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Jungheinrich ESD 220, Operating Instructions Manual

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Jungheinrich ESD 220 Operating Instructions Manual Download Page 45

D Battery - Servicing, Recharging,

Replacement

1

Safety instructions for handling lead-acid batteries

Maintenance personnel

Batteries  may  only  be  charged,  serviced  or  replaced  by  trained  personnel.  These
operating  instructions  and  the  manufacturer’s  instructions  concerning  batteries  and
charging stations must be observed when carrying out the work.

Fire Protection

Do  not  smoke  and  avoid  naked  flames  when  handling  batteries.  Wherever  an
industrial  truck  is  parked  for  charging  there  must  be  no  inflammable  material  or
consumables  capable  of  creating  sparks  within  a  minimum  distance  of  2,5  m  from
the truck. The room must be ventilated. Fire protection equipment 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.

u

Use powder extinguishers.

u

Never extinguish a burning battery with water.

43

10.19 en-GB

Summary of Contents for ESD 220

Page 1: ...ESD 220 06 10 Operating instructions 51190940 10 19 en GB ESD 220...

Page 2: ...2...

Page 3: ...SD 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 Mac...

Page 4: ...4 10 19 en GB...

Page 5: ...lar 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 follo...

Page 6: ...ht 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 10 19...

Page 7: ...ents 29 5 Identification Points and Data Plates 30 5 1 Data plate 32 5 2 Truck capacity plate 33 5 3 Double Decker Mode Capacity Plate 35 C Transport and Commissioning 37 1 Lifting by crane 37 2 Trans...

Page 8: ...eypad CanCode o 99 8 5 ISM access module o 117 8 6 Floor Spot 118 F Industrial Truck Maintenance 121 1 Spare Parts 121 2 Operational Safety and Environmental Protection 122 3 Maintenance Safety Regula...

Page 9: ...ety tests to be performed at intervals and after unusual incidents 143 8 Final de commissioning disposal 144 9 Human vibration measurement 144 G Maintenance Inspection and Changing of Maintenance Part...

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

Page 11: ...ngheinrich 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 o...

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

Page 13: ...nce are indicated on the capacity plate and must not be exceeded The load must rest on the load handler or be lifted by an attachment approved by the manufacturer The load must be fully raised see pag...

Page 14: ...weather conditions thunder lightning the industrial truck must not be operated outside or in endangered areas Operation in industrial and commercial environments Permissible temperature range 5 C to 4...

Page 15: ...ed 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 understo...

Page 16: ...14 10 19 en GB...

Page 17: ...d support arm lift Open bottom pallets pallets with transverse boards or roll cages can be lifted outside the area of the load wheels 1 1 Truck models and rated capacity The rated capacity depends on...

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 10 19 en G...

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

Page 20: ...ery 7 o Control display unit 16 t Load wheels 8 o CanCode code lock 17 t Load handler 9 o ISM access module 18 t Seat panel 10 t multiPILOT 19 t Steering wheel 11 t Mast 20 t Deadman switch 12 t Emerg...

Page 21: ...7 8 6 5 7 9 11 10 12 14 16 20 17 15 19 18 13 21 19 10 19 en GB...

Page 22: ...ck is switched on the system carries out a self diagnosis 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...

Page 23: ...braking with energy regeneration The driver can choose from 3 travel programs depending on the load and the environment from high performance to energy saving Controls and displays Ergonomic controls...

Page 24: ...e wheel arms lower automatically The wheel arms can only be lowered below this lift height Lift mast The mast sections and the load handler run on permanently lubricated and hence maintenance free can...

Page 25: ...3 2 1 Hourmeter Z Prepare the truck for operation see page 65 or see page 99 Service hours are counted while the truck is operational and the deadman button is pressed 23 10 19 en GB...

Page 26: ...rved 4 1 Performance data ESD 220 Q Rated capacity 1 2000 kg Travel speed w w o rated load 9 1 9 1 km h Lift speed with without rated load 0 20 0 39 m s Lower speed with without rated load 0 47 0 47 m...

Page 27: ...4 2 Dimensions d 25 10 19 en GB...

