Jungheinrich EJC 212-220 Operating Instructions Manual Download

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Operating Instructions

50460011

EJC 212-220

12.05 -

03.07

Summary of Contents for EJC 212-220

Page 1: ...Operating Instructions 50460011 EJC 212 220 G 12 05 03 07 ...

Page 2: ...t 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 ri...

Page 3: ...0108 GB ...

Page 4: ...by crane C 1 2 Securing the truck during transport C 2 3 Using the truck for the first time C 3 4 Operating the truck without its own drive system C 4 D Battery Maintenance Charging Replacement 1 Safety regulations for handling acid batteries D 1 2 Battery types D 2 3 Exposing the battery D 2 4 Charging the battery D 3 4 1 Charging the battery with an on board charger o D 3 4 2 Charging the batter...

Page 5: ...rational safety and environmental protection F 1 2 Maintenance Safety Regulations F 1 3 Servicing and inspection F 3 4 Maintenance Checklist F 4 5 EJC 212 220 Maintenance Schedule F 6 5 1 Consumables F 7 6 Maintenance Instructions F 8 6 1 Preparing the truck for maintenance and repairs F 8 6 2 Remove the front panel F 8 6 3 Remove the drive panel F 8 6 4 Checking the hydraulic oil level F 9 6 5 Fl...

Page 6: ...506 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instructions ...

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

Page 8: ...s 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 ...

Page 9: ...1004 GB A 2 ...

Page 10: ...th a steered drive wheel It is designed for use on level floors to lift and transport palletised goods Open bottom pallets or roll cages can be lifted The capacity can be obtained from the data plate The capacity with respect to lift height and load centre of gravity is indicated on the capacity plate ...

Page 11: ...cator hourmeter o CANDIS display instrument 5 t Tiller and grip 6 t Crawl button 7 t Travel switch 8 t Collision safety switch 9 t Mast 10 t Mast guard optional protective frame 11 t Battery panel 12 t Battery connector emergency disconnect 1 13 t Lift mechanism 14 o Charger 15 t Front panel 16 t Caster wheel 17 o Document pocket 18 t Drive wheel t Standard equipment o Optional Equipment 1 2 3 4 5...

Page 12: ...00 1700 2600 mm h1 Height retracted DZ1 1830 2250 1830 2250 mm h2 Free lift ZT 100 100 mm h2 Free lift ZZ 1223 2123 1223 2123 mm h2 Free lift DZ 1356 1776 1356 1776 h3 Lift mast dependent ZT 2500 4300 2500 4300 mm h3 Lift mast dependent ZZ 2500 4300 2500 4300 mm h3 Lift mast dependent DZ 4090 5350 4090 5350 mm h4 Extended mast height ZT 2977 4777 2977 4777 mm h4 Extended mast height ZZ 2977 4777 2...

Page 13: ...090 5350 mm h4 Extended mast height ZT 2927 4727 2977 4777 mm h4 Extended mast height ZZ 2927 4727 2977 4777 mm h4 Extended mast height DZ 4515 5775 4565 5825 mm h13 Load fork lowered 90 90 mm h14 Tiller height in min max travel position 768 1298 768 1298 mm y Wheelbase 1277 1357 1277 1357 mm l1 Overall length 1896 1976 1896 1976 mm l2 Headlength 746 826 826 mm b1 Truck width 802 802 mm b5 Width a...

Page 14: ...B 5 0306 GB h4 h3 h2 h13 s h14 h14 c Q y l l2 l1 m2 b5 Ast W a x max min h1 b11 b12 e l6 b10 a 2 a 2 b1 ...

Page 15: ...mit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to EN 12895 and the references to other standards contained therein Z No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer 3 5 Conditions of use Ambient temperature during operation 5 C to 40 C Z...

Page 16: ... Do not reach through the mast warning 20 Truck data plate 21 Attachment point for lifting by crane with ZZ mast in the middle 22 Do not step under the load handler warning 23 Serial number 24 Battery data plate 25 No passengers warning 26 UVV test label 24 22 21 20 19 18 21 23 26 25 ...

Page 17: ... of the truck as a function of the load centre of gravity distance D in mm and lift height H in mm in tabular form illustration as example only Item Description Item Description 29 Type 35 Manufacturer s logo 30 Serial no 36 Min max battery weight kg 31 Rated capacity kg 37 Output kW 32 Battery voltage V 38 Load centre of gravity mm 33 Net weight w o battery kg 39 Year of manufacture 34 Manufactur...

