Jungheinrich EJC 212z Operating Instructions Manual Download

Page: 9 / 250

Industrial Truck Maintenance

175

Operational Safety and Environmental Protection

175

Maintenance Safety Regulations

176

2.1

Working on the electrical system

177

2.2

Consumables and used parts

Lubricants and Lubrication Schedule

180

3.1

Handling consumables safely

Maintenance and repairs

184

4.1

Preparing the truck for maintenance and repairs

184

4.2

Front cover disassembly

185

4.3

Lifting and jacking up the truck safely

Checking the hydraulic oil level

190

4.6

Check wheel attachment and wear

192

4.7

Checking electrical fuses

194

4.8

Restoring the truck to service after maintenance and repairs

195

Decommissioning the Industrial Truck

196

5.1

Prior to decommissioning

196

5.2

Action to be taken during decommissioning

196

5.3

Restoring the truck to service after decommissioning

197

Safety tests to be performed at intervals and after unusual incidents

198

Final de-commissioning, disposal

198

Human vibration measurement

198

Maintenance, Inspection and Changing of Maintenance

Parts Requiring Replacement

199

Maintenance Contents EJC 212z/214z/216z

Maintenance Contents EJC 214/216

04.19 en-GB

Summary of Contents for EJC 212z

Page 1: ...EJC 214 220 EJC 212z 220z 11 10 Operating instructions 51141056 04 19 en GB EJC 212z EJC 214z EJC 216z EJC 220z EJC 214 EJC 216 EJC 220 ...

Page 2: ...2 ...

Page 3: ... EJC 220z EJC 214 EJC 216 EJC 220 On behalf of Date EU DECLARATION OF CONFORMITY The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006 42 EG Machinery Directive and 2014 30 EU Electromagnetic Compatibility EMC The manufacturer is authorised to compile the technical documentation 3 04 19 en GB ...

Page 4: ...4 04 19 en GB ...

Page 5: ...ular features of the truck should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are indicated by the following graphics DANGER Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death WARNING Indicates an extremely hazardou...

Page 6: ...ght Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com 6 04 19 en GB ...

Page 7: ...4 2 Dimensions 24 4 3 Weights 30 4 4 Tyre type 31 4 5 EN norms 32 4 6 Specifications according to RED guideline Radio Equipment Directive for radio units 33 4 7 Conditions of use 33 4 8 Electrical Requirements 33 5 Identification Points and Data Plates 34 5 1 Indication Points 34 5 2 Data plate 36 5 3 Truck capacity plate 37 5 4 Wind loads 40 5 5 Capacity Plate for Stacking and Transport Operation...

Page 8: ...wer 97 4 9 Lifting transporting and depositing loads 100 4 10 Use as a Lift Work Table 108 5 Troubleshooting 109 5 1 Truck does not start 110 5 2 Load cannot be lifted 112 6 Operating the truck without its own drive system 113 6 1 Release and activate the drive wheel brake 113 7 Load handler emergency lowering 115 7 1 EJC 214 216 220 115 7 2 EJC 212z 214z 216z 220z 116 8 Optional equipment 117 8 1...

Page 9: ... Checking the hydraulic oil level 190 4 6 Check wheel attachment and wear 192 4 7 Checking electrical fuses 194 4 8 Restoring the truck to service after maintenance and repairs 195 5 Decommissioning the Industrial Truck 196 5 1 Prior to decommissioning 196 5 2 Action to be taken during decommissioning 196 5 3 Restoring the truck to service after decommissioning 197 6 Safety tests to be performed a...

Page 10: ...10 04 19 en GB ...

Page 11: ...ungheinrich battery models If using another brand refer to the manufacturer s operating instructions 1 0506 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instructions ...

Page 12: ...0506 GB 2 0506 GB 2 ...

Page 13: ...han 1800 mm The bottom load must be heavier than the top load Carrying and lifting passengers see Lifting Passengers on page 11 Pushing or pulling loads 2 1 Lifting Passengers WARNING Risk of accident when using a work cage When working with a work cage high dynamic forces act on the truck which can impair its operational stability When using a work cage a minimum capacity of 1500 kg is required a...

Page 14: ...ross or at an angle on inclines Travel with the load facing uphill Operation in partially public traffic WARNING Use under extreme conditions Using the truck under extreme conditions can result in malfunctions and accidents uSpecial equipment and authorisation are required if the truck is to be constantly used in extreme conditions especially in dusty or corrosive atmospheres uThe truck cannot be ...

Page 15: ...on in Cold Stores with Cold Store Equipment o In addition to the permissible operating conditions in industrial and commercial environments the truck remains primarily in cold stores The truck should only leave the cold store briefly to hand over a load Permissible temperature range 28 C to 25 C Maximum air humidity 95 non condensing Thawing is permissible only if the truck can be subsequently dri...

Page 16: ...ded Furthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The operating company must ensure that all users have read and understood these operating instructions NOTICE Failure to comply with the operating instructions invalidates the warranty The same applies if improper work is carried out on the truck by the customer or thir...

Page 17: ... with respect to lift height and load centre of gravity is indicated on the capacity plate 1 1 Truck models and rated capacity The rated capacity depends on the model The rated capacity can be derived from the model name EJC 214 216 220 EJC 212z 214z 216z 220z EJC 214 216 220 EJC 212z 214z 216z 220z Type 2 Series 14 Rated capacity x 100 kg z Initial lift The rated capacity is not generally the sam...

Page 18: ... Travel direction definition The following determinations have been made for travel direction specification 1 2 3 4 Item Travel direction 1 Left 2 Drive direction 3 Load direction 4 Right 16 04 19 en GB ...

Page 19: ...3 Assemblies and Functional Description 3 1 Assembly Overview 12 14 13 15 17 19 21 16 11 10 9 8 7 5 6 20 18 17 04 19 en GB ...

Page 20: ...lication o ISM access module o Keypad o Transponder reader 16 o On board battery charger 9 t Emergency disconnect switch 17 o Mains plug on board charger 10 t Battery panel 18 t Document storage compartment for storage of the operating instructions 11 t Load handler o Double deck operation EJC 212z 214z 216z 220z only 19 t Drive wheel 12 t Slow travel button 20 t Front panel 13 t Tiller 21 t Suppo...

Page 21: ...st parts and the load Emergency stop safety concept The emergency stop is activated by the traction controller Each time the truck is switched on the system carries out a self diagnosis Electric steering o The steering controller sends a system status signal which is monitored by the traction controller If the signal fails to appear or a fault is identified the truck automatically brakes to a halt...

Page 22: ...energy saving Tiller The driver steers with an ergonomic tiller All travel and lift operations can be performed sensitively without having to reach The tiller has a steer angle of 180 Electric steering o The electric steering system is self monitoring The steering controller permanently monitors the entire steering system If an error is detected the traction controller interrupts travel and brakes...

Page 23: ...ng loads Z The extended mast height h4 increases according to the load backrest mounted on the load handler WARNING Risk of injury from falling loads Low or small item loads moved above the mast protection pane or grille o and protruding over the load backrest can fall endangering the operator and truck uSecure low or small item loads protruding over the load backrest e g by wrapping them in film ...

Page 24: ...oad ZT mast 0 37 0 34 0 37 0 34 m s Max gradeability with without load 8 16 7 16 Drive motor output S2 60 min 1 6 1 6 kW Lift motor output at S3 11 3 0 3 0 kW Model EJC 216 M EJC 216 L EJC 220 Q Rated capacity 1600 1600 2000 kg D Load centre distance 600 600 600 mm Travel speed with without load 6 0 6 0 6 0 6 0 5 3 5 4 km h Lift speed with without load ZT mast 0 16 0 25 0 15 0 25 0 10 0 18 m s Low...

Page 25: ...e motor output S2 60 min 1 6 1 6 kW Lift motor output at S3 11 2 2 6 3 kW Description EJC 216z EJC 220z Q Rated capacity 1600 2000 kg Capacity for mast lift 1 1600 2000 kg Capacity for support arm lift 2000 2000 kg D Load centre distance 600 600 mm Travel speed 2 6 0 6 0 5 0 5 0 km h Lift speed 2 Initial lift 0 04 0 05 0 03 0 04 m s Lowering speed 2 Initial lift 0 08 0 06 0 09 0 06 m s Lift speed ...

Page 26: ...4 2 Dimensions EJC 214 216 220 Ast e a 2 a 2 Ast a 2 Wa R y x l D s 900 170 Q h4 h1 h14 min h14 max l2 l1 h2 h1 3 h3 m2 b1 b10 l6 b11 b5 b12 35 24 04 19 en GB ...

Page 27: ...EJC 212z 214z 216z 220z D 25 04 19 en GB ...

Page 28: ...Track width front 507 507 mm b11 Track width rear 400 400 mm m2 Ground clearance 30 30 mm s e l Fork dimensions 56 185 1150 56 185 1150 mm Ast Aisle width 4 5 800 x 1200 longit in accordance with VDI 21993 7 22793 7 mm Ast Aisle width 4 6 1000 x 1200 transv in accordance with VDI 21493 8 22293 8 mm Wa Turning radius 4 Wheel arms raised 1488 1568 mm 1 Values for standard mast 290 ZT 2 min max 3 DZ ...

Page 29: ...70 mm b10 Track width front 507 507 507 mm b11 Track width rear 400 400 400 mm m2 Ground clearance 30 30 20 mm s e l Fork dimensions 56 185 1150 56 185 1150 61 195 1150 mm Ast Aisle width 4 5 800 x 1200 longit in accordance with VDI 21993 7 22793 7 22793 7 mm Ast Aisle width 4 6 1000 x 1200 transv in accordance with VDI 21493 8 22293 8 22293 8 mm Wa Turning radius 4 Wheel arms raised 1488 1568 156...