Page 28: ...wered height 90 mm l1 Length 2185 mm l2 Fork length including fork shank 995 mm b2 Overall width drive system 820 mm b5 Width across forks 570 mm s e l Fork dimensions 65 185 1190 mm b10 Front track d...

Page 29: ...rear battery 1358 1984 kg Axle load w o load front rear battery 968 371 kg Battery weight 380 kg 4 4 Tyre type ESD 220 Tyre size drive 230 x 77 mm Tyre size load section 85 x 85 mm Support wheel twin...

Page 30: ...ons of the 2002 44 EC Vibrations operator directive The manufacturer offers a special service to measure these human vibrations see page 144 Electromagnetic compatibility EMC The manufacturer confirms...

Page 31: ...in conditions of extreme temperature or condensing air humidity fluctuations 4 7 Electrical Requirements The manufacturer certifies compliance with the requirements for the design and manufacture of e...

Page 32: ...5 Identification Points and Data Plates 26 24 25 30 34 33 31 28 22 32 29 23 27 30 10 19 en GB...

Page 33: ...capacity plate 25 Prohibition plate Do not reach through the mast 26 Prohibition plate Do not step under the load handler 27 Floor plate adjustment 28 Type 29 Serial number 30 MULTI PILOT 31 Data pla...

Page 34: ...Net weight w o battery kg 44 Min max battery weight kg 38 Option 45 Manufacturer 39 Model 46 QR code 40 Serial number 47 Manufacturer s logo 41 Year of manufacture Z For queries regarding the truck or...

Page 35: ...e 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...

Page 36: ...ht limits The arrow shaped markings on the outer mast 49 and on the inner mast 48 indicate to the operator when the height limits specified on the capacity plate have been exceeded HH1 HH1 49 48 34 10...

Page 37: ...e decker mode Max lift height YYY mm Max capacity for high level lifting according ZZZ Max capacity for high and low level lifting alike XXX kg CAUTION Risk to operational stability In order not to je...

Page 38: ...36 10 19 en GB...

Page 39: ...cessories and lifting gear uWear personal protective equipment e g safety shoes safety helmet hi vis jacket protective gloves when loading by crane uDo not stand under suspended loads uDo not walk int...

Page 40: ...s Park the truck securely see page 67 Remove any mast guards Tools and Material Required Lifting gear Crane lifting gear Procedure Secure the lifting slings to the strap points 34 The truck can now be...

Page 41: ...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 tr...

Page 42: ...n the wooden beam or pallet between the front of the transport vehicle and the load handler to ensure a positive fit between the front of the transport vehicle and the load handler Attach the lashing...

Page 43: ...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 setu...

Page 44: ...42 10 19 en GB...

Page 45: ...void naked flames when handling batteries Wherever an industrial truck is parked for charging there must be no inflammable material or consumables capable of creating sparks within a minimum distance...

Page 46: ...can result in fire Damaged cables can cause short circuits setting the truck and battery on fire uBefore closing the battery cover make sure that the battery cables are not damaged Battery disposal B...

Page 47: ...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 capaci...

Page 48: ...table shows which combinations are included as standard Battery type Capacity Weight 24 volt battery 796 x 210 x 782 mm LXWXH 3 PzS 465 Ah 380 kg The battery weights can be taken from the battery dat...

Page 49: ...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 CAUTION Trapping...

Page 50: ...ge capacity uBefore charging check all cables and plug connections for visible signs of damage uVentilate the room in which the truck is being charged uThe battery cover must be open and the battery c...

Page 51: ...ions Switch on the charger charging begins automatically The battery is now charged 52 54 53 Completing battery charging restoring the truck to operation NOTICE If charging has been interrupted the fu...

Page 52: ...s 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 uU...

Page 53: ...tery replacement trolley o Procedure Remove the battery connector 52 from the truck Place the battery connector 52 on the battery 55 Pull the battery lock 51 up and anti clockwise as far as it will go...

Page 54: ...ery and the chassis Pull the battery 55 half way out of the truck Release the battery lock 51 Keep pulling the battery 55 out of the truck until the lock engages on the battery again Check the acid le...