Page 18: ... driver when he has exceeded the height limits specified by the capacity plate 18 4 3 Plate order inventory and service nos o Z The capacity plate with the full service number is only issued when a service agreement has been reached Item Description 44 Order no 45 Inventory no 46 Full service no 42 43 44 45 46 ...

Page 19: ...0306 GB B 10 ...

Page 20: ...the mast are for loading the truck with crane lifting gear Park the truck securely see Chapter E Secure the lifting slings to the attachment points 1 M Attach the crane slings to the strap points so that the truck cannot slip Lifting slings should be fastened to the harness in such a way that they do not come into contact with any parts of the truck when it is being raised 1 ...

Page 21: ...ure the truck attach the tensioning belt to the strap points 1 and secure them to the fastening rings Tighten the tensioning belt with the tensioner M Loading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case correct measurements shall be determined and appropriate safety measures adopted ...

Page 22: ...ads if the truck is operated via a tow lead with an external battery To prepare the truck after delivery or after transport proceed as follows Check the truck for completeness and satisfactory condition of the equipment Install battery where required Do not damage battery cable see chapter D Z Set the characteristic curve charging curve on the charger see Chapter D Charge the battery see Chapter D...

Page 23: ...adients To operate the truck in emergency conditions the electromagnetically applied brake must be released Remove the front panel see Chapter F Raise the anchor plate by screwing two off M4x20 screws in as far as the stop The truck can now be moved M Remove the screws again when you have parked the truck Braking is now restored again ...

Page 24: ...t coating of dielectric grease Batteries with non insulated terminals must be covered with a non slip insulation mat Battery Disposal Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws The manufacturer s disposal instructions must be followed M Before closing the battery cover make sure that the battery lead cannot be damaged F Batte...

Page 25: ...nced performance or maintenance free batteries F The battery weight and size will affect the capacity of the truck A truck will only have the capacity stated on the capacity data plate if the battery weight is as indicated on the data plate 3 Exposing the battery Park the truck securely see Chapter E Lift up the battery panel 1 Remove the battery connector 2 Chassis version Truck type 24V Pz batte...

Page 26: ... for charging see section 4 2 M To charge the battery the truck must be dry and parked in closed and properly ventilated rooms 4 1 Charging the battery with an on board charger o The charger must not be opened If damaged it must be replaced Z The switch 3 of trucks supplied without a battery is factory set to the 0 position The red LED 4 flashes to indicate the battery cannot be charged 3 4 ...

Page 27: ...eristics Set the characteristics as follows Switch 3 Position Selected charge curves characteristics 1 Wet cell batteries 100 300 Ah 2 Maintenance free 100 149 Ah 3 Maintenance free 150 199 Ah 4 Maintenance free 200 300 Ah 5 Wet cell batteries 200 400 Ah pulse characteristic 6 Wet cell batteries Jungheinrich 100 300 Ah Connect the battery This allows you to adjust via the charger Turn the setting ...

Page 28: ... 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 Mains connection Mains supply 230 V 6 Mains frequency 50 60 Hz 1 The mains cable of the charger 5 is located in the mains cable holder in the battery compartment Lift up the battery panel 1 Where necessary remove the insulating mat from the ...

Page 29: ...ly when charging is complete Partial charging The charger is designed to automatically adapt to partially charged batteries This keeps battery wear to a minimum 4 2 Charging the battery with a stationary charger o Park the truck securely see Chapter E M Only connect and disconnect the battery connector and the socket when the mains and charger are switched off Expose the battery see Section 3 LED ...

Page 30: ...e All safety instructions as provided by the battery supplier and battery charger supplier must be strictly observed Remove the battery plug 7 from the socket Where necessary remove the insulating mat from the battery Connect the charging cable of the battery charging station 6 to the battery connector 7 and switch on the charger M Charge the battery in accordance with the battery and charging sta...

Page 31: ... discharged Attach the lifting gear to the attachment eyes and lift out the battery F When replacing a battery always use the same battery type Extra weights must not be removed and must remain in the same position Installation is the reverse order When reinstalling the battery note the proper installation position and make sure the battery is connected correctly M After installing the battery aga...

