EFG 213-320

EFG 213-320
Operating Instructions
51099986
07.11
06.08-
G
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or his authorized representative in the Community
Type
Option
Serial No.
Year of construction
EFG 213
EFG 215
EFG 216k
EFG 216
EFG 218k
EFG 218
EFG 220
EFG 316k
EFG316
EFG318k
EFG 318
EFG 320
Additional information
Authorised signatory
Date
G EU Declaration of Conformity
09.09 EN
The signatories hereby certify that the specified powered industrial truck conforms to
the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatories are individually empowered in each
case to compile the technical documentation.
3
4
09.09 EN
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
M
Z
Used before safety instructions which must be observed to avoid danger to
personnel.
Used before notices which must be observed to avoid material damage.
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
0108.GB
www.jungheinrich.com
0108.GB
Table of contents
Correct Use and Application
B
Truck Description
1
2
2.1
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
4
4.1
4.2
4.3
4.4
Application ........................................................................................... B
Assemblies and Functional Description .............................................. B
Truck ................................................................................................... B
Standard Version Specifications ......................................................... B
EFG 213-220 performance data ......................................................... B
EFG 316-320 performance data ......................................................... B
EFG 213-220 dimensions ................................................................... B
EFG 316-320 dimensions ................................................................... B
EFG 213-220 weights ......................................................................... B
EFG 316-320 weights ......................................................................... B
EFG 213-220 tyres .............................................................................. B
EFG 316-320 tyres .............................................................................. B
EFG 213-320 mast versions ............................................................... B
EN norms ............................................................................................ B
Conditions of use ................................................................................ B
Identification points and data plates .................................................... B
Truck data plate .................................................................................. B
Truck load chart .................................................................................. B
Fork load diagram (basic model) ......................................................... B
Attachment load chart ......................................................................... B
C
Transport and Commissioning
1
2
3
4
5
6
7
Transport ............................................................................................. C
Lifting by crane .................................................................................... C
Securing the truck during transport ..................................................... C
Using the truck for the first time .......................................................... C
Operating the truck without its own drive system ................................ C
Moving the truck when the electric/hydraulic steering has failed ........ C
Towing the Truck ................................................................................. C
1
2
3
4
4
5
6
8
10
10
11
11
12
13
13
14
16
16
17
17
1
1
2
3
3
4
4
0608.GB
A
I1
D
Battery Maintenance, Charging & Replacement
1
2
3
3.1
3.2
3.3
3.4
4
4.1
4.2
Safety regulations for handling acid batteries ..................................... D
Battery types ....................................................................................... D
Battery removal and installation .......................................................... D
Removal and installation using a multi-adapter (o) ............................ D
Removal and installation using a worktable for crane loading (o) ...... D
Removal and installation using a fork shoe (o) .................................. D
Removal and assembly for maintenance ............................................ D
Charging the battery ............................................................................ D
Charging the battery with a stationary charger ................................... D
Charging the battery with an on-board charger ................................... D
E
Operation
1
2
2.1
2.2
2.3
2.4
2.5
3
3.1
Safety Regulations for the Operation of Forklift Trucks ...................... E
Controls and Displays ......................................................................... E
SOLOPILOT / MULTIPILOT ................................................................ E
Armrest control panel switch (o) ........................................................ E
Side pocket control panel switch (o) .................................................. E
Dashboard control panel and driver’s display ..................................... E
Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter .. E
Starting up the truck ............................................................................ E
Checks and operations to be performed before starting daily
operation ............................................................................................. E
Adjusting the driver’s seat ................................................................... E
Safety restraint belt ............................................................................. E
Mechanical safety restraint system (o) .............................................. E
Adjusting the steering column ............................................................. E
To prepare the truck for operation ....................................................... E
Industrial Truck Operation ................................................................... E
Safety regulations for truck operation ................................................. E
Travel, steering, braking ...................................................................... E
Operating the lift mechanism and attachments (SOLOPILOT t) ....... E
Operating the lift mechanism and attachments (MULTIPILOT o) ...... E
Emergency lowering ............................................................................ E
Adjusting the forks ............................................................................... E
Collecting, Lifting and Transporting Loads. ......................................... E
Parking the truck safely ....................................................................... E
Towing trailers ..................................................................................... E
Troubleshooting .................................................................................. E
Temperature control ............................................................................ E
1
2
4
5
5
6
11
12
12
12
14
15
16
16
17
17
19
22
24
26
26
27
28
29
30
30
0608.GB
3.2
3.3
3.4
3.5
3.6
4
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5
5.1
1
2
3
3
5
6
7
8
8
9
I2
Industrial Truck Maintenance
1
2
3
4
5
5.1
6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
7
7.1
7.2
7.3
8
9
Operational Safety and Environmental Protection ...............................F
Maintenance Safety Regulations .........................................................F
Servicing and Inspection ......................................................................F
Maintenance checklist ..........................................................................F
Lubrication Schedule ............................................................................F
Consumables .......................................................................................F
Maintenance Instructions .....................................................................F
Preparing the truck for maintenance and repairs .................................F
Opening the rear panel ........................................................................F
Checking the wheel attachments. ........................................................F
Rear wheel rated condition ..................................................................F
Checking the hydraulic oil level ............................................................F
Check transmission oil level .................................................................F
Draining the oil .....................................................................................F
Adding oil .............................................................................................F
Replacing the hydraulic oil filter ...........................................................F
Seat belt maintenance .........................................................................F
Checking electrical fuses .....................................................................F
Recommissioning .................................................................................F
Decommissioning the industrial truck ...................................................F
Prior to decommissioning .....................................................................F
During decommissioning ......................................................................F
Returning the truck to operation after decommissioning ......................F
Safety checks to be performed at intervals and after unusual events ..F
Final de-commissioning, disposal ........................................................F
1
1
3
4
6
7
8
8
8
8
8
9
10
10
10
10
11
12
15
15
15
15
16
16
16
0608.GB
F
I3
I4
0608.GB
Appendix
JH Traction Battery Operating Instructions
These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
M
If using a battery with closed EPzV and EPzV ironclad plates, this must first be
discussed with the manufacturer.
0506.GB
Z
1
2
0506.GB
A Correct Use and Application
Z
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be used, operated and serviced in accordance with the present instructions.
All other types of use lie beyond the scope of application and can result in damage to
personnel, the truck or property. In particular, avoid overloading the truck with loads
which are too heavy or placed on one side. The data plate attached to the truck and
the load diagram are binding with regard to the maximum load capacity. The owner
must ensure that any damaged and/or illegible load diagrams are replaced.
The industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust.
Proprietor responsibilities: For the purposes of the present operator manual the
“proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the truck is only used for the purpose it is designed
for and that any danger to life and limb of the user and third parties is avoided.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
M
Failure to comply with the operating instructions shall invalidate the warranty.
The same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which
affects or enhances the performance of the industrial truck requires the written
permission of the manufacturer. In some cases, local authority approval shall be
required.
Approval of the local authorities however does not constitute the manufacturer’s
approval.
0504.GB
Trailing and towed loads: The truck may only be used for trailing or towed loads for
which the truck has been approved.
A1
A2
0504.GB
B Truck Description
1
Application
The EFG is a three- or four-wheel electric sit-down counterbalanced truck. It is
cantilevered and the load handler mounted on the front of the truck can unload lorries
without hindrance and deposit the load on ramps or in aisles. Closed bottom pallets
can also be lifted.
Truck models and maximum capacity:
Max. capacity
1,300 kg
1500 kg
1600 kg
1600 kg
1800 kg
1800 kg
2000 kg
1600 kg
1600 kg
1800 kg
1800 kg
2000 kg
Load centre of gravity
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
500 mm
0708.GB
Type
EFG 213
EFG 215
EFG 216k
EFG 216
EFG 218k
EFG 218
EFG 220
EFG 316k
EFG 316
EFG 318k
EFG 318
EFG 320
B1
2
Assemblies and Functional Description
2
3
4
5
1
6
7
8
15
9
14
10
11
12
13
8
t Load handler
2
t Overhead guard
9
t Fork carriage
3
t Mast
10 t Drive axle
4
t Steering wheel
11 t Battery door
o Multifunction steering wheel
12 o
t SOLOPILOT
13 t Steering axle
o MULTIPILOT
14 t Trailer coupling
6
t Dashboard control panel
15 t Counterweight
7
t EMERGENCY DISCONNECT
switch
5
t = Standard equipment
B2
Item Description
t Driver's seat
On-board charger
(in battery compartment)
o = Optional equipment
0708.GB
Item Description
1
2.1
Truck
Safety mechanisms: The overhead guard (2) protects the driver from falling objects.
Pressing the EMERGENCY DISCONNECT switch rapidly disconnects all electrical
functions in hazardous situations. Travelling and lifting can only be activated when
the driver is seated. The dashboard control panel (6) displays the truck information.
Steering: The travel speed reduces as a function of the steering angle
(“CurveControl”). The steering angle is shown in the display.
Operator position: The driver’s seat (1) is a “comfort” seat, the steering column is
adjustable. There are storage facilities for paper and the driver's personal items.
The control and warning displays on the dashboard control panel (6) enable the
system to be monitored during operation, thereby ensuring a very high level of safety.
Electrical/Electronic System: The driver can choose from five travel programs,
depending on the load and the environment: from maximum performance to energy
saving. The latest threephase system using a CAN Bus allows for rapid
troubleshooting. The advanced controller is simple, safe and flexible.
Drive System and Brakes: The 2-motor front drive provides maximum traction to the
drive wheels at all times. Each motor receives the exact power it requires in
proportion to the steering angle. The wheels do not spin and energy is converted
efficiently.
The mechanical disk brake which acts as a service brake is maintenance-free.
Encapsulated, it allows the truck to be used even in hostile environments. The truck
also brakes to a halt regeneratively via the traction motors. This minimizes energy
consumption.
The parking brake is electrically actuated. It is also used for emergency braking.
A warning indicator appears when the parking brake is applied.
Brake system faults are shown on the driver’s display.
Emergency Stop Safety Feature: The emergency stop is controlled by the steering
and traction controllers. If an error is detected the truck automatically brakes to a halt.
Control displays on the driver’s display indicate the emergency stop. Every time the
truck is switched on, the system performs a self-diagnosis which only releases the
parking brake (emergency stop) if the functionality test is positive.
Hydraulic System: All functions must be performed sensitively. To ensure greater
efficiency, a hydraulic unit and a steering motor operate independently of each other.
The micro pressure filter can be replaced from the top (without spilling hydraulic oil).
0708.GB
Mast: The maximum strength steel sections are narrow, allowing for good fork
visibility in particular with the three-stage mast. The lift rails and the fork carriage run
on permanently-lubricated and hence maintenance-free angled rollers.
B3
3
Standard Version Specifications
Z
Technical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.
