Jungheinrich ESE 220 Operating Instructions Manual Download

Page: 121 / 170

4.7

Restoring the truck to service after maintenance and repairs

Procedure

• Thoroughly clean the truck, see page 114.
• Lubricate the truck according to the lubrication diagram, see page 111.
• Clean the battery, grease the terminals and connect the battery.
• Charge the battery, see page 38.
• Start up the truck, see page 54.

121

04.19 en-GB

Summary of Contents for ESE 220

Page 1: ...ESE 220 320 03 10 Operating instructions 51163703 04 19 en GB ESE 220 ESE 320...

Page 2: ...2...

Page 3: ...20 ESE 320 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...

Page 4: ...4 04 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 04 19...

Page 7: ...Equipment Directive for radio units 25 4 7 Conditions of use 25 4 8 Electrical Requirements 25 5 Identification Points and Data Plates 26 5 1 Data plate 27 5 2 Truck capacity plate 28 C Transport and...

Page 8: ...3 7 4 Keypad CanCode o 84 7 5 ISM access module o 102 7 6 Floor Spot 103 F Industrial Truck Maintenance 105 1 Operational Safety and Environmental Protection 105 2 Maintenance Safety Regulations 106 2...

Page 9: ...eration 153 4 3 Servicing lead acid batteries with armour plated cells 156 5 PzV and PzV BS lead acid batteries with sealed armour plated cells 158 5 1 Description 158 5 2 Operation 159 5 3 Servicing...

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

Page 11: ...ICE The maximum load and load distance 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 Th...

Page 12: ...without load Do not travel across or at an angle on slopes Transporting with the load facing uphill Operation in partially public traffic WARNING Use under extreme conditions Using the truck under ext...

Page 13: ...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 14: ...14 04 19 en GB...

Page 15: ...the area of the load wheels as well as roll cages It can transport low stacked loads over long distances The capacity is shown on the load chart Qmax 1 1 Truck models and rated capacity The rated cap...

Page 16: ...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 G...

Page 17: ...ge status indicator 12 t Armrest 6 t Key switch 13 t Floor plate height adjuster 7 o Control display unit 14 t Steering wheel 8 o CanCode code lock 15 t Load rollers 9 o ISM access module 16 t Battery...

Page 18: ...it o indicate the emergency stop Operator position The driver s seat and floor plate can be adjusted to suit different sized operators All travel and lift operations can be performed sensitively witho...

Page 19: ...rive system The drive wheel can be rotated 90 Automatic travel speed reduction as a function of the steer angle Curve Control o is optionally available Electrical system The truck has electronic tract...

Page 20: ...ications and additions reserved 4 1 Performance data ESE 220 ESE 320 Q Rated capacity 2000 kg Travel speed with without load 10 12 5 km h Lift speed with without load 0 06 0 07 m s Lowering speed with...

Page 21: ...l2 l1 h 3 x h 13 Ast a 2 a 2 b 1 Wa e b 11 b 5 ESE 220 ESE 320 c Load centre distance 600 mm x Load distance 868 mm y Wheelbase 15351 15412 mm h3 Lift 125 mm h7 Seat height 1020 mm h13 Lowered height...

Page 22: ...e load handler 540 mm b10 Track 544 645 mm b11 Track 385 mm s e l Load handler dimensions 60 185 1150 mm m2 Ground clearance centre of wheelbase 25 mm Ast Aisle width for pallet 800x1200 lengthways 21...

Page 23: ...ont rear 1896 1142 1902 1182 kg Axle load without load front rear 258 808 264 816 kg Battery weight 380 kg 4 4 Tyre type ESE 220 ESE 320 Tyre size drive 230 x 78 mm Tyre size load section 85 x 85 mm C...

Page 24: ...used with the human vibrations of the operator directive The manufacturer offers a special service to measure these human vibrations see page 124 Electromagnetic compatibility EMC The manufacturer con...

Page 25: ...SM 1800 1900 MHz 1 W Gateway ISM Online LTE 850 900 MHz 3 2 W 35 dBm Gateway ISM Online LTE 1800 1900 MHz 1 6 W 32 dBm Access module ISM Online 13 56 MHz 100 mW 4 7 Conditions of use Ambient temperatu...

