Jungheinrich ERE 224 Operating Manual

ERE 224

Operating Instructions

51086028

09.07

09.07-

G

Foreword

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number.

For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the following graphics:

F

Used before safety instructions which must be observed to avoid danger to personnel.

M

Used before notices which must be observed to avoid material damage.

Z

Used before notices and explanations.

t

Used to indicate standard equipment.

o

Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions .

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

Foreword

The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number.

For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the following graphics:

F

Used before safety instructions which must be observed to avoid danger to personnel.

M

Used before notices which must be observed to avoid material damage.

Z

Used before notices and explanations.

t

Used to indicate standard equipment.

o

Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions .

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - GERMANY

Telephone: +49 (0) 40/6948-0 www.jungheinrich.com

Table of Contents

A Correct use and application

B Truck Description

1

2

Application ........................................................................................... B 1

Assemblies .......................................................................................... B 2

3 Technical specifications ...................................................................... B 3

3.1

Performance data ................................................................................ B 3

3.2

Dimensions ......................................................................................... B 4

3.3

EN standards ...................................................................................... B 5

3.4

Operating Conditions .......................................................................... B 5

4 Identification points and data plates .................................................... B 6

4.1

Truck data plate .................................................................................. B 7

C Transport and Commissioning

1

2

3

4

Lifting by crane .................................................................................... C 1

Using the truck for the first time .......................................................... C 2

Operating the truck without its own drive system ................................ C 3

Securing the truck during transport. .................................................... C 4

D Battery Maintenance, Charging & Replacement

1

2

Safety regulations for handling acid batteries ..................................... D 1

Battery types ....................................................................................... D 2

3 Exposing the battery ........................................................................... D 2

3.1

Standard version ................................................................................. D 2

3.2

Battery panel for side battery removal: ............................................... D 3

4

5

Charging the battery ............................................................................ D 4

Battery removal and installation .......................................................... D 5

5.1

Removal to extract the battery (standard version) .............................. D 5

5.2

Lateral battery removal ( o ) ................................................................. D 6

5.3

Battery installation ............................................................................... D 6

E Operation

1

2

Safety regulations for the operation of industrial trucks ...................... E 1

Controls and displays .......................................................................... E 2

3 Starting up the truck ............................................................................ E 4

4 Industrial truck operation ..................................................................... E 5

4.1

Safety regulations for truck operation ................................................. E 5

4.2

Travel, steering, braking ...................................................................... E 6

4.3

Lifting and depositing loads ................................................................. E 10

4.4

Parking the truck securely ................................................................... E 11

5 Troubleshooting .................................................................................. E 12

I 1

Table of Contents


B Truck Description

1

2

Application ........................................................................................... B 1

Assemblies .......................................................................................... B 2

3 Technical specifications ...................................................................... B 3

3.1

Performance data ................................................................................ B 3

3.2

Dimensions ......................................................................................... B 4

3.3

EN standards ...................................................................................... B 5

3.4

Operating Conditions .......................................................................... B 5

4 Identification points and data plates .................................................... B 6

4.1

Truck data plate .................................................................................. B 7


1

2

3

4

Lifting by crane .................................................................................... C 1

Using the truck for the first time .......................................................... C 2

Operating the truck without its own drive system ................................ C 3

Securing the truck during transport. .................................................... C 4

D Battery Maintenance, Charging & Replacement

1

2

Safety regulations for handling acid batteries ..................................... D 1

Battery types ....................................................................................... D 2

3 Exposing the battery ........................................................................... D 2

3.1

Standard version ................................................................................. D 2

3.2

Battery panel for side battery removal: ............................................... D 3

4

5

Charging the battery ............................................................................ D 4

Battery removal and installation .......................................................... D 5

5.1

Removal to extract the battery (standard version) .............................. D 5

5.2

Lateral battery removal ( o ) ................................................................. D 6

5.3

Battery installation ............................................................................... D 6

E Operation

1

2

Safety regulations for the operation of industrial trucks ...................... E 1

Controls and displays .......................................................................... E 2

3 Starting up the truck ............................................................................ E 4

4 Industrial truck operation ..................................................................... E 5

4.1

Safety regulations for truck operation ................................................. E 5

4.2

Travel, steering, braking ...................................................................... E 6

4.3

Lifting and depositing loads ................................................................. E 10

4.4

Parking the truck securely ................................................................... E 11

5 Troubleshooting .................................................................................. E 12

I 1

I 2

F Industrial Truck Maintenance

3

4

5

1

2

Operational safety and environmental protection ................................ F 1

Maintenance safety regulations .......................................................... F 1

Servicing and inspection ..................................................................... F 3

Maintenance checklist ........................................................................ F 4

Lubrication schedule ........................................................................... F 6

5.1

Fuels, coolants and lubricants ............................................................. F 7

6 Maintenance and repairs ..................................................................... F 8

6.1

Preparing the truck for maintenance and repairs ................................ F 8

6.2

Opening the battery panel ................................................................... F 8

6.3

Opening the front panel ....................................................................... F 8

6.4

Checking the drive wheel bearing and attachment ............................. F 9

6.5

Checking the hydraulic oil level ........................................................... F 9

6.6

Operator platform height fine tuning .................................................... F 10

6.7

Checking electrical fuses .................................................................... F 11

6.8

Recommissioning ................................................................................ F 12

7 Decommissioning the industrial truck .................................................. F 12

7.1

Prior to decommissioning: ................................................................... F 12

7.2

During decommissioning: .................................................................... F 12

7.3

Returning the truck to operation after decommissioning ..................... F 13

8 Safety tests to be performed at intervals and after unusual events

( D : Accident prevention check according to BGV D27..................... F 13

9 Final de-commissioning, disposal ....................................................... F 13


3

4

5

1

2

Operational safety and environmental protection ................................ F 1

Maintenance safety regulations .......................................................... F 1

Servicing and inspection ..................................................................... F 3

Maintenance checklist ........................................................................ F 4

Lubrication schedule ........................................................................... F 6

5.1

Fuels, coolants and lubricants ............................................................. F 7

6 Maintenance and repairs ..................................................................... F 8

6.1

Preparing the truck for maintenance and repairs ................................ F 8

6.2

Opening the battery panel ................................................................... F 8

6.3

Opening the front panel ....................................................................... F 8

6.4

Checking the drive wheel bearing and attachment ............................. F 9

6.5

Checking the hydraulic oil level ........................................................... F 9

6.6

Operator platform height fine tuning .................................................... F 10

6.7

Checking electrical fuses .................................................................... F 11

6.8

Recommissioning ................................................................................ F 12

7 Decommissioning the industrial truck .................................................. F 12

7.1

Prior to decommissioning: ................................................................... F 12

7.2

During decommissioning: .................................................................... F 12

7.3

Returning the truck to operation after decommissioning ..................... F 13

8 Safety tests to be performed at intervals and after unusual events

( D : Accident prevention check according to BGV D27..................... F 13

9 Final de-commissioning, disposal ....................................................... F 13

I 2

Appendix

JH Traction Battery Operating Instructions

Z

These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

Appendix

JH Traction Battery Operating Instructions

Z

These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

1 1

2 2


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 or the load chart are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded.

Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The owner must ensure that all truck users have read and understood these operating instructions.

M

Failure to comply with the operating instructions shall invalidate the warranty.

The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.

Attaching accessories: The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required.

Approval of the local authorities however does not constitute the manufacturer’s approval.


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 or the load chart are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas, or areas threatened by corrosion or excessive dust.

Proprietor responsibilities: For the purposes of the present operator manual the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.

The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded.

Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The owner must ensure that all truck users have read and understood these operating instructions.

M

Failure to comply with the operating instructions shall invalidate the warranty.

The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.

Attaching accessories: The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required.

Approval of the local authorities however does not constitute the manufacturer’s approval.

A 1 A 1

A 2 A 2

1

B Truck Description

Application

The ERE 224 is a tiller operated threewheel electric lift truck with an operator platform which lifts (in conjunction with the forks) to pre-defined heights.

The truck is designed for lifting and transporting goods on a level surface. The truck can lift open bottom or diagonal board pallets as well as roll cages beyond the area of the load wheels.

The special design of the battery panel allows for easy side battery removal.

The rated capacity is shown on the data plate or the data capacity plate Qmax.

1

B Truck Description

Application

The ERE 224 is a tiller operated threewheel electric lift truck with an operator platform which lifts (in conjunction with the forks) to pre-defined heights.

The truck is designed for lifting and transporting goods on a level surface. The truck can lift open bottom or diagonal board pallets as well as roll cages beyond the area of the load wheels.