3.1
EFG 213-220 performance data
Description
213
Capacity
(where C = 500 mm) *)
Load centre of gravity
C
distance
Q
Travel speed
with / without load
Raise lift speed
with / without load
Lower lift speed
with / without load
Gradeability
(30 min)
with / without load
Max. gradeability
(5 min)
with / without load
Acceleration (10m)
with / without load
215
EFG
216k
218k
216
218
220
1300
1500
1600
1800
2000
kg
500
500
500
500
500
mm
16/16
16/16
16/16
16/16
16/16
km/h
0.48/0.60 0.46/0.60 0.49/0.60 0.44/0.55 0.40/0.55 m/s
0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 m/s
7.3/12.3
6.2/10.7
7.0/11.5
5.9/10.5
7.6/12.5 7.3/12.3
5.7/10.4
%
24.0/35.0
%
4.0 / 3.5
s
26.0/35.0
28.0/35.0 27.0/35.0 27.0/35.0
25.0/35.0
3.6/3.2
3.8/3.4
3.8/3.4
3.9/3.5
0708.GB
*) with vertical mast
B4
3.2
EFG 316-320 performance data
Description
Capacity
Q (where C =
500 mm) *)
C
Load centre of
gravity distance
EFG
316k
316
318k
318
320
1600
1600
1800
1800
2000
kg
500
500
500
500
500
mm
Travel speed
with / without load
17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 km/h
Raise lift speed
with / without load
0.49/0.60 0.49/0.60 0.44/0.55 0.44/0.55 0.40/0.55
m/s
Lower lift speed
with / without load
0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55
m/s
Gradeability
(30 min)
with / without load
7.3/12.3
7/11.5
6.2/10.7
5.9/10.5
5.7/10.4
%
27/35
27/35
26/35
25/35
24/35
%
3.8/3.4
3.8/3.4
3.9/3.5
3.9/3.5
4/3.5
s
Max. gradeability
(5 min rating)
with / without load
Acceleration (10m)
with / without load
0708.GB
*) with vertical mast
B5
3.3
EFG 213-220 dimensions
Z
All dimensions in mm
Description
EFG
213
215
216k
216
218k
218
220
h1 Mast height retracted
2000
2000
2000
2000
2000
h2 Free lift
h3 Lift
150
3000
150
3000
150
3000
150
3000
150
3000
h4 Mast height extended
h6 Overhead guard height
3560
2040
3560
2040
3560
2040
3587
2040
3587
2040
h7 Seat height
920
920
920
920
920
h10 Tow height
560
560
560
560
560
3037
3037
3145
3145
1887
1887
1995
1995
L1 Length including forks
2924
2924
L2 Length incl. fork shank 1)
1774
1774
b1 Overall width
e Fork width
Ground clearance
m1
with load below mast
Centre wheel base ground
m2
clearance
1060
100
1060
100
1060
100
1120
100
1120
100
80
80
80
80
80
100
100
100
100
100
3339
3339
3446
3446
3216
3216
3323
3323
1548
1548
1655
1655
Ast
Working Aisle Width
800 x 1200 longitudinal pallets
3226
3226
Ast
Working Aisle Width
1000 x 1200 traverse pallets
3104
3104
1440
1440
335
335
Wa Turning radius
x Load distance 1)
y Wheel base
1249
340
1357
1465
1465
1995
3446
3323
1655
340
1465
= + 25 mm DZ mast
0708.GB
1)
1249
340
1357
3145
B6
c
h4
Q
h3
h6
h1
h2
h 10
s
m1
x
y
h7
m2
L2
l
L1
a
2
a
2
l6
e
b 12
b
Wa
R
0708.GB
A st
B7
3.4
EFG 316-320 dimensions
Z
All dimensions in mm
Description
EFG
h1 Mast height retracted
316k
2000
316
2000
318k
2000
318
2000
320
2000
h2 Free lift
h3 Lift
150
3000
150
3000
150
3000
150
3000
150
3000
h4 Mast height extended
h6 Overhead guard height
3560
2040
33560
2040
3587
2040
3587
2040
3587
2040
h7 Seat height
920
920
920
920
920
h10 Tow height
410/
580
410/
580
410/
580
410/
580
410/
580
L1 Length including forks
3140
3248
3140
3248
3248
L2 Length including fork shank
b1 Overall width
1990
1060
2098
1060
1990
1120
2098
1120
2098
1120
e
100
100
100
100
100
80
80
80
80
80
100
100
100
100
100
3599
3725
3599
3701
3701
3403
3526
3403
3526
3526
1859
340
1400
1985
340
1508
1859
340
1400
1985
340
1508
1985
340
1508
Fork width
Ground clearance
m1
with load below mast
Centre wheel base ground
m2
clearance
Working Aisle Width
Ast
800 x 1200 longitudinal pallets
Working Aisle Width
Ast
1000 x 1200 traverse pallets
Wa Turning radius
x Load distance 1)
y Wheel base
= + 25 mm DZ mast
0708.GB
1)
B8
c
h4
Q
h3
h6
h1
h2
h 10
s
m1
x
y
h7
m2
L2
l
L1
a
2
a
2
l6
e
b 13
b 12
b
R
Wa
0708.GB
A st
B9
3.5
EFG 213-220 weights
Z
All dimensions in kg
Description
Truck weight
(including battery)
Front axle load
(without lifting load)
Front axle load
(with lifting load)
Rear axle load
(without lifting load)
Rear axle load
(with lifting load)
3.6
EFG 316-320 weights
Z
All dimensions in kg
213
215
2733
2978
1326
1310
3545
3870
1407
1668
488
608
Description
EFG
216k
216
218k
218
3000
3057
1411
1496
4052
4060
1589
1561
548
597
3256
3207
1409
1520
4380
4405
1846
1686
675
602
220
3382
1501
4706
1881
676
EFG
316k
316
318k
318
320
3035
3001
3175
3141
3306
Front axle load
(without lifting load)
1380
1493
1385
1499
1489
Front axle load
(with lifting load)
4004
4043
4336
4367
4676
Rear axle load
(without lifting load)
1655
1508
1790
1642
1817
Rear axle load
(with lifting load)
631
558
638
574
630
0708.GB
Truck weight
(including battery)
B 10
3.7
EFG 213-220 tyres
Description
EFG 213-216
SE
18 x 7 - 8, 16 PR
Rubber
Tyre size, front
Pneumatic
EFG 218
180/70 - 8
Diagonal,
16 PR; 7 bar
not available
140/55 - 9
Rubber
Pneumatic
200/50 - 10
18 x 7 x 12 1/8“
SE
Tyre size, rear
EFG 220
15 x 5 x 11 1/4”
15 x 4.5 - 8
Diagonal,
12 PR; 7 bar
not available
Z
Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries please
contact your Jungheinrich customer adviser.
3.8
EFG 316-320 tyres
Description
EFG 316
SE
Rubber
Tyre size, front
Pneumatic
200/50 - 10
18 x 7 x 12 1/8”
18 x 8 x 12 1/8”
180/70 - 8
Diagonal,
16 PR; 7 bar
not available
16 x 6 - 8
Rubber
Pneumatic
16 x 5 x 10 1/2”
150/75 - 8
Diagonal,
16 PR; 7 bar
not available
Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries please
contact your Jungheinrich customer adviser.
0708.GB
Z
EFG 320
18 x 7 - 8, 16 PR
SE
Tyre size, rear
EFG 318
B 11
3.9
EFG 213-320 mast versions
Z
All dimensions in mm
VDI 3596
Lift
Free lift
Description
h3
h2
EFG 213/ EFG 218k/
215/216k/ 218/220/
216/316/ 318/318k/
316k
320
2300
150
1650
2850
2885
3000
150
2000
3550
3585
3100
150
2050
3650
3685
3300
150
2150
3850
3885
3600
150
2300
4150
4185
4000
150
2500
4550
4585
4500
150
2800
5050
5085
5000
150
3050
5550
5585
5500
150
3400
6050
6085
ZT
ZZ
Height extended
h4
EFG 213/ EFG 218k/
215/216k/ 218/220/
216/316/ 318/318k/
316k
320
2300
1055
990
1605
2850
2915
3000
1405
1340
1955
3550
3615
3100
1455
1390
2005
3650
3715
3300
1555
1490
2105
3850
3915
3600
1705
1640
2255
4150
4215
4000
1905
1840
2455
4550
4615
4350
1405
1340
1955
4900
4965
4500
1455
1390
2005
5050
5115
4800
1555
1490
2105
5350
5415
5000
1630
1565
2180
5550
5615
5500
1805
1740
2355
6050
6115
6000
2005
1940
2555
6550
6615
6500
2255
2190
2805
7050
7115
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DZ
Height
retracted
h1
B 12
3.10
EN norms
EFG 213-220
noise emission level:
66 dB(A)
EFG 316-320
noise emission level:
67 dB(A)
in accordance with EN 12053 as harmonised with
ISO 4871.
Z
The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the driver’s ear.
EFG 213-220 vibration:
0.53 m/s2
EFG 316-320 vibration:
0.51 m/s2
In accordance with EN 13059.
Z
The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over bumps at constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with
tolerance levels for electromagnetic emissions and
resistance as well as static electricity discharge testing in
accordance with EN 12895 including the normative
procedures contained therein.
Z
No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.
3.11
Conditions of use
Ambient temperature
- operating at -20 °C to 40 °C
Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.
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Z
B 13
4
F
Identification points and data plates
Warnings and notices such as load charts, strap points and data plates must be
legible at all times. Replace if necessary.
18
19
17
16
XXX
20
21
22
29
23
(mm)
Q (kg)
D (mm)
24
18
27
25
26
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28
B 14
Item
Description
Do not travel with raised load or mast forward tilt with raised load
17
Wear seatbelt
18
Strap points
19
Tipover caution, no passengers
20
Lift limit
21
Do not step onto or beneath the load, risk of trapping
22
Read the operating instructions
23
Capacity
24
Risk of trapping, in chassis behind the battery door
25
Data plate
26
Jack contact points
27
Serial number, on chassis behind the battery door
28
Add hydraulic oil
29
Test sticker (o)
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16
B 15
4.1
Truck data plate
30
41
31
40
32
39
33
38
34
37
36
35
Item
30
31
32
33
34
35
Description
Type
Serial no.
Rated capacity (kg)
Battery: Voltage (V)
Net weight w.o. battery (kg)
Manufacturer’s logo
Item
36
37
38
39
40
41
Description
Manufacturer
Min./max. battery weight (kg)
Output (kW)
Load centre of gravity (mm)
Year of manufacture
Option
Z
For queries regarding the truck or ordering spare parts always quote the truck serial
number (31).
4.2
Truck load chart
The capacity plate (23) gives the capacity (Q) of the truck in kg for a vertical mast.
The maximum capacity is shown as a table with a given load centre of gravity D
(in mm) and the required lift height H (in mm).
Example of how to calculate the maximum capacity:
With a load centre of gravity D of 600 mm and a maximum lift height H of 3600 mm.
the max. capacity Q is 1105 kg.