Page 26: ...23 25 27 24 26 Item Description 19 Load handler lift lower 20 Truck capacity plate 21 multiPILOT 22 Floor plate adjustment 23 Data plate 24 Inspection plaque 25 Attachment points for loading by crane...

Page 27: ...l number 35 Load centre distance mm 30 Rated capacity kg 36 Nominal power 31 Battery voltage V 37 Min max battery weight kg 32 Net weight without battery kg 38 Manufacturer 33 Option 39 Manufacturer s...

Page 28: ...5 2 Truck capacity plate 40 The capacity plate 40 gives the maximum load bearing capacity Q of the truck in kg assuming the load on the load handler is evenly distributed 28 04 19 en GB...

Page 29: ...gloves when loading by crane uDo not stand under suspended loads uDo not walk into or stand in a hazardous area uAlways use lifting gear with sufficient capacity for truck weight see truck data plate...

Page 30: ...n road vehicles and in the use of load securing equipment When securing the truck the appropriate measures must be determined and applied for each individual case uThe truck must be securely fastened...

Page 31: ...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 32: ...ucks designed for use in cold stores have a cold store hydraulic oil uIf a truck with cold store oil is used outside the cold store the lowering speeds may increase Procedure Check the equipment is co...

Page 33: ...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 scaldi...

Page 34: ...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 35: ...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 36: ...line or with a raised load handler is dangerous 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 handle...

Page 37: ...truck securely see page 60 Procedure Fold up the arm rest 12 The battery connector 43 can be accessed The battery retainer 42 is accessible on the ESE 220 43 42 12 On the ESE 320 the battery latch 44...

Page 38: ...handling batteries uWherever an industrial truck is parked for charging there shall be no inflammable material or lubricants capable of creating sparks within 2 5 m around the truck uFire protection e...

Page 39: ...th the charger operating instructions Disconnect the battery connector 43 from the charging cable 46 of the stationary charger Attach the battery connector 43 to the industrial truck The truck is now...

Page 40: ...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 41: ...e battery 48 Pull the battery lock 47 up and anti clockwise as far as it will go Pull the battery 48 off the truck Z Observe the battery replacement trolley operating instructions The battery is now r...

Page 42: ...erial Required Battery replacement trolley o Procedure Remove the battery connector 43 from the truck Place the battery connector on the battery Turn the battery lock 44 over and pull it up Flip the b...

Page 43: ...on the battery tray so that it cannot be damaged when the battery is installed Push the battery 48 into the battery compartment Flip the battery retainer 47 back Insert the battery stop 44 in the tru...

Page 44: ...attery connector 43 on the battery 48 Pull the battery lock 47 up CAUTION Unsecured battery An unsecured battery can result in trapping and injury uWear safety shoes when removing and installing the b...

Page 45: ...ed battery An unsecured battery can result in trapping and injury uWear safety shoes when removing and installing the battery uDo not reach between the battery and the chassis Push the battery 48 into...

Page 46: ...ttery stop 44 over and pull it up Pull the battery 48 out of the truck Keep pulling the battery out of the truck until the battery is resting against the battery retainer Check the battery acid level...

Page 47: ...ge or faults to the truck or attachment Trucks which are unsafe for operation e g wheel or brake problems must not be used until they have been rectified Repairs The operator must not carry out any re...

Page 48: ...rgency disconnect switch key switch buttons horn strobe lights sensors panels etc can result in accidents and injury uReport any defects immediately to your supervisor uMark defective truck and take i...

Page 49: ...2 Displays and Controls 5 7 10 49 50 51 52 53 11 14 13 54 55 56 17 49 04 19 en GB...

Page 50: ...ey travel and lift parameters warning indicators notification of incorrect operation and event messages replaces the charge discharge indicator 10 multiPILOT t Function operation Forward reverse trave...

Page 51: ...and off Indicates when the seat heating is switched on 54 Seat adjustment lever t Adjusts the driver s seat horizontally 55 Seat cushioning adjusting wheel t Sets the ideal seat cushioning for the dri...

