform upwards (if available), do not reach between the standing platform and the truck’s side wall.
– Use one of the bevelled edges to
swing the driver’s standing platform upwards (if available).
3
8
7
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5 Keyboard (CANCODE) (o)
The operator keyboard is composed of 10 nu- meric keys, a Set key and an o-key. The green LED in key 1 indicates that the drive programme was switched on with key 1. The o-key indicates operating conditions by a red/green LED.
It has the following functions:
– Code lock function (setting the truck into oper-
ation). – Setting the travel and battery parameters, only in conjunction with the indicator in-
strument (CANDIS (o)).
The o-key has top priority and reset the truck from any condition to the basic condi- tion without modifying any settings.
5.1 Code lock
After entering the correct code, the truck is ready for operation. It is possible to assign an individual code to every truck, operator or even operator group.
Z
When delivered from the factory, the operator code (factory setting 2-5-8-0) is indicat- ed on a removable sticker.
M
Change the master and operator codes when setting the truck into operation for the first time! (refer to section 5.4).
1 2 3
4 5 6
7 8 9
0
Set
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Commissioning
After switching on the master switch and, if required, the key switch, the LED (20) lights up red.
After entering the correct operator code (factory setting 2-5-8-0) the LED (20) lights up red.
When an incorrect code has been entered, LED (20) lights up red for two seconds. After that you can enter a new code.
Z
The Set key (21) has no function in operating mode.
Switching off
The truck is switched off by actuating the o -key (25).
Z
The truck can be switched off automatically after a preset time. For that purpose the corresponding code lock parameter must be set (refer to section 5.4).
1 2 3
4 5 6
7 8 9
0
Set
22
21
20
25
2423
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5.2 Drive programme
The truck features one drive programme. The green LED (22) indicates the active programme, buttons 2 and 3 have no function.
Z
The drive programme can be individually adapted to match the truck application.
5.3 Parameters
In the programming mode, the operating keyboard allows code lock and drive pro- gramme to be adapted. Additionally, the battery parameters can be set.
Z
For trucks without indicator instrument (CANDIS (o)) only the code lock parameters can be set.
Parameter groups
The parameter number is composed of three digits. The first digit designated the pa- rameter group according to table 1. The second and third digits are sequentially num- bered from 00 to 99.
No. Parameter group 0xx Code lock settings
(codes, drive programme release, automatic cut-out, etc.)
1xx Travel programme 1 parameters
(Acceleration, coasting brake, speed, etc.)
4xx Programme-independent parameters
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5.4 Parameter settings
To change the truck settings the master code must be entered.
Z
The master code is factory-set to 7-2-9-5.
M
Change the master code when setting the truck into operation for the first time (refer to section 5.1).
F
Safety notes for trucks with indicator instrument (CANDIS (o))
– Parameter settings must be made carefully and only by special trained personnel .
If in doubt, consult the manufacturer's service. – Every setting procedure must be monitored on the LC display of the indicator
instrument (CANDIS (o)). If in doubt, the setting procedure must be cancelled by
pressing the o-key (25). – Since the truck's travel behaviour is changed, you must perform a trial in a specially
assigned and suitable working area run after changing any of the parameters.
Entering the master code:
– Press the o-key – Enter master code
Code lock parameters
Setting procedure for trucks without indicator instrument (CANDIS (o)):
– Enter the three-digit parameter number and confirm with Set key (21). – Enter or change the setting value according to the parameter list and confirm with
Set key (21).
Z
When the input is incorrect, the LED (20) of the o-key (25) lights up red. After entering the parameter number again, the setting value can be entered or changed.
Repeat the procedure to enter further parameters. To terminate the input, press the o-key (25).
Display instrument
(CANDIS)
LED (20)
o-key
LED (22)
Key 1
LED (23)
Key 2
LED (24)
Key 3
Operating hours are indicated
284.0
green
flashing
off off off
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Setting procedure for trucks with and without indicator instrument (CANDIS (o)):
– Enter the three-digit parameter number and confirm with Set key (21). – The indicator instrument (CANDIS (o)) continues to display the operating hours. If
the display changes, cancel the setting procedure with the o-key (25) and restart
from the beginning. – Enter or change the setting value according to the parameter list and confirm with
Set key (21).
Z
When the input is incorrect, the LED (20) of the o-key (25) lights up red. After enter- ing the parameter number again, the setting value can be entered or changed.
Repeat the procedure to enter further parameters. To terminate the input, press the o-key (25).
The following parameters can be entered:
Code lock parameter list
No. Function Range
Setting value
Default Setting
value
Comments
Work flow
Codeschloss
000 Change master code
The length of the master code (4 to 6 digits) also determines the length (4 to 6 digits) of the operator code. As long as operator codes have been programmed, only new codes with the same length can be entered. If the code length is to be changed, all operator codes must be deleted first.
0000 - 9999
or
00000 - 99999
or
000000 - 999999
7295 (LED 22 flashes)
Enter the current
code
confirm (Set)
(LED 23 flashes)
Enter a new code
confirm (Set)
(LED 24 flashes)
Repeat new code
Confirm (Set)
001 Add operator code
(max. 600)
0000 - 9999
or
00000 - 99999
or
000000 - 999999
2580 (LED 23 flashes)
Enter a code
confirm (Set)
(LED 24 flashes)
Repeat the code en-
try
Confim (Set)
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LED 22-24 are located in the key pad fields 1-3 (refer to section 5.2).
