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Jungheinrich ESE 420, Operating Instructions Manual

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Jungheinrich ESE 420 Operating Instructions Manual Download Page 21

11

04

.G

B

C 2

2

Parking brake transport lock

F

If a truck is supplied without a battery or with an uncharged battery, the transport lock
(2xM5) must be removed before starting to use the truck. The transport lock is used
to lock the compression spring which activates the parking brake, so that the truck is
not braked when de-energised. It consists of two bolts screwed into the magnetic
brake (on the drive motor). This prevents the compression spring from activating the
brake.

Removing the Transport Locks

– Push the driver’s seat out of the guide

towards the steering wheel. 

– Disconnect the fan connector on the

seat panel.

– Remove seat panel (see Chapter F).
– Disconnect the two-pin connector

from the magnetic brake.

– Unscrew the brake release screws

from the magnetic brake and insert
them in the drive plate holes.

The brake now operates without current.
The truck can now longer be moved
without the battery.

– Connect the two-pin connector to the magnetic brake.
– Fit the seat panel.
– Connect the fan connector on the seat panel.
– Position the driver’s seat in the guide.
– Fit and connect the battery.
– Switch on the isolator and key switch

The truck is now operational.

11

04

.G

B

C 2

2

Parking brake transport lock

F

If a truck is supplied without a battery or with an uncharged battery, the transport lock
(2xM5) must be removed before starting to use the truck. The transport lock is used
to lock the compression spring which activates the parking brake, so that the truck is
not braked when de-energised. It consists of two bolts screwed into the magnetic
brake (on the drive motor). This prevents the compression spring from activating the
brake.

Removing the Transport Locks

– Push the driver’s seat out of the guide

towards the steering wheel. 

– Disconnect the fan connector on the

seat panel.

– Remove seat panel (see Chapter F).
– Disconnect the two-pin connector

from the magnetic brake.

– Unscrew the brake release screws

from the magnetic brake and insert
them in the drive plate holes.

The brake now operates without current.
The truck can now longer be moved
without the battery.

– Connect the two-pin connector to the magnetic brake.
– Fit the seat panel.
– Connect the fan connector on the seat panel.
– Position the driver’s seat in the guide.
– Fit and connect the battery.
– Switch on the isolator and key switch

The truck is now operational.

Summary of Contents for ESE 420

Page 1: ...Operating Instructions 50454697 ESE 420 430 G 11 04 11 08 ...

Page 2: ...tiengesellschaft Am Stadtrand 35 22047 Hamburg GERMANY Telephone 49 0 40 6948 0 www jungheinrich com 0108 GB Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck The information is provided clearly and concisely The chapters are arranged by letter Each chapter starts with page 1 The page identification co...

Page 3: ...0108 GB 0108 GB ...

Page 4: ...battery D 2 4 Charging the battery D 3 5 Battery removal and installation D 4 6 Driver s display D 5 I 1 0708 GB Index A Correct use and application B Truck Description 1 Application B 1 2 Assemblies and Functional Description B 2 2 1 Truck B 3 3 Standard Version Specifications B 5 3 1 Performance data B 5 3 2 Dimensions B 6 3 3 EN norms B 7 3 4 Conditions of use B 7 3 5 Technical Description Load...

Page 5: ...at regular intervals and following any unusual incidents F 13 9 Final de commissioning disposal F 13 0708 GB I 2 E Operation 1 Safety Regulations for the Operation of Forklift Trucks E 1 2 Controls and Displays E 2 3 Starting up the truck E 4 3 1 Emergency stop device E 6 4 Industrial Truck Operation E 7 4 1 Safety regulations for truck operation E 7 4 2 Travel Steering Braking E 8 4 3 Collecting ...

Page 6: ...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 7: ...0506 GB 2 0506 GB 2 ...

Page 8: ...e required Approval of the local authorities however does not constitute the manufacturer s approval A 1 1104 GB A Correct use and application Z The Guidelines for the Correct Use and Application of Industrial Trucks VDMA are supplied with the truck The guidelines form part of these operating instructions and must be observed National regulations apply in full The truck described in the present op...