Page 52: ...s 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 I...

Page 53: ...isplay and cut out points of the battery discharge monitor must be set by manufacturer s service department If this adjustment is not made the battery may become damaged due to deep discharge If the r...

Page 54: ...ndustrial truck to service until you have identified and rectified the fault Inspection before daily operation Procedure Check the whole of the outside of the truck for signs of damage and leaks Damag...

Page 55: ...handler fully lowered Procedure Z Always enter and exit the truck facing the load direction To enter and exit hold onto the handle 58 Enter or leave the truck CAUTION No more than one person may oper...

Page 56: ...k 54 and push it forward or backward to the desired position Lock the seat in position again Undo the backrest lock 56 and bring the backrest into its required position Lock the backrest in position a...

Page 57: ...floor plate 59 to the correct height by standing on it discharging it Release the floor plate height adjustment button 13 The floor plate is now adjusted and locked at the required height 59 13 57 04...

Page 58: ...on the driver s seat Pull the emergency disconnect switch 11 to unlock it To switch on the truck 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...

Page 59: ...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 60: ...the lowered load handler uIf the brakes are not working place wedges underneath the wheels of the truck to prevent it from moving Parking the truck securely Procedure Park the truck on a level surface...

Page 61: ...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 62: ...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 63: ...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 64: ...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 65: ...t switch on in emergencies Releasing the Emergency Disconnect switch Procedure Pull the Emergency Disconnect switch 11 to unlock it All electrical functions are enabled and the truck is operational ag...

Page 66: ...are closed and properly locked Requirements Start up the truck see page 58 Procedure Press the deadman switch 17 Set the Multi Pilot 10 to the required travel direction Move the Multi Pilot 10 in the...

Page 67: ...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 68: ...ements Start up the truck see page 58 Procedure Turn the steering wheel 14 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 69: ...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 70: ...17 10 70 04 19 en GB...

Page 71: ...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 72: ...n the button until the load handler has reached the maximum height The load handler is raised 10 50 51 4 7 2 Lowering the load handler Requirements Prepare the truck for operation see page 58 Deadman...

Page 73: ...ng with the truck if people do not leave the 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...

Page 74: ...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 75: ...across or at an angle on inclines Do not turn on slopes and inclines and always drive with the load facing uphill see graphic 4 8 3 Depositing a load CAUTION Loads must not be set down on transport or...

Page 76: ...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 77: ...rect ISM access module transponder used Use correct transponder Incorrect CANCode PIN entered Enter correct PIN see page 86 5 2 Load cannot be lifted Possible Cause Remedy Truck not operational Carry...

Page 78: ...sing the brake Tools and 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...

Page 79: ...The brake is now released The truck can be moved 79 04 19 en GB...

Page 80: ...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 117 The brakes are now applied again The...

Page 81: ...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 62 during travel until you reach the required deceleration...

Page 82: ...e status 69 Discharge indicator 70 Set travel speed for current profile max 5 bars 71 Slow travel activated reduced travel speed 72 Profile number travel profile 1 2 or 3 73 Deadman button not pressed...

Page 83: ...8 secs until the Set Clock Time menu is displayed Set the time with the Up 77 and Down 81 keys Confirm with the Shift key 79 Set the minutes with the Up 77 and Down 81 keys Confirm with the Shift 79...

Page 84: ...aulic operations 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 pag...

Page 85: ...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 86 Code lock function commissioning the truck...

Page 86: ...on Z If the LED 86 flashes red this means the wrong code has been entered Enter the code again The Set key 85 has no function in operating mode 7 4 3 Switching off the truck with the keypad CanCode Sw...

Page 87: ...the SET key 85 The LEDs 82 86 flash green Enter the valid master code again with the digit keys Confirm with the SET key 85 The LEDs 83 86 flash green Enter the valid master code with the digit keys Z...

Page 88: ...hat the required master code can be used see page 91 Delete the user code so that the required master code can be used see page 93 The master codes to be changed do not match Switch off the truck see...