Page 30: ...0 570 mm b10 Track width front 507 507 mm b11 Track width rear 385 385 mm m2 Ground clearance 20 20 mm s e l Fork dimensions 56 185 1150 56 185 1150 mm Ast Aisle width 4 5 800 x 1200 longit in accordance with VDI 2267 7 3 2288 7 3 mm Ast Aisle width 4 6 1000 x 1200 transv in accordance with VDI 2217 8 3 2238 8 3 mm Wa Turning radius 4 Wheel arms raised 1777 9 1798 9 mm 1 Values for standard mast 2...

Page 31: ...570 570 mm b10 Track width front 507 507 mm b11 Track width rear 385 385 mm m2 Ground clearance 20 20 mm s e l Fork dimensions 56 185 1150 56 185 1150 mm Ast Aisle width 4 5 800 x 1200 longit in accordance with VDI 22887 3 22887 3 mm Ast Aisle width 4 6 1000 x 1200 transv in accordance with VDI 2238 8 3 2238 8 3 mm Wa Turning radius 4 Wheel arms raised 17989 17989 mm 1 Values for standard mast 280...

Page 32: ...30 870 1855 878 2329 kg Axle load w load front rear battery 724 320 764 361 805 402 kg Battery weight 243 288 288 kg EJC 212z EJC 214z Net weight incl battery 1180 1240 kg Axle load w load front rear battery 1105 1275 1180 1460 kg Axle load w load front rear battery 840 340 880 360 kg Battery weight 300 300 kg EJC 216z EJC 220z Net weight incl battery 1260 1330 kg Axle load w load front rear batte...

Page 33: ...le tandem Ø 85 x 110 Ø 85 x 85 Ø 85 x 85 mm Caster wheel 140 x 54 140 x 54 mm Wheels number front rear x driven 1 x 1 2 1 x 1 2 EJC 212z 214z 216z 220z size drive 230 x 70 mm Load section tyre size single tandem Ø 85 x 95 Ø 85 x 75 mm Castor wheel 140 x 54 mm Wheels number front rear x driven 1 x 1 2 31 04 19 en GB ...

Page 34: ...ssions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein Z No changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer WARNING Medical equipment can be damaged by non ionised radiation Electrical equipment on the truck emitting ...

Page 35: ...t temperature without cold store equipment operating at 10 C to 40 C see page 13 with cold store equipment operating at 28 C to 25 C see page 13 Z Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations 4 8 Electrical Requirements The manufacturer certifies compliance with the requirements ...

Page 36: ...oints and Data Plates Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary 5 1 Indication Points 23 24 29 33 25 27 22 26 30 32 28 31 34 04 19 en GB ...

Page 37: ...hibition plate Do not reach through the mast 25 Truck capacity plate 26 Serial number 27 Truck data plate 28 Capacity plate for stacking and transport operations or stacking double deck and transport operations o 29 Prohibition plate No passengers 30 Inspection plaque 31 Label cold store version o 32 Truck model 33 Battery data plate 35 04 19 en GB ...

Page 38: ...y kg 43 Min max battery weight kg 37 Battery voltage V 44 Manufacturer 38 Net weight w o battery kg 45 QR code 39 Option 46 Manufacturer s logo 40 Year of manufacture Z For queries regarding the truck or ordering spare parts always quote the truck serial number 35 QR code The QR code contains the serial number and product hierarchy of the truck 36 04 19 en GB ...

Page 39: ...he maximum capacity Q in kg for a given load centre distance D in mm and corresponding lift height H in mm for the truck when raising a load Example of how to calculate the maximum capacity The maximum capacity is Q1 at a load centre G within the load centre distance D1 and a lift height up to HH1 37 04 19 en GB ...

Page 40: ...re distances of 500 mm 600 mm and 700 mm The distances d1 and d2 depicted in the illustration between the load handler and the actual centre of gravity G of the load must be smaller or equal to the load centre distance D d1 D and d2 D to avoid the risk of overturning see page 100 Lift height limits 47 48 The arrow shaped markings on the outer mast 47 and on the inner mast 48 indicate to the operat...

Page 41: ...e entire volume the load centre distance is in the middle i e half the length half the height and half the width of the load Load centre distance of the load handler The capacity plate specifies valid load centre distances for the load handler of 500 mm 600 mm and 700 mm The second load centre distance suits the example load At 600 mm it is greater than the distances of 400 mm and 575 mm between t...

Page 42: ...fies the capacity Q in kg of the truck during stacking and transport operations 28 A B A Stacking operations storing and retrieving loads During high level lift mast lift observe the capacity depending on the lift height see page 37 B Transport operations Max capacity when transporting loads horizontally 2000 kg with the support arms raised and without high level lift mast lift Z During stacking o...

Page 43: ...ot to jeopardize the operational stability the heavier pallet should always be transported underneath Previous capacity plate The double decker mode capacity plate 28 indicates the capacity Q kg of the truck while travelling 28 A B C A No transporting with a raised load B Max capacity for horizontal transporting XXX kg with raised support arms without mast lift C Double decker mode Max lift height...

Page 44: ...00 kg with the support arms raised and without high level lift mast lift C Double decker operations Max capacity for high level lifting mast lift is ZZZ kg Max capacity for concurrent high level lifting mast lift and low level lifting support arm lift is 2000 kg Z During stacking operations with the low level lift support arm lift raised loads can be stored and retrieved up to a lift height of 180...

Page 45: ...the truck to crash when being loaded by crane Prevent the truck from hitting other objects during lifting and avoid uncontrolled movements If necessary secure the truck with guide ropes uThe truck may be loaded only by people who are trained in using lifting accessories and lifting gear uWear personal protective equipment e g safety shoes safety helmet hi vis jacket protective gloves when loading ...

Page 46: ... Requirements Park the truck securely see page 84 Tools and Material Required Lifting gear Crane lifting gear Procedure Secure the crane lifting gear to the strap points 22 The truck can now be lifted by crane 22 44 04 19 en GB ...

Page 47: ...n securing loads on road vehicles and handling load securing devices In each case correct measurements must be taken and appropriate safety measures applied uThe truck must be securely fastened when transported on a lorry or a trailer uThe lorry or trailer must have fastening rings uUse wedges to prevent the truck from moving uUse only fastening belts with sufficient strength uUse non slip materia...

Page 48: ...ansport vehicle and the load handler to ensure a positive fit between the front of the transport vehicle and the load handler Lay the lashing straps 49 over the truck attach to the transport vehicle and tension sufficiently Attach the lashing straps 49 to the industrial truck and the transport vehicle and tension sufficiently Z Use edge protectors to protect the truck and the lashing straps The tr...

Page 49: ...tection pane NOTICE Do not lift loads if the truck is operated via a tow lead with an external battery NOTICE Cold store trucks uTrucks designed for use in cold stores have a cold store hydraulic oil and a protective frame instead of a mast guard on the mast uIf a truck with cold store oil is used outside the cold store the lowering speeds may increase If the truck is delivered in multiple parts s...

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Page 51: ...ent must be available CAUTION The use of unsuitable fire protection equipment can result in scalding Extinguishing fires with water can cause a reaction with the battery acid This can result in scalding from the acid uUse powder extinguishers uNever extinguish a burning battery with water Battery maintenance The battery cell covers must be kept dry and clean The terminals and cable lugs must be cl...

Page 52: ...d by Jungheinrich for the truck can be hazardous The design weight and dimensions of the battery have a considerable effect on the operational safety of the truck in particular its stability and capacity The use of unsuitable batteries that have not been approved for the truck by Jungheinrich can lead to a deterioration of the braking characteristics of the truck during energy recovery causing con...

Page 53: ...210 230 624x284x537 24 volt battery 3PzV 225 230 624x284x537 24 volt battery 3 PzS 240 243 624X284X537 24 volt battery 3 PzV 240 230 624X284X537 24 volt battery 3 PzV 261 243 624X284X537 24 volt battery 3 PzS 270 243 624X284X537 24 volt battery 3 PzM 270 243 624X284X537 24 volt battery 3 PzV 300 273 624X284X628 24 volt battery XFC 316 273 624X284X628 24 volt battery 3 PzV 330 273 624X284X628 24 vo...

Page 54: ...lt battery 3 PzV 330 273 624X284X628 24 volt battery 3 PzS 375 273 624X284X628 24 volt battery 3 PzS 375 Lib Silver 273 624X284X628 24 volt battery 3 PzM 375 273 624X284X628 24 volt battery 3 PzQ 414 273 624X284X628 Z Optionally the truck can be fitted with a lithium ion battery see Li Ion battery 24V 110Ah 240 Ah 360 Ah operating instructions 52 04 19 en GB ...

Page 55: ... 792X212X635 24 volt battery 3 PzS 375 280 792X212X635 24 volt battery 3 PzS 375 Lib Silver 280 792X212X635 24 volt battery 3 PzM 375 280 792X212X635 24 volt battery 3 PzQ 414 280 792X212X635 Z Optionally the truck can be fitted with a lithium ion battery see Li Ion battery 24V 110Ah 240 Ah 360 Ah operating instructions The battery weights can be taken from the battery data plate Batteries with no...

Page 56: ...akes are not working place wedges underneath the wheels of the truck to prevent it from moving CAUTION A closing battery panel can pose a trapping hazard If the battery cover is not opened fully it can suddenly close on its own and cause bruising The battery cover is only properly opened at an angle greater than 90 It is then held by gravity uOpen the battery cover as far as the stop Requirements ...

Page 57: ...visible signs of damage uVentilate the room in which the truck is being charged uThe battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilation uDo not smoke and avoid naked flames when handling batteries uWherever an industrial truck is parked for charging there must be no inflammable material or consumables capable of creating sparks w...