Page 9: ...1104 GB A 2 1104 GB A 2 ...

Page 10: ...ted to the task of transporting Truck types and capacity Type Capacity ESE 420 2000kg ESE 430 3000kg B 1 1108 GB B Truck Description 1 Application The ESE 420_430 is a four wheel electric side seated pallet truck with a drive unit and electrical steering with a steer motor The truck is designed for use on level surfaces for transporting goods The truck can pick up outside the load wheel range pall...

Page 11: ...t belt 8 t Brake pedal t Standard equipment o Optional Equipment 1 6 12 2 4 3 5 11 13 10 9 8 7 15 14 1108 GB B 2 2 Assemblies and Functional Description Item Description Item Description 1 t Driver s display 9 t Accelerator pedal 2 t Hydraulic control button 10 t Driver s seat 3 t Parking brake 11 t Lift mechanism 4 t Key switch 12 t Drive wheels 5 t Main switch isolator emergency disconnect 13 t ...

Page 12: ...ight appears when the brake is applied Steering and braking faults are shown on the driver s display B 3 1108 GB 2 1 Truck Safety mechanisms Enclosed smooth truck geometry The wheels 12 13 are surrounded by a solid ram protection skirting This protects the load in the event of a collision The key switch 4 or isolator emergency disconnect 5 disconnects all electrical function in hazardous situation...

Page 13: ...lf diagnosis which only releases the parking brake emergency stop if the functional test is positive 1108 GB B 4 Emergency Stop Safety Feature The emergency stop is governed by the brake controller The steering controller transmits a system status signal which is monitored by the brake controller If the signal fails to appear or a fault is identified the truck automatically brakes until it comes t...

Page 14: ... 2 l2 L1 l x y Q 750 kg Q 750 kg Q 750 kg Q 750 kg 272 784 1200 1495 1730 a _ 2 a _ 2 Ast Wa b11 975 B 5 1108 GB 3 Standard Version Specifications Z Technical data specified in accordance with VDI 2198 Technical modifications and additions reserved 3 1 Performance data Load evenly distributed over the entire fork length Fork overhang 560 Description ESE 420 ESE 430 Q Rated capacity 2000 3000 kg c ...

Page 15: ...th for pallets 800 x 1200 length 3870 3870 a Safety distance 200 200 Net weight See truck data plate 1108 GB B 6 3 2 Dimensions all dimensions in mm Description ESE 420 ESE 430 h3 Lift 115 115 h7 Seat height 1200 1200 h13 Lowered fork height 90 95 l1 Overall length 4825 4825 l2 Headlength 1225 1225 b2 Truck width 1000 1000 b5 Width across forks 520 560 580 b10 Track width drive 604 604 b11 Track w...

Page 16: ...the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations B 7 1108 GB 3 3 EN norms Noise emission 68 dB A in accordance with EN 12053 as harmonised with ISO 4871 Z The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling lifting and when idle The noise level is measured at the dri...

Page 17: ...nt for crane lifting 18 Risk of trapping label 19 Test sticker o 18 17 17 16 19 Qmax 3000kg 15 17 17 1108 GB B 8 3 5 Technical Description Load Handler Lift mechanism The lift mechanism 11 and load fork is connected to the chassis via the lift cylinder and the lift linkage The load forks are raised when the lift cylinder is extended while simultaneously moving the load wheel support through the li...

Page 18: ...ht excl battery 30 Year of manufacture 25 Manufacturer 31 Option 20 21 22 23 24 25 29 28 27 26 31 30 B 9 1108 GB 4 1 Truck data plate Z For queries regarding the truck or ordering spare parts please quote the truck serial number 21 Item Description Item Description 20 Type 26 Manufacturer s logo 21 Serial no 27 Min max battery weight kg 22 Rated capacity kg 28 Output kW 23 Battery voltage V 29 Loa...

Page 19: ...1108 GB B 10 1108 GB B 10 ...