No. Function Range
Setting value
Default Setting
value
Comments
Work flow
Code lock
002 Change operator code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 22 flashes) Enter the current
code
Confirm (Set)
(LED 23 flashes)
Enter a new code
Confirm (Set)
(LED 24 flashes)
Repeat the code en-
try
Confirm
003 Delete operator code 0000 - 9999
or
00000 - 99999
or
000000 - 999999
(LED 23 flashes)
Enter a code
Confirm (Set)
(LED 24 flashes)
Repeat the code en-
try
Confirm (Set)
004 Clear code memory
(deletes all operator codes)
3265 3265 = delete
other entry = do not
delete
010 automatic switch-off 00 - 31 00 00 = none
Switch-off
01 to 30 =
Switch-off time in
minutes
31 = switch-off after
10 seconds
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*) only in conjunction with indicator instrument (CANDIS (o))
Keyboard error messages
The following errors are indicated by a red flashing LED (20):
– New master code is already operator code. – New operator code is already master code. – Operator code to be changed does not exist. – Tried to change the operator code to an existing code. – Operator code to be deleted does not exist.
Code memory full.
No. Function Range
Setting value
Default
Setting val-
ue
Comments
Work flow
Code lock
030 Display of the number of
used operator codes*
)
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5.5 Travel parameters
Z
For trucks without indicator instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service.
The following example shows the parameter setting for the acceleration of travel pro- gram 1 (parameter 101).
Acceleration example
– Select the edited travel program after changing the parameter value, confirm with
the Set key (21). – Check the LC display of the indicator instrument (CANDIS (o)) (parameter number
and current parameter value are displayed).
Z
If there is no input for approx. 5 seconds, the display switches back to operating hours indication.
F
If another parameter number than the one displayed is desired, you must wait until the operating hours are displayed again.
– Enter or change the parameter value according to the parameter list. – Check the LC display of the indicator instrument (CANDIS (o)) (confirm with the
Set key (21)). – The LED (20) of the o-key (25) switches briefly to steady light and start flashing
again after approx. 2 seconds.
Z
When the input is incorrect, the LED (20) of the o-key (25) lights up red. After entering the parameter number again, the setting value can be entered or changed.
Repeat the procedure to enter further parameters as soon as the LED (20) of the o-key (25) flashes. To terminate the input, press the o-key (25).
Display instrument
(CANDIS)
LED (20)
o-key
LED (22)
Key 1
LED (23)
Key 2
LED (24)
Key 3
current setting is displayed
101 6
green
flashing
off off off
changed setting is displayed
101 8
green
flashing
off off off
Parameter
number
Parame-
ter set-
ting value
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The following parameters can be entered:
Drive programme
Drive programme-independent parameters
Z
For trucks without indicator instrument (CANDIS (o)) the code lock parameters can only be set by the manufacturer's service.
The parameters are set in the same way as for the travel parameters.
The following parameters can be entered:
Setting value 0 / 1 is to be interpreted as: 0 = off 1 = on
No. Function Range
Setting value
Standard
Setting
value
Comments
101 Acceleration 0 - 9 9 102 Coasting brake 0 - 9 9 104 Maximum speed in drive
direction via controller
0 - 9 8 depending on
controller
105 Pedestrian-controlled op-
eration speed in drive di- rection via controller
0 - 9 5 depending on
controller
108 Maximum speed in fork di-
rection via controller
0 - 9 8 depending on
controller
109 Pedestrian-controlled op-
eration speed in fork di- rection via controller
0 - 9 5 depending on
controller
No. Function Range
Setting value
Standard
Setting
value
Comments
Battery parameters
411 Battery type (normal/
high-power/dry)
0 - 2 0 0 = Normal (wet)
1 = High-power (wet)
2 = Dry (maintenance-free)
412 Discharge monitor func-
tion
0 / 1 1
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6 Display instrument (CANDIS) (o)
The instrument indicates:
– Remaining battery charge (LED
bars (27)), – Operating hours
(LC display (29)).
In addition, error messages of the electronic components and parame- ter changes are displayed.
Discharge status indication
Depending on the battery type set, switch-on limits for the additional “Warning” (26) and “Stop” (28) indicators may result.
Number
Bars
Charging condition
Wet battery Maintenance-free battery
LED (yellow)
Warning
LED (red)
Stop
LED (yellow)
Warning
LED (red)
Stop
10 90.1- 100% Off Off Off Off
9 80.1 - 90% Off Off Off Off 8 70.1 - 80% Off Off Off Off 7 60.1 - 70% Off Off Off Off 6 50.1 - 60% Off Off Off Off 5 40.1 - 50% Off Off On Off 4 30.1 - 40% Off Off On On 3 20.1 - 30% On Off On On 2 10.1 - 20% On On On On
Avoid falling below the 20% limit for wet batteries resp. 40% limit for maintenance-free batteries.