The special design of the battery panel allows for easy side battery removal.

The rated capacity is shown on the data plate or the data capacity plate Qmax.

B 1 B 1

2 Assemblies

2

1

3

4

9

8

7

5 6 5

Item Description

1 t Isolator

2 t Jet Pilot

3 t Key switch

4 t Battery panel

5 t Castor wheel


6 t Drive wheel

7 t Operator platform

8 t Backrest switch

9 t Safety bar

B 2

2 Assemblies

2

1

3

4

9

8

7

5 6 5


1 t Isolator

2 t Jet Pilot

3 t Key switch

4 t Battery panel

5 t Castor wheel


6 t Drive wheel

7 t Operator platform

8 t Backrest switch

9 t Safety bar

B 2

3 Technical specifications

Z

Technical data specified in accordance with VDI 2198.

Technical modifications and additions reserved.

3.1

Performance data

Description

Q Capacity c Load centre of gravity (long load)

Travel speed*, rider mode w / w.o. load

Lift time w / w.o. load

Lowering speed w / w.o. load

Max. gradeability (above 5 mins) w / w.o. load

2,400 kg

1,200 mm

8.3 / 11.8 km/h

3.0 / 2.6 s

2.0 / 3.0 s

8.0 / 15.0 %

*: Travel speed reduction: when travelling in load direction and travelling in drive direction with platform lower than 170 mm: reduction to 2.5 km/h

Audible warning: when travelling in load direction and platform higher than 170 mm.

3 Technical specifications

Z

Technical data specified in accordance with VDI 2198.

Technical modifications and additions reserved.

3.1

Performance data

Description

Q Capacity c Load centre of gravity (long load)

Travel speed*, rider mode w / w.o. load

Lift time w / w.o. load

Lowering speed w / w.o. load

Max. gradeability (above 5 mins) w / w.o. load

2,400 kg

1,200 mm

8.3 / 11.8 km/h

3.0 / 2.6 s

2.0 / 3.0 s

8.0 / 15.0 %

*: Travel speed reduction: when travelling in load direction and travelling in drive direction with platform lower than 170 mm: reduction to 2.5 km/h

Audible warning: when travelling in load direction and platform higher than 170 mm.

170 215 170 215

B 3 B 3

3.2

Dimensions

(all dimensions in mm)

Description h

13 h

3

Lowered load fork height

Lift to operator platform height l1 Truck length b

1 b

5

Truck width

Outside straddle e Fork width l Fork length l

2

Long drive unit

Wa Turning radius

Net weight: see truck data plate mm

90

170 / 215

3713

770

510

172

2400

1313

2823

3.2

Dimensions

(all dimensions in mm)

Description h

13 h

3

Lowered load fork height

Lift to operator platform height l1 Truck length b

1 b

5

Truck width

Outside straddle e Fork width l Fork length l

2

Long drive unit

Wa Turning radius

Net weight: see truck data plate mm

90

170 / 215

3713

770

510

172

2400

1313

2823

B 4 B 4

3.3

EN standards

Noise emission: 68 dB(A) in accordance with prEN 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 sound pressure level is measured at the ear.

Vibration: 0.67 m/s

2 in accordance with prEN 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 prEN 12895 including the normative procedures contained therein.

Z

No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.

3.4

Operating Conditions

Ambient temperature

- operating at 5 ° C to 40 ° C

Z

Special equipment and authorisation is required if the truck is to operate constantly below 5 ° C or in a cold store or in extreme temperatures or conditions of fluctuating air humidity.

3.3

EN standards

Noise emission: 68 dB(A) in accordance with prEN 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 sound pressure level is measured at the ear.

Vibration: 0.67 m/s

2 in accordance with prEN 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 prEN 12895 including the normative procedures contained therein.

Z

No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.

3.4

Operating Conditions

Ambient temperature

- operating at 5 ° C to 40 ° C

Z

Special equipment and authorisation is required if the truck is to operate constantly below 5 ° C or in a cold store or in extreme temperatures or conditions of fluctuating air humidity.

B 5 B 5

4 Identification points and data plates

15

2400

16

14

17

18

19


14 Truck data plate

15 Attention: Read operating instructions. (see Chapter C)

16 Rated capacity

17 Strap point for crane lifting

18 Battery data plate

19 UVV test label

Z

The truck data plate (14) can be found by opening the battery panel

(see Chapter F).

The battery data plate (18) can be found by opening the battery panel

(see Chapter D).

B 6

4 Identification points and data plates

15

2400

16

14

17

18

19


14 Truck data plate

15 Attention: Read operating instructions. (see Chapter C)

16 Rated capacity

17 Strap point for crane lifting

18 Battery data plate

19 UVV test label

Z

The truck data plate (14) can be found by opening the battery panel

(see Chapter F).

The battery data plate (18) can be found by opening the battery panel

(see Chapter D).

B 6

4.1

Truck data plate

20

21

22

23

24

25

31

30

29

28

27

26

Item

20 Model

Description

21 Serial no.

22 Rated capacity (kg)

23 Battery voltage

24 Net weight w.o. battery (kg)

25 Manufacturer


26 Manufacturer’s logo

27 Min./Max. battery weight (kg)

28 Output (kW)

29 Load centre of gravity (mm)

30 Year of manufacture

31 Option

Z

For queries regarding the truck or ordering spare parts always quote the truck serial number (21).

4.1

Truck data plate

20

21

22

23

24

25

31

30

29

28

27

26

Item

20 Model

Description

21 Serial no.

22 Rated capacity (kg)

23 Battery voltage

24 Net weight w.o. battery (kg)

25 Manufacturer


26 Manufacturer’s logo

27 Min./Max. battery weight (kg)

28 Output (kW)

29 Load centre of gravity (mm)

30 Year of manufacture

31 Option

Z

For queries regarding the truck or ordering spare parts always quote the truck serial number (21).

B 7 B 7

B 8 B 8


1 Lifting by crane

F

Only use lifting gear with sufficient capacity (for truck weight see truck data plate,

Chapter B).

Z

Lifting gear attachment points are provided on the chassis (1) and the fork (2) in case the truck is to be lifted or transported by crane.

– Park the truck securely

(see Chapter E).

– Secure the lifting slings to the strap points.

M

The lifting gear must be attached to the attachment points in such a manner that it cannot slip under any circumstances and cannot come into contact with any attachments of the truck when the truck is lifted.

1

1

2


1 Lifting by crane

F

Only use lifting gear with sufficient capacity (for truck weight see truck data plate,

Chapter B).

Z

Lifting gear attachment points are provided on the chassis (1) and the fork (2) in case the truck is to be lifted or transported by crane.

– Park the truck securely

(see Chapter E).

– Secure the lifting slings to the strap points.

M

The lifting gear must be attached to the attachment points in such a manner that it cannot slip under any circumstances and cannot come into contact with any attachments of the truck when the truck is lifted.

1

1

2

C 1 C 1

2 Using the truck for the first time

M

Operate the truck only with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6 m in length.

Z

On post February 2001 trucks, a transport lock has been introduced.

F

If there is no battery in the truck, you cannot brake by plugging or with the service brake.

There is an instruction decal by the front panel for the transport retainer (3), this must be removed once the battery has been installed.

– Open the front panel (see Chapter F).

– Undo the M12 nut (SW19) and remove the transport retainer.

– Leave the transport retainer on the truck for later transportation without a battery.

2 Using the truck for the first time

M

Operate the truck only with battery current. Rectified AC current will damage the electronic components. The battery leads (tow cable) must be less than 6 m in length.

Z

On post February 2001 trucks, a transport lock has been introduced.

F

If there is no battery in the truck, you cannot brake by plugging or with the service brake.

There is an instruction decal by the front panel for the transport retainer (3), this must be removed once the battery has been installed.

– Open the front panel (see Chapter F).

– Undo the M12 nut (SW19) and remove the transport retainer.

– Leave the transport retainer on the truck for later transportation without a battery.

C 2

3

C 2

3

To prepare the truck after delivery or after transport, proceed as follows:

– Make sure the truck’s equipment is complete and in a satisfactory condition.

– Install battery (where required). Do not damage battery cable.

– Charge the battery (see Chapter D).

– If necessary, adjust the combination instrument to match the battery type

(see Chapter D).

– Start up the truck in accordance with instructions (see Chapter E).

Z

When the truck is parked the surface of the tyres will flatten. The flattening will disappear after a short period of operation.

3 Operating the truck without its own drive system

F

This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a fault has affected its operation, proceed as follows:

– Set the main switch “OFF”.

– Set the key switch OFF and remove the key.