Page 20: ...mstances and cannot come into contact with any attachments of the truck when the truck is lifted 1 2 C 1 1104 GB C Transport and Commissioning 1 Lifting by crane M Only use lifting gear with sufficient capacity for transport weight see truck data plate Remove the dummy plugs from the load section and screw in the two ring screws 1 If loading the truck with crane lifting gear attach the load hooks ...

Page 21: ...guide Fit and connect the battery Switch on the isolator and key switch The truck is now operational 1104 GB C 2 2 Parking brake transport lock F If a truck is supplied without a battery or with an uncharged battery the transport lock 2xM5 must be removed before starting to use the truck The transport lock is used to lock the compression spring which activates the parking brake so that the truck i...

Page 22: ...ruck Recovery Z You may hear slight brake grinding noises after the truck is used for the first time C 3 1104 GB Moving the truck without a battery Disconnect the battery Push the driver s seat out of the guide towards the steering wheel Disconnect the fan connector on the seat panel Remove seat panel see Chapter F Disconnect the two pin connector from the magnetic brake Unscrew the brake release ...

Page 23: ...1104 GB C 4 1104 GB C 4 ...

Page 24: ...al safety of the truck Battery equipment may only be replaced with the agreement of the manufacturer D 1 1104 GB D Battery Maintenance Charging Replacement 1 Safety regulations for handling acid batteries Park the truck securely before carrying out any work on the batteries see Chapter E Maintenance personnel Batteries may only be charged serviced or replaced by trained personnel The present opera...

Page 25: ...or attachment 2 48V PzS battery low maintenance 560 Ah 48V PzS battery maintenance free 560 Ah 1 2 3 1104 GB D 2 2 Battery types The truck will be equipped with different battery types depending on the application The following table shows which combinations can be included as standard The battery weights can be taken from the battery data plate Batteries with non insulated terminals must be cover...

Page 26: ...s essential to follow the safety regulations of the battery and charging station manufacturers 3 3 4 D 3 1104 GB 4 Charging the battery Park the truck securely see Chapter E F When charging the low maintenance battery the tops of the battery cells must be exposed to provide sufficient ventilation This is not necessary for maintenance free batteries Do not place any metal objects on the battery Bef...

Page 27: ...ter installing the battery again check all cables and plug connections for visible signs of damage 5 1104 GB D 4 5 Battery removal and installation Expose the battery see Section 3 F To prevent short circuits batteries with exposed terminals or connectors must be covered with a rubber mat When replacing a battery with a crane make sure the crane has sufficient capacity see battery weight on the ba...

Page 28: ...The number of operating hours 11 since the last reset are shown below the battery symbol 7 8 9 10 11 D 5 1104 GB 6 Driver s display Battery Discharge Indicator The battery charge status of the battery 7 is shown on the driver s display M The standard setting for the battery discharge indicator discharge monitor is based on standard batteries When a battery is discharged to the permissible discharg...

Page 29: ...1104 GB D 6 1104 GB D 6 ...

Page 30: ...s and Warning Signs Safety devices warning signs and warning instructions shall be strictly observed E 1 0706 GB E Operation 1 Safety Regulations for the Operation of Forklift Trucks Driver authorisation The forklift truck may only be used by suitably trained personnel who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to ope...

Page 31: ...eight for optimum seat damping The set weight is displayed t Standard equipment o Optional Equipment 0706 GB E 2 2 Controls and Displays Item Control Display Function 1 Steering wheel t Steers truck in desired direction 2 Driver s display t Displays key travel and lift parameters warnings notification of incorrect operation and service displays see Section 5 3 Switch for driver seat heating o Swit...

Page 32: ...E 3 0706 GB 2 1 6 10 8 11 16 15 14 17 18 12 13 19 3 4 5 7 9 20 E 3 0706 GB 2 1 6 10 8 11 16 15 14 17 18 12 13 19 3 4 5 7 9 20 ...

Page 33: ...nstructions When adjusting ensure that all controls are within easy reaching distance 20 17 18 22 19 0706 GB E 4 3 Starting up the truck F Before the truck can be commissioned operated or a load unit lifted the driver must ensure that there is nobody within the hazardous area Checks and operations to be performed before starting daily work The entire truck in particular wheels and load lifting dev...