Page 58: ...ger operating instructions The battery is charging Completing battery charging restoring the truck to operation NOTICE If charging has been interrupted the full battery capacity will not be available Requirements The battery is fully charged Procedure Complete charging in accordance with the charger operating instructions Disconnect the battery connector 50 from the charging cable 51 of the statio...

Page 59: ...se a short circuit or electric shock uDo not trap the mains cable when closing the battery panel uReport any defects immediately to your supervisor uNotify the customer service department uMark the defective truck and take it out of service uDo not return the industrial truck to service until you have identified and rectified the fault NOTICE Improper use of the on board charger can cause material...

Page 60: ...ched to the connector 53 52 53 CAUTION uRemove the mains connector before setting the respective charging curve Set the charging characteristic Requirements Battery connected Procedure Turn the setting switch 52 on the charger right to adapt the charging curve to the battery being used The validity of the new setting is acknowledged by the flashing of the green LED and the setting takes immediate ...

Page 61: ...00 Ah Wet cell battery PzS with pulse characteristic 200 414 Ah 6 Jungheinrich 100 300 Ah NOTICE uAll other switch positions 52 block the charger and the battery is not charged uFor PzM batteries with a capacity of less than 180 Ah set characteristic 1 beyond 180 Ah set characteristic 5 uWith PzS 200 300 Ah wet cell batteries both characteristic curves 1 and 5 can be used Characteristic 5 achieves...

Page 62: ...urves 5 and 6 are not supported by the ELH 2425 2435 Flashing sequence Selected charging curves characteristics 0 Truck without battery delivery condition 1 Wet cell battery PzS with 100 300 Ah Wet cell battery PzM with 100 179 Ah 2 Wet cell battery PzS with pulse characteristic 200 400 Ah Wet cell battery PzM with pulse characteristic 180 400 Ah Wet cell battery PzS with pulse characteristic 200 ...

Page 63: ...300 Ah wet cell batteries both characteristic curve 1 and characteristic curve 2 can be used uIf a characteristic curve is set on the ELH 2415 2425 that is not supported by the charger the charge display is lit a steady red uAll other characteristic curves 8 block the charger and the battery is not charged 61 04 19 en GB ...

Page 64: ...he battery see page 54 Correct charging program set on charger Procedure Remove any insulating mats from the battery The battery connector must remain plugged Attach the mains connector 17 to a mains socket Pull the Emergency Disconnect switch up The flashing LED indicates the charge status or a fault for flashing codes see LED Display table The battery is now charged 17 54 Z When the mains connec...

Page 65: ...ge compartment 54 If applicable place the existing insulating mats back over the battery Close the battery panel securely The truck is now ready for operation CAUTION Damaged mains cables can be hazardous uDo not trap the mains cable when closing the battery panel Charging times The duration of charge depends on the battery capacity Z Charging continues automatically after a mains failure Charging...

Page 66: ...cteristic curve set Red LED fault Lit Overtemperature Charging is interrupted Flashes slowly Safety charging time exceeded Charging is cancelled Mains must be disconnected for charging to restart Rapid flash Invalid characteristic curve setting Compensation charge The compensation charge starts automatically when charging is complete Partial charging The charger is designed to automatically adapt ...

Page 67: ...ries with insulated cells and terminal connectors uPark the truck on a level surface to prevent the battery from sliding out uMake sure the crane slings have sufficient capacity to replace the battery uUse only approved battery replacement devices battery roller stand replacement trolley etc uMake sure the battery is securely located in the truck s battery compartment CAUTION Trapping hazard There...

Page 68: ...he battery cable on the tray so that it cannot be severed when the battery is pulled out Attach the crane lifting gear to the eyes 56 Z The hooks must be fitted in such a way that when the crane lifting gear is slackened they do not fall onto the battery cells The lifting gear must exert a vertical pull so that the battery container is not compressed Lift the battery slowly out of the battery comp...

Page 69: ...ed when the battery is inserted Attach the battery connector to the truck connector CAUTION Trapping hazard There is a risk of trapping when you close the battery cover uDo not reach between the battery cover and chassis Hold the battery cover only by the designated recess uClose the battery panel carefully and slowly Close the battery cover The battery is now installed Z After installing the batt...

Page 70: ... 220 Z Lateral battery removal is an option only CAUTION Trapping hazard Trapping hazard when removing and installing the battery uWhen removing and installing the battery do not put your hands between the battery and the chassis 59 57 58 68 04 19 en GB ...

Page 71: ...truck securely see page 84 Procedure Z Installation is in the reverse order When reinstalling the battery note the proper installation position and make sure the battery is connected correctly Z Place the battery cable on the tray so that it cannot be severed when the battery is inserted Push the battery into its receptacle Push the battery lock 58 towards the battery tray as far as the stop Attac...

Page 72: ...ent station trolley Procedure Disconnect the battery connector from the truck connector Z Place the battery cable on the tray so that it cannot be severed when the battery is pulled out Flip the battery lock 58 back until the battery retainer 60 can move freely Raise the battery retainer 60 and flip back the lock 58 to secure the retainer in the upper position Position the battery trolley by the t...

Page 73: ...be severed when the battery is inserted Push the battery as far as the stop 61 in the battery compartment Flip the battery lock 58 back until the battery retainer 60 can move freely Flip the battery retainer 60 into the battery tray Push the battery lock 58 towards the battery tray as far as the stop Attach the battery connector to the truck connector The battery is now assembled Z After installin...

Page 74: ...72 04 19 en GB ...

Page 75: ...nstructions Safety shoes must be worn on pedestrian operated trucks Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator 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 informed immediately of any damage or faults to the truck or attac...

Page 76: ...e hazardous area stop the truck immediately Safety devices warning signs and warning instructions Safety devices warning signs see page 34 and warning instructions in the present operating instructions must be strictly observed WARNING Removing or disabling safety devices can cause accidents Removing or disabling safety devices such as the Emergency Disconnect switch key switch buttons horn strobe...

Page 77: ...2 Displays and Controls EJC 212z 214z 216z 220z 15 12 13 14 9 17 67 62 63 5 65 6 5 66 64 18 5 6 5 63 62 64 66 65 75 04 19 en GB ...

Page 78: ...EJC 214 216 220 15 12 13 14 9 17 67 62 5 65 6 5 18 6 5 63 62 65 65 5 5 6 5 63 63 62 76 04 19 en GB ...

Page 79: ...g zone braking can be overridden by pressing the button and the truck can move at reduced speed slow travel see page 93 13 Tiller t Used for steering and braking 14 Charge status indicator t Indicates the charge discharge status of the battery CanDis o Display instrument for Battery charge status Battery discharge status Service hours Event messages Parameter settings Display unit 2 inch display o...

Page 80: ...ay unit Truck release by entering set up and access codes Transponder reader o Replaces the key switch Provided only as a supplement to the display unit Activates the truck via a card transponder 18 Document storage compartment t Used to store the operating instructions 62 Fork lowering button t Lowers the forks The lowering speed can be infinitely controlled by the stroke of the switch 8 mm 63 Fo...

Page 81: ...adjustment is not made the battery may become damaged due to deep discharge NOTICE Full discharge can damage the battery Self discharge can cause the battery to fully discharge Full discharge shortens the useful life of the battery uCharge the battery at least every 2 months Z Charge the battery see page 55 If the residual capacity falls below the required level lifting is inhibited An alternating...

Page 82: ...us Green 40 100 Orange 30 40 Green orange flashes at 1 Hz 20 30 Red 0 20 Z If the LED is red the load can no longer be lifted Lifting is only enabled when the battery connected is at least 70 charged If the LED flashes red and the truck is not ready for operation inform the manufacturer s service department Red flashing is a truck controller code The flashing sequence indicates the type of fault 6...

Page 83: ...uck for signs of damage and leaks Damaged hoses must be replaced immediately Check the battery attachment and wire connections for damage and make sure they are secure Check the battery connectors are secure Check the load handler for visible signs of damage such as cracks bent or severe wear Check the drive wheel and load wheels for damage Check that the markings and labels are present clean and ...

Page 84: ...card or transponder in front of the ISM access module and depending on the setting press the green button on the ISM access module o Z The tiller 13 must be in the upper braking zone B If event message E 0914 is displayed on the CanDis display instrument o or on the display unit 2 inch display o move the tiller to the upper brake zone B see page 94 The truck is ready for operation t The charge sta...

Page 85: ...ervice until you have identified and rectified the fault Procedure Test warning indicators and safety equipment Test the emergency disconnect function by pressing the emergency disconnect switch The main circuit is disconnected and no truck operations can be performed Now pull the emergency disconnect switch to unlock it Test the horn by pressing the warning signal button Check braking efficiency ...

Page 86: ...d handler raised uPark the truck on a level surface In special cases the truck may need to be secured with wedges uFully lower the load handler when leaving the truck uSelect a place to park where no other people are at risk of injury from the lowered load handler uIf the brakes are not working place wedges underneath the wheels of the truck to prevent it from moving Park the truck securely Proced...

Page 87: ...low speed when negotiating bends or narrow passageways when passing through swing doors and at blind spots The operator must always observe an adequate braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times Abrupt stopping except in emergencies rapid U turns and overtaking at dangerous or blind spots are not permitted Do not lean out o...

Page 88: ...r 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 forklift truck must only enter the lift after the truck has come to a rest and must leave the lift before the truck The driver must ensure that the loading ramp dock cannot move or come loose during loading unloading Type of lo...

Page 89: ...ies CAUTION Faulty or non accessible Emergency Disconnect switches can cause accidents A faulty or non accessible Emergency Disconnect switch can cause accidents In dangerous situations the operator cannot bring the truck to a halt in time by applying the Emergency Disconnect switch uThe operation of the Emergency Disconnect switch must not be affected by any objects placed in its way uReport any ...