– Ensure that the vehicle cannot run away.

– Open the front panel and put it to one side (see Chapter F).

– Slacken the jam nuts (5) and tighten the screws (4).

The brake is now released and the truck can move.

F

On reaching your destination, make sure that the brake is restored to its initial state. The truck must on no account be parked with the brake in the released condition.

4

5

To prepare the truck after delivery or after transport, proceed as follows:

– Make sure the truck’s equipment is complete and in a satisfactory condition.

– Install battery (where required). Do not damage battery cable.


– If necessary, adjust the combination instrument to match the battery type

(see Chapter D).

– Start up the truck in accordance with instructions (see Chapter E).

Z

When the truck is parked the surface of the tyres will flatten. The flattening will disappear after a short period of operation.

3 Operating the truck without its own drive system

F

This operating mode is not permitted when negotiating inclines and gradients.

If the truck has to be moved after a fault has affected its operation, proceed as follows:

– Set the main switch “OFF”.

– Set the key switch OFF and remove the key.

– Ensure that the vehicle cannot run away.

– Open the front panel and put it to one side (see Chapter F).

– Slacken the jam nuts (5) and tighten the screws (4).

The brake is now released and the truck can move.

F

On reaching your destination, make sure that the brake is restored to its initial state. The truck must on no account be parked with the brake in the released condition.

4

5

C 3 C 3

4 Securing the truck during transport.

The truck must be securely fastened when transported on a lorry or a trailer. The lorry or trailer must have securing rings fitted to its body.

To fasten the truck fix the tensioning belt (3) to the chassis (1) and attach it to the fastening rings.

Tighten the tensioning belts with the tensioner (4).

1

3

4

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 dimensions must be determined and appropriate safety measures adopted.

4 Securing the truck during transport.

The truck must be securely fastened when transported on a lorry or a trailer. The lorry or trailer must have securing rings fitted to its body.

To fasten the truck fix the tensioning belt (3) to the chassis (1) and attach it to the fastening rings.

Tighten the tensioning belts with the tensioner (4).

1

3

4

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 dimensions must be determined and appropriate safety measures adopted.

C 4 C 4

D Battery Maintenance, Charging &

Replacement

1 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 regulations concerning batteries and charging stations shall be observed when work is being carried out.

Fire protection: Smoking and open flames are not permitted when handling 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 servicing: 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 specifications for the disposal must be heeded.

M

Before closing the battery panel make sure that the battery lead cannot be damaged.

F

Batteries contain an acid solution which is poisonous and corrosive Therefore, always wear protective clothing and eye protection when carrying out work on batteries.

Above all avoid any contact with battery acid.

Nevertheless, should clothing, skin or eyes come in contact with acid the affected parts should be rinsed with plenty of clean water - where the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.

M

Only batteries with a sealed battery container may be used.

F

The weight and dimensions of the battery have a considerable effect on the operational safety of the truck. Battery equipment changes may only be made with the agreement of the manufacturer.

D Battery Maintenance, Charging &

Replacement

1 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 regulations concerning batteries and charging stations shall be observed when work is being carried out.

Fire protection: Smoking and open flames are not permitted when handling 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 servicing: 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 specifications for the disposal must be heeded.

M

Before closing the battery panel make sure that the battery lead cannot be damaged.

F

Batteries contain an acid solution which is poisonous and corrosive Therefore, always wear protective clothing and eye protection when carrying out work on batteries.

Above all avoid any contact with battery acid.

Nevertheless, should clothing, skin or eyes come in contact with acid the affected parts should be rinsed with plenty of clean water - where the skin or eyes are affected call a doctor immediately. Immediately neutralise any spilled battery acid.

M

Only batteries with a sealed battery container may be used.

F

The weight and dimensions of the battery have a considerable effect on the operational safety of the truck. Battery equipment changes may only be made with the agreement of the manufacturer.

D 1 D 1

2 Battery types

The battery types correspond to EN 60254-2.

The following table shows the combinations to be used, with reference to their capacity:

Battery type

24 volt battery

24 volt battery

(enhanced)

Battery

3 EPzS 345 Ah

3 EPzS 375 Ah

The battery weights are indicated on the battery data plate.

Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.

F

When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.

3 Exposing the battery

F

Park the truck securely (see Chapter E).

3.1

Standard version

– Set the main switch (1) “OFF”.

– Lock the panel (4).

– Lift up the battery panel (2) using grips (3).

..

4

1

2

3

2 Battery types

The battery types correspond to EN 60254-2.

The following table shows the combinations to be used, with reference to their capacity:

Battery type

24 volt battery

24 volt battery

(enhanced)

Battery

3 EPzS 345 Ah

3 EPzS 375 Ah

The battery weights are indicated on the battery data plate.

Depending on the type of battery used, it is also possible to use models with enhanced performance or maintenance-free batteries.

F

When replacing or installing batteries, ensure that the battery is correctly secured in the battery compartment of the truck.

3 Exposing the battery

F

Park the truck securely (see Chapter E).

3.1

Standard version

– Set the main switch (1) “OFF”.

– Lock the panel (4).

– Lift up the battery panel (2) using grips (3).

..

4

1

2

3

D 2 D 2

3.2

Battery panel for side battery removal:

– Set the isolator (7) “OFF”.

– Push the panel lock (4) down to unlock it, lift the battery panel (5) forward and unlock the panel retainer (6).

– Move the battery panel (5) further down; it is held in place by a collector strap.

– Lift the battery retaining strap (8) up only for battery removal.

4 7 6

5

8

9

3.2

Battery panel for side battery removal:




– Lift the battery retaining strap (8) up only for battery removal.

4 7 6

5

8

9

D 3 D 3

4 Charging the battery

– Park the truck securely (see Chapter E).

F

Only connect and disconnect the battery connector and the socket when the truck is switched off.

– Expose the battery (see Section 3).

F

When charging, the top surfaces of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage.

It is essential to follow the safety regulations of the battery and charger station manufacturers.

– Remove the battery connector (8).

– Where necessary remove the insulating mat from the battery.

– Connect the charging cable (9) to the battery connector (8) and switch on the charger.

M

Recharge the battery in accordance with the instructions provided by the battery and battery charger suppliers.

4 Charging the battery

– Park the truck securely (see Chapter E).

F

Only connect and disconnect the battery connector and the socket when the truck is switched off.


F

When charging, the top surfaces of the battery cells must be exposed to provide sufficient ventilation. Do not place any metal objects on the battery. Before charging, check all cables and plug connections for visible signs of damage.

It is essential to follow the safety regulations of the battery and charger station manufacturers.

– Remove the battery connector (8).

– Where necessary remove the insulating mat from the battery.

– Connect the charging cable (9) to the battery connector (8) and switch on the charger.

M

Recharge the battery in accordance with the instructions provided by the battery and battery charger suppliers.

8

9

8

9

D 4 D 4

5 Battery removal and installation

F

The truck must be horizontal (and secured against rolling away). To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or the battery cable in such a way that they will not get caught on the truck when the battery is removed.

Z

When transporting batteries with the aid of a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must exert a vertical pull so that the battery container is not compressed. The hooks must be attached to the eyes (12) of the battery in such a way that they cannot fall onto the battery cells when the lifting gear is relieved.

5.1

Removal to extract the battery (standard version)


– Disconnect the battery.

– Attach the lifting gear to the attachment eyes (12) and lift out the battery.

5 Battery removal and installation

F

The truck must be horizontal (and secured against rolling away). To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. Place the battery connector or the battery cable in such a way that they will not get caught on the truck when the battery is removed.

Z

When transporting batteries with the aid of a crane, ensure that the crane is of adequate capacity (the battery weight is indicated on the battery identification plate at the battery trough). The lifting gear must exert a vertical pull so that the battery container is not compressed. The hooks must be attached to the eyes (12) of the battery in such a way that they cannot fall onto the battery cells when the lifting gear is relieved.

5.1

Removal to extract the battery (standard version)


– Disconnect the battery.

– Attach the lifting gear to the attachment eyes (12) and lift out the battery.

Z

The battery can also be removed using crane lifting gear.

12

D 5

Z

The battery can also be removed using crane lifting gear.

12

D 5

5.2

Lateral battery removal ( o )


– Move the battery trolley up to the side of the truck.



– Remove the battery retainer (9).

– Lift up the battery retaining strap (8).

– Roll the battery out to the side onto the battery trolley.

4 7 6

5

8

9

5.2

Lateral battery removal ( o )


– Move the battery trolley up to the side of the truck.



– Remove the battery retainer (9).

– Lift up the battery retaining strap (8).

– Roll the battery out to the side onto the battery trolley.