Page 34: ... 9 see Section 4 2 The current steering position is shown on the driver s display 2 2 15 7 9 8 10 11 E 5 0706 GB Attaching the safety restraint belt F The safety belt 21 must be worn at all times when travelling The belt must audibly lock in place when closed Place the safety belt 21 taught over your hips not over fixed or fragile objects in the pockets of your clothes The safety belt 21 should be...

Page 35: ...can only be operated by the emergency mechanical steering system for recovery purposes see Section 6 0706 GB E 6 3 1 Emergency stop device Z The truck is fitted with an emergency stop device After you switch on the isolator 11 and the key switch 10 there is an automatic safety prompt from the steering controller Emergency stop activation If a fault occurs in the steering system while travelling wh...

Page 36: ...st be driven such that the trailing vehicle is driven safely and can be stopped under any conditions E 7 0706 GB 4 Industrial Truck Operation 4 1 Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic Unauthorised persons must stay away from work areas Loads must only be stored in places specially designated for this ...

Page 37: ...slow speed see Section 4 1 Steering Turn the steering wheel to the left or right 2 16 9 8 11 V R R V 0706 GB E 8 4 2 Travel Steering Braking Emergency stop Press the isolator 11 down All electrical functions are deactivated Door contact switch The door contact switch must be applied door closed for all operating functions If the door contact switch is not applied all functions except for the batte...

Page 38: ... only apply the service brake Z The current steering setting is shown in the driver s display 2 15 8 E 9 0706 GB Braking F The braking pattern of the truck depends largely on the state of the ground The driver must take this into account when operating the truck The truck can be braked in two different ways using the service brake using the reversing brake Braking with the Service Brake Press the ...

Page 39: ...rks Set the isolator 11 OFF press it in Set the key switch 10 to the 0 position and remove the key 6 0706 GB E 10 4 3 Collecting and depositing loads F Before picking up a load the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded Drive the truck with forks as far as possible underneath the load Lift Press the Raise Load Forks hydraulic control b...

Page 40: ...e brake system to its operating condition The truck must not be parked with the brake released 22 22 E 11 0706 GB 5 Truck recovery in the event of electric steering failure F Recovery must only be undertaken by maintenance personnel who have been trained to operate the system Turn the EMERGENCY DISCON NECT switch and key switch off Prevent the truck from rolling away Push the driver s seat out of ...

Page 41: ...file key 37 to return to normal operating mode 31 32 40 39 38 37 26 27 28 29 30 25 33 36 34 35 24 23 0706 GB E 12 6 Display Components 6 1 Driver s display t The driver s display represents the operator interface to the truck It is both a display and control unit for the operator and the service engineer Press the four short stroke keys 37 38 39 40 to operate the driver s display and hence the tru...

Page 42: ...avel mode 38 Shift key for changing display and accessing service mode 39 No function 40 Slow travel E 13 0706 GB Item Description 23 Overtemperature red graphic symbol 24 Deadman button not applied yellow graphic symbol 25 Slow travel green graphic symbol 26 Service mode active yellow spanner graphic symbol Service interval exceeded flashing graphic symbol 27 Steering angle display in 30 incremen...

Page 43: ... Service interval exceeded flashing yellow spanner graphic symbol Overtemperature red graphic symbol 0706 GB E 14 You can use the four short stroke keys to derate the travel speed slow travel switch change the display to service mode shift key and select travel and lift modes The display shows The steering angle in 30 increments in arrow form The travel lift profile 1 2 or 3 The set speed drive di...

Page 44: ...e applied release brake switch Change display to service mode shift key Select travel and lift modes E 15 0706 GB 6 2 Driver s Display LED Buttons Driver s Display Switches SYMBOL Slow travel green graphic symbol SYMBOL Deadman button not applied yellow graphic symbol SYMBOL Service mode active yellow spanner graphic symbol SYMBOL Overtemperature red graphic symbol Travel speed derated slow travel...