Page 89: ...er code must also be different from the existing master code Confirm with the SET key 85 The LEDs 84 86 flash green Enter the new user code again with the digit keys Confirm with the SET key 85 Wait u...

Page 90: ...the 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 86 Choose a different user code see page 89 The newly entered user...

Page 91: ...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 85 The LEDs 84 86 flash green Enter the new user code agai...

Page 92: ...master code is the same length as the user code Operator code to be changed does not exist Switch off the truck see page 86 Check the user code entered The user codes to be changed do not match Switc...

Page 93: ...eys Confirm with the SET key 85 The LEDs 84 86 flash green Enter the user code to be deleted again with the digit keys Confirm with the SET key 85 Wait until the LED 86 flashes green The user code is...

Page 94: ...code Switch off the truck see page 86 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 se...

Page 95: ...flash green Enter the code 3 2 6 5 with the digit keys Confirm with the SET key 85 Wait until the LED 86 flashes green All user codes are deleted Press the O key 87 The truck is switched off and the...

Page 96: ...th 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 86...

Page 97: ...s 1 minute maximum cutout time is 30 minutes 31 After 10 seconds the truck cuts out automatically Confirm with the SET key 85 Wait until the LED 86 flashes green The setting is saved Press the O key 8...

Page 98: ...tic cutout period of the truck For the following events the LED 86 flashes red Cause Remedy Cutout time entered is out of range Switch off the truck see page 86 Enter the time again while making sure...

Page 99: ...y the 82 83 84 LEDs LED 82 lit travel program 1 activated LED 83 lit travel program 2 activated LED 84 lit travel program 3 activated The configuration code is four digit and is comprised as follows 1...

Page 100: ...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 101: ...e configuration code 4 digit for the travel programs again using the digit keys Confirm with the SET key 85 Wait until the LED 86 flashes green The travel programs are now assigned to the user code Pr...

Page 102: ...Blocked travel program defined as start travel program Switch off the truck see page 86 Try again making sure the configuration code is entered correctly 7 5 ISM access module o Z If the truck is equ...

Page 103: ...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 104: ...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 105: ...rer s spare parts Exception 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 succe...

Page 106: ...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 107: ...l 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...

Page 108: ...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 109: ...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 C...

Page 110: ...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 111: ...tion Schedule C 1 05 l A B A E 1 E a g Contact surfaces k Cold Store Application s Grease nipple a Transmission oil drain plug Hydraulic oil filler neck 1 Compound ratio for cold store usage 1 1 111 0...

Page 112: ...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 i...

Page 113: ...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 114: ...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 115: ...ater 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 af...

Page 116: ...lectrical system assemblies Requirements Prepare the truck for maintenance and repairs see page 113 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedur...

Page 117: ...e Allen key The drive compartment cover is now disassembled 90 89 Fitting the drive compartment panel Tools and Material Required Allen key Procedure CAUTION Arm trapping hazard There is a risk of tra...

Page 118: ...lie between the min and max markings 91 Add hydraulic oil if necessary Turn the lid 92 anti clockwise from the hydraulic reservoir 93 Add hydraulic oil of the correct grade until the oil level lies b...

Page 119: ...maintenance and repairs see page 113 Tools and Material Required Torque wrench Procedure Position the drive wheel 96 so that the wheel nuts 95 can be pulled through the hole 94 Tighten all the wheel...

Page 120: ...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 121: ...s Procedure Thoroughly clean the truck see page 114 Lubricate the truck according to the lubrication diagram see page 111 Clean the battery grease the terminals and connect the battery Charge the batt...

Page 122: ...ce department 5 1 Prior to decommissioning Procedure Thoroughly clean the truck see page 114 Prevent the truck from rolling away accidentally Check the hydraulic oil level and replenish if necessary s...

Page 123: ...dure Thoroughly clean the truck see page 114 Lubricate the truck according to the lubrication schedule see page 111 Clean the battery grease the terminal screws and connect the battery Charge the batt...

Page 124: ...ssioning 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...

Page 125: ...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 126: ...4 24 12 00 1 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 C...

Page 127: ...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 128: ...tery components for damage The function and secure seating of the battery connector and for damage Travel Wheels for wear and damage Chassis structure Industrial truck for damage and leaks Labels are...