4 7 6

5

8

9

5.3

Battery installation

Installation is the reverse order of removal.

F

After installing the battery, check all cables and plug connections for visible signs of damage.

Close the battery panel securely with the panel lock.

D 6

5.3

Battery installation

Installation is the reverse order of removal.

F

After installing the battery, check all cables and plug connections for visible signs of damage.

Close the battery panel securely with the panel lock.

D 6

E Operation

1 Safety regulations for the operation of industrial trucks

Permission to operate: The industrial 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. He shall be afforded all due rights. Safety shows must be worn for pedestrian operated trucks.

Prohibition of unauthorized use: 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 industrial 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.

Dangerous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.

F

Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warning instructions shall be strictly observed.

E Operation

1 Safety regulations for the operation of industrial trucks

Permission to operate: The industrial 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. He shall be afforded all due rights. Safety shows must be worn for pedestrian operated trucks.

Prohibition of unauthorized use: 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 industrial 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.

Dangerous area: A hazardous area is defined as the area in which a person is at risk due to truck movement, lifting operations, the load handler (e.g. forks or attachments) or the load itself. This also includes areas which can be reached by falling loads or lowering operating equipment.

F

Unauthorised persons must be kept away from the hazardous area. Where there is danger to personnel, a warning must be sounded with sufficient notice. If unauthorised personnel are still within the hazardous area the truck shall be brought to a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warning instructions shall be strictly observed.

E 1 E 1

2 Controls and displays

Item Operating or display element

1 Main switch / isolator

(emergency disconnect)

2

3

4

5

6

7

8

9

10

11

12

Jet Pilot

Key switch

Unigage/combination instrument

Controller

“Lower” button

“Lift” button

Warning signal (horn) button

STOP button

“Lift override” switch

Travel release pressuresensitive mat

Jet Pilot adjuster

Function

The supply current is interrupted, all electrical functions are deactivated and the truck automatically brakes.

Steers the truck.

Switches current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.

Indicates the battery’s residual capacity and number of service hours completed by the truck

(see Chapter D).

Controls the direction of travel as well as the travel speed.

Lowers forks and operator platform.

Raises forks and operator platform to first level.

Triggers a warning signal.

The truck brakes at the maximum deceleration rate until it comes to a halt.

Press continually in conjunction with (7).

Lift to highest level.

– Pressure-sensitive mat pressed:

truck ready for operation.

– Pressure-sensitive mat abandoned.

truck brakes.

Adjusts the angle of the Jet Pilot

2 Controls and displays

Item Operating or display element

1 Main switch / isolator

(emergency disconnect)

2

3

4

5

6

7

8

9

10

11

12

Jet Pilot

Key switch

Unigage/combination instrument

Controller

“Lower” button

“Lift” button

Warning signal (horn) button

STOP button

“Lift override” switch

Travel release pressuresensitive mat

Jet Pilot adjuster

Function

The supply current is interrupted, all electrical functions are deactivated and the truck automatically brakes.

Steers the truck.

Switches current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel.

Indicates the battery’s residual capacity and number of service hours completed by the truck

(see Chapter D).

Controls the direction of travel as well as the travel speed.

Lowers forks and operator platform.

Raises forks and operator platform to first level.

Triggers a warning signal.

The truck brakes at the maximum deceleration rate until it comes to a halt.

Press continually in conjunction with (7).

Lift to highest level.

– Pressure-sensitive mat pressed:

truck ready for operation.

– Pressure-sensitive mat abandoned.

truck brakes.

Adjusts the angle of the Jet Pilot

E 2 E 2

1

5

6

8

7

2

9

12

10

4

3

11

E 3

1

5

6

8

7

2

9

12

10

4

3

11

E 3

3 Starting up the truck

F

Before the truck can be started, operated or a load lifted, the driver must ensure that there is nobody within the hazardous area.

Daily checks and operations to be performed before starting work

– Visually inspect the entire truck (in particular wheels and load handler) for obvious damage.

– Check the steering play.

– Visibly check battery and cable connections

– Stand on the operator platform.

– After releasing the control handle adjuster (12), set the

Jet Pilot (2) to the required position and then release the control handle adjuster.

– Pull up the isolator (1).

– Using the key, set the key switch (3) to “I”

– Test the horn (8).

– Test the controller (5).

1

Z

The truck is now operational.

The combination instrument (4) indicates the available battery capacity.

5

8

12

3

2

3 Starting up the truck

F

Before the truck can be started, operated or a load lifted, the driver must ensure that there is nobody within the hazardous area.

Daily checks and operations to be performed before starting work

– Visually inspect the entire truck (in particular wheels and load handler) for obvious damage.

– Check the steering play.

– Visibly check battery and cable connections

– Stand on the operator platform.

– After releasing the control handle adjuster (12), set the

Jet Pilot (2) to the required position and then release the control handle adjuster.

– Pull up the isolator (1).

– Using the key, set the key switch (3) to “I”

– Test the horn (8).

– Test the controller (5).

1

Z

The truck is now operational.

The combination instrument (4) indicates the available battery capacity.

5

8

12

3

2

E 4 E 4

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.

Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the industrial truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area.

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.

Persons riding in the lift with the industrial truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck.

Nature of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or falling down. Never transport loads stacked higher than the top of the fork carriage or the load guard.

Towing trailers: Do not exceed the maximum trailer load specified for the industrial truck for trailers with or without brakes. The trailer load must be secured in accordance with regulations and must not exceed the dimensions permitted for that roadway. After coupling and before starting the driver shall ensure that the trailer coupling cannot become detached. Industrial trucks pulling a load must be driven such that the trailing vehicle is driven safely and can be stopped under any conditions.

E 5

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.

Driving conduct: The driver must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots. The driver must always observe an adequate braking distance between the industrial truck and the vehicle in front and must be in control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns and overtaking at dangerous or blind spots are not permitted. It is forbidden to lean out of or reach beyond the working and operating area.

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.

Persons riding in the lift with the industrial truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck.

Nature of loads to be carried: The operator must make sure that the load is in a satisfactory condition. Do not carry loads unless they are positioned safely and carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from tipping or falling down. Never transport loads stacked higher than the top of the fork carriage or the load guard.

Towing trailers: Do not exceed the maximum trailer load specified for the industrial truck for trailers with or without brakes. The trailer load must be secured in accordance with regulations and must not exceed the dimensions permitted for that roadway. After coupling and before starting the driver shall ensure that the trailer coupling cannot become detached. Industrial trucks pulling a load must be driven such that the trailing vehicle is driven safely and can be stopped under any conditions.

E 5

4.2

Travel, steering, braking

F

Be extremely careful when driving and steering, especially when parts of the body protrude from the truck contour.

In walk-along mode make sure you have sufficient distance from the truck.

The electric steering system is self-monitoring.

The steering controller monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering controller reduces the travel speed of the truck to slow travel. If such a fault occurs, the travel speed is not reset to normal travel by switching the truck off and on again. This prevents a fault being cancelled without being rectified.

As the steering system is a safety-critical component, the fault must be rectified by the manufacturer's service department.

Emergency Disconnect

Press the isolator (1) down. All electrical functions are switched off.

4.2

Travel, steering, braking

F

Be extremely careful when driving and steering, especially when parts of the body protrude from the truck contour.

In walk-along mode make sure you have sufficient distance from the truck.

The electric steering system is self-monitoring.

The steering controller monitors the fault frequency over a certain period. If the same fault is detected several times during this period, the steering controller reduces the travel speed of the truck to slow travel. If such a fault occurs, the travel speed is not reset to normal travel by switching the truck off and on again. This prevents a fault being cancelled without being rectified.

As the steering system is a safety-critical component, the fault must be rectified by the manufacturer's service department.

Emergency Disconnect

Press the isolator (1) down. All electrical functions are switched off.

E 6 E 6

Travel

V

5

8

1

R

4

3

11

V

F

Do not drive the truck unless the panels are closed and properly locked.

– Start up the truck (see Section 3).

– Enter the truck and step on the pressure-sensitive mat to release travel (11).

– Turn the controller (5) in the desired travelling direction: forward (V) or reverse (R).

Z

The truck will move in the selected direction.

The travel speed is governed by the controller (5).

Note on speed reduction and audible warning

– Travel speed reduction: when travelling in load direction and travelling in drive direction with platform < 170 mm: reduction to 2.5 km/h

– Audible warning: when travelling in load direction and platform above 170 mm.

Travelling on inclines

M

Loads must always be carried at that end of the truck facing uphill.