Page 45: ...3 flashing Steering controller overtemperature 31 32 40 39 38 37 26 27 28 29 30 25 33 36 34 35 24 23 0706 GB E 16 Driver s Display Warning Messages Display Other action Meaning LED 31 flashing Battery empty main lift cutout LED 24 on Safety switch not pressed INFO 07 LED 25 flashing At least 1 control not in home position when system starts INFO 09 LED 25 on Crawl speed applied or forced by batter...

Page 46: ... starting the truck for the first time change the master and operating codes 1 2 3 4 5 6 7 8 9 0 Set E 17 0706 GB 7 Keypad CANCODE o The keypad consists of 10 number keys a Set key and a o key The o key indicates operating statuses via a red green LED It contains the following functions Code lock function starting up the truck 7 1 Code Lock When the correct code has been entered the machine is rea...

Page 47: ...Settings Codes travel program release automatic cutout etc 1 2 3 4 5 6 7 8 9 0 Set 43 42 41 46 45 44 0706 GB E 18 Starting the truck for the first time After switching on the isolator and if necessary the key switch the LED 41 turns red When you enter the correct operator code the LED 41 turns green If the wrong code is entered LED 41 flashes red for two seconds The correct code can then be entere...

Page 48: ...d or changed To enter more parameters repeat the procedure To complete your entry press the o key 46 E 19 0706 GB 7 3 Parameter Settings To change the truck setting you must enter the master code Z The factory setting for the master code is 7 2 9 5 m When starting the truck for the first time change the master code To enter the master code Press the o key Enter master code Code Lock Parameters Tru...

Page 49: ...00000 999999 2580 LED 44 flashes Enter code Confirm Set LED 45 flashes Repeat code entry Confirm Set 0706 GB E 20 The following parameters may be entered Code Lock Parameter List No Function Range of Setting Standard Setting Comments Procedure Code Lock 000 Change Master Code The length 4 6 digits of the master code also pre determines the length of the operator code 4 6 digits Provided the operat...

Page 50: ...tomatic time cutout 00 31 00 00 no cutout 01 to 30 Cutout time in minutes 31 Cutout after 10 seconds E 21 0706 GB LEDs 43 45 are located in key fields 1 3 see Section 7 No Function Range of Setting Standard Setting Comments Procedure Code Lock 002 Change Operator Code 0000 9999 or 00000 99999 or 000000 999999 LED 43 flashes Enter current code Confirm Set LED 44 flashes Enter new code Confirm Set L...

Page 51: ...the next PIN m Changes to the service mode may only be made by the manufacturer s service department 0706 GB E 22 Error messages on keypad LED 41 flashes red to indicate the following errors New master code is already an operator code New operator code is already a master code Operator code to be changed does not exist Tried to change the operator code to an existing operator code Tried to delete ...

Page 52: ... does not start Hydraulic oil level too low Check the hydraulic oil level Faulty fuse Check fuse 2F1 E 23 0706 GB 9 Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation When locating a fault proceed in the order shown in the table Z If the fault cannot be rectified after carrying out the remedial procedure notify the manu...

Page 53: ...0706 GB E 24 0706 GB E 24 ...

Page 54: ...ised water After cleaning the truck carry out the activities detailed in the Recommissioning section F 1 0708 GB F Forklift Truck Maintenance 1 Operational safety and environmental protection The servicing and inspection operations contained in this chapter must be performed in accordance with the intervals indicated in the servicing checklists F Any modification to the forklift truck assemblies i...

Page 55: ...d every six years When replacing hydraulic components also replace the hoses in the hydraulic system 0708 GB F 2 Electrical System Only suitably trained personnel may operate on the truck s electrical system Before working on the electrical system take all precautionary measures to avoid electric shocks For battery operated trucks also de energise the truck by removing the battery connector Weldin...

Page 56: ...ice hours or after repair work the owner must check the wheel nuts bolts and re tighten if necessary F 3 0708 GB 3 Servicing and inspection Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment M The service interval...