Page 32: ...r batterychangingstation F Do not put your fingers between the truck frame and the battery Observe the operating instructions of the battery changing station manufacturer When installing the battery note the following Installation is in the reverse order of removal When reinstalling the battery note the required installation position and make sure the battery is connected correctly Push the batter...

Page 33: ...ced to a maximum of 10 within 3 minutes The displayed status cannot rise again during the present operation The status display is reset to 100 when the battery type is adjusted If the LED flashes red and the truck is not ready for operation inform the manufacturer s service department Red flashing is a fault code of the truck controller The flashing sequence indicates the type of fault LED colour ...

Page 34: ...ere is a battery residual capacity of 30 for standard batteries 50 for maintenance free batteries a warning symbol appears 14 A battery charge is recommended If there is a battery residual capacity of 20 for standard batteries 40 for maintenance free batteries the warning symbol goes out and a flashing STOP symbol 16 appears After 5 minutes the STOP symbol is permanently lit The battery must be ch...

Page 35: ...0606 GB D 12 ...

Page 36: ...assengers or lift other people Damage and Faults The supervisor must be immediately informed of any damage or faults to the forklift truck 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 ...

Page 37: ...de settings Release and select the travel programs Enter travel parameters ISM access module o Code settings Release and select the travel programs Enter travel parameters 5 Battery discharge indicator t Battery charge status Display instrument CANDIS o Operating hours meter Battery charge status Displays service messages and travel parameters in combination with CANCODE 6 Tiller t Used to steer a...

Page 38: ...E 3 0606 GB 1 2 3 4 5 6 7 8 9 8 10 11 12 13 ...

Page 39: ... forks The lift speed can be infinitely controlled via the switch stroke 8 mm 11 Load fork lower switch t Lowers the load forks The lowering speed can be infinitely controlled via the switch stroke 8 mm 12 Warning signal horn button t Activates a warning signal 13 Integrated charger o Used to charge the battery see Chapter D t Standard equipment o Optional Equipment ...

Page 40: ...E 5 0606 GB 1 2 3 4 5 6 7 8 9 8 10 11 12 13 ...

Page 41: ...rk Visually inspect the entire truck in particular wheels and load handler for obvious damage Visually inspect the battery attachment and cable connections Switching on the truck Make sure the battery is connected 1 Insert the key in the key switch 3 and turn it to the right as far as it will go position I or for CANCODE 4 o enter the activation code see Section 6 Test the warning button 12 The tr...

Page 42: ...E 7 0606 GB 1 3 4 5 6 12 ...

Page 43: ...ck as a lookout Negotiating slopes and inclines Slopes or inclines may only be negotiated if they are designated traffic routes are clean and have a non slip surface and providing they can be safely negotiated in accordance with the technical specifications of the truck The truck must always be driven with the load unit facing uphill The industrial truck must not be turned operated at an angle or ...

Page 44: ...ller moves slowly to the upper brake zone the cause of this fault must be rectified If necessary replace the gas pressure spring Travel M Travel with raised forks raised load beyond 500 mm above the ground is prohibited M Do not drive the truck unless the panels are closed and properly locked Start up the truck refer to section 3 The travel speed is governed by the travel switch 8 Set the tiller 6...

Page 45: ...nitoring The steering controller permanently monitors the entire steering system If an error is detected the traction controller interrupts travel brakes regeneratively and the magnetic brake is applied F As the steering system is a safety critical component the fault must be rectified by the manufacturer s service department Improper maintenance or repair work by untrained personnel can result in...

Page 46: ...brake The mechanical brake handbrake applies when the truck comes to rest Driving on inclines M Loads must always be carried on the end of the truck facing uphill Preventing the truck from rolling downhill With the travel switch set to zero the brake automatically applies after a short jerk the controller detects the truck is rolling back on the slope The service brake is released again via the tr...

Page 47: ...as been reached Z The lift speed can be infinitely controlled via the switch stroke 8 mm Short switch stroke slow lift Long switch stroke fast lift Lowering Press the Lower Load Forks switch 11 until the required lifting height has been reached Z The lowering speed can be infinitely controlled via the switch stroke 8 mm Short switch stroke slow lower Long switch stroke fast lower M Avoid suddenly ...