Example:
23
850
1105
1250
850
1105
1250
600
850
850
500
600
700
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4250
3600
2900
B 16
The arrow shape markings (42 and 43)
on the inner and outer masts show the
driver when the prescribed lift limits have
been reached.
4.3
42
43
Fork load diagram (basic model)
The fork load diagram give the truck’s capacity Q in kg. The maximum capacity for
the various load centres of gravity (D in mm) is shown in chart form.
4.4
Attachment load chart
The attachment load chart gives the truck’s capacity Q in combination with the
respective attachment in kg. The serial number specified in the load chart must match
the data plate of the attachment, as the capacity for each truck is specifically indicated
by the manufacturer. It is shown in the same way as the truck’s capacity and can be
determined accordingly.
For loads with a centre of gravity above 500 mm upward, the capacities are reduced
by the difference of the altered centre of gravity.
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Z
B 17
B 18
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C Transport and Commissioning
1
Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions:
– Vertically, with the mast assembled (for low heights)
– Vertically, with the mast dismantled (for large heights), all hydraulic lines between
the basic truck and the mast separated.
Safety Instructions for Assembly and Commissioning
F
On site assembly of the truck, commissioning and driver instruction may only be
carried out by personnel trained and authorised by the manufacturer
The hydraulic lines may only be connected to the basic truck / mast interface and the
truck commissioned when the mast has been properly assembled.
2
Lifting by crane
M
Only use lifting gear with sufficient
capacity
(transport weight = net. weight + battery
weight, see truck data plate).
– Park the truck safely
(see Chapter E).
– Attach the crane slings to the top
cross member of the mast (1) and the
trailer coupling (2).
1
2
Always attach the crane belts or chains
to the eyes of the upper cross member
(mast) and the trailer hitch.
The mast must be tilted back fully.
The crane belt or the chain on the mast
must be at least 2 m long.
M
Lifting slings should be fastened to the harness in such a way that they do not come
into contact with any attachments or the overhead guard when it is being raised.
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M
C1
3
Securing the truck during transport
F
The truck must be securely fastened when transported on a lorry or a trailer.
The lorry / trailer must have fastening rings and a wooden floor.
– To fasten the truck attach the tensioning belt (3) to the upper cross member of the
mast (1) or over the mudguard (5) and attach it to the trailer hitch (2).
– Tighten the tensioning belt (3) with the tensioner (4).
M
Loading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703. In each case
correct measurements must be made and appropriate safety measures adopted.
Attaching without a mast
Attaching with a mast
1
3
3
4
2
2
5
4
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The following illustration shows the approximate centre of gravity.
C2
4
F
M
Using the truck for the first time
Commissioning and driver instruction must be performed by trained personnel.
If several trucks have been delivered, make sure that always the serial numbers of
the load handlers, masts and basic trucks match each other.
Only operate the truck with battery current. Rectified AC current will damage the
electronic components. The battery leads (tow cable) must be less than 6m long.
To prepare the truck for operation after delivery or transport the following tasks must
be carried out:
– Fit and charge the battery if required,
see “Battery removal and installation” and “Charging the battery” in Chapter D.
– Start up the truck as indicated.
see “Starting up the truck” in chapter E.
5
Operating the truck without its own drive system
To move the truck without power supply, the brake must be released as follows
F
Before the driver leaves the truck with
the brake released, the truck must be
prevented from accidentally rolling away
by using suitable means.
– Place the auxiliary tool (6) on the lever
(8) with the notches (7) (Jungheinrich
symbol can be read from the left hand
side of the truck).
– Pull the lever (6) forward (forks direction) or backward (towards the operator position) and lock it in position. The
lever should engage. The drive
wheels are no longer blocked / braked
by the brake.
The auxiliary tool (6) to apply the
lever (8) is located in the document
pocket in the backrest of the seat.
M
Before starting the truck again, the
lever (6) must be restored to the centre
“travel” position. The truck can only
operate in the travel position.
6
8
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Z
7
C3
6
Moving the truck when the electric/hydraulic steering has failed
M
The truck cannot be steered if the steering hydraulic system or the truck electronics
are damaged.
To steer the truck without power, apply the steering as follows.
– Turn the EMERGENCY DISCONNECT
switch and key switch off.
– Secure the truck to prevent it from
rolling away
– Undo the sensor connector above the
motor shaft (pull the red unlocking
lever) and place the auxiliary tool (6) on
the hex. socket screw and turn the
drive to the required steering position.
7
6
Towing the Truck
To tow the truck, proceed as follows:
0708.GB
– Attach the tow bar / rope to the trailer coupling of the recovery vehicle and the truck
to be recovered.
– Disconnect the battery.
– Release the parking brake.
– Steer the truck as indicated in “Moving the truck when the electric/hydraulic
steering has failed”.
C4
D Battery
Maintenance,
Replacement
1
Charging
&
Safety regulations for handling acid batteries
Park the truck securely before carrying out any work on the batteries (see Chapter E).
Maintenance personnel: Batteries may only be charged, serviced or replaced by
trained personnel. The present operator manual and the manufacturer’s instructions
concerning batteries and charging stations must be observed when carrying out the
work.
Fire protection: Smoking and naked flames must be avoided when working with
batteries Wherever a truck is parked for charging there shall be no inflammable
material or operating fluids capable of creating sparks within 2 metres around the
truck. The area must be well ventilated. Fire protection equipment must be provided.
Battery maintenance: The battery cell covers must be kept dry and clean. The
terminals and cable shoes must be clean, secure and have a light coating of dielectric
grease. Batteries with non insulated terminals must be covered with a non slip
insulating mat.
Battery Disposal: Batteries may only be disposed of in accordance with national
environmental protection regulations or disposal laws. The manufacturer’s disposal
instructions must be followed.
M
F
M
Batteries contain an acid solution which is poisonous and corrosive. Therefore,
always wear protective clothing and eye protection when carrying out work on
batteries. Above all avoid any contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water - where the skin or eyes are affected
call a doctor immediately. Immediately neutralise any spilled battery acid.
Only batteries with a sealed battery container may be used.
The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.
0608.GB
F
Before closing the battery door make sure that the battery lead cannot be damaged.
D1
2
Battery types
The truck will be equipped with different battery types, depending on the application.
The following table shows which combinations can be included as standard:
EFG 213
EFG 215
EFG 216k
EFG 216
EFG 218k
EFG 218
EFG 220
48 V - 4PzS 460 Ah battery
48 V - 4PzS 460 Ah battery
48 V - 5PzS - 575 Ah battery
48 V - 6PzS 690 Ah battery
48 V - 5PzS - 575 Ah battery
48 V - 6PzS 690 Ah battery
48 V - 6PzS – 690 Ah battery
EFG 316k
EFG 316
EFG 318k
EFG 318
EFG 320
48 V - 5PzS - 575 Ah battery
48 V - 6PzS 690 Ah battery
48 V - 5PzS - 575 Ah battery
48 V - 6PzS 690 Ah battery
48 V - 6PzS 690 Ah battery
The battery weights are indicated on the battery data plate.
F
When replacing/installing the battery make sure the battery is securely located in the
battery compartment of the truck.
similar to
DIN 43531
48 volt drive battery
Truck
L max.
EFG 213/215
EFG 216k/
218k/
316k/318k
EFG 216/
218/220/
316/318/320
830
830
Dimension inch (mm)
Rated weight
W max. H1 +/- 2 mm H2 +/- 2 mm (-5/+8%) in
(kg)
522
612
627
715
400 - 480 Ah
500 - 630 Ah
630
612
627
855
600 - 720 Ah
738
612
627
1025
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830
D2
3
F
Battery removal and installation
To prevent short circuits, batteries with exposed terminals or connectors must be
covered with a rubber mat. When replacing a battery with a crane, make sure the
crane has sufficient capacity (see battery weight on the battery data plate on the
container).
The battery plug and socket may only withdrawn or connected when the main switch
and the charging equipment are switched off.
Z
Park the truck securely, see “Parking the Truck Securely” in Chapter E.
3.1
Removal and installation using a multi-adapter (o)
– Open the battery door (1) as far
as the stop.
1
– Disconnect the battery.
2
Z
On trucks with a long battery lead
fit the battery connector to the
battery connector bracket (4).
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4
D3
– Push the lift truck with the multiadapter as far as the stop (5)
underneath the battery.
– Set the multi-adapter to the
straight-ahead position using the
alignment (6).
5
– Raise the lift truck until the multiadapter is up to the height
stop (7).
– Prevent the lift truck from rolling
away.
– Undo the battery lock (3).
6
3
7
– Remove the battery.
M
The battery must engage fully with
the safety catch (8).
– Lower the lift truck slightly to
move it.
– Bring the battery to the charging
station for charging.
8
Battery assembly is the reverse order.
Insert the battery in the battery compartment and at the same time undo the safety
catch (8) with your foot.
M
After inserting the battery close the battery lock and then lower the lift truck.
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Z
D4
3.2
Removal and installation using a worktable for crane loading (o)
– Open the battery door as far as the stop.
– Disconnect the battery connector.
Z
See “Removal and installation using a multi-adapter” (o)
– Push the lift truck with the
worktable as far as the stop (5)
underneath the battery.
5
– Raise the lift truck and worktable
up to the height stop (9).
– Undo the battery lock.
9
– Remove the battery.
Z
The battery must engage fully with
the safety catch (8).
– Strap the crane lifting harness to
the battery container. The hooks
must be fitted in such a way that
when the crane lifting harness is
slackened, they do not fall onto
the battery cells.
– Undo the safety catch (8) and lift
out the battery for transporting to
the charger station.
8
0608.GB
Battery assembly is the reverse order.
Z
Insert the battery in the battery compartment and at the same time undo the safety
catch (8) with your foot.
Z
After inserting the battery close the battery lock and then lower the lift truck.
D5
3.3
Removal and installation using a fork shoe (o)
– Open the battery door as far as the stop.
– Disconnect the battery connector.
– Undo the battery lock.
Z
See “Removal and installation using a multi-adapter” (o)
– Place the fork shoe onto the forks of a
second lift truck with a minimum
1000 kg capacity and secure it to the
fork carriage with a chain (10).
– Tilt the mast forward.
10
– Move the fork shoe up to the stop (11)
underneath the battery.
– Raise the fork carriage until the battery
is resting on the forks.
– Pull out the battery as far as the
stop (12) on the truck chassis.
12 11
– Raise the fork carriage.
– Tilt the mast back fully and bring the
battery to the charging station to be
charged.
13
Z
D6
Installation is the reverse order of
removal. Make sure the rollers (13) on
the battery are inserted into the guides in
the battery compartment.
14
0608.GB
– Place the battery carefully onto the
charging station (14).
3.4
Removal and assembly for maintenance
– Open the battery door as far as the stop.
– Disconnect the battery connector.
– Undo the battery lock.