Preventing the truck from “rolling downhill”:

With the controller (5) set to “0”, the service brake is automatically applied after a short jerk (the controller detects downhill motion on an incline). The service brake is released again via the controller (5), which is also used to select the speed and the travel direction.

Jet Pilot

Z

Turn the steering arm (2) to the left or right.

E 7

Travel

V

5

8

1

R

4

3

11

V

F

Do not drive the truck unless the panels are closed and properly locked.

– Start up the truck (see Section 3).

– Enter the truck and step on the pressure-sensitive mat to release travel (11).

– Turn the controller (5) in the desired travelling direction: forward (V) or reverse (R).

Z

The truck will move in the selected direction.

The travel speed is governed by the controller (5).

Note on speed reduction and audible warning

– Travel speed reduction: when travelling in load direction and travelling in drive direction with platform < 170 mm: reduction to 2.5 km/h

– Audible warning: when travelling in load direction and platform above 170 mm.

Travelling on inclines

M

Loads must always be carried at that end of the truck facing uphill.

Preventing the truck from “rolling downhill”:

With the controller (5) set to “0”, the service brake is automatically applied after a short jerk (the controller detects downhill motion on an incline). The service brake is released again via the controller (5), which is also used to select the speed and the travel direction.

Jet Pilot

Z

Turn the steering arm (2) to the left or right.

E 7

Braking

F

The brake pattern of the truck depends largely on the ground conditions. This must be taken into account by the driver for his driving behaviour.

The truck can brake in three different ways:

– using the service brake

– by regenerative braking (coasting)

– by inversion braking (controller)

F

In emergencies, the truck must only be braked with the service brake.

During normal operation, the generator brake and plugging can be applied. These methods of braking reduce wear and require less energy (energy recovery).

4

3

V

8

1

V

5

11

R

Braking

F

The brake pattern of the truck depends largely on the ground conditions. This must be taken into account by the driver for his driving behaviour.

The truck can brake in three different ways:

– using the service brake

– by regenerative braking (coasting)

– by inversion braking (controller)

F

In emergencies, the truck must only be braked with the service brake.

During normal operation, the generator brake and plugging can be applied. These methods of braking reduce wear and require less energy (energy recovery).

4

3

V

8

1

V

5

11

R

E 8 E 8

Braking with the service brake:

– Apply the brake button (9).

The truck brakes at the maximum possible deceleration rate until it comes to a halt.

Z

The truck can only start again when the controller (5) has been set to “0”.

Braking via the generator brake (coasting):

– Release the controller (5) - the controller assumes the zero position.

Depending on the setting, the truck brakes via the generator brake, coasting to a stop.

Inversion braking

– When travelling, set the controller (5) to the opposite direction.

The truck brakes regeneratively until it starts to move in the opposite direction.

The brake force depends on the position of the controller.

5

9

8

Braking with the service brake:

– Apply the brake button (9).

The truck brakes at the maximum possible deceleration rate until it comes to a halt.

Z

The truck can only start again when the controller (5) has been set to “0”.

Braking via the generator brake (coasting):

– Release the controller (5) - the controller assumes the zero position.

Depending on the setting, the truck brakes via the generator brake, coasting to a stop.

Inversion braking

– When travelling, set the controller (5) to the opposite direction.

The truck brakes regeneratively until it starts to move in the opposite direction.

The brake force depends on the position of the controller.

5

9

8

E 9 E 9

4.3

Lifting and depositing loads

M

Before collecting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded.

– Drive the truck with forks as far as possible underneath the load. Do not lift long loads at an angle.

M

Pick up the load, ensuring that it does not protrude excessively beyond the fork tines

(< 50 mm).

Lift & Lower

Press the “Lift” (7) or “Lower” (6) buttons to lift or lower the forks and the operator platform at a fixed speed.

Z

There are two lifting levels provided so that the operator platform can be raised at height h1 = 170 mm and height h2 =

215 mm above ground level.

Lifting to height h1

– Press the “lift” button (7). Keep pressing the button until you reach height h1.

Lowering

– Press the “Lower” button (6) button to lower the forks and the operator platform.

6 7


– Press the “Lift” button (7) and one of the two lift override buttons (10) in the backrest simultaneously. Keep pressing the button until you reach height h2.

Lowering


10

10

4.3

Lifting and depositing loads

M

Before collecting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded.

– Drive the truck with forks as far as possible underneath the load. Do not lift long loads at an angle.

M

Pick up the load, ensuring that it does not protrude excessively beyond the fork tines

(< 50 mm).

Lift & Lower

Press the “Lift” (7) or “Lower” (6) buttons to lift or lower the forks and the operator platform at a fixed speed.

Z

There are two lifting levels provided so that the operator platform can be raised at height h1 = 170 mm and height h2 =

215 mm above ground level.


– Press the “lift” button (7). Keep pressing the button until you reach height h1.

Lowering


6 7


– Press the “Lift” button (7) and one of the two lift override buttons (10) in the backrest simultaneously. Keep pressing the button until you reach height h2.

Lowering


10

10

E 10 E 10

4.4

Parking the truck securely

When you leave the truck it must be securely parked even if you only intend to leave it for a short time.

– Do not park the truck on an incline.

– Fully lower the load forks.

– Turn switch key (3) to the "0" position and remove the key.

– Press the main switch (1) "Off".

Fold in the folding safety bar (where applicable).

1

3

4.4

Parking the truck securely

When you leave the truck it must be securely parked even if you only intend to leave it for a short time.

– Do not park the truck on an incline.

– Fully lower the load forks.

– Turn switch key (3) to the "0" position and remove the key.

– Press the main switch (1) "Off".

Fold in the folding safety bar (where applicable).

1

3

E 11 E 11

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

Truck does not travel

Load cannot be lifted

No display on battery discharge indicator

Probable cause

– Battery connector not plugged in

– Isolator pressed

– Key switch in “0” position

Action

– Check battery plug and plug in if necessary

– Release isolator

– Set key switch to “I”

– Battery charge too low – Check battery charge, charge battery if necessary

– Faulty fuse – Check fuses F1, 1F1 and 3F9

– Truck not operational – Carry out all measures listed under

“Truck does not start”

– Hydraulic oil level too low

– Excessive load

– Check the hydraulic oil level

– Note maximum capacity

(see data plate)

– Battery discharge monitor has cut out and indicates “STOP”

– Charge battery

– Faulty fuse – Check fuse 2F1

– Truck not operational – Check battery plug and plug in if necessary


– Faulty fuse


– Check fuse 6F1

Z

If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service organisation, as any further troubleshooting can only be performed by specially trained and qualified service personnel.

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

Truck does not travel

Load cannot be lifted

No display on battery discharge indicator

Probable cause

– Battery connector not plugged in


– Key switch in “0” position

Action

– Check battery plug and plug in if necessary


– Set key switch to “I”

– Battery charge too low – Check battery charge, charge battery if necessary

– Faulty fuse – Check fuses F1, 1F1 and 3F9

– Truck not operational – Carry out all measures listed under

“Truck does not start”

– Hydraulic oil level too low

– Excessive load

– Check the hydraulic oil level

– Note maximum capacity

(see data plate)

– Battery discharge monitor has cut out and indicates “STOP”

– Charge battery

– Faulty fuse – Check fuse 2F1

– Truck not operational – Check battery plug and plug in if necessary


– Faulty fuse


– Check fuse 6F1

Z

If the fault cannot be rectified after carrying out the remedial procedure, notify the manufacturer’s service organisation, as any further troubleshooting can only be performed by specially trained and qualified service personnel.

E 12 E 12


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 servicing checklists.

F

Any modifications to the industrial truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.

M

Only original spare parts have been certified by our quality assurance department.

To ensure safe and reliable operation of the truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.

Upon completion of inspection and servicing, the tasks contained in the “Recommissioning” section must be performed (see Chapter F).

2 Maintenance safety regulations

Maintenance personnel: Industrial trucks must only be serviced and maintained by the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend 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.

For jack points see Chapter B.

Cleaning operations: 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. Use only low vacuum air, low compressed air and non-conducting, antistatic brushes for the cleaning of 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.

Cleaning by means of a steam jet is not permitted.

After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.

F 1


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 servicing checklists.

F

Any modifications to the industrial truck assemblies, in particular the safety mechanisms, is prohibited. The operational speeds of the truck must not be changed under any circumstances.

M

Only original spare parts have been certified by our quality assurance department.

To ensure safe and reliable operation of the truck, use only the manufacturer's spare parts. Used parts, oils and fuels must be disposed of in accordance with the relevant environmental protection regulations. For oil changes, contact the manufacturer’s specialist department.