Page 48: ... in the controller manually activate the valve 14 on the hydraulic unit Set key switch 3 to 0 Disconnect the battery see chapter D Open the front panel see Chapter F Section 6 2 Using a suitable object pen tool or similar gently press the valve slide inØ approx 3 mm and hold it firm The lifting mechanism lowers F Only operate the truck once the fault has been removed 14 ...

Page 49: ...via a red green LED It contains the following functions Code lock function commissioning the truck Travel program selection Setting the travel and battery parameters only in conjunction with the display instrument CANDIS o The o switch has top priority and resets the truck from any condition to its default condition without modifying any settings 6 1 Code Lock When the correct code has been entere...

Page 50: ... 0 the LED 15 turns green If the wrong code is entered LED 15 flashes red for two seconds The correct code can then be entered Z The Set key 16 has no function in operating mode Switching off To switch the truck off press the o switch 20 Z The truck can switch off automatically after a pre determined time To do this you need to set the corresponding code lock parameter see Section 6 4 15 16 17 18 ...

Page 51: ...enables you to set the code lock functions and adapt travel programs In addition the battery parameters can also be set Z For trucks without a display instrument CANDIS o only the code lock parameters can be set Parameter Groups The parameter number is composed of three digits The first digit refers to the parameter group as shown in Table 1 The second and third digits are numbered in sequence fro...

Page 52: ...arameter will affect the truck s travel pattern you must carry out a test run in a specially designated work area To enter the master code Press theo key Enter master code Code Lock Parameters Setting procedure for trucks without a display instrument CANDIS o Enter the three digit parameter number confirm with the Set key 16 Enter the setting according to the parameter list or change and confirm w...

Page 53: ...inish entering press the o key 20 The following parameters may be entered Code Lock Parameter List No Function Range Setting Standard Setting Comments Procedure Code Lock 000 Change Master Code The length 4 6 digits of the master code also pre determines the length of the operator code 4 6 digits Provided the operator codes are programmed only news codes of the same length can be entered If the co...

Page 54: ...onfirm Set LED 18 flashes Enter new code Confirm Set LED 19 flashes Repeat code entry confirm 003 Delete user code 0000 9999 or 00000 99999 or 000000 999999 LED 18 flashes Enter code Confirm Set LED 19 flashes Repeat code entry Confirm Set 004 Delete code memory Deletes all user codes 3265 3265 delete other inputs do not delete 010 Automatic time cutout 00 31 00 00 no cutout 01 to 30 Cutout time i...

Page 55: ...deleted does not exist Code memory full Start program blocked Travel program to be blocked is the start travel program No Function Range Setting Standard Setting Comments Procedure Code Lock 020 Start travel program 1 3 2 1 Travel program 1 2 Travel program 2 3 Travel program 3 021 Travel program 1 Release 0 or 1 1 0 Travel program not enabled 1 Travel program enabled 022 Travel program 2 Release ...

Page 56: ...splay of the display instrument CANDIS o confirm with the Set key 16 The LED 15 of the o key 20 switches briefly to a steady light and starts flashing again after approx 2 seconds Z If the entry is incorrect the LED 15 of the o key 20 turns red If you enter the parameter number again the setting can be entered or changed Repeat the process to enter more parameters as soon as the LED 15 of the o ke...

Page 57: ...epending on travel switch 108 Maximum speed in fork direction using travel switch 0 9 2 8 6 2 km h 3 4 0 km h depending on travel switch No Function Range Setting Standard Setting Comments Travel program 2 201 Acceleration 0 9 0 2 2 0 m s 2 0 6 m s 202 Coasting brake 0 9 0 2 2 0 m s 4 0 6 m s 204 Maximum speed in tiller direction using travel switch 0 9 2 8 6 2 km h 7 5 6 km h depending on travel ...

Page 58: ...d Setting Comments Travel program 3 301 Acceleration 0 9 0 2 2 0 m s2 4 1 0 m s2 302 Coasting brake 0 9 0 2 2 0 m s2 6 0 8 m s2 304 Maximum speed in tiller direction using travel switch 0 9 2 8 6 2 km h 8 6 0 km h depending on travel switch 308 Maximum speed in fork direction using travel switch 0 9 2 8 6 2 km h 8 6 0 km h depending on travel switch No Function Range Setting Standard Setting Comme...