Page 55: ...Release the battery lock 51 Keep pushing the battery 55 into the truck until the lock engages on the battery again The acid level has now been checked 53 10 19 en GB...

Page 56: ...54 10 19 en GB...

Page 57: ...ponsibilities and be instructed in the operation of the truck and shall be familiar with the operating instructions Safety shoes must be worn on pedestrian operated trucks Unauthorised use of truck Th...

Page 58: ...lifting operations of the truck its load handler or the load This also includes the area within reach of falling loads or lowering falling operating equipment uInstruct unauthorised persons to leave...

Page 59: ...2 Displays and Controls 1 7 10 56 57 23 6 58 12 19 14 59 60 61 20 21 57 10 19 en GB...

Page 60: ...ification of incorrect operation and event messages replaces the charge discharge indicator 10 multiPILOT t Controls Forward reverse travel Load handler lift lower 12 Emergency disconnect switch t Dis...

Page 61: ...the seat heating is switched on 59 Seat adjustment lever t Adjusts the driver s seat horizontally 60 Seat cushioning adjusting wheel t Sets the ideal seat cushioning for the driver s weight 61 Backres...

Page 62: ...s service department Red flashing is a truck controller code The flashing sequence indicates the type of fault 2 2 Battery discharge monitor Z Die serienm ige Einstellung des Batterieentladew chters...

Page 63: ...uDo not return the industrial truck to service until you have identified and rectified the fault Pre start inspections Procedure Check the whole of the outside of the truck for signs of damage and lea...

Page 64: ...handler fully lowered Procedure Z Always enter and exit the truck facing the load direction To enter and exit hold onto the handle 63 Enter or leave the truck CAUTION No more than one person may oper...

Page 65: ...n the floor plate height adjustment button 14 The floor plate can now be adjusted Set the floor plate 64 to the correct height by standing on it discharging it Release the floor plate height adjustmen...

Page 66: ...ng Adjusting the driver s seat Procedure Sit down on the driver s seat Loosen the seat lock 59 and push it forward or backward to the desired position Lock the seat in position again Undo the backrest...

Page 67: ...e 62 Pull the Emergency Disconnect switch 12 to unlock it Switch on the truck to do this Insert the key in the key switch 6 and turn it as far to the right as it will go Enter the code in the code loc...

Page 68: ...until you have identified and rectified the fault Procedure Test warning indicators and safety devices Test the Emergency Disconnect function by pressing the Emergency Disconnect switch The main circu...

Page 69: ...ngerous and is strictly prohibited uPark the truck on a level surface In special cases the truck may need to be secured with wedges uFully lower the load handler uSelect a place to park where no other...

Page 70: ...rection Set the drive wheel to Straight ahead Switch off the truck to do this Turn the key in the key switch 6 anti clockwise as far as it will go Remove the key from the key switch 6 For CanCode 8 pr...

Page 71: ...t loading on the travel lanes At blind spots get a second person to assist The driver must ensure that the loading dock dock leveller cannot be removed or come loose during loading unloading Travel co...

Page 72: ...r uIf the truck tips over on the right side of the load direction hold onto the option bar with both hands uIf the truck tips over on the left side in the load direction hold onto the steering wheel o...

Page 73: ...eave the lift before the truck The driver must ensure that the loading ramp dock cannot move or come loose during loading unloading Type of loads to be carried The operator must make sure that the loa...

Page 74: ...ent risk due to removing or disabling of safety devices Removal or disabling of safety devices such as the Emergency Disconnect switch deadman switch horn warning lights gates protective window covers...

Page 75: ...es 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 ca...

Page 76: ...gency Disconnect switch on in emergencies Releasing the Emergency Disconnect switch Procedure Pull the Emergency Disconnect switch 12 to unlock it All electrical functions are enabled and the truck is...

Page 77: ...6 8 12 20 10 3 2 7 75 10 19 en GB...

Page 78: ...rs are closed and properly locked Requirements Start up the truck see page 65 Procedure Press the deadman switch 20 Set the Multi Pilot 10 to the required travel direction Move the Multi Pilot 10 in t...

Page 79: ...6 8 12 20 10 3 2 7 77 10 19 en GB...

