Jungheinrich 50435801 Operating Instructions Manual Download

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Operating instructions

50435801

04.04-

03.07

ECE 220

Summary of Contents for 50435801

Page 1: ...Operating instructions 50435801 G 04 04 03 07 ECE 220...

Page 2: ...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 materi...

Page 3: ...0108 GB...

Page 4: ...cation B 6 4 Identification locations and identification plates B 7 4 1 Truck identification plate B 8 C Transportation and commissioning 1 Transportation by crane C 1 2 Commissioning C 1 3 Operating...

Page 5: ...splay E 29 6 3 Switch on test E 29 7 Fault location E 30 F Maintenance of the fork lift truck 1 Operational safety and environmental protection F 1 2 Safety regulations applicable to truck maintenance...

Page 6: ...06 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instruct...

Page 7: ...0506 GB 2...

Page 8: ...f or on whose behalf it is used In special cases e g leasing or renting the user is consid ered the person who in accordance with existing contractual agreements between the owner and the user of the...

Page 9: ...0404 GB A 2...

Page 10: ...on level surfaces for transporting and order picking goods Pallets with open ground support or pallets fitted with lateral boards provided that the boards are outside the range of the load bearing wh...

Page 11: ...o Storage compartment 4 t Master switch emergency stop 14 o Lift mechanism 5 t Controller 15 t Jet Pilot 6 t Brake key 16 t Seat XL version only 7 o Keyboard CANCODE 17 o Castor wheel 8 o Display ins...

Page 12: ...Rapid drive Q Rated capacity 2000 2000 2000 2000 kg c Load centre distance with standard fork length 600 600 600 600 mm Travelling speed with without rated load 8 5 10 5 9 5 12 5 8 5 10 5 9 5 12 5 km...

Page 13: ...2nd level 1867 1877 hr Height of backrest without or der picking on 2nd level 1255 1266 hb Height of battery hood 959 1009 hf Height of driver standing plat form 132 142 b1 Truck width 805 805 b3 Dis...

Page 14: ...3867 2430 3697 2579 1530 2438 2797 3905 2550 3817 2799 1750 2550 3017 4017 2850 4117 3099 2050 2850 3317 4317 2900 4167 3149 2100 2900 3367 4367 3100 4367 3349 2300 3100 3567 4567 l l1 y1 x1 l6 Wa 1...

Page 15: ...ical plane It is determined by driving over bumps with a constant speed Electromagnetic compatibility EMC The manufacturer confirms compliance with the limit val ues for electromagnetic emission and i...

Page 16: ...he load should be distributed as evenly as possible on the forks Item Model 19 Truck data plate 20 Attention Touch Mode warning decal for Touch mode only in drive direction option 21 Accident preventi...

Page 17: ...of the truck Item Designation Item Designation 27 Type 33 Manufacturer 28 Serial No 34 Min max battery weight in kg 29 Rated capacity in kg 35 Drive power in kW 30 Battery Voltage V 36 Load centre di...

Page 18: ...into contact with any at tachments of the truck when the truck is lifted 2 Commissioning M The truck must only be operated on battery current Rectified alternate current will damage the electronics Ca...

Page 19: ...he isolator OFF Set the key switch OFF 0 and remove the key Prevent the truck from rolling away Open the battery panel see chapter D Open the front panel 5 and put it to one side see chapter F Screw o...

Page 20: ...cable shoes must be clean lightly greased with pole grease and must be securely tightened Batteries with bare terminal posts must be covered using a non skid insulating mat Disposal of the battery Ba...

Page 21: ...you must make sure that the battery is safely fastened in the battery compartment of the truck 3 Exposing the battery F Park the truck and render it safe refer to chapter E Pull lever 1 upward and at...

Page 22: ...tery cells must be exposed to en sure adequate ventilation No metal objects must be placed on the battery Prior to starting the recharging operation check all cable connections and plugged connec tion...

Page 23: ...the battery cells Expose the battery refer to section 3 Pull out the battery plug 4 from the holder 5 Fold back the battery locking mechanism 9 Pull the battery 10 laterally onto the battery exchange...

Page 24: ...uck or on the attach ments must immediately be brought to the notice of the person in charge fork lift trucks that cannot be safely operated e g due to worn tyres or defective brakes must not be used...

Page 25: ...si ble deceleration rate until it stands still 6 Controller t Controls the direction of travel as well as the travelling speed 7 Control shaft t Is used to steer the truck 8 Jet Pilot o Is used to ste...