Page 59: ...displays will depend on the battery type Numb er of bars Charge status Standard battery Maintenance free battery LED yellow Warning LED red Stop LED yellow Warning LED red Stop 10 90 1 100 Off Off Off Off 9 80 1 90 Off Off Off Off 8 70 1 80 Off Off Off Off 7 60 1 70 Off Off Off Off 6 50 1 60 Off Off Off Off 5 40 1 50 Off Off On Off 4 30 1 40 Off Off On On 3 20 1 30 On Off On On 2 10 1 20 On On On ...

Page 60: ...n E for error with alternating three digit error number If several errors occur simultaneously they are displayed one after the other The errors are displayed as long as they are present always in combination Cxxx Exxx Error messages overwrite the service hour display Most errors cause the emergency stop to be triggered Errors remain displayed until the control circuit is switched off Code lock If...

Page 61: ...tery plug not connected Check the battery connector and connect if necessary Key switch in 0 position Set key switch to I Incorrect CANCODE code Check code Battery charge too low Check battery charge charge battery if necessary Tiller not set to travel range F Set tiller to travel range F Faulty fuse Check fuses F1 and F15 On board charger connected Disconnect on board charger from mains Load cann...

Page 62: ...rsonnel 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 ...

Page 63: ... otherwise the data plate specifications will not be kept When changing wheels and tyres ensure that the truck does not slew e g when replacing wheels always left and right simultaneously Lift chains Lift chains wear rapidly if not lubricated The intervals stated in the service checklist apply to normal duty use More demanding conditions dust temperature require more regular lubrication The prescr...

Page 64: ... by wear The service intervals stated are based on single shift operation under normal operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts The following maintenance checklist states the tasks and intervals after which they should be carried out Maintenance intervals are defined as W Every 50 serv...

Page 65: ...tting t 2 6 Check contactors and relays t 2 7 Test safety switch t 2 8 Test cable and motor attachments t 2 9 Check carbon brush wear replace if necessary t Energy supply 4 1 Battery visual inspection k t 4 2 Check battery connections are secure grease terminals if necessary k t 4 3 Check acid density acid level and battery voltage k t Travel 5 1 Check transmission for noise and leakage t 5 2 Test...

Page 66: ...pe lines and their connections are secure check for leaks and damage and tighten connections if necessary k t 7 10 Check cylinders and piston rods for damage and leaks and make sure they are secure k t 7 11 Check the hydraulic oil level k t 7 12 Replace hydraulic oil this may have to be performed using a special environmental service truck t t 7 13 Replace the hydraulic oil filter t 7 14 Test tie ...

Page 67: ...0307 GB F 6 5 EJC 212 220 Maintenance Schedule g Contact surfaces Hydraulic oil filler plug c Hydraulic oil drain plug 1 Compound ratio for cold store usage 1 1 E A G ...

Page 68: ...n 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 Quantity Description Used for A 50449669 5 0 l H LP 46 DIN 51524 Hydraulic system B 50380904 5 0 l Fuchs Titan Cytrac HSY 75W 9...

Page 69: ...lift truck secure it to prevent it from tipping or sliding away When raising the truck also refer to the instructions in the Transport and Commissioning section 6 2 Remove the front panel Open the battery panel Remove the three screws 6 Carefully lift off the front panel 2 6 3 Remove the drive panel The drive panel consists of two halves 3 and 4 Set the tiller 45 to the right in the travel directi...

Page 70: ...ic oil level in hydraulic reservoir M There are markings on the hydraulic reservoir The oil level must be checked when the load forks are lowered If necessary add hydraulic oil of the correct grade see Section 5 1 see table M Assembly is the reverse order Tank capacity level 1 5 7 litres 2 6 6 litres 3 7 4 litres Max 7 9 litres ZT All ZZ up to 280 over 280 DZ All ...

Page 71: ...2 Undo the union 8 Remove connection and take out the gauze filter insert a clean new filter M Assembly is the reverse order 6 6 Replace the filter cartridge Preparing the truck for maintenance and repairs see Section 6 1 Remove the front panel see Section 6 2 Unscrew the reservoir lid 7 and remove filter cartridge from the filter cone M Assembly is the reverse order 7 8 ...