26
27
28
29
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6.1 Discharge monitor function
With the discharge monitor function enabled, the lifting function switches of when reaching the discharge limit (the Stop LED switches on). Travelling and lowering is still possible. For wet batteries the residual capacity is 20%, for maintenance-free bat- teries it is 40%. At 30% for wet batteries resp. 50% for maintenance-free batteries the batteries should be recharged (the yellow LED lights up as warning indication).
6.2 Operating hours display
Display range between 0.0 and 99,999.0 hours. Travel and lifting movements are logged. This is a backlit display.
Z
For maintenance-free batteries a “T” symbol is shown in the operating hours display (29).
Error messages
The operating hours display is also used for indicating errors. The error is displayed in two parts and starts with a “C” for component and a three-digit component number, then an “E” for error with alternating three-digit error number. If several errors occur they are displayed one after the other. The errors are displayed as long as they are present (always in combination Cxxx / Exxx). Errors are displayed as long as they persist. The operating hours display is overwritten with an error mes- sage. Most errors cause the emergency stop to be triggered. The error display is maintained until the control circuit is switched off (Code lock).
Z
Detailed component descriptions including error codes are available at the manufac- turers service.
Display for parameter changes (travel programmes)
The LC display (29) is used in conjunction with the operator keyboard (CANCODE (o)) to display the setting parameters. The first three digits of the display show the parameter numbers, the last three digits indicate the parameter value.
Z
Setting values of parameter group 0XX (code lock) are not displayed.
6.3 Switch-on test
After switching on the display shows:
– the software version of the display instrument (short-term), – the operating hours – the charging condition
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7 Fault location
This chapter enables the user to locate and to remedy simple faults or the conse- quences of operating errors. Fault locating operations should be performed in the or- der as set out in the table below.
Z
If it was not possible to eliminate the fault by performing the remedial actions indicat- ed above, please inform the manufacturer’s service organisation as more intricate faults can only be rectified by specially trained and qualified service staff.
Fault Possible cause Remedy
Truck does not move
– Battery connector not
connected
– Check the battery connector and con-
nect if necessary.
– Master switch de-
pressed
– Release the master switch.
– Key switch in
position “0”
– Set the key switch to position “I”.
– Battery exhausted – Check the charging condition of the bat-
tery and recharge if necessary.
– Fuse defective – Check fuses F1, 1F1 and 3F9.
Load cannot be lifted
– Truck not operative – Perform all remedial actions listed un-
der the fault “Truck does not move”.
– Hydraulic oil level too
low
– Check the hydraulic oil level.
– Load is too heavy – Heed the maximum capacity (see the
identification plate).
– The battery discharge
monitor has switched off and indicates “STOP”
– Charge the battery.
– Fuse defective – Check fuse 2F1.
No display on the battery discharge monitor
– Truck not operative – Check the battery connector and con-
nect if necessary.
– Master switch de-
pressed
– Release the master switch.
– Fuse defective – Check fuse 6F1.
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F 1
F Maintenance of the fork-lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists.
F
Modifications of fork-lift truck assemblies, especially of the safety installations, are not permitted. On no account must the operational speeds of the truck be changed.
M
Only original spare parts have been certified by our quality assurance service. To en- sure safe and reliable operation of the fork-lift truck, only spare parts of the manufac- turer must be used. Used parts, oils and fuels must be disposed of in accordance with the applicable environmental protection regulations. For oil changes, the oil service of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork-lift truck must only be serviced
and maintained by trained personnel of the manufacturer. The service organization of the manufacturer has external technicians trained especially for these assign- ments. We thus recommend signing a maintenance contract with the relevant service location of the manufacturer.
Lifting and jacking up: When a fork-lift truck is to be lifted, the lifting gear must only be secured to the points specially provided for this purpose. When the truck is to be jacked up, suitable measures must be taken to prevent the truck from slipping or tip- ping over (use of wedges, wooden blocks). Work underneath the raised load lifting device must only be carried out when the fork is immobilised and supported by a chain of adequate strength.
Cleaning operations: No inflammable liquids must be used when cleaning the fork- lift truck. Prior to commencing cleaning operations, all safety measures that are re- quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-oper- ated fork-lift trucks, the battery plug must be removed. Only weak indraft, weak com- pressed air and non-conducting, antistatic brushes must be used for the cleaning of electric or electronic assemblies.
M
If the fork-lift truck is to be cleaned using a water jet or a high-pressure cleaner, all electric and electronic components must be carefully covered beforehand because moisture can lead to incorrect functioning. Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis- sioning” must be performed.
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Work on the electric system: Work on the electric system of the truck must only be performed by personnel specially trained for such operations. Before commencing any work on the electric system, all measures required to prevent electric shocks have to be taken. For battery-operated fork-lift trucks, the truck must also be depow- ered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components, these have to be removed from the fork-lift truck before any welding operations are undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or assemblies, all truck-specific settings have to be retained.