Page 90: ... Disconnect switch on in emergencies Releasing the Emergency Disconnect switch Procedure Pull the Emergency Disconnect switch 9 to unlock it All electrical functions are enabled and the truck is operational again provided the truck was operational before the Emergency Disconnect was pressed Z Trucks with CanCode and ISM access module remain switched off 9 88 04 19 en GB ...

Page 91: ...k of collision due to a defective tiller Operating the truck with a defective tiller can lead to collisions with persons or objects uIf the tiller returns to the brake position slowly or not at all the truck must be taken out of service until the cause of this fault is be rectified uContact the manufacturer s customer service department B B 89 04 19 en GB ...

Page 92: ...d direction 3 Travel in load direction Rotate the travel switch 5 slowly in the drive direction 2 Travel in drive direction Control the travel speed with the travel switch 5 The further the travel switch 5 is rotated the greater the travel speed Control the travel speed by rotating the travel switch 5 further or less Z After releasing the travel switch 5 it automatically returns to the neutral pos...

Page 93: ...he load handler is fully lowered EJC 212z 214z 216z 220z only When the load handler is fully lowered the truck can only travel at reduced speed The load handler must be raised in order to use the maximum available speed 91 04 19 en GB ...

Page 94: ... travel switch is released in time uAfter setting off in the opposite direction apply the travel switch gently or not at all uDo not perform any sudden steering operations uAlways face in the direction of travel uMaintain an adequate overview of the route you are travelling Changing direction during travel Procedure Set the travel switch 5 to the opposite direction while travelling The truck decel...

Page 95: ...ng Z The truck can be operated with an upright tiller 13 e g in confined spaces elevators Switch on the slow travel function Procedure Press and hold down the slow travel button 12 Rotate the travel switch 5 in the required travel direction The brake is released The truck travels at slow speed Switching off slow travel Procedure Release the slow travel button 12 If the tiller is in brake zone B th...

Page 96: ...ground is wet or dirty uThe operator must be aware of floor conditions and take them into account when braking uBrake with care to prevent the load from slipping CAUTION uIn hazardous situations set the tiller to the brake position The truck can brake in three different ways By using the service brake brake zone B With the coasting brake By inversion braking braking and changing direction 4 7 1 Br...

Page 97: ...Z When braking regeneratively energy is returned to the battery ensuring a longer service time 95 04 19 en GB ...

Page 98: ...en braking regeneratively energy is returned to the battery ensuring a longer service time 5 13 4 7 3 Inversion braking Procedure Set the travel switch 5 to the opposite direction while travelling see page 92 The truck brakes regeneratively until it starts to move in the opposite direction 4 7 4 Parking brake Z The mechanical brake applies automatically when the truck comes to rest 96 04 19 en GB ...

Page 99: ...ed in accordance with regulations Use suitable precautions to prevent parts of the load from tipping or falling down uNever exceed the maximum loads specified on the capacity plate uNever stand underneath a raised load handler uDo not stand on the load handler uDo not lift other people on the load handler uNever reach or climb into moving truck parts uDo not climb onto parts of the building or oth...

Page 100: ...it When you have reached the mechanical stops of the load handler do not press the Raise load handler button any more Otherwise the hydraulic unit could suffer material damage Z The lift lower speed can be infinitely controlled via the movement of the button approx 8 mm Short stroke slow lift lower Long stroke fast lift lower The load handler is raised Tiller from above 71 72 63 62 Tiller from bel...

Page 101: ...approx 8 mm Short switch stroke slow lower Long switch stroke fast lower The load handler is lowered 4 8 3 Raising the wheel arms Z EJC 212z 214z 216z 220z only Requirements Prepare the truck for operation see page 82 Procedure Press the support arm raise button 72 until you reach the desired support arm lift The support arms are raised 4 8 4 Lowering the wheel arms Z EJC 212z 214z 216z 220z only ...

Page 102: ...er uPreferably the load should be configured and picked up so that its centre distance lies within the load centre distance of the load handler d1 D and d2 D see area DD in the illustration uA load with a centre of gravity outside of the load centre distance of the load handler d1 D and or d2 D should only be moved very carefully as this load case has not been checked on a truck tested according t...

Page 103: ...ximum loads specified on the load diagram uNever stand underneath a raised load handler uDo not stand on the load handler uDo not lift other people on the load handler uInsert the load handler as far as possible underneath the load CAUTION uDo not lift long loads at an angle NOTICE With the two stage Duplex mast ZZ and the three stage Triplex mast DZ a short centre mounted free lift cylinder initi...

Page 104: ...rial damage to the hydraulic unit When the mechanical stops of the load handler have been reached release the raise load handler button Otherwise the hydraulic unit may suffer material damage Z The lifting lowering speed can be infinitely controlled via the movement of the button approx 8 mm Short stroke slow lift lower Long stroke fast lift lower EJC 212z 214z 216z 220z only With the low level li...

Page 105: ...onditions of the route and the load you are transporting Travel at a constant speed Be prepared to brake at all times Brake gently in normal circumstances Only stop suddenly in dangerous situations Watch out for other traffic at crossings and passageways Always travel with a lookout at blind spots Do not travel across or at an angle on inclines Do not turn on slopes and inclines and always drive w...

Page 106: ...he load down abruptly Lower the load handler so that it is clear of the load see page 99 Carefully drive the load handler out from beneath the pallet The load is deposited NOTICE Avoid depositing the load suddenly to avoid damaging the load load handler and the rack NOTICE The soft landing feature reduces the lowering speed of the load just before it reaches the ground approx 100 300 mm Z The soft...

Page 107: ...rated capacity Load handler evenly laden for heavy loads Procedure Drive the truck slowly up to the pallet Insert the load handler slowly into the first pallet until the pallet is resting against the back of the load handler see right hand graphic Z The load must not extend by more than 50 mm beyond the load handler tips Raise the load handler until you reach the desired height see page 98 Z In do...

Page 108: ...e heavier pallet should always be transported underneath Requirements Load raised correctly Load handler lowered as far as possible but without touching the lower load Good ground conditions Procedure Accelerate and decelerate with care Adapt your travel speed to the conditions of the route and the load you are transporting Travel at a constant speed Watch out for other traffic at crossings and pa...

Page 109: ... truck carefully up to the first storage location Lower the support arms until the load is resting on the floor Carefully move the support arms out of the pallet Lower the load handler see page 103 Drive the truck carefully up to the second storage location Lowers the load handler Z To avoid damaging the load and the load handler avoid setting the load down abruptly Lower the load handler so that ...

Page 110: ... leakage According to DIN EN ISO 3691 1 the load handler may lower by up to 100 mm during the first 10 minutes at the rated capacity with the hydraulic oil at normal operating temperature uNever stand underneath a raised load handler WARNING Risk of injury from falling loads Falling loads can cause injuries uNever stand underneath a raised load handler uNever manually load or unload loads that cou...

Page 111: ... the electronics system is displayed with a corresponding error code contact the manufacturer s service department Troubleshooting must only be performed by the manufacturer s customer service department The manufacturer has a service department specially trained for these tasks In order for customer services to react quickly and specifically to the fault the following information is essential Tru...

Page 112: ...display o Enter correct code see page 121 Raise load handler button Lower load handler button not in home position when truck switched on for CanDis o or the display unit 2 inch display o event message E 2951 appears Do not actuate the button Travel switch not in home position when truck switched on for CanDis o or the display unit 2 inch display o event message E 1901 appears Do not actuate the t...

Page 113: ...nch display o event message E1953 appears Follow the operating sequence 1st Swivel the tiller into the travel zone F or press the slow travel button 2nd Actuate the travel switch see page 121 Slow travel button actuated when truck switched on for CanDis o or the display unit 2 inch display o event message E 1925 appears Do not actuate the slow travel button see page 121 Switch in mast not plausibl...

Page 114: ...play o event message E 1901 appears Do not actuate the travel switch Collision safety switch actuated when truck switched on for CanDis o or the display unit 2 inch display o event message E 1914 appears Do not actuate the collision safety switch Slow travel button actuated when truck switched on for CanDis o or the display unit 2 inch display o event message E 1901 appears Do not actuate the butt...

Page 115: ...eleasing the brake Tools and Material Required Two M5x35 screws Spanner wrench Procedure Switch off the truck to do this Turn the key in the key switch 15 anti clockwise as far as it will go Remove the key from the key switch 15 For CanCode o press the O key Press the red button on the ISM access module o Press the Emergency Disconnect switch 9 Open the battery panel see page 54 Disconnect the bat...

Page 116: ...rs can cause injury and accidents uThe covers battery cover side panels drive compartment cover etc must be closed during operation Install the front panel 20 see page 185 The brake has been reactivated The brake is now be applied without current WARNING Only return the truck to service when you have identified and rectified the fault 114 04 19 en GB ...

Page 117: ...tive truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fault 7 1 EJC 214 216 220 Load handler emergency lowering Requirements Load handler is not in the rack Tools and Material Required Fork wrench SW 8 EJC 214 216 220 Procedure Set the key switch 15 to 0 Depress the Emergency Disconnect switch 9 see page 87 Lift off the front ...

Page 118: ...ing range 1 4 Nm Procedure Park the truck securely see page 84 Open the front panel see page 185 Loosen the lock nut 75 on the valve block Remove the valve screw 76 in stages anti clockwise The load handler is lowered Z After the emergency lowering insert the valve screw 76 as far as the stop 1 5 Nm 0 5 Nm and secure with the lock nut 75 75 76 116 04 19 en GB ...