Z
See “Removal and installation using a multi-adapter” (o)
– Place a standard hand pallet truck
(800 mm fork length) under the
battery.
Z
If the forks are longer they must be
inserted 950 mm underneath the
battery, measured from the fork tip. This
must be indicated on the forks before
removing the battery.
– Raise the battery with the hand pallet
truck until the battery is resting on the
forks and is not in contact with the
chassis.
– Remove the battery for maintenance.
Z
The battery is guided on rollers. Remove
the rollers as far as the stop (4).
Installation is the reverse order of
removal.
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4
D7
4
F
4.1
Charging the battery
Only connect and disconnect the battery and charger when the charger is
switched off.
To charge the battery, the truck must be dry and parked in closed and properly
ventilated rooms. The battery door must remain at least 200 mm open to ensure
adequate ventilation. Do not place any metal objects on the battery.
Before charging, check all cables and plug connections for visible signs of damage.
All safety instructions as provided by the battery supplier and battery charger supplier
must be strictly observed.
Charging the battery with a stationary charger
– Disconnect the battery connector (10) from the truck connector (9).
– Connect the battery connector (10) with the charging lead (11) of the stationary
charger and turn on the charger.
9
10
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11
D8
4.2
F
Charging the battery with an on-board charger
The on-board charger consisting of a battery charger and battery controller must not
be opened. If damaged, it must be replaced.
The charger must only be used for batteries supplied by Jungheinrich or other
approved batteries provided it has been adapted by the manufacturer's service
department. Batteries must never be swapped from truck to truck.
Mains connection
The mains lead may vary depending on the size of the on-board charger.
On-board charger with 65 Ah:
16 A; 230 V; 3 pin
On-board charger with 130 Ah: 16 A; 400 V; 5 pin
M
Only use mains leads with a maximum length of 30 m. If a cable reel is being used,
it must be fully rolled up.
Only use original manufacturer’s mains leads.
Insulation safety, acid and caustic ratings must comply with the manufacturer's mains
lead.
Charging
Open the battery door.
Connect the on-board charger to the local mains socket using the mains cable.
Charging begins automatically.
When the truck is switched on the charging status and the residual capacity are
shown on the display.
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–
–
–
–
D9
Battery charger LED displays
Green LED
Flashing
Lit
Red LED
Flashing
Meaning
Charging
Charging complete
Meaning
Error
Battery controller LED displays
White LED
Flashing
Blue LED
Lit
Meaning
Radio network activated
Meaning
Electrolyte level too low
(measured after each charge)
Yellow LED
Meaning
Flashing rolling Charging
Lit
Charge status
Red LED
Flashing
Z
Meaning
Error
For display messages see “Pictograms and Display” in chapter E.
Float charge:
The float charge starts automatically when charging is complete.
Partial charging:
The charger is designed to automatically adapt to partially charged batteries.
This keeps battery wear to a minimum.
Z
If you need to interrupt a charge, press
button (12). Remove the mains connector
only when the green LED goes out.
Charging recommences when the mains lead
is connected back to the mains socket.
0608.GB
12
D 10
E Operation
1
Safety Regulations for the Operation of Forklift Trucks
Driver authorisation: The forklift truck may only be used by suitably trained
personnel, who have demonstrated to the proprietor or his representative that they
can drive and handle loads and have been authorised to operate the truck by the
proprietor or his representative.
Driver’s rights, obligations and responsibilities: The driver must be informed of
his duties and responsibilities and be instructed in the operation of the truck and shall
be familiar with the operator manual. The driver shall be afforded all due rights.
Safety shoes must be worn for pedestrian operated trucks.
Unauthorised use of truck: The driver is responsible for the truck during the time it
is in use. The driver must prevent unauthorised persons from driving or operating the
truck. Do not carry passengers or lift other people.
Damage and faults: The supervisor must be immediately informed of any damage
or faults to the forklift truck or attachment. Trucks which are unsafe for operation
(e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the industrial truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
Hazardous area: A hazardous area is defined as the area in which a person is at risk
due to truck movement, lifting operations, the load handler (e.g. forks or attachments)
or the load itself. This also includes areas which can be reached by falling loads or
lowering operating equipment.
F
Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, a warning must be sounded with sufficient notice. If
unauthorised personnel are still within the hazardous area the truck shall be brought
to a halt immediately.
07.11.GB
Safety devices and warning signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
E1
2
Controls and Displays
Item Control / Display
Function
1
Steering wheel
t Steers the truck.
2
SOLOPILOT
t Operating the functions:
o – Forward / reverse travel direction
– Lift/lower load handler
– Mast forward / reverse tilt
– Horn switch
– Side shift left / right (o)
– Aux. hydraulics (o)
MULTIPILOT
Key switch
t Switches control current on and off. Removing
the key prevents the truck from being switched
on by unauthorised personnel.
ISM Access Module
o Powers up the truck.
4
Dashboard control
panel
t Displays the battery capacity, service hours,
errors, key warning indicators, wheel position
and travel direction.
5
Brake pedal single
pedal control
t Provides infinitely variable braking control.
3
Brake pedal twin pedal o
control
6
Accelerator pedal
t Provides infinite control of travel speed.
7
Twin pedal control
“Forward” accelerator
pedal
o Truck travels forward when actuated.
The travel speed is infinitely controlled.
8
Twin pedal control
“Reverse” accelerator
pedal
o Truck reverses when actuated.
The travel speed is infinitely controlled.
9
On-board charger
o Charges the truck.
10
EMERGENCY
DISCONNECT switch
t Switches power supply on and off.
11
Armrest / side pocket
control panel
o Options
12
Steering column stop
t Adjusts and fixes the steering column
at the required distance and height.
o = Optional equipment
07.11.GB
t = Standard equipment
E2
1
2
12
3
11
4
10
11
2
5
6
7
8
5
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9
E3
2.1
SOLOPILOT / MULTIPILOT
SOLOPILOT (t)
SOLOPILOT (o)
14
14
13
13
MULTIPILOT with ZH1-ZH3(o)
MULTIPILOT (o)
13
13
14
14
Item Control / Display
Function
13
Travel direction switch
Selects travel direction / neutral position
14
Horn
Activates the horn
t Travel direction switch
– To select forward gear, push the direction switch (13) forward.
– To select reverse gear, push the direction switch (13) backward.
o If a travel direction has been pre-selected before the truck starts, set the truck first to
neutral and then in the required direction.
Otherwise, travel will be inhibited.
t Horn
07.11.GB
– Press the horn button (14) to sound the horn.
E4
2.2
Armrest control panel switch (o)
Function
Work lights
Front windscreen wipers
– Press 1x > intermittent,
– 2x > fast,
– 3x > off
– Hold down on the button > Switch on the windscreen washing
system
Rear windscreen wiper
– Press 1x > intermittent,
– 2x > fast,
– 3x > off
– Hold down on the button > Switch on the windscreen washing
system
Sideshift centre position
Lift cutout override
2.3
Side pocket control panel switch (o)
Function
Rear window heating
Beacon
Truck lighting
Warning indicator
Parking light
07.11.GB
Lift cutout override
E5
2.4
Dashboard control panel and driver’s display
The control panel display shows the operating data, the battery charge, the service
hours and error details and information. Pictograms in the left top section of the
dashboard control panel act as warning indicators.
Pictograms
15
17 19 21 23
16 18 20 22
24
31
am
pm
100 %
30
km/h
inch lbs
m kg eff code
29
28
27
err
26 25
Item
Control / Display
Function
15
Parking brake indicator t
Parking brake active
– Truck operational, parking brake active
16
WARNING
17
Battery indicator
t
t
o
Seat switch indicator
t
18
07.11.GB
Seat belt lock indicator
o
(flashing symbol)
WARNING
– Lights up to indicate error
– Flashes when battery capacity is less
than 10%
WARNING
– Electrolyte level too low
– Battery cells faulty
– Battery temperature too high
On-board charger on radio network
Seat switch not closed
– Truck operational but driver’s seat not
occupied
– Truck operational, belt lock not closed
E6
Item
Control / Display
Function
Service interval exceeded (1000 service
t hours) or annual UVV test due (flashing
indicator).
19
Service display
20
Flashing indicator
o Function of right/left flashing indicators (o)
21
Crawl speed indicator
t Crawl speed activated
22
Toggle button
t Changes the display
23
SET button
t Confirms entries
24
Driver’s display
t Shows the operating data, see displays.
25
Program selector
t
Selects the travel program (moves up
a o level in the travel program list.)
26
Program selector
t
Selects the travel program (moves down
a level in the travel program list.)
27
Parking brake button
t
Button for applying / releasing the parking
brake
28
Control and motor
overtemperature
indicator
– Lights up when the controllers and motor
overheat.
t
– Performance continually reduces with
respect to the temperature.
29
Inching button
Travel speed max. 6 km/h (adjustable).
No function
31
No function
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30
E7
Displays
32
33
am
pm
100 %
34
km/h
inch lbs
m kg eff code
38
37
err
36
35
Item Function
32
Residual time display with on-board battery (hours : minutes)
Residual charging time (o)
33
Time display (hours : minutes)
34
Travel program display
– Displays the travel program in use
Error display:
– If an error (Err) or a warning (Inf) occurs, the error or info code is displayed.
– If several errors occur they are displayed alternately at intervals of
1.5 seconds. A warning is sounded.
Battery capacity display
– Battery discharge status
– Charge status display for on-board charger (o)
Hourmeter display
Travel direction, speed and wheel position display
– Indicates the pre-selected travel direction (forward or reverse) or the
position of the steered wheels.
– Flashing direction arrow = no travel direction selected
35
36
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37
38
E8
Driver’s display information messages
The information messages have a four-digit code. The first digits refers to the
functional assembly, the remaining three digits designate the error.
Function
group
0
1
2
3
4
5
Display
Meaning
General message
General message
Travel
Steering
Lift
Battery management
Meaning
Accelerator pedal pressed during power-up
1904
No travel direction selected when travel switch applied.
1908
Seat switch not closed
– Truck operational, but driver’s seat not occupied
1909
Accelerator pressed while parking brake applied
5915
Truck not operational but battery door open (o)
1917
Accelerator pedal and brake pedal pressed simultaneously.
1918
Truck operational but cabin door open (o)
2951
Hydraulic function applied during power-up
5990
Electrolyte level too low (o)
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1901
E9
Set time:
– Press the toggle button (22) for 3 seconds.
The display (33) via the battery shows the current time. This allows you to toggle
the display between the time and the residual time.
–
–
–
–
–
Press toggle button (22) for 8 seconds until the "Set Time" menu is displayed.
Set the hours with the “Up” (25) & “Down” (26) keys.
Confirm with the toggle button (22).
Set the minutes with the “Up” (25) & “Down” (26) keys.
Press the toggle button (22) to return to the normal operating mode.
Keep pressing the Up and Down keys to set the time and to change between 24 hour
and 12 display (SET HOUR 24 H <-> SET HOUR 12 H).