Page 26: ...E 3 1106 GB S T O P 3 4 5 11 10 9 12 13 14 9 10 11 4 3 16 15 1 2 6 3 4 2 2 6 6 4 3 5 7 8 S T O P 3 4 5 11 10 9 12 13 14 9 10 11 4 3 16 15 1 2 6 3 4 2 2 6 6 4 3 5 7 8...

Page 27: ...operating hours of the trucks 14 Code lock t Switches the truck on and off Removing the key secures the truck against switching on by unauthorised per sonnel 15 Control shaft adjustment t The control...

Page 28: ...E 5 1106 GB S T O P 12 13 14 16 15 17...

Page 29: ...the lifting device for vis ible damage Visually check the battery attachment and the cable connections M When mounting the truck make sure that the controller and the operating key Pedestrian o are n...

Page 30: ...ngs Negotiating slopes and inclines Negotiating of slopes and inclines is permitted only when they are recognised lanes when they are clean and non slipping and when the technical specification of the...

Page 31: ...t without eliminating the fault F As the steering system is a safety relevant component the fault must be eliminated by the manufacturer s service personnel Emergency stop Depress the master switch 1...

Page 32: ...urn the controller 6 in the desired travelling direction forward V or reverse R Z The truck will move in the selected direction The travelling speed is controlled by means of the controller 6 For truc...

Page 33: ...system detects rolling downhill on an incline The service brake is released again via the controller 6 which is also used to select the speed and the travelling direction Steering Control shaft t Swiv...

Page 34: ...brake Press the brake key 5 The truck is braked at the maximum possible deceleration rate until it stands still Z Driving is only possible after the controller has been set to 0 Braking by means of t...

Page 35: ...x speed There are two variants of key operated control by using the controller 6 via Pedestrian button 9 11 in the backrest M For the inching function in drive direction only option the pedestrian con...

Page 36: ...up long loads crosswise is not permitted M Pick up the load ensuring that it does not project excessively from the tips of the lifting device less than 50 mm Lifting and lowering Z When operating the...

Page 37: ...the battery hood 20 if needed When order picking operations are performed at the second level the operator must hold on to the handles 18 and not use the control shaft or Jet Pilot as support No cont...

Page 38: ...To fold in the seat slide it to the highest position and fold it in 4 7 Safe parking of the truck If the truck is left unattended even for only short periods of time it must be rendered safe F Never...

Page 39: ...eters only in conjunction with the indicator instrument CANDIS o The o key has top priority and reset the truck from any condition to the basic condition without modifying any settings 5 1 Code lock A...

Page 40: ...incorrect code has been entered LED 21 lights up red for two seconds After that you can enter a new code Z The Set key 22 has no function in operating mode Switching off The truck is switched off by a...

Page 41: ...e setting of the code lock func tions and the adaption of the travel programmes Additionally the battery parameters can be set Z For trucks without indicator instrument CANDIS o only the code lock par...

Page 42: ...ehaviour is changed you must perform a trial in a specially assigned and suitable working area run after changing any of the parameters Entering the master code Press the o key Enter master code Code...

Page 43: ...minate the input press the o key 26 The following parameters can be entered Code lock parameter list No Function Range Setting value Default Setting value Comments Work flow Codeschloss 000 Change mas...

Page 44: ...Confirm Set LED 24 flashes Enter a new code Confirm Set LED 25 flashes Repeat the code en try Confirm 003 Delete operator code 0000 9999 or 00000 99999 or 000000 999999 LED 24 flashes Enter a code Con...

Page 45: ...e Comments Work flow Code lock 020 Start up drive programme 0 3 2 0 There is no start up programme 1 Drive programme 1 start up drive programme 2 Drive programme 2 start up drive programme 3 Drive pro...

Page 46: ...e parameter value according to the parameter list Check the LC display of the indicator instrument CANDIS o confirm with the Set key 22 The LED 21 of the o key 26 switches briefly to steady light and...

Page 47: ...in rider controlled operation 0 9 2 102 Coasting brake in rider controlled operation 0 9 3 103 Coasting brake in pedestrian controlled operation 0 9 3 Value of parameter 103 Parameter 102 104 Maximum...

Page 48: ...rive direction via controller 0 9 8 depending on controller 205 Pedestrian controlled operation speed in drive direction via controller 0 9 5 depending on controller 206 Pedestrian controlled operatio...