Upon completion of inspection and servicing, the tasks contained in the “Recommissioning” section must be performed (see Chapter F).

2 Maintenance safety regulations

Maintenance personnel: Industrial trucks must only be serviced and maintained by the manufacturer’s trained personnel. The manufacturer’s service department has field technicians specially trained for these tasks. We therefore recommend 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.

For jack points see Chapter B.

Cleaning operations: 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. Use only low vacuum air, low compressed air and non-conducting, antistatic brushes for the cleaning of 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.

Cleaning by means of a steam jet is not permitted.

After cleaning the truck, carry out the activities detailed in the “Recommissioning” section.

F 1

F 2

Work on the electric 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 is not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.

Work on the electric 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 is not lubricated. The intervals stated in the service checklist apply to normal duty use. More demanding conditions (dust, temperature) require more regular lubrication. The prescribed chain spray must be used in accordance with the instructions. Applying grease externally will not provide sufficient lubrication.

Hydraulic hoses: The hoses must be replaced every six years. When replacing hydraulic components, also replace the hoses in the hydraulic system.

F 2

3 Servicing and inspection

Thorough and expert servicing is one of the most important preconditions for 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 listed 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 specifies the tasks and intervals after which they should be carried out. The servicing intervals are defined as follows:

W = Every 50 service hours, at least weekly

A = Every 500 service hours, or at least every six months.

B = Every 1000 service hours, or at least annually.

C = Every 2000 service hours, or at least annually.

Z

W service intervals must be performed by the owner.

During the run-in period – after approx. 100 service hours – the owner must check the wheel nuts/bolts and re-tighten if necessary.

3 Servicing and inspection

Thorough and expert servicing is one of the most important preconditions for 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 listed 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 specifies the tasks and intervals after which they should be carried out. The servicing intervals are defined as follows:

W = Every 50 service hours, at least weekly

A = Every 500 service hours, or at least every six months.

B = Every 1000 service hours, or at least annually.

C = Every 2000 service hours, or at least annually.

Z

W service intervals must be performed by the owner.

During the run-in period – after approx. 100 service hours – the owner must check the wheel nuts/bolts and re-tighten if necessary.

F 3 F 3

4 Maintenance checklist

Maintenance intervals

Standard

Cold store

= t W A B C

= k

Chassis/ structure:

Drive system:

Wheels:

Steering:

Brake system:

Hydraulic system:

1.1 Check all load bearing components for damage

1.2 Check screw connections

1.3 Test the operator’s platform and check for damage

2.1 Check transmission for noise and leakage

2.2 Checking the transmission oil level

2.3 Change transmission oil

3.1 Check wheels for wear and damage

3.2 Test suspension and tightness

4.1 Check the steering play

4.2 Check the steering chain and the chain sprocket for wear; adjust and grease

4.3 Check the mechanical parts of the steering column; grease if necessary

5.1 Test operation and settings

5.2 Check gas pressure springs recuperate, are sealed and not damaged

6.1 Test operation

6.2 Check connections and ports for leaks and damage

6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure t k t t

5.3 Check the brake lining wear t

5.4 Check brake mechanism, adjust and lubricate if necessary k t k t k t k t

6.4 Check oil level t t t t t k t t k t t k t k t

6.5 Replace hydraulic oil and filter cartridge

6.6 Test operation of pressure relief valves k t k t

Electrical system:

7.1 Test operation

7.2 Make sure wire connections are secure and check for wire t t damage

7.3 Check fuse rating t

7.4 Test switches and trip cams and make sure they are secure

7.5 Check contactors and relays; if necessary replace any worn t t parts

Electric motors:

7.6 Test all warning devices and safety switches.

8.1 Check carbon brush wear

8.2 Check motor attachment

8.3 Vacuum-clean motor housing and check commutator for wear k t t t k t

4 Maintenance checklist


Standard

Cold store

= t W A B C

= k

Chassis/ structure:

Drive system:

Wheels:

Steering:

Brake system:

Hydraulic system:

1.1 Check all load bearing components for damage

1.2 Check screw connections

1.3 Test the operator’s platform and check for damage

2.1 Check transmission for noise and leakage

2.2 Checking the transmission oil level

2.3 Change transmission oil

3.1 Check wheels for wear and damage

3.2 Test suspension and tightness

4.1 Check the steering play

4.2 Check the steering chain and the chain sprocket for wear; adjust and grease

4.3 Check the mechanical parts of the steering column; grease if necessary

5.1 Test operation and settings

5.2 Check gas pressure springs recuperate, are sealed and not damaged

6.1 Test operation

6.2 Check connections and ports for leaks and damage

6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure t k t t

5.3 Check the brake lining wear t

5.4 Check brake mechanism, adjust and lubricate if necessary k t k t k t k t

6.4 Check oil level t t t t t k t t k t t k t k t

6.5 Replace hydraulic oil and filter cartridge

6.6 Test operation of pressure relief valves k t k t

Electrical system:

7.1 Test operation

7.2 Make sure wire connections are secure and check for wire t t damage

7.3 Check fuse rating t

7.4 Test switches and trip cams and make sure they are secure

7.5 Check contactors and relays; if necessary replace any worn t t parts

Electric motors:

7.6 Test all warning devices and safety switches.

8.1 Check carbon brush wear

8.2 Check motor attachment

8.3 Vacuum-clean motor housing and check commutator for wear k t t t k t

F 4 F 4


Battery:

Lift mechanism:

Lubrication:

General measurements:

Presentation:

Standard

Cold store

9.1 Check acid density, acid level and cell voltage

9.2 Check terminals are securely attached, and apply grease

= t W A B C

= k t t

9.3 Clean battery plug connections, make sure they are firmly secured t

9.4 Check battery cables for damage, replace if necessary.

t

10.1 Check operation, wear and setting

10.2 Visually inspect rollers, slide pieces and stops

10.3 Check forks and fork carriage for wear and damage

11.1 Lubricate truck in accordance with Lubrication

Schedule.

12.1 Check electrical system for accidental earth t t t t

12.2 Test travel speed and braking distance

12.3 Test lift and lowering speeds

12.4 Test safety devices and cutouts

13.1 Test run with rated load

13.2 After carrying out maintenance, present the truck to the supervisor.

t t t t t t

Z

Maintenance intervals apply to normal operating conditions. In more arduous conditions, reduce accordingly.


Battery:

Lift mechanism:

Lubrication:

General measurements:

Presentation:

Standard

Cold store

9.1 Check acid density, acid level and cell voltage

9.2 Check terminals are securely attached, and apply grease

= t W A B C

= k t t

9.3 Clean battery plug connections, make sure they are firmly secured t

9.4 Check battery cables for damage, replace if necessary.

t

10.1 Check operation, wear and setting

10.2 Visually inspect rollers, slide pieces and stops

10.3 Check forks and fork carriage for wear and damage

11.1 Lubricate truck in accordance with Lubrication

Schedule.

12.1 Check electrical system for accidental earth t t t t

12.2 Test travel speed and braking distance

12.3 Test lift and lowering speeds

12.4 Test safety devices and cutouts

13.1 Test run with rated load

13.2 After carrying out maintenance, present the truck to the supervisor.

t t t t t t

Z

Maintenance intervals apply to normal operating conditions. In more arduous conditions, reduce accordingly.

F 5 F 5

5 Lubrication schedule 5 Lubrication schedule s E F s E F

F 6 g Contact surfaces s Grease nipple

Hydraulic oil filler neck b Transmission oil filler neck a Transmission oil drain plug

Cold storage

1) Compound ratio for cold store usage 1 : 1

2) 1.25 – 1.3 litres depending on the type of transmission (always up to the lower mark of the filler neck)

F 6 g Contact surfaces s Grease nipple

Hydraulic oil filler neck b Transmission oil filler neck a Transmission oil drain plug

Cold storage

1) Compound ratio for cold store usage 1 : 1

2) 1.25 – 1.3 litres depending on the type of transmission (always up to the lower mark of the filler neck)

5.1

Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions.

Z

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.

A

B

C

29 200 670

50 380 904

29 200 810

D

E

F

29 200 150

29 201 430

29 200 100

G 29 201 280

Grease data

Package quantity

5.0 l

5.0 l

5.0 l

1.0 l

1.0 kg

1.0 kg

0.51 kg

Model Used for

H-LP 46, DIN 51524 Hydraulic system

Fuchs Titan Gear

HSY 75W-90

Transmission

H-LP 10, DIN 51524 Transmission, hydraulic system

Brake fluid Braking system

Grease, DIN 51825 Lubrication

Grease, TTF52 Lubrication

Chain spray Chains

Code Saponification Dew point

°C

E

F

Lithium

—

185

—

Worked penetr. at 25 °C

265 - 295

310 - 340

NLG1 class

2

1

Application temperature °C

-35 / +120

-52 / +100

5.1

Fuels, coolants and lubricants

Handling consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions.