22
33
am
pm
100 %
km/h
inch lbs
m kg eff code
25
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26
err
E 10
2.5
Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter
Battery Discharge Indicator: The charge status of the battery (36) is shown on the
driver’s display. The lower section of the battery symbol is shown as being empty. It
indicates the residual capacity of the battery which cannot be used to avoid damaging
the battery.
M
The standard setting for the battery discharge indicator / discharge monitor is based
on standard batteries.
If using maintenance-free batteries, the display must be re-set. This setting must be
carried out by the service department. If this adjustment is not made the battery may
become damaged through excessive depletion.
When a battery is discharged to the permissible discharge level, the battery symbol
is displayed empty.
Battery Discharge Monitor: If the residual capacity falls below the required level,
lifting is inhibited. A message will be indicated on the driver’s display unit.
Z
Lifting is only released when the battery connected is at least 40% charged.
To complete the lifting operation, turn the key switch off and on again. You can then
continue to raise for another 30 - 40 seconds.
Residual time display: The time remaining to reach the residual capacity is
displayed.
To display the residual time (residual charge time o) the display above the battery
can be switched by holding down the toggle button (22) for three seconds.
Z
This allows you to toggle the display between the time and the residual time.
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Hourmeter: The service hours are counted when the truck is switched on and the
seat switch is closed.
E 11
3
F
3.1
Starting up the truck
Before the truck can be started, operated or a load lifted, the driver must ensure that
there is nobody within the hazardous area.
Checks and operations to be performed before
starting daily operation
– The entire truck (in particular wheels and load
handler) must be inspected for damage.
– Make sure the load chains are evenly tensioned.
38a
– Visually inspect the battery attachment and cable
connections.
38b
– Test the seat belt.
– Test the seat switch.
– Test the Drive-Control (o), the truck should travel slowly when the load is raised.
– Check the fork stop (38a) and fork retainer (38b).
3.2
Adjusting the driver’s seat
Z
To avoid risk to health and property, check and adjust the individual driver’s seat
setting before starting up the truck.
The driver’s seat must be occupied in order to adjust to the driver’s weight.
Adjusting the driver's weight:
– Move the lever (43) as far
as it will go in the arrow
direction. To adjust, move
the lever up or down and
then restore it to its home
position.
– Move the lever up and
down to set the seat to a
higher weight.
– Move the lever down and
up to set the seat to a lower
weight.
Z
39
45
44
43
40
The driver's weight is correct
41
42
if the arrow is in the middle of
the display window (44).
The min. or max. weight setting is reached when you can feel a return stroke on the
lever.
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– After adjusting the weight, move the lever back fully until it engages.
E 12
Adjusting the backrest:
F
The backrest must be securely engaged in the set position. The backrest setting must
not be changed during travel!
– Lift up the locking lever (41) and adjust the incline of the backrest.
– Release locking lever (41) to lock the backrest in position.
Adjusting the seat position:
F
Hold the locking lever (42) only in the recess, do not reach through underneath the
lever.
The driver’s seat must be securely engaged in the set position. The driver’s seat
setting must not be changed during travel!
Do not lift the locking lever with your leg or thighs!
– Pull up the locking lever (42) of the driver’s seat lock in the direction of the arrow
and push the seat forwards or backwards to the desired position.
– Engage locking lever (42) in position again.
Seat heating (o):
Apply the switch (39): 1 = seat heating ON; 0 = seat heating OFF
Lumbar vertebrae support (o):
Hand wheel (40) in position 0 = no bending in lumbar vertebrae area.
Turn hand wheel (40) to position 1 = Increased bending in upper lumbar vertebrae
area.
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Turn hand wheel (40) to position 2 = Increased bending in lower lumbar vertebrae
area.
E 13
3.3
F
Safety restraint belt
Fit the safety restraint belt each time before starting the industrial truck.
The belt protects you from serious injury!
Protect the belt from contamination (e.g. cover it when the truck is idle) and clean it
regularly. Frozen belt locks or pulleys must be thawed out and dried to prevent them
from freezing up again.
Z
F
The dry temperature of the warm air should not exceed +60°C!
Do not alter the belt setting!
This will increase the risk of malfunctioning.
– Always replace the safety restraint belt after an accident.
– Only original spare parts must be used for retrofits or repairs.
F
Damaged or non-operational belts must only be replaced by contractual dealers or
branches.
Starting the industrial truck on steep slopes
The automatic blocking system locks the belt in the retractor when the truck is
positioned on a steep slope. This prevents the belt from being pulled out of the
retractor.
M
Carefully drive the truck off the slope and then put on the belt.
Hazardous situations
F
If the truck is about to tip over, do not undo the restraint belt and try to jump out.
This will only increase the risk of injury!
Correct procedure:
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– Lean your upper body over the steering wheel.
– Grip the steering wheel with both hands and brace feet.
– Tilt your body in the opposite direction of fall.
E 14
3.4
Mechanical safety restraint system (o)
F
Test the restraint system before starting the truck.
• Never use the truck with a non-functional restraint system.
• After an accident, have the restraint system system checked by specialist
personnel from the manufacturer's service department.
• Do not alter the restraint system.
• When the driver’s seat is occupied,
maintain a 90 mm gap between the
gate (46) and the seat to ensure
safety.
46
– Push the safety gate out and lift it up.
– When the gate has been released, it
automatically drops down and locks.
Hazardous situations
F
If the truck is in danger of tipping over, do not try to jump out. This will only increase
the risk of injury.
Correct procedure
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– Lean your upper body over the steering wheel.
– Grip the steering wheel with both hands and brace feet.
– Tilt your body in the opposite direction of fall.
E 15
3.5
Adjusting the steering column
– Release the steering column lock (12) and set the steering wheel to the required
position (height and tilt).
– Now fix the steering column lock again.
3.6
To prepare the truck for operation
– Unlock the EMERGENCY DISCONNECT switch (10).
To do this:
Press the rocker in (s) and pull it up until you feel the EMERGENCY DISCONNECT
engaging.
– Insert the key in the key switch (3) and turn it clockwise as far as it will go to the “I”
position.
– Test the horn (14).
F
Z
Test the brake pedal and parking brake.
When you have pulled the EMERGENCY DISCONNECT and turned the key switch
to the right, the truck carries out a self test for approx. 3-4 seconds (tests the
controllers and motors). During this time the truck cannot move or lift. If the
accelerator or a control lever is applied during this time, an information message will
be displayed.
12
3
14
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10
E 16
4
Industrial Truck Operation
4.1
Safety regulations for truck operation
Travel routes and work areas: Only use lanes and routes specifically designated for
truck traffic. Unauthorised third parties must stay away from work areas. Loads must
only be stored in places specially designated for this purpose.
Travel conduct: The driver must adapt the travel speed to local conditions. The truck
must be driven at slow speed when negotiating bends or narrow passageways, when
passing through swing doors and at blind spots. The driver must always observe an
adequate braking distance between the forklift truck and the vehicle in front and must
be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid
U turns and overtaking at dangerous or blind spots are not permitted. Do not lean out
or reach beyond the working and operating area.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. Loads that affect visibility must be positioned at the
rear of the truck. If this is not possible, a second person must walk in front of the truck
as a lookout.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. The truck must always be driven with the load unit facing uphill.
The industrial truck must not be turned, operated at an angle or parked on inclines or
slopes. Inclines must only be negotiated at slow speed, with the driver ready to brake
at any moment.
Negotiating lifts and docks: Lifts and docks must only be used if they have sufficient
capacity, are suitable for driving on and authorised for truck traffic by the owner.
The driver must satisfy himself of the above before entering these areas. The truck
must enter lifts with the load in front and must take up a position which does not allow
it to come into contact with the walls of the lift shaft. People travelling in the lift with
the forklift truck must only enter the lift after the truck has come to a halt and must exit
the lift before the truck.
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Type of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Only carry loads that are positioned safely and carefully.
Use suitable precautions to prevent parts of the load from tipping or falling down.
E 17
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Towing trailers or the truck itself being towed are only permitted occasionally,
on secure, level routes, with a maximum deviation of +/- 1% and at a max. speed
of 5 km/h. The truck must not be permanently used with trailers.
There must be no load on the forks when the truck is being pulled.
Do not exceed the maximum trailer load specified for the forklift truck for trailers with
or without brakes. The specified trailer load only applies for the auxiliary coupling in
the counterbalance of the forklift. If a different trailer coupling is used on the truck,
the instructions of the coupling manufacturer must be observed.
After coupling and before starting the driver shall ensure that the trailer coupling
cannot become detached.
Trucks pulling a load must be operated in such a manner that the trailing vehicle is
driven safely and can be stopped at all times.
E 18
4.2
Travel, steering, braking
4.2.1 Emergency Disconnect
– Press the EMERGENCY DISCONNECT switch (10) down.
All electrical functions are deactivated.
F
The operation of the EMERGENCY DISCONNECT switch must not be affected by
any objects placed in its way.
4.2.2 Travel
Safety switch, driver’s seat
Z
F
If the driver’s seat is not occupied (seat belt (o) not closed) travel is inhibited by the
seat switch.
Do not drive the truck unless the panels and doors are closed and properly locked.
Travel routes must be free of obstacles.
Adapt the travel speed to the conditions of the travel lane, the work area and the load.
– Set the travel direction switch (13) to
neutral.
– Raise the fork carriage approx. 200
mm so that the fork tines are clear of
the ground.
– Tilt the mast fully backward.
27
13
Travelling with a single pedal t
F
Make sure that the travel area is clear.
11
– Release the parking brake (27).
– Apply the travel direction switch (13).
– Slowly apply the accelerator pedal (7)
until you reach the required travel
speed.
7
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6
E 19
Forward travel (twin pedal o)
F
Make sure that the travel area is clear.
– Release the parking brake (27)
9
– Slowly apply the accelerator pedal (8)
Z
There is no travel direction switch on
trucks with a twin pedal.
6
8
4.2.3 Steering
M
Very minimal steering effort is required for the electric steering, therefore turn the
steering wheel sensitively.
Negotiating right hand bends
– Turn the steering wheel clockwise according to the required steering radius.
Negotiating left hand bends
– Turn the steering wheel anti-clockwise according to the required steering radius.
4.2.4 Braking
F
The braking pattern depends largely on the ground conditions. The driver must take
this into consideration when handling the truck. Brake with care to prevent the load
from slipping.
If you are travelling with an attached load you must increase the braking distance.
There are four ways of braking:
–
–
–
–
Service brake
Coasting brake
Reversing brake
Parking brake
27
13
Service brake:
– Depress the brake pedal (6) until you feel
the brake pressure.
7
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6
E 20
Coasting brake:
– Take your foot off the accelerator pedal (7)
(8/9). The truck brakes regeneratively via
the traction controller.
Z
This method saves energy.
9
6
8
Reversing brake (single pedal):
– Set the travel direction button (13) to the opposite direction while travelling.