Page 49: ...rive direction via controller 0 9 8 depending on controller 305 Pedestrian controlled operation speed in drive direction via controller 0 9 5 depending on controller 306 Pedestrian controlled operatio...

Page 50: ...s are set in the same way as for the travel parameters The following parameters can be entered Setting value 0 1 is to be interpreted as 0 off 1 on No Function Range Setting value Standard Setting val...

Page 51: ...itional Warning 27 and Stop 29 indicators may result Number Bars Charging condition Wet battery Maintenance free battery LED yellow Warning LED red Stop LED yellow Warning LED red Stop 10 90 1 100 Off...

Page 52: ...r then an E for error with alternating three digit error number If several errors occur they are displayed one after the other The errors are displayed as long as they are present always in combinatio...

Page 53: ...ency stop depressed Key switch in position 0 Code lock switched off Battery exhausted Platform switch not actuat ed Fuse defective Check the battery connector and connect if necessary Release the mast...

Page 54: ...ians trained especially for these assignments We thus recommend signing a maintenance contract with the relevant service location of the manufacturer Lifting and jacking up When a fork lift truck is t...

Page 55: ...he quality of the tyres greatly affects the stability and the driving behaviour of the fork lift truck The factory mounted tyres must only be replaced by original spare parts of the manufacturer since...

Page 56: ...e temper ature fluctuations or multiple shift operation the servicing intervals must be shortened accordingly The following servicing checklist indicates the operations to be performed and the re spec...

Page 57: ...e brake linkage adjust and grease if necessary l t Hydraulic system 6 1 Performance check t 6 2 Check all connections for leakage and damage t 6 3 Check the hydraulic cylinders for leakage damage and...

Page 58: ...rm a visual check of rollers sliding elements and stops l t 10 3 Check the fork tines and fork carrier for wear and damage l t Lubrication 11 1 Grease the vehicle in accordance with the lubrication sc...

Page 59: ...edule ECE 220 g Gliding surfaces s Grease nipples Filler plug for hydraulic oil b Filler plug for gear oil a Drain plug for gear oil Cold store usage 1 Compound for cold store usage 1 1 A C A 0 7 l 1...

Page 60: ...ades or qualitiies resp except if mix ing is expressively prescribed in these operating instructions Avoid spilling Spilt liquid must be removed immediately using a suitable binding agent and the mixt...

Page 61: ...uck suitable measures must be taken to prevent any dropping tilting or slipping of the fork or truck When lifting the truck the instructions contained in chapter Transportation and commissioning have...

Page 62: ...d Open battery cover refer to chapter D Remove the screws 5 Lift front hood 4 and put aside Installation occurs in the reverse order of steps F Do not drive the truck unless the hoods are closed and l...

Page 63: ...n 6 3 Referring to the table check all fuses for correct rating and damage replace fuses where required Reinstall the front hood see section 6 3 Item Designation Protection of Value 7 6F1 Battery disc...

Page 64: ...more than 6 months additional meas ures must be discussed with the Service Department of the manufacturer 7 1 Operations to be performed prior to decommissioning Thoroughly clean the fork lift truck...

Page 65: ...k ked by a qualified inspector The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects uninfluenced by any company or economic circumstances The ins...

Page 66: ...tive 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...

Page 67: ...d 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...

Page 68: ...ucks is the standard which ap plies to the operation traction batteries in industrial trucks 2 1 Discharging Be sure that all breather holes are not sealed or covered Electrical connections e g plugs...

Page 69: ...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...

Page 70: ...ound 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 ba...

Page 71: ...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 meas...

Page 72: ...l battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer s logo 14 Safety instructions and warnings Typ 1 T ype Nennspannung 5 Nomin...

Page 73: ...sing batteries which comply with I and II it is important to follow the in structions on maintaining the respective protection class during operation see asso ciated certification Cell series Aquamati...

Page 74: ...d 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...

Page 75: ...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 serviceMobi...

Page 76: ...ve 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...

Page 77: ...en tral supply pipe This is connected to the water supply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple ident no 50219538 is mounted...

Page 78: ...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 5027...

Page 79: ...g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity should be avoided deep discharg...

Page 80: ...0 0171 Ex I in areas with a firedamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 81: ...1000 4 Care of the battery The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of Vehicle Trac...

Page 82: ...raction battery CE mark is only for batteries with a nominal voltage greater than 75 volt Item Designation Item Designation 1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin material 3 Battery...

Page 83: ...0506 GB 18...

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