Tyres: The quality of the tyres greatly affects the stability and the driving behaviour of the fork-lift truck. Changes must only be made following consultations with the manufacturer. When replacing wheels or tyres, it must be ensured that the fork-lift truck remains level (tyres and wheels must always be replaced in pairs, i.e. left and right together).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service checklist apply to normal duty. If requirements are higher (dust, temperature), lubri- cation is required more often. The specified chain spray must be used as specified. The external application of grease does not provide sufficient lubrication.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy- draulic components, also renew the hoses in this hydraulic system.
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F 3
3 Servicing and inspection
Thorough and expert servicing is one of the most important preconditions for safe op- eration of the fork-lift truck. The neglect of regular servicing intervals can lead to fork- lift truck failure and constitutes a potential hazard to personnel and equipment.
M
The indicated servicing intervals are based on single-shift operation under normal op- erating conditions. For applications in dusty environments, or involving large temper- ature fluctuations or multiple-shift operation, the servicing intervals must be shortened accordingly.
The following servicing checklist indicates the operations to be performed and the re- spective intervals to be observed. The servicing intervals are defined as follows:
W = every 50 operating hours, but at least once per week A = every 500 operating hours, or at least every six months B = every 1000 operating hours, or at least annually C = every 2000 operating hours, or at least annually
Z
W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner must check the wheel nuts/bolts and re-tighten if necessary.
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4 Maintenance checklist
Maintenance intervals
Standard = t WA B C Cold store = k
Chassis/ super- structure:
1.1 Check all load bearing elements for damage t
1.2 Check all bolted connections t
1.3 Check platform for correct functioning and damage t
Drive unit: 2.1 Check the transmission for noises and leakage t
2.2 Checking the transmission oil level t
2.3 Change the transmission oil kt
Wheels: 3.1 Check for wear and damage t
3.2 Check the wheel bearings and ensure secure fastening of wheels
kt
Steering: 4.1 Check the steering wheel play t
4.2 Check the steering chain and the chain sprocket for wear; adjust and grease
kt
4.3 Check the mechanical parts of the steering column; grease if necessary
t
Brake system:
5.1 Check performance and adjustment kt
5.2 Check the gas spring for proper resetting function, for leaks and for damage
t
5.3 Check the brake linings for wear t
5.4 Check the brake linkage; adjust and grease if necessary kt
Hydraulic system:
6.1 Performance check kt
6.2 Check all connections for leakage and damage kt
6.3 Check the hydraulic cylinders for leakage, damage and secure attachment
kt
6.4 Check the oil level kt
6.5 Replace the hydraulic oil and the filter cartridge kt
6.6 Check the pressure relief valves for correct functioning kt
Electrical system:
7.1 Performance check t
7.2 Check all cables for secure connection and damage t
7.3 Check the fuses for correct amperage t
7.4 Check switches and trip cams for secure attachment and correct functioning
t
7.5 Check contactors and relays; replace wearing parts if nec- essary
t
7.6 Check the warning installations and safety circuits for cor- rect functioning
kt
Electric motors:
8.1 Check the carbon brushes for wear t
8.2 Check the motor for secure attachment t
8.3 Clean motor housing by means of a vacuum cleaner and check the commutator for wear
kt
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F 5
Maintenance intervals
Standard = t WA B C Cold store = k
Battery: 9.1 Check acid density, acid level and cell voltage t
9.2 Check the terminals for secure attachment and apply grease
t
9.3 Clean the battery connections; check for tight fitting t
9.4 Check the battery cables for damage, renew if necessary t
Lifting device:
10.1 Check performance, wear and adjustment t
10.2 Perform a visual check of rollers, sliding elements, and stops
t
10.3 Check the fork tines and fork carrier for wear and damage t
Lubrication: 11.1 Grease the vehicle in accordance with the lubrication
schedule
t
General measure- ments:
12.1 Check the electrical system for a grounding fault t
12.2 Check the driving speed and braking distance t
12.3 Check the lifting and lowering speed t
12.4 Check safety and shutdown devices t
Demon- stration:
13.1 Perform a trial run under a nominal load t
13.2 Upon completion of servicing operations, demonstrate the vehicle to the person responsible
t
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5 Lubrication schedule
g Slide surfaces 1) Compound for cold store usage 1:1
s Grease nipple
Filler plug for hydraulic oil 2) 1.25 l - 1.3 l
depending on the transmission variant (level must always reach the lower edge of the filler neck)
b Filler plug for transmission oil a Drain plug for transmission oil
Cold store operation
Es F
A
0,7l
A+C
1)
b
B B+C
1)
G
C
a
E F
E F sg
Es F
1,25l - 1,3l
2)
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F 7
5.1 Consumption-type materials
Handling consumption-type materials: Consumption-type materials must always
be handled properly. Manufacturer's instructions are to be observed.
Z
Improper handling is injurious to health, life, and environment. Consumption-type ma- terials must be stored in adequate containers. They might be inflammable and, there- fore, must not come into contact with hot components or open fire.
When filling in consumption-type materials, use clean containers only. It is prohibited to mix consumption type materials of different grades or qualities, except if mixing is expressively prescribed in these operating instructions.
Avoid spilling. Spilt liquid must be removed immediately using a suitable binding agent, and the mixture of consumption-type material and binding agent is to be dis- posed of according to the regulations.