The truck brakes regeneratively via the traction controller until the truck starts to
travel in the opposite direction.
Parking brake:
– Apply the parking brake (27).
Z
You cannot travel against the parking brake; the parking brake indicator (15) will be
displayed.
15
am
pm
100 %
km/h
inch lbs
m kg eff code
err
27
The parking brake applies approx. 5 seconds (adjustable) after the truck has come to
rest.
When you stop on the ramp the truck is held electrically until the parking brake
applies.
When you set off, before the parking brake is released, a torque builds up on the drive
motor to prevent the truck from rolling back.
The parking brake will hold the truck with maximum load, on a clean ground surface,
on inclines of up to 15%.
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F
E 21
4.3
F
Operating the lift mechanism and attachments (SOLOPILOT t)
Do not lift other people with the lifting mechanism and do not allow anyone to stand
under a raised load.
The SOLOPILOT must only be operated from the driver’s seat. The driver must be
trained to handle the lift mechanism and the attachments.
Lifting
– Pull the control lever (47) in direction (H).
Z
47
S
The lift speed is determined by the
inclination of the control lever.
H
– Activate the control lever until the
desired height is reached.
Z
When the limit position is reached (there
will be a noise from the pressure relief
valve) set the control lever back to its
starting position.
Lowering
– Push the control lever (47) in direction (S).
Z
M
The lift speed is determined by the inclination of the control lever.
Avoid dropping the load abruptly, in order to protect the load and the rack surface.
Tilting the mast forward / backward
F
When tilting the mast back, keep all
parts of your body from between the
mast and the front wall.
48
V
R
– Push the control lever (48) in direction
(V) to tilt forward.
– To tilt back, pull the control lever (48)
in direction (R).
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2
E 22
Operating attachments (o)
F
Note the manufacturer’s operating instructions and the capacity of the attachment.
The control levers (49 and 50) are
used to operate auxiliary hydraulics I
and II. Auxiliary hydraulics III are
operated by control lever (50) in
conjunction with button (51). The
integrated sideshift (ISS) is operated
with control lever (49) as described
below.
49
(X5)
X3
50
X4
(X6)
X1
X2
Operating the integrated sideshift
(ISS)
Z
The references to left and right are
based on the load handler as viewed
from the operator’s position.
51
(X5/X6)
2
Sideshift left (from driver’s position):
– Push the control lever (49) in direction (X1).
Sideshift right (from driver’s position):
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– Pull the control lever (49) in direction (X2).
E 23
4.4
F
Operating the lift mechanism and attachments (MULTIPILOT o)
Do not lift other people with the lifting mechanism and do not allow anyone to stand
under a raised load.
The MULTIPILOT must only be operated
from the driver’s seat. The driver must be
instructed in how to handle the lift
mechanism and the attachments!
S
V
2
Lifting
– Pull
the
MULTIPILOT
direction (H).
Z
(2)
in
R
The lift speed is determined by the
inclination of the control lever.
– Activate the control lever until the
desired height is reached.
Z
H
When the limit position is reached (there
will be a noise from the pressure relief valve) set the control lever back to its starting
position.
Lowering
– Push the MULTIPILOT (2) in direction (S).
Z
M
The lowering speed is determined by the inclination of the control lever.
Avoid dropping the load abruptly, in order to protect the load and the rack surface.
Tilting the mast forward / backward
F
When tilting the mast back, keep all parts of your body from between the mast and
the front wall.
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– To tilt forward, push the MULTIPILOT (2) in direction (V).
– To tilt back, pull the MULTIPILOT (2) in direction (R).
E 24
Operating the integrated sideshift (ISS)
Z
The references to left and right are based on
the load handler as viewed from the
operator’s position.
53
52
2
Sideshift left (from driver’s position):
– Press the left button (52).
Sideshift right (from driver’s position):
– Press the right button (52).
54
Aux. hydraulics II
F
Note
the
manufacturer’s
operating
instructions and the capacity of the attachment.
– Pull or push the button (53) to control the attachment.
Auxiliary hydraulics III
– Using button (54) change to auxiliary hydraulics III.
– Pull or push the button (53) to control the auxiliary hydraulic function.
Controlling the speed of the lifting device
Tilting the MULTIPILOT controls the speed of the hydraulic cylinder.
When the control lever is released it automatically reverts to neutral and the lifting
device remains in the position it has reached.
Always apply the control lever sensitively, never with a sudden jerk. Release the
MULTIPILOT as soon as the lifting device reaches the limit position.
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M
E 25
4.5
Emergency lowering
F
Keep all personnel out of the hazardous area when applying emergency lowering.
If the mast does not lower due to a fault in the lift controller, apply the emergency
lowering valve (55) on the valve block below the floor board.
F
Never reach through the mast!
Do not stand underneath the load.
– Turn the EMERGENCY DISCONNECT
switch and key switch off.
– Disconnect the battery connector.
– Place the auxiliary tool (56) on the
emergency lowering valve (55) with
the recess 57 (Jungheinrich symbol
visible).
– Release the emergency lowering
valve (55) in the forks direction.
– The mast and load handler will lower.
– If necessary the load can be stopped
by closing the valve.
55
Do not operate the truck until the fault
has been rectified.
56
57
4.6
F
Adjusting the forks
Unsecured and incorrectly adjusted forks
can cause accidents
Before adjusting the forks make sure the
retaining bolts (38b) are fitted.
38b
F
Adjust the fork tines in such a way that
both are equally distanced from the
outer edge of the fork carriage and the
load centre of gravity lies in the middle of
the fork tines.
58
– Raise the locking lever (59).
– Push the forks (58) into the correct
position on the fork carriage (60).
– Turn the locking lever down and move
the fork tine until it engages in a slot.
59
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60
E 26
4.7
F
Collecting, Lifting and Transporting Loads.
Only move the truck with or without a load when the mast is tilted back and the load
handler lowered.
Do not exceed the capacity of the truck.
Note the load chart!
Do not lift other people with the lifting mechanism and do not allow anyone to stand
under a raised load.
– Approach the load with care.
– Set the travel direction switch (13) to
neutral.
– Set the mast vertical.
– Raise the forks to the correct height for
the load unit.
– Set the travel direction switch to
forward travel.
– Insert the forks under the load
– Set the travel direction switch (13) to
neutral.
– Lift the load unit clear.
– Set the travel direction switch to
reverse.
F
13
Make sure you have enough space to
reverse into.
– Reverse carefully and slowly until the
load unit is outside the storage area.
Never reach through the mast!
13
– Tilt the mast fully backward.
– Bring the load unit into the transport
position (approx. 150...200 mm).
– Transport the load unit.
– Set the travel direction switch (13) to
neutral.
– Set the mast vertical.
– Position the load unit at the correct height
– Set the travel direction switch (13) to forward.
– Carefully enter the storage area.
– Slowly lower the load unit until the forks are free.
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F
E 27
4.8
F
Parking the truck safely
When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.
– Drive the truck onto a level surface.
– Apply the parking brake button (27).
– Fully lower the load forks and tilt the
mast forward.
F
Never park and abandon a truck with a
raised load.
27
10
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– Turn the key in the key switch (4)
to “0”.
– Remove the key from the key
switch (4).
– Press
the
EMERGENCY
DISCONNECT switch (10) down.
4
E 28
4.9
Towing trailers
The truck can occasionally be used to tow a light trailer on a dry, level and well
maintained surface.
Z
The max. tow load is the capacity indicated on the capacity data plate (see decals
diagram in chapter B).
The tow load consists of the weight of the trailer and the stated capacity.
If a load is transported on the forks, the tow load must be reduced by the same
amount.
F Important notes for safe towing
•
A truck must not be continually operated with trailers.
•
No supporting loads are permitted.
•
The maximum speed is 5km/h.
•
Towing must only be performed on level, secure travel routes.
•
Follow the instructions of the coupling manufacturer if using special trailer
couplings.
•
The owner must test trailer operation with the permissible tow load by means of a
trial run under the applicable operating conditions on site.
Attaching the trailer
61
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– Push the tow pin (61) down and turn
it 90 degrees.
– Pull the tow pin up and insert the tiller
of the trailer vehicle into the opening.
– Insert the tow pin, push it down, turn
it 90 degrees and engage it.
E 29
5
Troubleshooting
This chapter allows the user to identify and rectify basic faults or the effects of
incorrect operation. When trying to locate a fault, proceed in the order shown in the
table.
Fault
Probable Cause
Truck does
not start
– Battery connector – Check battery plug and plug in if necessary.
not plugged in
Action
– EMERGENCY
– Unlock the EMERGENCY DISCONNECT
DISCONNECT
pressed.
– Key switch in "0" – Set key switch to “I”
position.
– Battery
too low
charge – Check battery charge, charge battery if
necessary
– Battery door open – Finish charge / close door
/
on-board
charger active
Load cannot
be lifted
Error
message
displayed
– Faulty fuse
– Check fuses
– Truck
not – Carry out all measures listed under “Truck
operational
does not move”
– Hydraulic oil level – Check hydraulic oil level
too low
– Faulty fuse
– Check fuses
– Truck
not – Press the EMERGENCY DISCONNECT
operational
isolator or turn key switch to 0, after approx.
3 seconds try to perform the desired
operation again
M
If the fault cannot be rectified after carrying out the above procedures, notify the
manufacturer’s service department, as further troubleshooting can only be performed
by specially trained and qualified service personnel.
5.1
Temperature control
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If a temperature switch applies the power is reduced. This operates as a function of
the temperature:
for crawl speed,
for the “half lift speed” hydraulic function,
for the “continual power deacitvation” controllers.
E 30
F Industrial Truck Maintenance
1
Operational Safety and Environmental Protection
The servicing and inspection duties contained in this chapter must be performed in
accordance with the intervals indicated in the maintenance checklists.
F
M
Any modification to the forklift truck assemblies, in particular the safety mechanisms,
is prohibited. Do not alter the trucks’ operating speeds under any circumstances.
Only original spare parts have been certified by our quality assurance department.
To ensure safe and reliable operation of the truck, use only the manufacturer's spare
parts. Used parts, oils and fuels must be disposed of in accordance with the relevant
environmental protection regulations. For oil changes, contact the manufacturer’s
specialist department.
Upon completion of inspection and servicing, the tasks contained in the
“Recommissioning” section must be performed (see chapter F).
2
Maintenance Safety Regulations
Maintenance personnel: Industrial trucks must only be serviced and maintained by
the manufacturer’s trained personnel. The manufacturer’s service department has
field technicians specially trained for these tasks. We therefore recommend a
maintenance contract with the manufacturer’s local service centre.
Lifting and jacking up: When an industrial truck is to be lifted, the lifting gear must
only be secured to the points specially provided for this purpose. When jacking up the
truck, take appropriate measures to prevent the truck from slipping or tipping over
(e.g. wedges, wooden blocks). You may only work underneath a raised load handler
if it is supported by a sufficiently strong chain.