Page 72: ... front panel see Section 6 2 Check the fuse rating and condition in accordance with the table replace if necessary Item Description To protect Rating 9 F1 Overall control fuse 10 A 10 6F1 Discharge indicator hourmeter 2 A 11 4F1 Horn 3 A 12 3F1 Steering controller o 30 A 13 1F1 Traction controller 300 A 9 10 11 12 13 ...

Page 73: ...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 i...

Page 74: ...safety viewpoint without regard to operational or economic circumstances The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and principles governing the inspection of forklift trucks The inspection must include a comprehensive check of the technical conditio...

Page 75: ...0307 GB F 14 ...

Page 76: ...itive tubular plates type EPzS and EPzB 2 6 Type plate Jungheinrich traction battery 7 Instruction for use Aquamatic BFS III water refilling system 8 12 2 Jungheinrich traction battery Maintenance free traction batteries with positive tubular plates type EPzV and EPzV BS 13 17 Type plate Jungheinrich traction battery 17 ...

Page 77: ...nd 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 ...

Page 78: ...rucks is the standard which ap plies to the operation traction batteries in industrial trucks 2 1 Discharging Be sure that all breather holes are not sealed or covered Electrical connections e g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 80 of the rated capacity should be avoided deep discharge This ...

Page 79: ...n The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past 2 3 Equalising charge Equalising charges are used to safeguard the life of the battery and to maintain its capacity They are necessary after deep discharges repeated incomplete recharges and charges to an IU characteristic curve Equalising charges are carried out follo ...

Page 80: ...und 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...

Page 81: ...d be taken into account when considering the life of the battery 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called in without delay The measurements taken in point 3 3 will facilitate fault fin ding and their elimination A service contract with us will make it easier to detect and correct faults in good time Back to the manufacturer Batt...

Page 82: ...al 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 Nominal V oltage Hersteller 9 Manufacturer Kapazität 6 Capacity Zellenzahl 7 Number of Cells Batteriegewicht min max 8 Battery mass min max Serien Nr 3 Serial Nr Lieferanten Nr 4 Supplier No Baujahr 2 Yea...

Page 83: ...using batteries which comply with I and II it is important to follow the in structions on maintaining the respective protection class during operation see asso ciated certification Cell series Aquamatic plug type length EPzS EPzB Frötek yellow BFS black 2 120 10 600 2 42 12 252 50 5 mm 51 0 mm 2 160 10 800 2 64 12 384 50 5 mm 51 0 mm 2 84 12 504 50 5 mm 51 0 mm 2 110 12 660 50 5 mm 51 0 mm 2 130 1...

Page 84: ...ed by means of a central sealing coupler through the hose connections in the individual Aquamatic BFS plugs 2 Application The Aquamatic BFS battery water refilling system is used in traction batteries for forklift trucks The water refilling system is provided with a central water connection for the water supply Soft PVC hose is used for this connection and for the hose con nections for the individ...

Page 85: ... 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 ...

Page 86: ...ave 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...

Page 87: ...cen tral supply pipe This is connected to the water supply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple ident no 50219538 is mounted and the customer must place a sealing coupler construction on the water supply side obtainable under ident no 50219537 11 Functional data PS self sealing pressure Aquamatic 1 2 bars BFS system none D...

Page 88: ... 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 ...

Page 89: ... g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity should be avoided deep discharge They reduce the battery life considerable To measure the state of discharge use only the battery manufacturer recommended discharge indicators Discharged batteries must be recharged immediately and...

Page 90: ...70 0171 Ex I in areas with a firedamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected 2 3 Equalising charge Equalising charges are used to safeguard the life of the battery and to maintain its capacity Equalising charges are carried out following normal charging They are necessary after deep discharges and repeated incomplete recharges For the equalising...

Page 91: ... 1000 Ω 4 Care of the battery The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of Vehicle Traction batteries Any liquid in the battery tray must be extracted and disposed of in the prescribed man ner Damage to the insulation of the tray should be repaired after cleaning to ensure that the i...

Page 92: ...traction battery CE mark is only for batteries with a nominal voltage greater than 75 volt Item Designation Item Designation 1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin material 3 Battery type 10 Nominal battery voltage 4 Battery number 11 Nominal battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer s logo 14 Safet...

Page 93: ...0506 GB 18 ...

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Jungheinrich EJC 212-220, Operating Instructions Manual

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