Z

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.

A

B

C

29 200 670

50 380 904

29 200 810

D

E

F

G

29 200 150

29 201 430

29 200 100

29 201 280

Grease data

Package quantity

5.0 l

5.0 l

5.0 l

1.0 l

1.0 kg

1.0 kg

0.51 kg

Model Used for

H-LP 46, DIN 51524 Hydraulic system

Fuchs Titan Gear

HSY 75W-90

Transmission

H-LP 10, DIN 51524 Transmission, hydraulic system

Brake fluid Braking system

Grease, DIN 51825 Lubrication

Grease, TTF52 Lubrication

Chain spray Chains

Code Saponification Dew point

°C

E

F

Lithium

—

185

—

Worked penetr. at 25 °C

265 - 295

310 - 340

NLG1 class

2

1

Application temperature °C

-35 / +120

-52 / +100

F 7 F 7

6 Maintenance and repairs

6.1

Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents during maintenance and repair work. The following preparatory operations must be performed:

– Parking the truck securely

(see Chapter E).

Z

Opening the battery panel

(see Chapter D).

– Disconnect the battery (2) to prevent the truck from accidentally starting.

– When working under a raised lift truck, secure it to prevent it from lowering, tipping or sliding away.

F

When raising the truck also refer to the instructions in the “Transport and

Commissioning” section (see Chapter C ).

3

4

6.2

Opening the battery panel

(see Chapter D).

6.3

Opening the front panel

– Unlock the panel latches (3) using a spanner (width 8).

– Lift off the panel (4) and place it next to the truck.

When the work is finished, closed the panel (4).

3

6 Maintenance and repairs

6.1

Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents during maintenance and repair work. The following preparatory operations must be performed:

– Parking the truck securely

(see Chapter E).

Z

Opening the battery panel

(see Chapter D).

– Disconnect the battery (2) to prevent the truck from accidentally starting.

– When working under a raised lift truck, secure it to prevent it from lowering, tipping or sliding away.

F

When raising the truck also refer to the instructions in the “Transport and

Commissioning” section (see Chapter C ).

3

4

6.2

Opening the battery panel

(see Chapter D).

6.3

Opening the front panel

– Unlock the panel latches (3) using a spanner (width 8).

– Lift off the panel (4) and place it next to the truck.

When the work is finished, closed the panel (4).

3

F 8 F 8

6.4

Checking the drive wheel bearing and attachment

– Prepare the truck for maintenance and repairs (see Section 6.1).

– Open the front panel

(see Section 6.2).

– Raise the truck so that the drive wheel (8) runs freely.

– Manually turn the drive wheel and make sure there is no noise.

– Put the truck down.

– Turn the Jet Pilot as far to the left as it will go.

– Tighten the wheel nuts (9) crosswise with a torque wrench.

8 / 9

Z

Torque

– 1. Torque M

A

– 2. Torque M

A

= 10 Nm

= 105 Nm

– Set the operator platform (4) in position and secure with the mounting screws.

– Restore the control line connections to the operator platform.

6.5

Checking the hydraulic oil level



(see Section 6.2).

– Check hydraulic oil level in hydraulic reservoir (11).

Z

There are markings (10) on the hydraulic reservoir. The oil level should lie between the "max" and "min" markings when the forks are lowered.

If necessary, add hydraulic oil of the correct grade up to the "max" mark.

(for hydraulic oil specification, see Section 5).

max min

10

11

6.4

Checking the drive wheel bearing and attachment



(see Section 6.2).

– Raise the truck so that the drive wheel (8) runs freely.

– Manually turn the drive wheel and make sure there is no noise.

– Put the truck down.

– Turn the Jet Pilot as far to the left as it will go.

– Tighten the wheel nuts (9) crosswise with a torque wrench.

8 / 9

Z

Torque

– 1. Torque M

A

– 2. Torque M

A

= 10 Nm

= 105 Nm

– Set the operator platform (4) in position and secure with the mounting screws.

– Restore the control line connections to the operator platform.

6.5

Checking the hydraulic oil level



(see Section 6.2).

– Check hydraulic oil level in hydraulic reservoir (11).

Z

There are markings (10) on the hydraulic reservoir. The oil level should lie between the "max" and "min" markings when the forks are lowered.

If necessary, add hydraulic oil of the correct grade up to the "max" mark.

(for hydraulic oil specification, see Section 5).

max min

10

11

F 9 F 9

6.6

Operator platform height fine tuning

The two pre-set operator platform heights (170 and 215 mm) can be adjusted if required.

For this there are two vertical, adjustable proximity initiators (A,B) in the drive compartment acting as sensors.

Sensor (A) controls the top height

(215 mm), sensor (B) the lower height

(170 mm).

A

B

C

6.6

Operator platform height fine tuning

The two pre-set operator platform heights (170 and 215 mm) can be adjusted if required.

For this there are two vertical, adjustable proximity initiators (A,B) in the drive compartment acting as sensors.

Sensor (A) controls the top height

(215 mm), sensor (B) the lower height

(170 mm).

A

B

C

Height adjustment

Sensor A:

Loosen the Allen screws (C), move sensor (A) and set it to the required position.

If necessary readjust sensor (B) as well.

Sensor B:

Loosen sensor (B) and set it to the required position.

Height adjustment

Sensor A:

Loosen the Allen screws (C), move sensor (A) and set it to the required position.

If necessary readjust sensor (B) as well.

Sensor B:

Loosen sensor (B) and set it to the required position.

F 10 F 10

6.7

Checking electrical fuses

– Preparing the truck for maintenance and repairs

(see Section 6.1).

– Open the front panel (see Section 6.2).

– Check rating of all fuses in accordance with table, replace if necessary.

16

10

11

15

14

12 13

13

14

15

16

Item

10

11

12

Model

3F9

1F10

2F1

1F1

F1

6F2

--

To protect:

Steer motor ( o )

Field travel

Pump motor

Drive motor

Overall control circuit fuse

Battery discharge indicator /hourmeter

Steering controller ( o )

Value

30 A

40 A

150 A

150 A

10 A

10 A

--

F 11

6.7

Checking electrical fuses

– Preparing the truck for maintenance and repairs

(see Section 6.1).

– Open the front panel (see Section 6.2).

– Check rating of all fuses in accordance with table, replace if necessary.

16

10

11

15

14

13

14

15

16

Item

10

11

12

12 13

Model

3F9

1F10

2F1

1F1

F1

6F2

--

To protect:

Steer motor ( o )

Field travel

Pump motor

Drive motor

Overall control circuit fuse

Battery discharge indicator /hourmeter

Steering controller ( o )

Value

30 A

40 A

150 A

150 A

10 A

10 A

--

F 11

6.8

Recommissioning

The truck may only be restored to service after cleaning or repair work, once the following operations have been performed.

– Test horn.

– Test main switch operation.

– Test brakes.

– Lubricate the truck in accordance with the lubrication chart.

7 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.

M

On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.

If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.

7.1

Prior to decommissioning:

– Thoroughly clean the truck.

– Check the brakes.

– Check the hydraulic oil level and replenish as necessary (see Chapter F).

– Apply a thin layer of oil or grease to any non-painted mechanical components.

– Lubricate the truck in accordance with the lubrication schedule (see Chapter F).


– Disconnect the battery, clean it and apply grease to the battery poles.

Z

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:


M

Battery powered trucks:

The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.

F 12

6.8

Recommissioning

The truck may only be restored to service after cleaning or repair work, once the following operations have been performed.

– Test horn.

– Test main switch operation.

– Test brakes.

– Lubricate the truck in accordance with the lubrication chart.

7 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. for operational reasons, it must be parked in a frost-free and dry location and all necessary measures must be taken before, during and after decommissioning as described.

M

On decommissioning the truck must be jacked up so that all the wheels are clear of the ground. This is the only way of ensuring that the wheels and wheel bearings are not damaged.

If the truck is to be out of service for more than 6 months, further measures must be taken in consultation with the manufacturer’s service department.

7.1

Prior to decommissioning:


– 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.



– Disconnect the battery, clean it and apply grease to the battery poles.

Z

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:


M


The battery must be charged at regular intervals to avoid depletion of the battery through self-discharge. The sulfatisation would destroy the battery.

F 12

7.3

Returning the truck to operation after decommissioning



– Clean the battery, grease the terminals and connect the battery.