Z
For jack points see Chapter B.
Cleaning: Do not use flammable liquids to clean the industrial truck. Prior to cleaning,
implement all necessary safety measures to prevent sparking (e.g. through short
circuits). For battery-operated trucks, the battery connector must be removed. Only
weak suction or compressed air and non-conductive antistatic brushes may be used
for cleaning electric or electronic assemblies.
M
If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electrical
and electronic components must be carefully covered beforehand as moisture can
cause malfunctions.
Do not clean with pressurised water.
0708.GB
After cleaning the truck, carry out the activities detailed in the “Recommissioning”
section.
F1
Electrical System: Only suitably trained personnel may operate on the truck’s
electrical system. Before working on the electrical system, take all precautionary
measures to avoid electric shocks. For battery-operated trucks, also de-energise the
truck by removing the battery connector.
Welding: To avoid damaging electric or electronic components, remove these from
the truck before performing welding operations.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, always note the truck-specific settings.
Tyres: The quality of tyres affects the stability and performance of the truck. When
replacing tyres fitted at the factory, only use the manufacturer’s original spare parts.
Otherwise the data sheet specifications of the truck cannot be guaranteed. When
changing wheels and tyres, ensure that the truck does not slew (e.g. when replacing
wheels always left and right simultaneously).
Lift chains: Lift chains wear rapidly if not lubricated. The intervals stated in the
service checklist apply to normal duty use. More demanding conditions (dust,
temperature) require more regular lubrication. The prescribed chain spray must be
used in accordance with the instructions. Applying grease externally will not provide
sufficient lubrication.
0708.GB
Hydraulic hoses: The hoses must be replaced every six years. When replacing
hydraulic components, also replace the hoses in the hydraulic system.
F2
3
Servicing and Inspection
Thorough and expert servicing is one of the most important requirements for the safe
operation of the industrial truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment.
M
The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer adviser carries out an application
analysis on site to work out specific service intervals to prevent damage due to wear.
The service intervals stated are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in
conditions of extreme dust, temperature fluctuations or multiple shifts.
The following maintenance checklist states the tasks and intervals after which they
should be carried out. Maintenance intervals are defined as:
W
A
B
C
Z
=
=
=
=
Every
50 service hours, at least weekly
Every 500 service hours
Every 1000 service hours, or at least annually.
Every 2000 service hours, or at least annually.
W service intervals must be performed by the owner.
0708.GB
During the run-in period – after approx. 100 service hours – the owner must check the
wheel nuts/bolts and re-tighten if necessary.
F3
4
Maintenance checklist
Maintenance Intervals
Standard
= t W A B C
Brakes
1.1 Check air gap
1.2 Test service and parking brakes
t
t
Electrical
system
2.1
2.2
2.3
2.4
t
t
2.5
2.6
2.7
2.8
2.9
Test instruments, displays and control switches
Test warning and safety device
Check fuse ratings
Make sure wire connections are secure and check
for damage
Test micro switch setting
Check contactors and relays
Test for frame leakage
Test cable and motor attachments
Check lighting
t
t
t
t
t
t
t
Power supply 3.1 Visually inspect battery
3.2 Check battery cable connections are secure, grease
terminals if necessary.
3.3 Check acid density, acid level and battery voltage
t
t
Travel
4.1 Check transmission for noise and leakage
4.2 Check travel mechanism, adjust and lubricate
if necessary
4.3 Check wheels for wear and damage
4.4 Check wheel suspension and attachments
t
t
5.1
5.2
5.3
5.4
t
t
t
t
Check mast attachment
Check chassis for damage.
Check labels
Make sure overhead guard is secure and check
for damage
5.5 Check driver’s seat
5.6 Test restraint systems
t
t
t
t
0708.GB
Truck
structure
t
F4
Maintenance Intervals
Standard
= t W A B C
6.1 Check mast bearings.
6.2 Check setting of slide pieces and stops, and adjust if
necessary
6.3 Visually inspect mast rollers and check contact surface
wear level
6.4 Check lateral clearance of mast connections and of fork
carriage
6.5 Check load chain setting and tighten if necessary
6.6 Check forks and fork carriage for wear and damage
6.7 Check tilt cylinder
6.8 Check mast tilt angle
6.9 Test hydraulic system.
6.10 Check that hose and pipe lines and their connections
are secure, check for leaks and damage.
6.11 Check cylinders and piston rods for damage and leaks,
and make sure they are secure
6.12 Check hydraulic oil level
6.13 Replace hydraulic oil. (This may have to be performed
via a specialist environmental service truck) *)
6.14 Replace the hydraulic oil filter
6.15 Check the attachment
t
t
Agreed
performance
levels
7.1 Lubricate truck in accordance with Lubrication
Schedule.
7.2 Test run
7.3 Demonstration after servicing
t
Steering
system
8.1 Test electric steering
8.2 Check the swivelling bolster
t
t
Hydraulic
operation
t
t
t
t
t
t
t
t
t
t
t
t
t
t
0708.GB
*) Every 2000 service hours or at least every 2 years.
F5
5
Lubrication Schedule
G
E
c
E
B
A
b -N
a
Contact surfaces
c
Hydraulic oil drain plug
s
Grease nipple
b
Transmission oil filler neck
Hydraulic oil filler neck
a
Transmission oil drain plug
0708.GB
g
F6
5.1
Consumables
Handling consumables: Consumables must always be handled correctly. Follow
the manufacturer’s instructions.
F
Improper handling is hazardous to health, life and the environment. Consumables
must only be stored in appropriate containers. They may be flammable and must
therefore not come into contact with hot components or naked flames.
Only use clean containers when filling up with consumables. Do not mix consumables
of different grades. The only exception to this is when mixing is expressly stipulated
in the Operating Instructions.
Avoid spillage. Spilled liquids must be removed immediately with suitable bonding
agents and the bonding agent / consumable mixture must be disposed of in
accordance with regulations.
Code
Order no.
50426072
50429647
A
50124051
51082888
Quantity
50124051
1)
2)
3)
F
50157382
G
29201280
N
50468784
Hydraulic system
(BIO hydraulic oil)
HLPD 32 1)
HLPD 22 2)
2,5 l
51082888
E
Used for
440AH = 18L HLPD 22 2)
550AH = 23L HV 68 3)
660AH = 28L Plantosyn 46 HVI
50426072
50429647
B
Description
HLPD 32 1)
Steering system
(EFG316-320)
HV 68 3)
Plantosyn 46 HVI
(BIO hydraulic oil)
2 x 0.35 l
Lubrication grease K-L Steering axle
3N3)
(EFG 316-320)
Chain spray
Chains
Transmission oil, Shell
Transmission
Spirax MA 80 W
applicable for temperatures -5/+30 °C
applicable for temperatures -20/-5 °C
applicable for temperatures +30/+50 °C
The trucks are filled at the factory with H-LPD 22/32 hydraulic oil or Plantosyn 46 HVI
BIO hydraulic oil.
You cannot change from “Plantosyn 46 HVI” BIO hydraulic oil to H-LPD 22. The same
applies to changing from H-LPD 22 hydraulic oil to Plantosyn 46 HVI BIO hydraulic
oil.
Furthermore you cannot mix H-LPD 22 hydraulic oil with Plantosyn 46 HVI BIO
hydraulic oil.
0708.GB
Grease guidelines
Code Saponification Dew point
°C
E
Lithium
185
Worked penetration at 25 °C
265-295
NLG1 class
2
Application
temperature °C
-35/+120
F7
6
Maintenance Instructions
6.1
Preparing the truck for maintenance and repairs
All necessary safety measures must be taken to avoid accidents when carrying out
maintenance and repairs. The following preparations must be made:
– Park the truck securely (see Chapter E).
– Disconnect the battery so that the truck cannot be started by unauthorised persons
(refer to chapter D).
F
6.2
When working under a raised load fork or a raised truck, secure them to prevent them
from lowering, tipping or sliding away. When raising the truck also refer to the
instructions in the “Transport and Commissioning” section.
When working on the parking brake, prevent the truck from rolling away.
Opening the rear panel
– Undo the two quick release locks, pull the rear panel back and remove it.
The fuses, steer motor and other electrical components can now be reached.
6.3
Checking the wheel attachments.
– Park the truck securely (see
Chapter E).
– Tighten the wheel nuts (1) crosswise
with a torque wrench.
Torque
Drive wheels
Rear wheels
MA = 240 Nm
MA = 240 Nm
1
1
6.4
Rear wheel rated condition
The diameter of the rear wheels must differ by no more than 15 mm.
0708.GB
The tyres must always be replaced in pairs. Always use tyres of the same make,
model and profile, see chapter B.
F8
6.5
Checking the hydraulic oil level
F
Fully lower the load handler.
– Park the truck on a horizontal surface.
– Prepare the truck for maintenance and repairs (see Sections 6.1 and 6.2).
– Visually inspect the hydraulic oil level on the hose (2).
Z
If the reservoir is filled sufficiently, the hose will be approx. 1 cm full from the bottom.
– Add hydraulic oil if necessary until the oil can be seen in the hose
M
You can damage the system by adding more oil to the hydraulic reservoir.
Used consumables must be disposed of in accordance with the relevant
environmental protection regulations.
.
2
Trucks with bio hydraulic oil have a warning notice on the hydraulic
reservoir: “Fill only with hydraulic oil”. Use only bio hydraulic oil, see
“Lubricants” section.
0708.GB
F
F9
6.6
F
Check transmission oil level
Transmission oil must never enter the
ground; therefore place a collection tray
underneath the gear unit.
– Park the truck securely (see
Chapter E).
– Unscrew the oil dipstick (3).
– Check transmission oil level, top up if
necessary
Z
The oil level should reach the bottom
mark of the oil check hole (3).
M
Used consumables must be disposed
of in accordance with the relevant
environmental protection regulations.
6.7
Draining the oil
5
3
– Drain oil at operating temperature.
– Prepare an oil collection tray
underneath.
– Unscrew the oil drain plug (4) and drain the transmission oil.
4
Z
To ensure swift and complete draining of the transmission oil, unscrew the oil
dipstick (3).
6.8
Adding oil
– Insert the oil drain plug (4).
– Unscrew the oil dipstick (3) and add new transmission oil in the filler hole (5).
6.9
Replacing the hydraulic oil filter
– Unscrew the hydraulic oil filter cap (6).
The filter element is located on the
cap.
– Replace the filter insert; if the O ring is
damaged it will also need to be
replaced. Apply a thin layer of oil to the
O ring on assembly.
– Refit the cap with the new filter
element in place.
0708.GB
6
F 10
6.10
Seat belt maintenance
– Pull out the belt completely and check for fraying
– Test the belt buckle and make sure the belt returns correctly into the retractor.
– Check the cover for damage.
Testing the automatic blocking system:
– Park the truck on a horizontal surface
– Pull out the seat belt with a jerk
The interlock must prevent the belt from coming out.