Page 57: ...l k t 6 5 Replace the hydraulic oil and the filter cartridge t t 6 6 Test pressure relief valves k t 0708 GB F 4 4 ESE 420 430 Maintenance Checklist Maintenance intervals Standard t W A B C Cold Store k Chassis Structure 1 1 Check all load bearing components for damage t 1 2 Check screw connections t Drive 2 1 Check the transmission for noises and leakage t 2 2 Check transmission oil level t 2 3 C...

Page 58: ...Test run with rated load t 13 2 After completing maintenance present the truck to the supervisor l t F 5 0708 GB Maintenance intervals Standard t W A B C Cold Store k Electrical System 7 1 Test operation t 7 2 Make sure wire connections are secure and check for damage t 7 3 Check fuse ratings t 7 4 Test operation of switches and trip cams and make sure they are secure t 7 5 Test operation of warni...

Page 59: ... Compound ratio for cold store usage 1 1 s s E g F A C A 0 7 l 1 B B C 1 2 9 l 195 10 Nm D 0 2 l E F 0708 GB F 6 5 ESE 420 430 Lubrication Schedule g Contact surfaces s Grease nipples Hydraulic oil filler plug b Transmission oil filler neck a Transmission oil drain plug Cold store application t Brake fluid filler neck 1 Compound ratio for cold store usage 1 1 s s E g F A C A 0 7 l 1 B B C 1 2 9 l ...

Page 60: ...ation at 25 C NLG1 class Application temperature C E Lithium 185 265 295 2 35 120 F 310 340 1 52 100 F 7 0708 GB 5 1 Fuels coolants and lubricants Handling consumables Consumables must always be handled correctly Follow the manufacturer s instructions F Improper handling is hazardous to health life and the environment Consumables must only be stored in appropriate containers They may be flammable ...

Page 61: ...rking brake prevent the truck from rolling away 6 2 Opening the truck door o Open the truck door 1 1 0708 GB F 8 6 Maintenance Instructions 6 1 Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs The following preparations must be made Park the truck securely see Chapter E Disconnect the battery pl...

Page 62: ...he hex socket screws 2 Lift up the door attachment 3 Z The battery is accessible for servicing 2 3 4 F 9 0708 GB 6 3 Lift up the door attachment if necessary open the truck door 1 Push the driver s seat to the furthest stop at the front Loosen and unscrew the hex socket screws 2 Lift up the door attachment 3 Z The battery is accessible for servicing 2 3 4 ...

Page 63: ...ntactor 30A 28 1F1 Traction controller 250A 16 15 14 13 12 11 10 23 25 24 28 27 26 22 21 20 19 18 17 0708 GB F 10 6 4 Checking electrical fuses Prepare the truck for maintenance and repairs see Section 6 1 Open the steering controller see Section 6 4 Check rating of all fuses in accordance with table replace if necessary Item Description To protect Rating 10 Vacant 11 3F1 Measurement Discharge ind...

Page 64: ...to avoid depletion of the battery through self discharge The sulfatisation would destroy the battery F 11 0708 GB 6 5 Recommissioning The truck may only be recommissioned after cleaning or repair work once the following operations have been performed Test horn Test main switch operation Test brake Lubricate the truck in accordance with the lubrication schedule 7 Decommissioning the industrial truc...

Page 65: ... applying them repeatedly F Perform several brake tests immediately after re commissioning the truck 0708 GB F 12 7 3 Restoring the truck to operation after decommissioning Thoroughly clean the truck Lubricate the truck in accordance with the lubrication schedule see chapter F Clean the battery grease the terminals and connect the battery Charge the battery see Chapter D Check transmission oil for...

Page 66: ...ons governing the disposal of batteries fuels and electronic and electrical systems must be observed F 13 0708 GB 8 Safety checks to be performed at regular intervals and following any unusual incidents Z Carry out a safety check in accordance with national regulations Junheinrich recommends checks in accordance with FEM Guideline 4 004 Jungheinrich has a special safety department with trained per...

Page 67: ......

