Jungheinrich ETVC 16 Operating Instructions Manual Download | Manualshive

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F 11

120

7.GB

6.8

Safety belt maintenance

o

It is recommended that the driver checks daily condition and function of the safety belt
daily before starting up the floor conveyor. Only regular checks ensure that a fault or
defective is detected in time.

– Pull out the belt completely and check the fibres for wear and tear.
– Check the function of the belt buckle and control whether the belt is perfectly

winding up in the reel-up device.

Checking the blocking mechanism:

– Park the floor conveyor in horizontal position.
– Pull out the belt jerkily.

M

The mechanism must block the pull-out movement.

F

Do not operate the floor conveyor with a defective safety belt - have it exchanged
immediately!

F 11

120

7.GB

6.8

Safety belt maintenance

o

It is recommended that the driver checks daily condition and function of the safety belt
daily before starting up the floor conveyor. Only regular checks ensure that a fault or
defective is detected in time.

– Pull out the belt completely and check the fibres for wear and tear.
– Check the function of the belt buckle and control whether the belt is perfectly

winding up in the reel-up device.

Checking the blocking mechanism:

– Park the floor conveyor in horizontal position.
– Pull out the belt jerkily.

M

The mechanism must block the pull-out movement.

F

Do not operate the floor conveyor with a defective safety belt - have it exchanged
immediately!

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Summary of Contents for ETVC 16

Page 1: ...Operating instructions 50052734 ETVC 16 20 G 05 99 12 07 ...

Page 2: ...mast interface and commission the truck only after having installed the mast as per the instructions 1 0903 GB Important notes on transporting and mounting load lifting devices to reach trucks Transport Depending on the overall height of the lifting mast and the local conditions transport can be performed in three different ways Standing with the lifting mast mounted for trucks with low overall he...

Page 3: ...0903 GB 2 0903 GB 2 ...

Page 4: ...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 5: ...0108 GB 0108 GB ...

Page 6: ...nstalling the battery D 4 6 Battery discharge indicator battery discharge monitor and hour meter D 5 I 1 0106 GB Table of contents A Correct use and application of the truck B Description of the truck 1 Application B 1 2 Assembly description and functional description B 2 2 1 Truck B 3 2 2 Load lifting system B 5 3 Technical data Standard version B 6 3 1 Output data for standard truck version B 6 ...

Page 7: ...tch ESA Electrical lifting limitation E 24 7 7 LED Lateral traversing device in centre position E 24 0106 GB I 2 E Operation 1 Safety regulations governing the operation of the truck E 1 2 Description of the operating controls and indicators E 2 3 Start up of truck E 6 3 1 How to use the safety belt o E 7 4 Truck operation E 9 4 1 Safety regulations applicable when operating the truck E 9 4 2 Driv...

Page 8: ...intervals and following any untoward incidents D Accident prevention check according to BGV D27 F 14 I 3 0106 GB F Maintenance of the fork lift truck 1 Operational safety and environmental protection F 1 2 Safety regulations applicable to truck maintenance F 1 3 Servicing and inspection F 3 4 Maintenance Check F 4 5 Lubrication Schedule F 6 5 1 Fuels coolants and lubricants F 7 5 2 Reservoir filli...

Page 9: ...0106 GB I 4 0106 GB I 4 ...

Page 10: ...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 11: ...0506 GB 2 0506 GB 2 ...

Page 12: ...l obtained from local authorities does not however make the approval by the manufacturer unnecessary A 1 0800 GB A Correct use and application of the truck Z The Guidelines for the Correct Use and Application of Industrial Trucks VDMA are included in the scope of delivery for this truck The guidelines are part of these ope rating instructions and must always be heeded National regulations are full...

Page 13: ...0800 GB 0800 GB ...

Page 14: ...dentification label Type Capacity Load centre distance ETVC 16 1600 kg 600 mm ETVC 20 2000 kg 600 mm B 1 0205 GB B Description of the truck 1 Application The ETVC 16 20 is an electrically driven three wheel truck incorporating a traversing mast and a lateral seat Used inside and outside for lifting and transporting goods It can pick up pallets of open ground support pallets provided with lateral b...