Page 119: ...equirements Truck prevented from rolling away Charged battery in truck Tools and Material Required Service key GF60 with lock bar Procedure Insert the service key GF60 in the key switch Z The service key GF60 with lock bar can only be inserted and turned on one side If inserted in the wrong direction the key will not turn Turn service key to position 1 Move the lock bar on the head of the key Turn...

Page 120: ...ock bar returns to its original position The brake is now activated again WARNING Only return the truck to service when you have identified and rectified the fault Z The GF30 key without lock bar is for normal operation The key can be inserted in both directions and can only be turned to position 1 in the key switch GF 30 118 04 19 en GB ...

Page 121: ...eters the settings in the code lock can be changed Parameter Description 0 0 0 Change master code see page 122 0 0 1 Add user codes see page 124 0 0 2 Change a user code see page 126 0 0 3 Delete a user code see page 128 0 0 4 Delete all user codes see page 130 0 1 0 Switch on the truck automatically see page 132 0 2 4 Assign travel programs to the user codes see page 134 In the as supplied condit...

Page 122: ...ey Pressing the o key switches the truck off and sets it to non operational status The o key indicates the follow operating conditions via a red green LED 81 Code lock function commissioning the truck Error display configuring the user code Adjusting the travel program depending on the setting and truck Setting and changing parameters SET key When you change the parameters the SET key 80 acts as a...

Page 123: ... Enter the code again The Set key 80 has no function in operating mode 8 2 3 Switching off the truck with the keypad CanCode Switching off the truck Procedure Press the O key 82 The truck is switched off and the LED 81 is lit red Z The truck can cut out automatically after a specified time If no travel steering or hydraulic operations are performed within a set time the truck switches off automati...

Page 124: ... the SET key 80 The LEDs 77 81 flash green Enter the valid master code again with the digit keys Confirm with the SET key 80 The LEDs 78 81 flash green Enter the valid master code with the digit keys Z The new master code must be different from existing user codes Confirm with the SET key 80 The LEDs 79 81 flash green Enter the new master code again with the digit keys Confirm with the SET key 80 ...

Page 125: ...at the required master code can be used see page 126 Delete the user code so that the required master code can be used see page 128 The master codes to be changed do not match Switch off the truck see page 121 Enter the master code again see page 122 The master code entered is not the same length as the user code Switch off the truck see page 121 Repeat the entry making sure that the length of the...

Page 126: ...er code must also be different from the existing master code Confirm with the SET key 80 The LEDs 79 81 flash green Enter the new user code again with the digit keys Confirm with the SET key 80 Wait until the LED 81 flashes green The setting is saved Press the O key 82 The truck is switched off and the LED 81 is lit red Check the new user code Switch on the truck with the new user code see page 12...

Page 127: ...e master code is the same length as the user code New user code is already occupied by a master code Switch off the truck see page 121 Choose a different user code see page 124 The newly entered user codes do not match Switch off the truck see page 121 Add the user code again see page 124 Code log full Switch off the truck see page 121 Delete individual user codes see page 128 Delete all user code...

Page 128: ...as that of the previously entered master code The new user code must also be different from the existing master code Confirm with the SET key 80 The LEDs 79 81 flash green Enter the new user code again with the digit keys Confirm with the SET key 80 Wait until the LED 81 flashes green The setting is saved Press the O key 82 The truck is switched off and the LED 81 is lit red Check the new user cod...

Page 129: ...master code is the same length as the user code Operator code to be changed does not exist Switch off the truck see page 121 Check the user code entered The user codes to be changed do not match Switch off the truck see page 121 Change the user code again see page 126 Tried to change the operator code to another user code that already exists Switch off the truck see page 121 Choose a different use...

Page 130: ...keys Confirm with the SET key 80 The LEDs 79 81 flash green Enter the user code to be deleted again with the digit keys Confirm with the SET key 80 Wait until the LED 81 flashes green The user code is now deleted Press the O key 82 The truck is switched off and the LED 81 is lit red Check that the user code has been deleted Switch the truck on with the user code to be deleted see page 121 After en...

Page 131: ...de Switch off the truck see page 121 Repeat the entry making sure that the master code is the same length as the user code Tried to delete an operator code that does not exist Switch off the truck see page 121 Check the user code entered The user codes to be changed do not match Switch off the truck see page 121 Delete the user code again see page 128 129 04 19 en GB ...

Page 132: ...1 flash green Enter the code 3 2 6 5 with the digit keys Confirm with the SET key 80 Wait until the LED 81 flashes green All user codes are deleted Press the O key 82 The truck is switched off and the LED 81 is lit red Check that the user codes have been deleted Switch on the truck with a previous user code see page 121 After entering the user code the LED 81 flashes red and the truck remains swit...

Page 133: ... can be changed all user codes must be deleted The length of the user code 4 6 digit is always determined by the length of the master code Requirements To prepare the truck for operation see page 121 Procedure Delete all user codes see page 130 Enter the new master code 4 6 digit see page 122 Add user codes again see page 124 The length of the new master code is now changed and user codes have bee...

Page 134: ...aved Press the O key 82 The truck is switched off and the LED 81 lights up red Checking the truck s automatic cutout Switch on the truck with a valid operator code see page 121 When you have entered a valid operator code the LED 81 lights up green the travel program selected is indicated by the corresponding LEDs 77 78 79 and the truck is switched on Do not perform any travel steering or hydraulic...

Page 135: ...Z This setting can be changed if required 133 04 19 en GB ...

Page 136: ...y the 77 78 79 LEDs LED 77 lit travel program 1 activated LED 78 lit travel program 2 activated LED 79 lit travel program 3 activated The configuration code is four digit and is comprised as follows 1st digit Specifies the authorisation for travel program 1 2nd digit Specifies the authorisation for travel program 2 3rd digit Specifies the authorisation for travel program 3 4 digit Specifying the s...

Page 137: ...4th digit 0 When the truck has been switched on with the selected user code no travel program is activated 1 When the truck has been switched on with the selected user code travel program 1 is activated 2 When the truck has been switched on with the selected user code travel program 2 is activated 3 When the truck has been switched on with the selected user code travel program 3 is activated Z The...

Page 138: ...e configuration code 4 digit for the travel programs again using the digit keys Confirm with the SET key 80 Wait until the LED 81 flashes green The travel programs are now assigned to the user code Press the O key 82 The truck is switched off and the LED 81 is lit red Checking the travel program configuration to the user code Switch on the truck with the configured user code see page 121 After ent...

Page 139: ...programs For the following events the LED 81 flashes red Cause Remedy Blocked travel program defined as start travel program Switch off the truck see page 121 Try again making sure the configuration code is entered correctly 137 04 19 en GB ...

Page 140: ...it parameter number 0256 and confirm with the SET key 80 Enter sub index enter 2 and confirm with the SET key 80 Z The parameter and sub index are displayed alternately with the current reading 0256 2 0000 3 Enter the parameter according to the parameter list and confirm with the Set key 80 Z The LED 81 of the O key 82 switches briefly to steady light and start flashing again after approx 2 second...

Page 141: ...ode and can be checked Z To continue setting confirm with the Set key 80 again Saving travel parameters Requirements Enter all parameters Procedure Run SaveParameters by pressing 1 2 3 Set Confirm with the O key 82 139 04 19 en GB ...

Page 142: ...0 m s2 Maximum speed in drive direction via travel switch 0 60 0 6 0 km h 40 4 0 km h Maximum speed in load direction via travel controller 0 60 0 6 0 km h 40 4 0 km h Travel program 2 Function Setting range Standard setting Acceleration 20 200 0 2 2 0 m s2 70 0 7 m s2 Coasting brake 20 330 0 2 3 3 m s2 90 0 9 m s2 Maximum speed in drive direction via travel switch 0 60 0 6 0 km h 56 5 6 km h Maxi...

Page 143: ...ller 0 60 0 6 0 km h 60 6 0 km h Common parameters Function Range Setting Standard Setting Comments Reduction brake 20 120 0 2 1 2 m s2 40 0 4 m s2 Deceleration for travel switch setting reduction Service Brake 50 330 0 5 3 3 m s2 170 1 7 m s2 Deceleration for tiller in brake position Body protection brake 50 200 0 5 20 m s2 200 2 0 m s2 Speed reduction when body protection switch applied Standard...

Page 144: ... battery 1388 ELH battery charger charging characteristic 0 6 1 0 No charging function 1 PzS wet cell batteries 100 300 Ah and PzM batteries from 0 179 Ah 2 PzS wet cell batteries with pulse characteristic 200 414 Ah and PzM batteries from 180 400 Ah 3 PzV batteries maintenance free 100 150 Ah 4 PzV batteries maintenance free 151 200 Ah 5 PzV batteries maintenance free 201 300 Ah 6 PzV batteries m...

Page 145: ...g only when stationary lowering only with authorisation 7 Lowering only with authorisation lowering only with authorisation 8 Lowering only when stationary 9 Lifting only with authorisation lowering only when stationary 10 Lifting and lowering when stationary 11 Lifting only with authorisation and only when stationary lowering only when stationary 12 Lowering only with authorisation and only when ...

Page 146: ...ering only when stationary 14 Lifting and lowering only when stationary lowering only with authorisation 15 Lifting and lowering only with authorisation and only when stationary 5 With authorisation with tiller in travel range F or with slow travel switch applied 6 Stationary No travel operations performed 144 04 19 en GB ...

Page 147: ...ed alternately with the current reading E g 1377 2 0000 1 corresponds to battery type high performance wet Enter parameter 2 according to the parameter list and confirm with the Set key The LED of the O key switches briefly to continuous light and starts flashing again after approx 2 seconds If the entry is incorrect the LED of the O key turns red Enter the parameter number again to repeat the set...