Page 80: ...the Multi Pilot is released in time uAfter setting off in the opposite direction apply the Multi Pilot gently or not at all uDo not perform any sudden steering operations uAlways face the direction of...

Page 81: ...ements Start up the truck see page 65 Procedure Turn the steering wheel 19 to the left or right Z The wheel position is indicated on the display 7 o The truck is steered in the required direction 10 1...

Page 82: ...switch Using the regenerative brake coasting brake CAUTION uIn emergencies only use the service brake for braking Braking with the service brake Procedure During travel take your foot off the deadman...

Page 83: ...20 10 81 10 19 en GB...

Page 84: ...other people to move out of the hazardous area of the truck Stop working with the truck if people do not leave the hazardous area uIf people do not leave the hazardous area despite the warning prevent...

Page 85: ...ort movement slow lift lower Large movement fast lift lower The load handler is raised 10 10 4 7 2 Lowering the load handler Requirements Prepare the truck for operation see page 65 Deadman switch pre...

Page 86: ...on the button until the wheel arms have reached their maximum height The wheel arms are raised 10 57 23 4 7 4 Lowering the wheel arms Requirements Prepare the truck for operation see page 65 Deadman s...

Page 87: ...hazardous area uOnly carry loads that have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping over or falling off the truck uDamaged loads must n...

Page 88: ...s against the back of the load handler see graphic to the right Z The load must not extend by more than 50 mm beyond the load handler tips Raise the load handler until the desired height is reached se...

Page 89: ...oad CAUTION Loads must not be set down on transport or escape routes in front of safety installations or factory equipment that must be accessible at all times Requirements Storage location suitable f...

Page 90: ...he support arms Raise the support arms see page 84 Lower the load forks as far as possible without the load coming into contact with the support arms Both pallets are raised 4 8 5 Transporting Two Pal...

Page 91: ...dure Drive the truck carefully up to the first storage location Lower the load support arms until the load rests Carefully move the support arms out of the pallet Lower the forks for correct transport...

Page 92: ...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 departme...

Page 93: ...e Charge battery if necessary see page 48 Faulty fuse Check fuses see page 139 Incorrect ISM access module transponder used Use correct transponder Incorrect CANCode PIN entered Enter correct PIN see...

Page 94: ...Material Required Two M5x45 screws Spanner wrench Procedure Switch off the truck to do this Turn the key in the key switch 6 anti clockwise as far as it will go Remove the key from the key switch 6 Fo...

Page 95: ...njury and accidents uThe covers battery cover side panels drive compartment cover etc must be closed during operation Fit the drive compartment cover see page 135 The brakes are now applied again The...

Page 96: ...he hazardous area of the truck during emergency lowering uDo not stand underneath a raised load handler uIf the load handler is lowered with the emergency lowering device below it the operator must be...

Page 97: ...diameter pin tool etc Procedure Fully lower the floor plate 64 see page 63 Remove the screws 67 from the seat cover 68 Remove the seat cover 68 Using a suitable object push in and hold down on the em...

Page 98: ...c o Pedal for reducing the travel speed and for braking the truck to a halt Braking with the brake pedal Procedure Press down the brake pedal 21 during travel until you reach the required deceleration...

Page 99: ...e status 76 Discharge indicator 77 Set travel speed for current profile max 5 bars 78 Slow travel activated reduced travel speed 79 Profile number travel profile 1 2 or 3 80 Deadman button not pressed...

Page 100: ...the Set Clock Time menu is displayed Set the time with the Up 84 and Down 85 keys Confirm with the Shift key 86 Set the minutes with the Up 84 and Down 85 keys Confirm with the Shift 86 or profile 87...

Page 101: ...rations The code lock is in programming mode When you enter one of the following parameters the settings in the code lock can be changed Parameter Description 0 0 0 Change master code see page 102 0 0...

Page 102: ...y 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 92 Code lock function commissioning the truck...

Page 103: ...n Z If the LED 92 flashes red this means the wrong code has been entered Enter the code again The Set key 91 has no function in operating mode 8 4 3 Switching off the truck with the keypad CanCode Swi...