F
Do not operate the truck with a faulty seat belt. Replace it immediately.
0708.GB
M
F 11
6.11
Checking electrical fuses
–
–
–
–
F
Prepare the truck for maintenance and repairs.
Open the rear panel.
Unscrew the cover.
Check condition and rating of the fuses in accordance with the table.
To avoid damaging the electrical system, only use fuses with the correct ratings.
12
13
14
15
6
7
8
9
10 11
16
18
17
0708.GB
19 - 36
F 12
Electrical system fuses
Item
6
7
8
9
10
11
12
Description
3F10
F23
7F1
1F9
4F1
F18
F1
Electric circuit
Steering threephase controller fuse
Control fuse 48V
Magnetic brake control fuse
Travel/Lift electronics control fuse
Horn control fuse
Power on contactor control fuse
Overall control circuit fuse
Rating / type
40A
5A
7.5A
5A
3A
3A
63A
EMERGENCY DISCONNECT fuses
Item
13
14
Description
F4
F8
Electric circuit
Main contactor control fuse
Positive wire main fuse
Rating / type
5A
425A
Traction and lift controller fuses
Item
15
16
17
Description
2F1
1F2
1F1
Electric circuit
Hydraulic motor fuse
RH drive motor fuse
LH drive motor fuse
Rating / type
250A
250A
250A
On-board charger fuse (o)
Description
F10
Electric circuit
On-board charger fuse
Rating / type
170A
0708.GB
Item
18
F 13
20
19
21
22
23
24
25
26
27
36
35
34
33
32
31
30
29
28
Options fuses (o)
Item
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
Electric circuit
Windscreen wiper control fuse
Windscreen washer pump fuse
Rear windscreen wiper control fuse
DC/DC converter control fuse
DC/DC converter control fuse
Searchlight control fuse
Strobe control fuse
48 volt heating fuse
24 volt heating fuse
Output card fuse
Windscreen heating fuse
Seat heating control fuse
Beacon control fuse
Lighting control fuse
Rear RH work lights fuse
RH reverse lights fuse
Rear LH work lights fuse
LH reverse lights fuse
Front RH work lights fuse
Front LH work lights fuse
Rating / type
5A
5A
5A
20A
20A
10A
5A
40A
15A
20A
7.5A
5A
5A
15A
5A
5A
5A
5A
0708.GB
35
36
Description
9F1
9F33
9F14
7F3
7F4
5F1
4F14
F14
F14.1
F24
9F5
9F2
4F4
5F5
5F11.3
5F3.2
5F11.2
5F3.1
5F11.1
5F11
F 14
6.12
Recommissioning
The truck may only be restored to service after cleaning or repair work, once the
following operations have been performed:
–
–
–
–
7
Test horn.
Test main switch operation.
Test brakes.
Lubricate the truck in accordance with the lubrication chart.
Decommissioning the industrial truck
If the industrial truck is to be decommissioned for more than two months, e.g. for
operational reasons, it must be parked in a frost-free and dry location and all
necessary measures must be taken before, during and after decommissioning as
described.
M
On decommissioning the truck must be jacked up so that all the wheels are clear of
the ground. This is the only way of ensuring that the wheels and wheel bearings are
not damaged.
If the truck is to be out of service for more than 6 months, further measures must be
taken in consultation with the manufacturer’s service department.
7.1
Prior to decommissioning
–
–
–
–
–
–
–
Z
Thoroughly clean the truck.
Check the brakes.
Check the hydraulic oil level and replenish as necessary (see Chapter F).
Apply a thin layer of oil or grease to any non-painted mechanical components.
Lubricate the truck in accordance with the lubrication schedule (see Chapter F).
Charge the battery (see Chapter D).
Disconnect the battery, clean it and grease the terminals.
In addition, follow the battery manufacturer’s instructions.
– Spay all exposed electrical contacts with a suitable contact spray.
7.2
During decommissioning
Every 2 months:
– Charge the battery (see Chapter D).
Battery powered trucks:
The battery must be charged at regular intervals to avoid depletion of the battery
through self-discharge. The sulfatisation would destroy the battery.
0708.GB
M
F 15
7.3
Returning the truck to operation after decommissioning
–
–
–
–
–
–
–
Z
Thoroughly clean the truck.
Lubricate the truck in accordance with the lubrication schedule (see Chapter F).
Clean the battery, grease the terminals and connect the battery.
Charge the battery (see Chapter D).
Check transmission oil for condensed water and replace if necessary.
Check hydraulic oil for condensed water and replace if necessary.
Start up the truck (see Chapter E).
Battery powered trucks:
If there are switching problems in the electrical system, apply contact spray to the
exposed contacts and remove any oxide layers on the contacts of the operating
controls by applying them repeatedly.
F
Perform several brake tests immediately after re-commissioning the truck.
8
Safety checks to be performed at intervals and after unusual events
Z
Carry out the safety check in accordance with national regulations.
Junheinrich recommends checks in accordance with FEM 4.004. Jungheinrich has a
special safety department with trained personnel to carry out such checks.
The truck must be inspected at least annually (refer to national regulations) or after
any unusual event by a qualified inspector. The inspector shall assess the condition
of the truck from purely a safety viewpoint, without regard to operational or economic
circumstances. The inspector shall be sufficiently instructed and experienced to be
able to assess the condition of the truck and the effectiveness of the safety
mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by
possible improper use. A test report shall be provided. The test results must be kept
for at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
9
Final de-commissioning, disposal
Z
Final, correct de-commissioning or disposal of the truck must be performed in
accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
0708.GB
Z
F 16
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
0506.GB
Type plate Jungheinrich traction battery............................................17
1
1
Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB
Rating Data
1.
2.
3.
4.
Nominal capacity C5:
Nominal voltage:
Discharge current::
Nominal S.G. of electrolyte*
Type EPzS:
Type EPzB:
5. Rated temperature:
6. Nominal electrolyte level:
See type plate
2,0 V x No of cells
C5/5h
1,29 kg/l
1,29 kg/l
30° C
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.
0506.GB
•Dangerous electrical voltage!
•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!
2
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:
M 10
steel
23 ± 1 Nm
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 applies 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 discharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
0506.GB
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 exceeded. 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.
3
Battery container lids and the covers of battery compartments must be opened or removed. 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 correct. (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 batteries 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 potentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flammability 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 following normal charging. The charging current must not exceed 5 A/100 Ah of rated capacity (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 temperatures shorten the life of the battery, lower temperatures reduce the capacity available. 55°C is the upper temperature limit and is not acceptable as an operating temperature.
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 temperatures 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.
0506.GB
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
4
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 battery 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 recorded.
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 ȍ 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 ȍ.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
0506.GB
Any liquid in the battery tray must be extracted and disposed of in the prescribed manner. 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.
5
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 finding 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!
0506.GB
We reserve the right make technical modification.
6
7. Type plate, Jungheinrich traction battery
2/3
4
10
12
7
8
1
2
Typ
Type
3
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
Zellenzahl
Number of Cells
9
Hersteller
Manufacturer
4
6
5
Batteriegewicht min/max
Battery mass min/max
8
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
1
Pb
9
Item
1
2
3
4
5
6
7
6
5
11
13
Baujahr
Year of manufacture
Serien-Nr.
Serial-Nr.
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
14
Item
8
9
10
11
12
13
14
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
7
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
Cell series*
EPzS
EPzB
2/120 – 10/ 600
2/ 42 – 12/ 252
2/160 – 10/ 800
2/ 64 – 12/ 384
–
2/ 84 – 12/ 504
–
2/110 – 12/ 660
–
2/130 – 12/ 780
–
2/150 – 12/ 900
–
2/172 – 12/1032
–
2/200 – 12/1200
–
2/216 – 12/1296
2/180 – 10/900
–
2/210 – 10/1050
–
2/230 – 10/1150
–
2/250 – 10/1250
–
2/280 – 10/1400
–
2/310 – 10/1550
–
Aquamatic plug type (length)
Frötek (yellow)
BFS (black)
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
50,5 mm
51,0 mm
56,0 mm
56,0 mm
56,0 mm
56,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
61,0 mm
72,0 mm
66,0 mm
72,0 mm
66,0 mm
* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600.
Aquamatic plug with
diagnostics hole
length
stroke
length
stroke
These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120.
Aquamatic plug BFS III with
diagnostics hole
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.
0506.GB
When using batteries which comply with I and II, it is important to follow the instructions on maintaining the respective protection class during operation (see associated certification).
8
Diagrammatic view
Equipment for the
water refilling system
1. Water tank
2. Level switch
4. Discharge point with solenoid valve
5. Charger
at least 3 m
3. Discharge point with ball
valve
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 adjusting 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 density. All battery cells of the design series EPzS; EPzB can be equipped with the Aquamatic/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 connections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
0506.GB
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 system, 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.
9
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 filling.
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 water feed pipe must be separated from the battery after filling.
7. Water quality
0506.GB
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.
10
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 temperature 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 systems 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
0506.GB
Only the appertaining special-purpose tool may be used to disassemble the plug systems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems.
11
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pressure 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 battery'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 central 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
0506.GB
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.
12
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 where 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.
0506.GB
• Dangerous electrical voltage!
• Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!
13
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:
M 10
steel
23 ± 1 Nm
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which applies 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 discharged.
This also applies to partially discharged batteries.
2.2 Charging
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 removed.
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0506.GB
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 modifications. 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.
With the charger switched off connect up the battery, ensuring that the polarity is correct (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 temperatures 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 chargers.
Watch the temperature!
2.4 Temperature
A battery temperature of 30°C is specified as the rated temperature. Higher temperatures 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 temperature.
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
0506.GB
Charge the battery immediately after every discharge.
15
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 ȍ 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 ȍ.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Cleaning 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 manner.
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.
The storage time should be taken into account when considering the life of the battery.
16
0506.GB
2. float charging at a charging voltage of 2.25 V x the number of cells.
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 finding 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
2/3
4
10
12
7
8
1
2
3
Lieferanten Nr.
Supplier No.
5
Kapazität
Capacity
Nennspannung
Nominal Voltage
7
9
6
5
Batteriegewicht min/max
Battery mass min/max
Zellenzahl
Number of Cells
Hersteller
Manufacturer
4
8
Jungheinrich AG, D-22047 Hamburg, Germany
Pb
1
Pb
9
Item
1
2
3
4
5
6
7
6
5
11
13
Baujahr
Year of manufacture
Typ
Type
Serien-Nr.
Serial-Nr.
Designation
Logo
Battery designation
Battery type
Battery number
Battery tray number
Delivery date
Battery manufacturer's logo
14
Item
8
9
10
11
12
13
14
Designation
Recycling symbol
Dustbin/material
Nominal battery voltage
Nominal battery capacity
Number of battery cells
Battery weight
Safety instructions and warnings
0506.GB
* CE mark is only for batteries with a nominal voltage greater than 75 volt.
17
18
0506.GB