Page 148: ...r code Enter the four digit parameter number 1377 and confirm with the Set key Enter sub index 2 and confirm with the Set key The parameter with subindex are displayed alternately with the current reading E g 1377 2 0000 2 corresponds to the dry maintenance free battery type Press the O key The parameter has now been checked 146 04 19 en GB ...

Page 149: ... list and confirm with the SET key Z The LED of the O key 82 switches briefly to steady light and start flashing again after approx 2 seconds Z If the entry is incorrect the LED of the O key 82 turns red Enter the parameter number again to repeat the setting Z The parameter and sub index are displayed alternately with the current reading 1388 2 0000 5 Charging characteristics for the maintenance f...

Page 150: ...parameter with sub index are displayed alternately with the current reading E g 1388 2 0000 5 corresponds to the charging characteristics for the maintenance free battery with 201 300 Ah Press the O key The parameter has now been checked 148 04 19 en GB ...

Page 151: ...git LCD Service hours Parameter entry and changes Event messages Charge status display The charge status is shown through eight LED bars Eight lit LED bars correspond to a fully charged battery One lit LED bar corresponds to an almost discharged battery When the Attention symbol 85 starts to flash it is advisable to charge the battery If the Attention symbol 85 is lit steadily the battery must be ...

Page 152: ...al batteries the T 87 symbol flashes in the service hour display 8 7 3 Event Messages The service hours display is also used to display event messages The event messages overwrite the service hour display Event message start with an E for Event and a four digit error number The event message is displayed as long as the fault persists If there are several event messages they are displayed consecuti...

Page 153: ...pe characteristics Displays the set battery type or set battery characteristic curve 7 1 Maintenance free gel dry cell battery 2 Special battery for example XFC 93 Travel program Shows the active travel program 94 Service hours see page 21 95 Button allocation see page 152 96 Buttons Selection buttons for the functions shown above them 7 If the setting is for normal or high performance wet cell ba...

Page 154: ...itch the travel program down Travel program up To switch the travel program up Settings o To change to the menu to administer the codes or transponders Switch off o Allows the truck to be switched off Switch off is only available in the display if the truck is switched on with an access code 152 04 19 en GB ...

Page 155: ...t access code transponder To add or delete access codes and transponders Up selection To select access codes or transponders Down selection To select access codes or transponders Clear To delete selected access codes Add To add new access codes Back Cancels the current procedure and returns to the previous menu Confirm To confirm an entry or a transponder code 153 04 19 en GB ...

Page 156: ...el functions reduced Red Overtemperature detected Lifting lowering and travel functions deactivated Lithium ion battery low temperature o yellow Lithium ion battery low temperature detected Discharge currents and energy recovery are reduced at low temperatures Lithium ion battery below permissible temperature range The truck switches off via the battery contactor Side arm yellow Illuminates if bot...

Page 157: ...ifting limit has been reached Support arm lift lowering limit yellow Illuminates if Lower support arms button pressed if the support arm lift lowering limit has been reached Charging process Green Battery charge display on board charger only Flashing Charging in progress Steady light Charging complete Red Charging interrupted 155 04 19 en GB ...

Page 158: ...ription 97 Display unit EasyAccess Softkey Description see page 151 Entry of 4 digit set up and access codes Up to 10 access codes can be stored For set up and access codes with the numbers 1 to 4 98 Keypad EasyAccess PINCode Consists of keys 0 to 9 and C clear Entry of 4 digit set up and access codes Up to 100 access codes can be stored 99 Transponder reader EasyAccess Transponder Up to 100 trans...

Page 159: ...en an invalid code has been entered or a invalid transponder used a red cross is displayed and the entry must be repeated Z If the truck is not used for a certain length of time the display unit switches to standby mode Pressing any key cancels the standby mode The following additional settings can be performed by the manufacturer s customer service department 8 11 Commissioning the Keypad and the...

Page 160: ...change the set up code The new set up code must not be the same as the default set up code or an access code Press the key below the Delete symbol 102 The set up code is deleted Enter the new set up code using the keypad 98 Press the key below the Confirm symbol 103 The new set up code is displayed Z If the new set up code was entered incorrectly the procedure can be repeated using the key below t...

Page 161: ...e symbol 102 The set up code is deleted Hold a transponder in front of the transponder reader 99 This transponder thus becomes the set up transponder Press the key below the Confirm symbol 103 The code for the set up transponder is displayed Z If the wrong transponder has been used the procedure can be repeated using the key below the Delete symbol 102 To return to the main menu press the key belo...

Page 162: ...nnect switch see page 87 Enter the access code with the buttons below the display 97 The truck is switched on 8 12 2 Switching off the truck Procedure Press the key under the Switch off symbol 105 in the display unit Press the Emergency Disconnect switch see page 87 The truck is switched off 105 160 04 19 en GB ...

Page 163: ...Press the key below the Delete symbol 102 The set up code is deleted Enter the new set up code using the keys below the display unit 97 Z The new set up code must be different from existing access codes Press the key below the Confirm symbol 103 The new set up code is displayed Z If the new set up code has been entered incorrectly delete it and add a set up code again To return to the main menu pr...

Page 164: ...e displayed Press the key below the Add symbol 107 Enter the new access code using the keys below the display unit 97 Z The new access code must be different from existing access codes Press the key below the Confirm symbol 103 The new access code is displayed Z If the new access code has been entered incorrectly delete it see page 168 and add an access code again To return to the main menu press ...

Page 165: ...set up code is requested Enter the set up code using the keys below the display unit 97 All the access codes are displayed Select the access code to be deleted using the key below the Down selection symbol 108 Press the key below the Delete symbol 102 The access code has been deleted To return to the main menu press the key below the Back symbol 104 102 100 97 104 102 108 106 163 04 19 en GB ...

Page 166: ...ey below the Log in process symbol 109 Enter the set up code using the keys below the display unit 97 The set up code entered is shown as filled in circles To scroll forward press the button under the Down selection symbol 108 as many times as necessary The display area moves Additional earlier log ins are displayed To scroll back press the button under the Up selection symbol 110 as many times as...

Page 167: ...truck is switched on 98 Procedure Press the key under the Switch off symbol 105 in the display unit Press the Emergency Disconnect switch see page 87 The truck is switched off 8 13 2 Switching off the truck Procedure Press the key under the Switch off symbol 105 in the display unit Press the Emergency Disconnect switch see page 87 The truck is switched off 105 165 04 19 en GB ...

Page 168: ...ircles Press the key below the Delete symbol 102 The set up code is deleted Enter the new set up code using the keypad 98 Z The new set up code must be different from existing access codes Press the key below the Confirm symbol 103 The new set up code is displayed Z If the new set up code has been entered incorrectly delete it and enter the correct set up code To return to the main menu press the ...

Page 169: ...nit 97 Press the key below the Add symbol 107 Enter a new access code using the keypad 98 Z The new access code must be different from existing access codes Press the key below the Confirm symbol 103 The new access code is shown on the display unit 97 Z If the new access code has been entered incorrectly delete it see page 168 and enter the correct access code To return to the main menu press the ...

Page 170: ...he set up code is requested Enter the set up code using the keypad 98 All access codes are shown on the display unit 97 Select the access code to be deleted using the key below the Down selection symbol 108 Press the key below the Delete symbol 102 The access code has been deleted To return to the main menu press the key below the Back symbol 104 98 100 97 104 102 108 106 168 04 19 en GB ...

Page 171: ...below the Log in process symbol 109 Enter the set up code using the keypad 98 The set up code entered is shown in the display unit 97 as filled in circles To scroll forward press the button under the Down selection symbol 108 as many times as necessary The display area moves Additional earlier log ins are displayed To scroll back press the button under the Up selection symbol 110 as many times as ...

Page 172: ...as been confirmed If there is no confirmation within 20 seconds the access prompt appears Press the button below the Confirm symbol 103 The truck is switched on 99 103 Z The truck can only be switched on when the display unit 97 is lit If the display unit is in standby the code or transponder will not be recognised Pressing any key cancels standby mode 8 14 2 Switching the truck off transponder re...

Page 173: ...e Delete symbol 102 A dashed line is shown Place the new set up transponder on the transponder reader 99 Z The new set up transponder code must be different from existing transponder codes Press the key below the Confirm symbol 103 The new code for the set up transponder is displayed Z If the wrong transponder has been used the procedure can be repeated using the key below the Delete symbol 102 To...

Page 174: ... the Add symbol 107 Place the new transponder on the transponder reader 99 Z The new transponder code must be different from existing transponder codes Press the key below the Confirm symbol 103 The new transponder code is displayed Z If the wrong transponder has been used delete it see page 173 and add a correct transponder To return to the main menu press the key below the Back symbol 104 A new ...

Page 175: ...nder is requested Place the set up transponder on the transponder reader 99 All transponder codes are shown on the display unit 97 Select the transponder code to be deleted using the key below the Down selection symbol 108 Press the key below the Delete symbol 102 The transponder has been deleted To return to the main menu press the key below the Back symbol 104 100 104 102 108 99 106 97 173 04 19...

Page 176: ...l 109 Place the set up transponder on the transponder reader 99 To scroll forward press the button under the Down selection symbol 108 as many times as necessary The display area moves Additional earlier log ins are displayed To scroll back press the button under the Up selection symbol 110 as many times as necessary The display area moves More recent log ins are displayed To return to the main me...

Page 177: ...alist engineer in industrial trucks taking safety into account Keep permanent graphic records of the plans tests and completion of the changes Carry out and have authorised the respective changes to the capacity data plates decals and stickers as well as the operator and service manuals Attach permanent and clearly visible marking to the truck indicating the types of changes made the date of the c...

Page 178: ...o the following target groups Customer Services Customer Services are specially trained in the use of the truck and are able to carry out maintenance and repairs independently Customer Services are aware of the relevant standards guidelines and safety regulations as well as potential risks Operating company The maintenance personal of the operating company has the technical expertise and experienc...