Page 104: ...the SET key 91 The LEDs 88 92 flash green Enter the valid master code again with the digit keys Confirm with the SET key 91 The LEDs 89 92 flash green Enter the valid master code with the digit keys Z...

Page 105: ...t the required master code can be used see page 106 Delete the user code so that the required master code can be used see page 108 The master codes to be changed do not match Switch off the truck see...

Page 106: ...r code must also be different from the existing master code Confirm with the SET key 91 The LEDs 90 92 flash green Enter the new user code again with the digit keys Confirm with the SET key 91 Wait un...

Page 107: ...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 101 Choose a different user code see page 104 The newly entered user c...

Page 108: ...s 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 91 The LEDs 90 92 flash green Enter the new user code again...

Page 109: ...aster code is the same length as the user code Operator code to be changed does not exist Switch off the truck see page 101 Check the user code entered The user codes to be changed do not match Switch...

Page 110: ...eys Confirm with the SET key 91 The LEDs 90 92 flash green Enter the user code to be deleted again with the digit keys Confirm with the SET key 91 Wait until the LED 92 flashes green The user code is...

Page 111: ...e Switch off the truck see page 101 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 112: ...flash green Enter the code 3 2 6 5 with the digit keys Confirm with the SET key 91 Wait until the LED 92 flashes green All user codes are deleted Press the O key 93 The truck is switched off and the...

Page 113: ...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 101 P...

Page 114: ...s 1 minute maximum cutout time is 30 minutes 31 After 10 seconds the truck cuts out automatically Confirm with the SET key 91 Wait until the LED 92 flashes green The setting is saved Press the O key 9...

Page 115: ...ic cutout period of the truck For the following events the LED 92 flashes red Cause Remedy Cutout time entered is out of range Switch off the truck see page 101 Enter the time again while making sure...

Page 116: ...the 88 89 90 LEDs LED 88 lit travel program 1 activated LED 89 lit travel program 2 activated LED 90 lit travel program 3 activated The configuration code is four digit and is comprised as follows 1s...

Page 117: ...th 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 activate...

Page 118: ...configuration code 4 digit for the travel programs again using the digit keys Confirm with the SET key 91 Wait until the LED 92 flashes green The travel programs are now assigned to the user code Pre...

Page 119: ...Blocked travel program defined as start travel program Switch off the truck see page 101 Try again making sure the configuration code is entered correctly 8 5 ISM access module o Z If the truck is eq...

Page 120: ...ION Risk of accident due to restricted view Looking directly at the LED light can dazzle and temporarily impair eyesight uDo not look directly at the LED light uPractise travelling and working with th...

Page 121: ...0 nm blue light can potentially damage the retina of the human eye uCheck that the warning notice Caution Potentially dangerous optical radiation is present and legible and replace if necessary uDo no...

Page 122: ...120 10 19 en GB...

Page 123: ...ety size accuracy and material The installation or use of non original spare parts can negatively affect the specified properties of the product and impair safety The manufacturer cannot be held liabl...

Page 124: ...eption Operating companies should only make changes or have changes made to powered industrial trucks if the manufacturer is no longer operating in the field and there is no successor to the business...

Page 125: ...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 awa...

Page 126: ...re an environmental 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...

Page 127: ...r 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...

Page 128: ...lift chains are cleaned by wiping or brushing Significant contamination can be softened by a paraffin derivative such as petroleum uDo not clean lift chains with high pressure steam jets or chemical...

Page 129: ...rked 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 Instructio...

Page 130: ...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 com...

Page 131: ...1 05 l A B A D D 1 D a c D g Contact surfaces Cold store application s Grease nipple a Transmission oil drain plug c Hydraulic oil drain plug Hydraulic oil filler plug 1 Compound ratio for cold store...

Page 132: ...51825 Lubrication The trucks are delivered ex works with a special hydraulic oil the Jungheinrich hydraulic oil with a blue colouration and the cold store hydraulic oil red colouration The Jungheinri...

Page 133: ...st only be secured to the points specially provided for this purpose In order to raise and jack up the truck safely proceed as follows uJack up the truck only on a level surface and prevent it from mo...