– Check transmission oil for condensed water and replace if necessary.

– Check hydraulic oil for condensed water and replace if necessary.

– Start up the truck (see Chapter E).

Z


If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.

F

Perform several brake tests immediately after re-commissioning the truck.

8 Safety tests to be performed at intervals and after unusual events

( D : Accident prevention check according to BGV D27

The truck must be inspected at least annually 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 industrial trucks.

A complete test must be carried out on the vehicle concerning its engineering condition with regard to safety. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified.

Z

The manufacturer has a safety department with trained personnel to carry out inspections. A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.

9 Final de-commissioning, disposal

Z

Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

7.3

Returning the truck to operation after decommissioning



– Clean the battery, grease the terminals and connect the battery.


– Check transmission oil for condensed water and replace if necessary.

– Check hydraulic oil for condensed water and replace if necessary.

– Start up the truck (see Chapter E).

Z


If there are switching problems in the electrical system, apply contact spray to the exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly.

F

Perform several brake tests immediately after re-commissioning the truck.

8 Safety tests to be performed at intervals and after unusual events

( D : Accident prevention check according to BGV D27

The truck must be inspected at least annually 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 industrial trucks.

A complete test must be carried out on the vehicle concerning its engineering condition with regard to safety. The truck must also be examined for damage caused by possible improper use. A test report shall be provided. The test results must be kept for at least the next 2 inspections.

The owner is responsible for ensuring that faults are immediately rectified.

Z

The manufacturer has a safety department with trained personnel to carry out inspections. A test plate is attached to the truck as proof that it has passed the safety inspection. This plate indicates the due date for the next inspection.

9 Final de-commissioning, disposal

Z

Final, proper decommissioning or disposal of the truck must be performed in accordance with the regulations of the country of application. In particular, regulations governing the disposal of batteries, fuels and electronic and electrical systems must be observed.

F 13 F 13

F 14 F 14

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


Instructions for use

Jungheinrich traction battery

Table of contents

1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB ..........................................2-6


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


1 1

1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB

Rating Data

1. Nominal capacity C5:

2. Nominal voltage:

3. Discharge current::

4. 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.

•Dangerous electrical voltage!

•Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!

2

1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB

Rating Data


2. Nominal voltage:

3. Discharge current::

4. Nominal S.G. of electrolyte*

Type EPzS:

Type EPzB:


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.

•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

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

Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void.


1. Commissioning filled and charged batteries. For commissioning of unfilled batteries see separate instructions!


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


2.1 Discharging

Be sure that all breather holes are not sealed or covered.



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

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

4

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.

The electrolyte must conform to the purity regulations in DIN 43530 part 2.

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.


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).


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.

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 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.

For batteries up to 20 V nominal voltage the minimum value is 1000 Ω .

4. Care of the battery

The battery should always be kept clean and dry to prevent tracking currents. 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 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

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


The tests on the insulation resistance of the battery must be conducted in accordance with DIN EN 60254-1.







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

6

5. Storage

If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made:

1. a monthly equalising charge as in point 2.3

2. float charging at a charging voltage of 2.23 V x the number of cells. The storage time should be taken into account when considering the life of the battery.

6. Malfunctions

If malfunctions are found on the battery or the charger our service department should be called in without delay. The measurements taken in point 3.3 will facilitate fault 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.

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.






6

7. Type plate, Jungheinrich traction battery

2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5

Batteriegewicht min/max

Battery mass min/max

8

7

8

9

Hersteller

9

Manufacturer

Jungheinrich AG, D-22047 Hamburg, Germany

Pb Pb

6

5

11

13

1

14

Item Designation

1 Logo

2 Battery designation

3 Battery type

4 Battery number

5 Battery tray number

6 Delivery date

7 Battery manufacturer's logo


8

9

10

11

Recycling symbol

Dustbin/material

Nominal battery voltage

Nominal battery capacity

12 Number of battery cells

13 Battery weight

14 Safety instructions and warnings

* CE mark is only for batteries with a nominal voltage greater than 75 volt.


2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5


8


7

8

9

Hersteller

Manufacturer


Pb Pb

6

5

11

13

1

14


1 Logo


3 Battery type

4 Battery number


6 Delivery date



8

9

10

11

Recycling symbol

Dustbin/material



12 Number of battery cells

13 Battery weight



7 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

–

2/180 – 10/900

2/210 – 10/1050

2/230 – 10/1150

2/250 – 10/1250

2/280 – 10/1400

2/310 – 10/1550

2/216 – 12/1296

–

–

–

–

–

–

Aquamatic plug type

Frötek

(yellow)

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

72,0 mm

72,0 mm

(length)

BFS

(black)

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

66,0 mm

66,0 mm

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column

EPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.

2 EPzS 120.

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

–

2/180 – 10/900

2/210 – 10/1050

2/230 – 10/1150

2/250 – 10/1250

2/280 – 10/1400

2/310 – 10/1550

2/216 – 12/1296

–

–

–

–

–

–

Aquamatic plug type

Frötek

(yellow)

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

50,5 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

72,0 mm

72,0 mm

(length)

BFS

(black)

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

51,0 mm

56,0 mm

56,0 mm

61,0 mm

61,0 mm

61,0 mm

61,0 mm

66,0 mm

66,0 mm

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column

EPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g.

2 EPzS 120.

8

Aquamatic plug with diagnostics hole

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.

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

Aquamatic plug with diagnostics hole

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.

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).

Diagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with solenoid valve

5. Charger

6. Sealing coupler

7. Closing nipple

8. Ion exchange cartridge with conductance meter and solenoid valve

9. Connection for untreated water

10. Charging lead

1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically 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.

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

Diagrammatic view

Equipment for the water refilling system

1. Water tank

2. Level switch

3. Discharge point with ball valve

4. Discharge point with solenoid valve

5. Charger

6. Sealing coupler

7. Closing nipple

8. Ion exchange cartridge with conductance meter and solenoid valve

9. Connection for untreated water

10. Charging lead

1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically 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.

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

10

4. Filling (manual/automatic)

The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week.

5. Connection pressure

The water refilling unit is to be operated in such a way that the water pressure in the water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair the system's functional reliability. This wide pressure range permits three types of 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

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.

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

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

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.

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

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 11

12

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

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.

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

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


2. Nominal voltage:

3. Discharge current:


See type plate

2,0 Volt x No of cells

C5/5h

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.

• Dangerous electrical voltage!

• Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!

13

2 Jungheinrich traction batterie

Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS

Rating Data


2. Nominal voltage:

3. Discharge current:


See type plate

2,0 Volt x No of cells

C5/5h

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.

• Dangerous electrical voltage!

• Caution! Metal parts of the battery are always live. Do not place tools or other metal objects on the battery!

13

14

Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void.


1. Commissioning


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


2.1 Discharging

Ventilation openings must not be sealed or covered.



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

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.

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.

14

Ignoring the operation instructions, repair with non-original parts and non authorised interventions will render the warranty void.


1. Commissioning


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


2.1 Discharging

Ventilation openings must not be sealed or covered.



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

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.

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.

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.


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.


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

Charge the battery immediately after every discharge.

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.


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.


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

Charge the battery immediately after every discharge.

15 15

16

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


The tests on the insulation resistance of the battery must be conducted in accordance with DIN 43539-1.







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.

2. float charging at a charging voltage of 2.25 V x the number of cells.

The storage time should be taken into account when considering the life of the battery.

16

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


The tests on the insulation resistance of the battery must be conducted in accordance with DIN 43539-1.







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.

2. float charging at a charging voltage of 2.25 V x the number of cells.

The storage time should be taken into account when considering the life of the battery.

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.







2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5



8

7

8

9

Hersteller

9

Manufacturer


Pb Pb

6

5

11

13

1

14


1 Logo


3 Battery type

4 Battery number


6 Delivery date



8 Recycling symbol

9 Dustbin/material

10

11

12



Number of battery cells

13 Battery weight



17

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.







2/3

4

10

12

Typ

1

Type

Serien-Nr.

3

Serial-Nr.

Nennspannung

5

Nominal Voltage

Zellenzahl

7

Number of Cells

Baujahr

2

Year of manufacture

Lieferanten Nr.

Supplier No.

4

Kapazität

Capacity

6

5


8


7

8

9

Hersteller

Manufacturer


Pb Pb

6

5

11

13

1

14


1 Logo


3 Battery type

4 Battery number


6 Delivery date



8 Recycling symbol

9 Dustbin/material

10

11

12



Number of battery cells

13 Battery weight



17

18 18

Jungheinrich ERE 224 Operating Manual

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