Grease data
Code Order-no. Supply qty. Designation Used for:
A 50 449 669 5.0 l H-LP 46, DIN 51524 Hydraulic system B 50 380 904 5.0 l Fuchs Titan Cytrac
HSY 75W-90
Transmission
C 29 200 810 5.0 l H-LP 10, DIN 51524 Hydraulic system D 29 200 150 1,0 l Brake fluid Brake system E 29 201 430 1.0 kg Grease, DIN 51825 Lubrication
F 29 200 100 1.0 kg Grease, TTF52 Lubrication
G 29 201 280 0.51 kg Chain spray Chains
Code Saponification Dropping
point °C
Worked penetr. at
25°C
NLG1
class
Operating tem-
perature °C E Lithium 185 265-295 2 -35/+120 F -- -- 310-340 1 -52/+100
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6 Description of the servicing and maintenance operations
6.1 Preparing the truck for the performance of the servicing and maintenance op- erations
All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations. The following preparatory operations must be performed:
– Park the truck and render it safe
(refer to chapter E).
Z
For opening the battery hood, refer to chapter D.
– Disconnect the battery plug (2) so that
the truck cannot be started by unau- thorised persons.
– When work is to be carried out under
the jacked up truck, immobilise the truck in such a way that it cannot sink in, tip over or slip.
F
When lifting the truck, also refer to the in- structions contained in chapter “Trans- port and commissioning” (see chapter C).
6.2 Opening the front hood
Refer to chapter D.
6.3 Opening the front hood
Trucks with hinged standing platform:
– Swing down the standing platform (5).
General:
– Release the cover lock (3) using a
size 8 Allen key.
– Lift the hood (4) and deposit it next to
the truck.
Refit the cover (4) upon completion of the work.
21 21
3
4
3
5
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6.4 Checking the mounting and the attachment of the drive wheel
– Prepare the truck for the performance
of servicing and maintenance opera-
tions (refer to section 6.1). – Open the front hood (refer to section
6.2).
– Separate the control lead connections
to the standing platform (6). – Unscrew the standing platform attach-
ment screws (7) and remove the
standing platform (this step also ap-
plies to the fixed driver standing plat-
form). – Raise the truck so that the driven
wheel (8) can rotate freely. – Turn the driven wheel by hand and
check that it runs noiselessly. – Lower the truck to the ground again. – Swivel the control shaft fully to the left. – Using a torque wrench, tighten the
wheel screws (9) crosswise.
Z
Tightening torque
– Step 1 - MA = 10 Nm – Step 2 - MA = 105 Nm – Mount the standing platform (4) and secure it in place by means of the attachment
screws. – Reconnect the control lead connections to the standing platform.
6.5 Checking the hydraulic oil level
– Prepare the truck for the performance
of servicing and maintenance opera-
tions (refer to section 6.1). – Open the front hood (refer to
section 6.3). – Check the hydraulic oil level at the hy-
draulic oil reservoir (11).
Z
The hydraulic oil reservoir is provided with markings (10). With the fork in the lowered position, the oil level must be between the markings “max.” and “min.”.
If necessary, top up to the “max.” mark- ing using hydraulic oil of the prescribed specification (refer to the hydraulic oil specification, section 5).
JUN
G
HE
INR
ICH
JUNGH
EINR
ICH
JUNGHEINRICH
7 7
6
8 / 9
min
max
11
10
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6.6 Checking the electric fuses
– Prepare the truck for the performance of servicing and maintenance operations (re-
fer to section 6.1). – Open the front hood (refer to section 6.3). – Refer to the table and check all fuses for correct rating. Replace if required.
Item Designation Protection of: Value
10 3F9 Steering motor (o)30 A 11 1F10 Field - driving 40 A 12 2F1 Pump motor 150 A 13 1F1 Drive motor 150 A 14 F1 General control fuse 10 A 15 6F2 Battery discharge monitor / operating hour meter 10 A 16 -- Steering control system (o)--
16
14
15
11
10
1312
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6.7 Recommissioning the truck
Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed:
– Check the horn for proper functioning. – Check the master switch for correct functioning. – Check the brake for correct functioning. – Lubricate truck according to lubrication schedule.
7 Decommissioning the fork-lift truck
If the fork-lift truck is to be decommissioned for more than two months, it must be parked in a frost-free and dry location and all measures to be taken before, during and following decommissioning must be performed as detailed below.
M
During decommissioning, the fork-lift truck must be jacked up, ensuring that the wheels are clear of the ground. Only this measure will ensure that wheels and wheel bearings do not suffer damage.
If the fork-lift truck is to be decommissioned for more than 6 months, additional meas- ures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork-lift truck. – Check the brakes for correct function. – Check the hydraulic oil level and top up if required (refer to chapter F). – Apply a thin film of oil or grease to all parts not protected by a paint coating. – Grease the fork-lift truck as detailed in the lubrication chart (refer to chapter F). – Recharge the battery (refer to chapter D). – Disconnect and clean the battery. Apply pole grease to the battery poles.
Z
In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
M
Battery-operated fork-lift trucks: Regular recharging of the battery is very important; otherwise, exhaustive depletion of the battery caused by self-discharging would occur. Owing to sulfatisation, this will result in the destruction of the battery.