Page 134: ...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 malfunction...

Page 135: ...d 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 clean...

Page 136: ...trical system assemblies Requirements Truck prepared for maintenance and repair work see page 131 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure...

Page 137: ...Allen key The drive compartment cover is now disassembled 96 95 Fitting the drive compartment panel Tools and Material Required Allen key Procedure CAUTION Arm trapping hazard There is a risk of trap...

Page 138: ...5 5 Replacing the drive wheel Z The drive wheel must only be replaced by the manufacturer s authorised customer service department 136 10 19 en GB...

Page 139: ...or maintenance and repair work see page 131 Tools and Material Required Torque wrench Procedure Position the drive wheel 99 so that the wheel nuts 98 can be pulled through the hole 97 Tighten all whee...

Page 140: ...ic oil if necessary Z For the first filling approximately 0 6 l more hydraulic oil should be added Turn the lid 100 anti clockwise from the hydraulic reservoir 102 Add hydraulic oil of the correct gra...

Page 141: ...eck the fuse ratings against the table and replace if necessary Close the armrest The fuses are now checked F15 F1 6F1 9F22 3F1 F17 Description To protect Rating A F 15 Main fuse 300 F1 Main control f...

Page 142: ...s Procedure Thoroughly clean the truck see page 132 Lubricate the truck according to the lubrication diagram see page 129 Clean the battery grease the terminals and connect the battery Charge the batt...

Page 143: ...ent 6 1 Prior to decommissioning Procedure Thoroughly clean the truck see page 132 Prevent the truck from rolling away accidentally Check the hydraulic oil level and replenish if necessary see page 13...

Page 144: ...dure Thoroughly clean the truck see page 132 Lubricate the truck according to the lubrication schedule see page 129 Clean the battery grease the terminal screws and connect the battery Charge the batt...

Page 145: ...inspector The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose A complete test must be carried out on the technical condition of t...

Page 146: ...rained personnel in accordance with the procedures as specified by the manufacturer 9 Human vibration measurement Z Vibrations that affect the operator over the course of the day are known as human vi...

Page 147: ...uck 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...

Page 148: ...1 Owner To be 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...

Page 149: ...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...

Page 150: ...amage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel Wheels for wear and damage Chassis structure Industrial truc...

Page 151: ...wing points must be checked Lead acid battery international Power supply Battery and battery components for damage Battery cable connections are secure Lead acid battery Power supply Battery cable con...

Page 152: ...ssis structure Check that the panels and covers as well as the floor plate with mounting brackets are secure Ensure that they function correctly and are safe Hydraulic operations Test the lift sensors...

Page 153: ...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 batte...

Page 154: ...adman switch and for damage Drivetrain 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 Chassi...

Page 155: ...or damage The function of the hydraulic system The forks or load handler for wear and damage Tie plunger rods are uniformly adjusted and for wear and damage Steering The function of the electric steer...

Page 156: ...stem 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...

Page 157: ...ance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Transmission oil 2000 12 1 2 3 2 Optional equipment Cold store application maintenance part service hours...

Page 158: ......

Page 159: ...cts 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 instruction...

Page 160: ...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 jungheinric...

Page 161: ...ed 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 sy...

Page 162: ...02 16 EN 6...

Page 163: ...g 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...

Page 164: ...02 16 EN 8 14 Safety instructions and warning information...

Page 165: ...ng 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...

Page 166: ...crease 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 com...

Page 167: ...e 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 availab...

Page 168: ...ive 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 N...

Page 169: ...ed 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...

Page 170: ...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 densi...

Page 171: ...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 1...

Page 172: ...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 differ...

Page 173: ...lectrolyte 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 plate...

Page 174: ...ging 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 ign...

Page 175: ...tery 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 appropria...

Page 176: ...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 Compen...

Page 177: ...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 betwe...

Page 178: ...k 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...

Page 179: ...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 batter...

Page 180: ...ubing 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 b...

Page 181: ...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 pass...

Page 182: ...ed 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 throug...

Page 183: ...lose 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...

Page 184: ...t 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 T...

Page 185: ...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 fr...

Page 186: ......

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