Page 179: ...vironmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations Oil changes should be carried out by the manufacturer s customer service department whose staff are specially trained for this task uNote the safety regulations when handling these materials 2 3 Wheels WARNING The use of wheels that do not comply with the manufac...

Page 180: ...or immediately in the event of an injury uDo not touch pressurised hydraulic hoses uReport any defects immediately to your supervisor uMark defective truck and take it out of service uDo not return the industrial truck to service until you have identified and rectified the fault NOTICE Testing and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regul...

Page 181: ...s be clean and well lubricated uLift chains should only be cleaned with paraffin derivatives e g petroleum or diesel fuels uDo not clean lift chains with high pressure jets or chemical cleaning agents uImmediately after cleaning dry the lift chain with compressed air and apply a chain spray uAlways lubricate a chain when it is discharged uLubricate a lift chain with particular care around the pull...

Page 182: ...d containers uAlways fill consumables in clean containers uDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the operating instructions CAUTION Spilled consumables can cause slipping and endanger the environment Risk of slipping from spilled consumables The risk is greater when combined with water uDo not spill consumables uSpilled co...

Page 183: ... when handling oil uAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has come into contact with your skin rinse your skin with water uIf oil has come into contact with your eyes rinse them with water and seek medical assistance immediately uReplace oil soaked clothing and sh...

Page 184: ...e Cold store application Hydraulic oil filler plug b Transmission oil filler neck o Lifting kinematics of initial lift EJC 212z 214z 216z 220z only 1 Mixture ratio for cold store usage 1 1 2 Transmission oil is a guideline The spur wheel should be dipped approx 2 mm into the transmission oil 182 04 19 en GB ...

Page 185: ... penetration at 25 C NLG1 class Application temperature C E Lithium 220 280 310 2 35 120 The trucks are factory equipped with a special hydraulic oil the Jungheinrich hydraulic oil with a blue colouration and the cold store hydraulic oil red colouration The Jungheinrich hydraulic oil can only be obtained from the Jungheinrich service department The use of named alternative hydraulic oils is not pr...

Page 186: ...4 Disconnect the battery to prevent the truck from being switched on accidentally WARNING Risk of accidents when working under the load handler and lift truck uWhen working under a raised load handler or a raised truck secure them to prevent the truck from from lowering tipping or sliding away uWhen raising the truck follow the instructions see page 43 When working on the parking brake prevent the...

Page 187: ... and Material Required Allen key opening 5 Procedure Turn or slightly tilt tiller towards the edge of the truck Remove the screws 111 with the Allen key Carefully remove the front panel 20 and put it to one side The front cover has been removed Z When installing the front panel 20 tighten the screws 111 to 3 Nm 111 20 185 04 19 en GB ...

Page 188: ...ack up the truck safely proceed as follows uJack up the truck only on a level surface and prevent it from moving accidentally uAlways use a jack with sufficient capacity When jacking up the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks uIn order to raise the truck the lifting gear must only be secured to the points specially provided for this ...

Page 189: ... necessary safety measures to prevent sparking before cleaning e g by short circuiting CAUTION Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity uCover all electronic system assemblies controllers sensors motors etc before cleaning the truck with a pressure washer uDo not hold the jet of the pressure washer by the marked poi...

Page 190: ...water based solvents and water Use a sponge or cloth to clean In particular clean the following areas Window s Oil filler ports and their surroundings Grease nipples before lubrication Dry the truck after cleaning e g with compressed air or a dry cloth Carry out all the tasks in the section Recommissioning the truck after cleaning or maintenance work see page 195 The truck is now clean 188 04 19 e...

Page 191: ...electrical system assemblies Requirements Prepare the truck for maintenance and repairs see page 184 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure Expose the electrical system see page 185 Clean the electrical system assemblies with weak suction or compressed air use a compressor with a water trap and not a conductive anti static brush Fit th...

Page 192: ...sary add transmission oil of the correct grade see page 183 refer to table Z For the first filling approximately 0 6 l more hydraulic oil should be added The oil level has now been checked Z If a leak is discovered in the hydraulics cylinder unions lines the truck must be decommissioned and repaired by specialist personnel Marking Litres Lift heights h3 ZT ZZ DZ 3 approx 8 3 2 approx 7 5 EJC 214 2...

Page 193: ...Z After adding hydraulic oil tighten the lock to 10 Nm M 10Nm 191 04 19 en GB ...

Page 194: ...s Requirements Prepare the truck for maintenance and repairs see page 184 Tools and Material Required Torque wrench Procedure Position the drive wheel 114 so that the wheel nuts 115 can be pulled through the hole 113 Tighten all the wheel nuts 115 through the hole 113 in the impact buffer with the socket wrench To do this tighten the wheel nuts in the prescribed order First of all tighten to 10 Nm...

Page 195: ...115 113 114 112 193 04 19 en GB ...

Page 196: ...ure Check the fuse ratings against the table and replace if necessary The fuses have been checked 119 116 120 117 118 121 Item Description To protect Rating A 116 F15 Drive lift motor 200 117 F1 Overall control circuit fuse 4 118 6F1 Battery indicator 2 119 9F22 Electromechanical components 4 120 3F6 Steer motor 30 121 F17 Radio data o 4 194 04 19 en GB ...

Page 197: ...rs Procedure Thoroughly clean the truck see page 187 Lubricate the truck according to the lubrication diagram see page 182 Clean the battery grease the terminals and connect the battery Charge the battery see page 55 Start up the truck see page 81 195 04 19 en GB ...

Page 198: ...ment 5 1 Prior to decommissioning Procedure Thoroughly clean the truck see page 187 Prevent the truck from rolling away accidentally Check the hydraulic oil level and replenish if necessary see page 190 Apply a thin layer of oil or grease to any non painted mechanical components Lubricate the truck according to the lubrication schedule see page 182 Charge the battery see page 55 Disconnect the bat...

Page 199: ...edure Thoroughly clean the truck see page 187 Lubricate the truck according to the lubrication schedule see page 182 Clean the battery grease the terminal screws and connect the battery Charge the battery see page 55 Start up the truck see page 81 197 04 19 en GB ...

Page 200: ...issioning or disposal of the truck in must be performed in accordance with the regulations of the country of use In particular regulations governing the disposal of batteries consumables and electronic and electrical systems must be observed The truck must only be disassembled by trained personnel in accordance with the procedures as specified by the manufacturer 8 Human vibration measurement Z Vi...

Page 201: ...ruck have a considerable impact on component wear The following service inspection and replacement intervals are based on single shift operation under normal operating conditions The intervals must be reduced accordingly if more stringent requirements are placed on the equipment e g use in conditions of extreme dust temperature fluctuations or multiple shifts uTo prevent damage due to wear the man...

Page 202: ...performed every 50 service hours but at least once a week 1 1 1 Maintenance contents 1 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains Correct the hydraulic oil level Steering Test the tiller return function 200 04 19 en GB ...

Page 203: ...l equipment Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised water 201 04 19 en GB ...

Page 204: ...he battery connector and for damage Travel The function of the collision safety switch and for damage Wheels for wear and damage Chassis structure Industrial truck for damage and leaks Labels are legible complete and plausible Doors and or covers for damage Hydraulic operations The function of the hydraulic system The secure seating of the hydraulic connections hoses and pipes and for leaks and da...

Page 205: ...amatik Power supply The function of the Aquamatik plug hose connections and float and for leaks The function of the flow indicator and for leaks Lead acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead acid battery Power supply Battery cable connections are secure 203 04 19 en GB ...

Page 206: ...rs as well as mounting brackets are secure Ensure they function correctly and are safe Hydraulic operations Test the lift sensors in the mast Adjust the slide pieces Adjust the load chains Lubricate the load chains Test emergency lowering Correct the hydraulic oil level Test the pressure relief valve Agreed services Carry out a test run with the rated load or a customer specific load Demonstration...

Page 207: ...n the scanner and terminal Lead acid battery international Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using demineralised water Lead acid battery Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using...

Page 208: ...e and leaks Wheel bearings and attachment for wear and damage Wheels for wear damage and secure mounting Chassis structure Industrial truck for damage and leaks The secure seating of the chassis and screw connections and for damage Labels are legible complete and plausible The secure seating of the mast Protective mechanism against trapping and shearing is present secure functions correctly and is...

Page 209: ...tops are present and secure Tie plunger rods are uniformly adjusted and for wear and damage The secure seating of the hoses pipes and connections and for wear leaks damage blisters and kinks Steering Lateral play of the tiller The steering components for play and damage Battery charger The mains plug and mains cable for damage The secure seating of the cables and electrical connections and for dam...

Page 210: ...em The shock sensor data recorder is secure and for damage Data radio System components The function and secure seating of the scanner and terminal and for damage Fuse ratings The secure seating of the cables and for damage Access module Electrical system Access module is secure and functions correctly and for damage Protective window grid Chassis structure The presence and secure seating of the p...

Page 211: ...Lead acid battery Power supply The secure seating of the battery battery cables and cell connectors and for damage 209 04 19 en GB ...

Page 212: ...2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Hydraulic oil filter 2000 12 Transmission oil 10000 1 2 3 2 Optional equipment Cold store application maintenance part service hours months Hydraulic oil 1000 12 Hydraulic oil additive 1000 12 210 04 19 en GB ...

Page 213: ...formed every 50 service hours but at least once a week 2 1 1 Maintenance contents 2 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains Correct the hydraulic oil level Steering Test the tiller return function 211 04 19 en GB ...

Page 214: ...l equipment Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demineralised water 212 04 19 en GB ...