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7.3 Recommissioning the truck
– Thoroughly clean the fork-lift truck. – Lubricate the fork-lift truck according to the lubrication chart (refer to chapter F). – Clean the battery. Grease the pole screws using pole grease and reconnect the
battery. – Recharge the battery (refer to chapter D). – Check if the gear oil contains condensed water and change if required. – Check if the hydraulic oil contains condensed water and change if required. – Start up the fork-lift truck (refer to chapter E).
Z
Battery-operated fork-lift trucks: If switching troubles are experienced in the electric system, spray the exposed con- tacts with contact spray and remove any oxide layer on the contacts of the operating controls by repeated operation.
F
Perform several brake tests immediately after recommissioning the truck.
8 Safety checks to be performed at regular intervals and following any untoward
incidents (D: Accident prevention check according to BGV D27)
At least once yearly, or after any untoward incident, the fork-lift truck has to be chek- ked by a qualified inspector. The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects, uninfluenced by any company or economic circumstances. The inspector must be adequately informed and experi- enced to be able to assess the condition of the fork-lift truck and the effectiveness of the safety installations based on the technical rules and principles governing the in- spection of fork-lift trucks.
The inspection must comprise a comprehensive check of the technical condition of the fork-lift truck with regard to accident prevention aspects. Apart from this, the fork- lift truck must be thoroughly inspected for damage possibly caused by incorrect use of the fork-lift truck. The inspection results must be recorded in an inspection report which must be kept available for a period spanning at least the next two inspection intervals.
The user has to ensure that all defects are eliminated without delay.
Z
The manufacturer has set up a special safety service with specially qualified staff. As visual proof that the fork-lift truck has passed the safety inspection, a plaque is affixed to it. This plaque indicates in which month of which year the next test will be due.
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Instructions for use
Jungheinrich traction battery
Table of contents
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB.......................................... 2-6
Type plate Jungheinrich traction battery............................................ 7
Instruction for use
Aquamatic/BFS III water refilling system ......................................................8-12
2 Jungheinrich traction battery
Maintenance free traction batteries with positive tubular plates type EPzV and EPzV-BS
............................................................................................13-17
Type plate Jungheinrich traction battery............................................ 17
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2
1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte* Type EPzS: 1,29 kg/l Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C
6. Nominal electrolyte level: up to electrolyte level mark „max.“
* Will be reached within the first 10 cycles.
•Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only!
•Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN 50110-1!
•No smoking!
•Do not expose batteries to naked flames, glowing embers or sparks, as it may cause the battery to explode!
•Acid splashes in the eyes or on the skin must be washed with water. In case of accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water.
•Risk of explosion and fire, avoid short circuits!
•Electrolyte is highly corrosive!
•Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear in accordance with VDI 3616.
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other me- tal objects on the battery!
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Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors are:
The level of the electrolyte must be checked. If it is below the antisurge baffle or the top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap- plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit condition.
To achieve the optimum life for the battery, operating discharges of more than 80% of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di- scharge. Discharged batteries must be recharged immediately and must not be left discharged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts, unacceptable gassing and the escape of electrolyte from the cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be excee- ded. If the charger was not purchased together with the battery it is best to have its suitability checked by the manufacturers service department. When charging, proper provision must be made for venting of the charging gases.
steel
M 10 23 ± 1 Nm
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4
Battery container lids and the covers of battery compartments must be opened or re- moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor- rect. (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the electrolyte rises by about 10°C, so charging should only begin if the electrolyte temperature is below 45°C. The electrolyte temperature of batteries should be at least +10°C before charging otherwise a full charge will not be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage have remained constant for two hours. Special instructions for the operation of batte- ries in hazardous areas. This concerns batteries which are used in accordance with EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po- tentially explosive areas). During charging and subsequent gassing the container lids must be removed or opened so that the explosive mixture of gases loses its flamma- bility due to adequate ventilation. The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its capacity. They are necessary after deep discharges, repeated incomplete recharges and charges to an IU characteristic curve. Equalising charges are carried out follo- wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca- pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem- peratures shorten the life of the battery, lower temperatures reduce the capacity avai- lable. 55°C is the upper temperature limit and is not acceptable as an operating tem- perature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C and the nominal electrolyte level in the cell in fully charged condition. Higher tempe- ratures reduce the specified gravity of the electrolyte, lower temperatures increase it. The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
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3. Maintenance
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“ level mark.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the bat- tery is charged regularly with a IU characteristic curve an equalising charge must be carried out (see point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured with the charger switched on, and recorded. After charging has ended the specific gravity and the temperature of the electrolyte in all cells should be measured and re- corded.
If significant changes from earlier measurements or differences between the cells or bloc batteries are found further testing and maintenance by the service department should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of 50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea- ning must be done in accordance with the ZVEI code of practice «The Cleaning of Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man- ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call in our service department for this.
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6
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3
2. float charging at a charging voltage of 2.23 V x the number of cells. The storage time should be taken into account when considering the life of the battery.
6. Malfunctions
If malfunctions are found on the battery or the charger our service department should be called in without delay. The measurements taken in point 3.3 will facilitate fault fin- ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
We reserve the right make technical modification.