Page 68: ...with positive tubular plates type EPzV and EPzV BS 13 17 Type plate Jungheinrich traction battery 17 1 0506 GB Instructions for use Jungheinrich traction battery Table of contents 1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB 2 6 Type plate Jungheinrich traction battery 7 Instruction for use Aquamatic BFS III water refilling system 8 12 2 Jungheinrich traction bat...

Page 69: ...Metal parts of the battery are always live Do not place tools or other me tal objects on the battery 0506 GB 2 1 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Data 1 Nominal capacity C5 See type plate 2 Nominal voltage 2 0 V x No of cells 3 Discharge current C5 5h 4 Nominal S G of electrolyte Type EPzS 1 29 kg l Type EPzB 1 29 kg l 5 Rated temperature 30 C 6 ...

Page 70: ...ent When charging proper provision must be made for venting of the charging gases steel M 10 23 1 Nm 3 0506 GB Ignoring the operation instructions repair with non original parts or using additives for the electrolyte will render the warranty void For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with see relevant c...

Page 71: ... S G of 1 29 kg l at 30 C The electrolyte must conform to the purity regulations in DIN 43530 part 2 0506 GB 4 Battery container lids and the covers of battery compartments must be opened or re moved The vent plugs should stay on the cells and remain closed With the charger switched off connect up the battery ensuring that the polarity is cor rect positive to positive negative to negative Now swit...

Page 72: ...y corrosion If it is necessary to remove cells it is best to call in our service department for this 5 0506 GB 3 Maintenance 3 1 Daily Charge the battery after every discharge Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water The electrolyte level must not fall below the anti surge baffle or the top of the separa...

Page 73: ...ling process must be disposed of as hazardous waste We reserve the right make technical modification 0506 GB 6 5 Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry frost free room To ensure the battery is always ready for use a choice of charging methods can be made 1 a monthly equalising charge as in point 2 3 2 float c...

Page 74: ...Year of manufacture Jungheinrich AG D 22047 Hamburg Germany 5 Pb Pb 2 3 6 5 11 13 1 14 4 10 12 7 8 9 7 0506 GB 7 Type plate Jungheinrich traction battery CE mark is only for batteries with a nominal voltage greater than 75 volt Item Designation Item Designation 1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin material 3 Battery type 10 Nominal battery voltage 4 Battery number 11 Nominal b...

Page 75: ...ngth stroke length Aquamatic plug with diagnostics hole Aquamatic plug BFS III with diagnostics hole 0506 GB 8 Aquamatic BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates Aquamatic plug arrangement for the Operating Instructions The cell series comprise cells with two to ten twelve positive plates e g column EPzS 2 120 10 600 The...

Page 76: ... with five times the buoyant force and consequently interrupt the water supply reliably at least 3 m 9 0506 GB Diagrammatic view Equipment for the water refilling system 1 Water tank 2 Level switch 3 Discharge point with ball valve 4 Discharge point with sole noid valve 5 Charger 6 Sealing coupler 7 Closing nipple 8 Ion exchange cartridge with conductance meter and solenoid valve 9 Connection for ...

Page 77: ...ter element optional with a max passage opening of 100 to 300 µm into the battery s main supply pipe 0506 GB 10 4 Filling manual automatic The batteries should be filled with battery water as soon as possible before the battery charging comes to an end this ensures that the refilled water quantity is mixed with the electrolyte In normal operation it is usually sufficient to fill once a week 5 Conn...

Page 78: ...reatest of care must be employed when prising out the plug to prevent any damage to the plug systems 11 0506 GB 8 Battery hose connections Hose connections for the individual plugs are laid along the existing electric circuit No changes may be made 9 Operating temperature The temperature limit for battery operation is set at 55 C Exceeding this temperature damages the batteries The battery filling...

Page 79: ...2 to 0 6 bars in the Aquamatic system and operating pressure range 0 3 to 1 8 bars in the BFS system 0506 GB 12 10 2 1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to increase the contact pres sure of the hose connection on the plugs hose couplings and to loosen it again 10 3 Filter element For safety reasons a filter element ident no 50307282 can be fitted into the...

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