Page 215: ...he function and secure seating of the battery connector and for damage Travel The function of the collision safety switch and for damage Wheels for wear and damage Chassis structure Industrial truck for damage and leaks Labels are legible complete and plausible Doors and or covers for damage Protective mechanism against trapping and shearing is present secure functions correctly and is free of dir...

Page 216: ...oard charger Battery charger The mains plug and mains cable for damage Lead acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead acid battery Power supply Battery cable connections are secure 214 04 19 en GB ...

Page 217: ...on resistance test Clean the motor engine with compressed air Chassis structure Check that the panels and covers as well as mounting brackets are secure Ensure they function correctly and are safe Hydraulic operations Adjust the slide pieces Adjust the load chains Lubricate the load chains Test emergency lowering Correct the hydraulic oil level Test the pressure relief valve Agreed services Carry ...

Page 218: ...n the scanner and terminal Lead acid battery international Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using demineralised water Lead acid battery Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using...

Page 219: ...ivetrain bearings for wear and damage Transmission for noise and leaks Wheel bearings and attachment for wear and damage Wheels for wear damage and secure mounting Chassis structure Industrial truck for damage and leaks The secure seating of the chassis and screw connections and for damage Labels are legible complete and plausible The secure seating of the mast Protective mechanism against trappin...

Page 220: ...The function of the hydraulic system Mast and fork carriage stops are present and secure The secure seating of the hoses pipes and connections and for wear leaks damage blisters and kinks Steering Lateral play of the tiller The steering components for play and damage 218 04 19 en GB ...

Page 221: ...ectrical system The shock sensor data recorder is secure and for damage Data radio System components The function and secure seating of the scanner and terminal and for damage Fuse ratings The secure seating of the cables and for damage Access module Electrical system Access module is secure and functions correctly and for damage Lead acid battery international Power supply The secure seating of t...

Page 222: ...2 3 1 Standard equipment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Hydraulic oil filter 2000 12 Transmission oil 10000 2 2 3 2 Optional equipment Cold store application maintenance part service hours months Hydraulic oil 1000 12 Hydraulic oil additive 1000 12 220 04 19 en GB ...

Page 223: ...ects of the equipment No guarantee of particular features of the traction battery should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are indicated by the following graphics DANGER Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury...

Page 224: ...6 EN 4 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com ...

Page 225: ...ted cells 17 5 1 Description 17 5 2 Operation 18 5 3 Servicing PzV and PzV BS lead acid batteries with sealed armour plated cells 21 6 Aquamatik water replenishment system 22 6 1 Water replenishment system design 22 6 2 Functional Description 23 6 3 Adding water 23 6 4 Water pressure 23 6 5 Filling time 24 6 6 Water quality 24 6 7 Battery tubing 24 6 8 Operating temperature 24 6 9 Cleaning measure...

Page 226: ...02 16 EN 6 ...

Page 227: ...ng with the battery or using electrolyte additives will invalidate the warranty Observe the instructions for maintaining the safety rating during operation for batteries in accordance with Ex I and Ex II see relevant certification 2 Data plate 1 3 7 9 11 5 2 4 8 6 13 12 14 10 1 Model battery name 2 Production week production year 3 Serial number 4 Supplier number 5 Rated voltage 6 Capacity 7 Numbe...

Page 228: ...02 16 EN 8 14 Safety instructions and warning information ...

Page 229: ...ing Keep away from naked flames and strong heat sources Always wear protective clothing e g safety goggles and safety gloves when working on cells and batteries Always wash your hands after completing the work Use only insulated tools Do not mechanically machine the battery strike crush compress notch dent or modify it in any way Hazardous electric voltage The metal parts of the battery cells are ...

Page 230: ...ncrease the electrolyte density The corresponding adjustment factor is 0 0007 kg l per K e g electrolyte density 1 28 kg l at 45 C corresponds to a density of 1 29 kg l at 30 C The electrolyte must comply with the purity regulations of DIN 43530 Part 2 Name Explanation PzS Lead acid battery with Standard armour plated cells and liquid electrolyte Battery cell width 198 mm PzB Lead acid battery wit...

Page 231: ...ge current C5 5h 5 Nominal electrolyte density1 1 Reached within the first 10 cycles 1 29 kg l 6 Nominal temperature2 2 Higher temperatures shorten the useful life lower temperatures reduce the available capacity 30 C 7 System rated electrolyte level up to Max electrolyte level marking Limit temperature3 3 Not permissible as operating temperature 55 C ...

Page 232: ...tive to negative and check that contacts on the battery terminal conducting system are secure Check the M10 terminal screws of the conductors and connectors are secure and if necessary torque to 23 1 Nm Charge the battery see page 13 Check the electrolyte level of each battery cell after charging and top up if necessary Open the plug 15 Z The electrolyte level should not be less than the Min elect...

Page 233: ...ted to the battery in terms of voltage charge capacity and battery technology Before charging check all cables and plug connections for visible signs of damage Ventilate the room in which the truck is being charged Battery cell surfaces must remain exposed during charging in order to ensure sufficient ventilation see truck operating instructions chapter D Charging the Battery Do not smoke and avoi...

Page 234: ... charger ensuring the terminals are connect positive to positive and negative to negative Switch on the charger The battery is charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compensation charging is used to ensure the useful life and maintain capacity after full discharge and repeated insu...

Page 235: ... suitable for the production of electrolyte 4 3 2 Daily Charge the battery after each discharge After charging check the electrolyte level of each battery cell and replenish as required Open the plug 15 If necessary add electrolyte with pure water up to the Max electrolyte level marking 17 Close the plug 15 Z The electrolyte level should not be less than the Min electrolyte marking 16 and must not...

Page 236: ... electrolyte density and the electrolyte temperature in all the cells Compare the results with the previous ones Z If you find significant differences compared with the previous measurements or differences between the cells contact the manufacturer s customer service department 4 3 5 Annually Measure the insulation resistance of the truck in accordance with EN 1175 1 Measure the insulation resista...

Page 237: ...electrolyte is sulphuric acid which is fixed in gel The density of the electrolyte cannot be measured 5 1 1 Battery nominal data Name Explanation PzV Lead acid battery with Standard closed armour plated cells and electrolyte in gel compound Battery cell width 198 mm PzV BS Lead acid battery with British Standard closed armour plated cells and electrolyte in gel compound Battery cell width 158 mm 1...

Page 238: ...rging can cause explosions The battery gives off a mixture of oxygen and hydrogen electrolytic gas during charging Gassing is a chemical process This gas mixture is highly explosive and must not be ignited Always disconnect the charger and truck before connecting or disconnecting the charger and battery The charger must be adapted to the battery in terms of voltage charge capacity and battery tech...

Page 239: ...ttery cell Always charge the battery with DC current All DIN 41773 charging procedures are permitted in the format approved by the manufacturer Always connect the battery to a charger that is appropriate to the size and type of the battery If necessary have the charger checked by the manufacturer s customer service department for suitability Do not exceed the limit curents in accordance with DIN E...

Page 240: ...d with 0 004 V C per C The battery is charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compensation charging is used to ensure the useful life and maintain capacity after full discharge and repeated insufficient charging Z Compensation charging should be carried out weekly Trickle charging B...

Page 241: ...ous ones Z Carry out the measurements after full charging and subsequent resting for at least 5 hours Z If you find significant differences compared with the previous measurements or differences between the cells contact the manufacturer s customer service department 5 3 4 Annually Measure the insulation resistance of the truck in accordance with EN 1175 1 Measure the insulation resistance of the ...

Page 242: ...ik water replenishment system 6 1 Water replenishment system design 18 Water container 19 Tap connection with ball cock 20 Flow indicator 21 Shut off cock 22 Locking coupling 23 Battery lock connector 18 19 20 21 22 23 3 m ...

Page 243: ... securely The plug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port 6 3 Adding water Water should be added to the batteries just before the battery is fully charged This ensures that the amount of water added is mixed with the electrolyte 6 4 Water pressure The water replenishment system must be operated with a water ...

Page 244: ...tubing of the individual plugs is in accordance with the existing electric circuit No changes should be made 6 8 Operating temperature Batteries with automatic water replenishment systems should only be stored in rooms with temperatures 0 C as otherwise the systems could freeze 6 9 Cleaning measures The plug systems must only be cleaned with purified water in accordance with DIN 43530 4 No parts o...

Page 245: ...t be checked and replaced if necessary Battery connection A hose is attached to the pump module which together with the charge leads is routed from the charger to the charging connector The air is passed on to the battery via the electrolyte circulation coupling ducts in the connector When routing make sure the hose is not bent Pressure monitoring module The electrolyte circulation pump is activat...

Page 246: ...ted to severe temperature fluctuations the electrolyte may flow back into the hose system Attach a separate coupling system to the air inlet line such as locking coupling to the battery side and through coupling to the air supply side Schematic illustration Electrolyte circulation on the battery and air supply via the charger ...

Page 247: ...close to a drainage system for processing the electrolytic rinsing water All health and safety as well as water and waste disposal regulations are observed when disposing of used electrolyte or rinsing water Protective goggles and clothing are worn Cell plugs are not removed or opened Clean the plastic components of the battery in particular the cell containers only with water or water based cloth...

Page 248: ...at the temperature does not exceed 60 C at a distance of 30cm behind the outlet nozzle Observe the maximum operating pressure of 50 bar Observe a minimum distance of 30 cm from the top of the battery The battery should be sprayed over its entire surface to avoid localised overheating Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the maximum battery surface tempera...

Page 249: ...f cells for PzV batteries If the battery is to be taken out of service for a long period 3 months it should as far as possible be charged to 50 of its charge level and stored in a dry room protected from frost 10 Troubleshooting If any faults are found on the battery or charger contact the manufacturer s customer service department immediately Z The operations required must be carried out by the m...

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