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7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin/material 3 Battery type 10 Nominal battery voltage 4 Battery number 11 Nominal battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5 11 13
1
14
4
10 12
7
8
9
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8
Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
These are cells with the positive plate 60Ah. The type designation of a cell is e.g. 2 EPzS 120.
Non-adherence to the operating instructions, repairs carried out with non-original spare parts, unauthorised interference, and the use of additives for the electrolytes (alleged improvement agents) will invalidate any claim for warranty.
When using batteries which comply with I and II, it is important to follow the in- structions on maintaining the respective protection class during operation (see asso- ciated certification).
Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (yellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm 2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm – 2/110 – 12/ 660 50,5 mm 51,0 mm – 2/130 – 12/ 780 50,5 mm 51,0 mm – 2/150 – 12/ 900 50,5 mm 51,0 mm – 2/172 – 12/1032 50,5 mm 51,0 mm – 2/200 – 12/1200 56,0 mm 56,0 mm – 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm 2/210 – 10/1050 – 61,0 mm 61,0 mm 2/230 – 10/1150 – 61,0 mm 61,0 mm 2/250 – 10/1250 – 61,0 mm 61,0 mm 2/280 – 10/1400 – 72,0 mm 66,0 mm 2/310 – 10/1550 – 72,0 mm 66,0 mm
stroke
length
stroke
length
Aquamatic plug with
diagnostics hole
Aquamatic plug BFS III with
diagnostics hole
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Diagrammatic view
Equipment for the water refilling system
1. Water tank
2. Level switch
3. Discharge point with ball valve
4. Discharge point with sole- noid valve
5. Charger
6. Sealing coupler
7. Closing nipple
8. Ion exchange cartridge with conductance meter and solenoid valve
9. Connection for untreated water
10. Charging lead
1. Design
The Aquamatic/BFS battery water refilling systems are used for automatically adjus- ting the nominal electrolyte level. Venting holes are provided for letting off the gases which arise during charging. In addition to the optical level indicator, the plug systems also have a diagnostics hole for measuring the temperature and the electrolyte den- sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua- matic/BFS filling systems. The water can be refilled by means of a central sealing coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
The Aquamatic/BFS battery water refilling system is used in traction batteries for forklift trucks. The water refilling system is provided with a central water connection for the water supply. Soft PVC hose is used for this connection and for the hose con- nections for the individual plugs. The hose ends are put onto the hose connection sleeves located on the T or < pieces.
3. Function
The quantity of water required in the refilling process is controlled by the valve located in the plug in combination with the float and the float rods. In the Aquamatic System the existing water pressure at the valve turns off the water supply and ensures that the valve closes securely. When the maximum filling level is reached in the BFS sys- tem, the float and the float rods through a lever system close the valve with five times the buoyant force and consequently interrupt the water supply reliably.
at least 3 m
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4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair the system's functional reliability. This wide pressure range permits three types of fil- ling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For the Aquamatic System the installation height is 2 m to 6 m and for the BFS system the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary filling pressure. No difference in height is permitted between the standing level of the ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which the battery is used, the ambient temperatures and the type of filling and/or the filling pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa- ter feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For safety reasons it is recommendable to insert a filter element (optional) with a max. passage opening of 100 to 300 µm into the battery's main supply pipe.
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8. Battery hose connections
Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made.
9. Operating temperature
The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a tempe- rature range of > 0° C to a maximum of 55° C.
CAUTION: Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may freeze).
9.1 Diagnostics hole
To be able to measure the acid density and temperature easily, the water refilling sys- tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs).
9.2 Float
Different floats are used depending on the cell design and type.
9.3 Cleaning
The plug systems may only be cleaned with water. No parts of the plugs may come in contact with soap or fabrics which contain solvents.
10. Accessories
10.1 Flow indicator
To monitor the filling process, a flow indicator can be inserted into the water feed pipe on the battery side. During the filling process, the paddlewheel is turned by the flowing water. When the filling process ends, the wheel stops and this indicates the end of the filling process. (ident no.: 50219542).
10.2 Plug lifter
Only the appertaining special-purpose tool may be used to disassemble the plug sys- tems (plug lifter). The greatest of care must be employed when prising out the plug to prevent any damage to the plug systems.
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10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres- sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- ry's main supply pipe for supplying battery water. This filter element has a maximum passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen- tral supply pipe. This is connected to the water supply system at the battery charging station by means of a sealing coupler system. On the battery side a closing nipple (ident no.: 50219538) is mounted and the customer must place a sealing coupler construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
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2 Jungheinrich traction batterie
Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS
Rating Data
1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 Volt x No of cells
3. Discharge current: C5/5h
4. Rated temperature: 30° C
EPzV batteries are valve-regulated batteries with an immobilised electrolyte and whe- re a water refilling isn’t permitted during the whole battery life. Instead of a vent plug there are valves used, who will be destroyed when they are opened.
When operating valve-regulated lead-acid batteries the same safety requirements as for vented cells apply to protect against hazards from electric current, from explosion of electrolytic gas and in case of the cell container is damaged, from the corrosive electrolyte.
• Pay attention to the operation instruction and fix them close to the battery!