Page 129: ...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 130: ...test Clean the motor engine with compressed air Chassis structure Check that the panels and covers as well as the floor plate with mounting brackets are secure Ensure that they function correctly and...

Page 131: ...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 132: ...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 ar...

Page 133: ...orks or load handler for wear and damage 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 ki...

Page 134: ...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...

Page 135: ...Lead acid battery Power supply The secure seating of the battery battery cables and cell connectors and for damage 135 04 19 en GB...

Page 136: ...ment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Hydraulic oil filter 2000 12 Hydraulic system venting plug 2000 12 Transmission oil 10000 1 2...

Page 137: ...4 24 12 00 2 1 Owner To be performed 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 C...

Page 138: ...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 139: ...tery components for damage The function and secure seating of the battery connector and for damage Travel Wheels for wear and damage Chassis structure Industrial truck for damage and leaks Labels are...

Page 140: ...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 141: ...test Clean the motor engine with compressed air Chassis structure Check that the panels and covers as well as the floor plate with mounting brackets are secure Ensure that they function correctly and...

Page 142: ...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 143: ...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 ar...

Page 144: ...orks or load handler for wear and damage 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 ki...

Page 145: ...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...

Page 146: ...Lead acid battery Power supply The secure seating of the battery battery cables and cell connectors and for damage 146 04 19 en GB...

Page 147: ...ment maintenance part service hours months Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Hydraulic oil filter 2000 12 Hydraulic system venting plug 2000 12 Transmission oil 10000 2 2...

Page 148: ...148 04 19 en GB...

Page 149: ...y rating during operation for batteries in accordance with Ex I and Ex II see relevant certification 2 Data plate 97 98 101 103 38 31 34 99 102 100 105 39 106 104 97 Model battery name 34 Production w...

Page 150: ...rom 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 o...

Page 151: ...ctrolyte Battery cell width 158 mm PzS Lib Lead acid battery with Standard armour plated cells and liquid electrolyte Lead acid battery with extended maintenance interval Battery cell width 198 mm PzM...

Page 152: ...5 Nominal electrolyte density 1 1 29 kg l 6 Nominal temperature 2 30 C 7 System rated electrolyte level up to Max electrolyte level marking Limit temperature 3 55 C 1 Reached within the first 10 cycl...

Page 153: ...e the terminals are correct positive to positive and negative to negative and check that contacts on the battery terminal conducting system are secure Check the M10 terminal screws of the conductors a...

Page 154: ...in terms of voltage charge capacity and battery technology uBefore charging check all cables and plug connections for visible signs of damage uVentilate the room in which the truck is being charged u...

Page 155: ...ng 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...

Page 156: ...duction of electrolyte 4 3 2 Daily Battery cell cross section Top view of a battery cell 107 108 109 107 108 109 Charge the battery after each discharge After charging check the electrolyte level of e...

Page 157: ...ensity 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...

Page 158: ...sulphuric acid which is fixed in gel The density of the electrolyte cannot be measured Name Explanation PzV Lead acid battery with Standard closed armour plated cells and electrolyte in gel compound B...

Page 159: ...losions 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 uAlways disco...

Page 160: ...s charge the battery with DC current uAll DIN 41773 charging procedures are permitted in the format approved by the manufacturer uAlways connect the battery to a charger that is appropriate to the siz...

Page 161: ...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 chargin...

Page 162: ...ry 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 c...

Page 163: ...t system 6 1 Water replenishment system design 110 111 112 113 114 115 3 m 110 Water container 111 Tap connection with ball cock 112 Flow indicator 113 Shut off cock 114 Locking coupling 115 Battery l...

Page 164: ...lug 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 befor...

Page 165: ...ndividual 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 ro...

Page 166: ...d 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 b...

Page 167: ...emperature fluctuations the electrolyte may flow back into the hose system uAttach a separate coupling system to the air inlet line such as locking coupling to the battery side and through coupling to...

Page 168: ...nage 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 Protect...

Page 169: ...ure 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 sho...

Page 170: ...V 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 T...

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