• Work on batteries to be carried out by skilled personnel only!
• Use protective glasses and clothes when working on batteries!
• Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!
• No smoking!
• Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode!
• Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
• Clothing contaminated by acid should be washed in water.
• Risk of explosion and fire, avoid short circuits!
• Electrolyte is highly corrosive!
• In the normal operation of this batteries a contact with acid isn´t possible. If the
cell containers are damaged, the immobilised electrolyte (gelled sulphuric acid) is corrosive like the liquid electrolyte.
• Batteries and cells are heavy!
• Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
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Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate).
1. Commissioning
The battery should be inspected to ensure it is in perfect physical condition.
The battery end cables must have a good contact to terminals, check that the polarity is correct.
Otherwise battery, vehicle or charger could be destroyed.
The battery has to be charged according to item 2.2
The specified torque loading for the pole screws of the end cables and connectors are:
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap- plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Ventilation openings must not be sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit condition.
To achieve the optimum life for the battery, operating discharges of more than 60% of the rated capacity should be avoided (deep discharge).
They reduce the battery life considerable. To measure the state of discharge use only the battery manufacturer recommended discharge indicators.
Discharged batteries must be recharged immediately and must not be left dischar- ged.
This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. Charging procedures according to DIN 41773 and DIN 41774 must only be applied in the manufacturer approved modifica- tions. Therefore only battery manufacturer approved chargers must be used. Only connect the battery assigned to a charger, suitable for the size of battery, in order to avoid overloading of the electric cables and contacts and unacceptable gassing of the cells. EPzV batteries have a low gas emission.
When charging, proper provision must be made for venting of the charging gases. Battery container lids and the covers of battery compartments must be opened or re- moved.
steel
M 10 23 ± 1 Nm
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With the charger switched off connect up the battery, ensuring that the polarity is cor- rect (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35° C. The battery temperature should be at least +15°C before charging otherwise a full charge will not be achieved. Are the tem- peratures a longer time higher than +40° C or lower than +15° C, so the chargers need a temperatures regulated voltage.
The correction factor is, in accordance with DIN EN 50272-1, -0,005 V/c and Kelvin.
Special instructions for the operation of batteries in hazardous areas.
This concerns batteries which are used in accordance with EN 50 014, DIN VDE 0170 / 0171 Ex I (in areas with a firedamp hazard) or Ex II (in potentially explosive areas). The attention pictograms has to be respected.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its capacity. Equalising charges are carried out following normal charging.
They are necessary after deep discharges and repeated incomplete recharges. For the equalising charges has to be used only the battery manufacturer prescribed char- gers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher tempera- tures shorten the life of the battery, lower temperatures reduce the available capacity. 45° C is the upper temperature limit and is not acceptable as an operating tempera- ture.
2.5 Electrolyte
The electrolyte is immobilised in a gel. The density of the electrolyte can not be measured.
3. Maintenance
Don’t refill water!
3.1 Daily
Charge the battery immediately after every discharge.
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3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage.
3.3 Quarterly
After the end of the charge and a rest time of 5 h following should be measured and recorded:
• the voltages of the battery
• the voltages of every cells
If significant changes from earlier measurements or differences between the cells or bloc batteries are found, further testing and maintenance by the service department should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance with DIN 43539-1.
The insulation resistance of the battery thus determined must not be below a value of 50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea- ning must be done in accordance with the ZVEI code of practice «The Cleaning of Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man- ner.
Damage to the insulation of the tray should be repaired after cleaning, to ensure that the insulation value complies with DIN EN 50272-3 and to prevent tray corrosion. If it is necessary to remove cells it is best to call our service department for this.
5. Storage
If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room.
To ensure the battery is always ready for use a choice of charging methods can be made:
1.a quarterly full charging like charge as in point 2.2. If any consumer is connected
with, e.g. measure or controlling systems, it can be, that this charging is necessary every 14 days.
2.float charging at a charging voltage of 2.25 V x the number of cells.
The storage time should be taken into account when considering the life of the batte- ry.
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6. Malfunctions
If malfunctions are found on the battery or the charger our service department should be called without delay. The measurements taken in point 3.3 will facilitate fault fin- ding and their elimination.
A service contract with us will make it easier to detect and correct faults in good time.
Back to the manufacturer!
Batteries with this sign must be recycled.
Batteries which are not returned for the recycling process must be disposed of as hazardous waste!
We reserve the right make technical modification.
7.Type plate, Jungheinrich traction battery
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
Item Designation Item Designation
1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin/material 3 Battery type 10 Nominal battery voltage 4 Battery number 11 Nominal battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer's logo 14 Safety instructions and warnings
Typ
1
Type
Nennspannung
5
Nominal Voltage
Hersteller
9
Manufacturer
Kapazität
6
Capacity
Zellenzahl
7
Number of Cells
Batteriegewicht min/max
8
Battery mass min/max
Serien-Nr.
3
Serial-Nr.
Lieferanten Nr.
4
Supplier No.
Baujahr
2
Year of manufacture
Jungheinrich AG, D-22047 Hamburg, Germany
5
Pb Pb
2/3 6
5 11 13
1
14
4
10 12
7
8
9
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