Page 15: ...o Safety belt t Standard equipment o Optional equipment 18 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 16 17 0205 GB B 2 2 Assembly description and functional description Item Designation Item Designation 1 t Clear view lifting mast 10 t Drive wheel 2 t Overhead guard 11 t Footstep 3 t Free lift cylinder 12 t Foot switch 4 o Auxiliary hydraulics ZH2 13 t Battery trolley unlocking system 5 t Control lever ...

Page 16: ...a ble to the driver s physique Accelerator and brake pedals are arranged as found in normal vehicles B 3 0205 GB 2 1 Truck Safety installations The enclosed truck contour featuring rounded edges ensures safe handling of the ETVC 16 20 truck The driver is protected by the overhead guard 2 The drive wheel 10 and the load bearing wheels 8 are enclosed by a sturdy collision guard The master switch 16 ...

Page 17: ...o Safety belt t Standard equipment o Optional equipment 18 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 16 17 0205 GB B 4 Item Designation Item Designation 1 t Clear view lifting mast 10 t Drive wheel 2 t Overhead guard 11 t Footstep 3 t Free lift cylinder 12 t Foot switch 4 o Auxiliary hydraulics ZH2 13 t Battery trolley unlocking system 5 t Control lever Mast tilting 14 t Parking brake 6 t Control lever ...

Page 18: ...on of the truck Attachments Mechanical and hydraulic attachments are available as optional equipment B 5 0205 GB Operating controls and indicators The operating controls and indicators are clear ly laid out and arranged at the driver position Control lever 5 is used to operate the Mast tilting function control lever 6 to ope rate the Forward backward traversing of mast function The following funct...

Page 19: ... 4250 6500 4700 7400 mm h4 Max height 3544 5044 4894 7144 5446 8146 mm s h2 l4 l7 l1 h1 h6 h3 h4 Q c 0205 GB B 6 3 Technical data Standard version Z Technical data to VDI 2198 Technical data are subject to alteration and extension in scope 3 1 Output data for standard truck version 3 2 Standard hoist frame versions Description ETVC 16 ETVC 20 Q Capacity where C 600 mm 1600 2000 kg C Load centre of...

Page 20: ...h for pallets 1000x1200 traverse 2783 2799 c 2867 c mm Net weight see truck data plate Ast b1 b2 W a B 7 0205 GB 3 3 Dimensions a G Fork length 800 mm 560 Ah battery 0 mm 700 Ah battery 90 mm b G 560 Ah battery 0 mm 700 Ah battery 90 mm c G 560 Ah battery 0 mm Description ETVC 16 ZT DZ ETVC 20 DZ s Lowered fork height 40 50 mm h6 Height above overhead guard 2155 2270 2295 mm l1 Overall length 2132...

Page 21: ...temperatures below 5 C or in cold stores respectively with extre me temperatures or humidity changes 0205 GB B 8 3 4 EN standards Continuous sound level 67 dB A according to EN 12053 as stipulated in ISO 4871 Z The continuous sound level is a value averaged according to standard regulations taking the sound pressure level into account when driving lifting and idling The sound pressure level is mea...

Page 22: ...kundigen Nächste Prüfung Ihr Kundendienst Partner Kundendienst JUNGHEINRICH V JU NG HE IN RIC H V 22 B 9 0205 GB 4 Location of instruction labels and identification plates Item Designation 19 Drive direction when locking the steering wheel option 20 Load diagram capacity lateral traversing device 21 Load diagram capacity load centre lifting height 22 Sign Put on safety belt 23 Prohibitive sign Do ...

Page 23: ...39 32 40 31 41 30 21 500 600 700 850 850 600 X XXXX XX XX 1250 1105 850 1250 1105 850 2900 3600 4250 0205 GB B 10 4 1 Truck identification plate Z In event of queries relating to the truck or spare part orders please state the serial no 31 of the truck 4 2 Load diagram capacity load centre lifting height The load diagram 21 shows the capacity of the truck in Q kg with the hoist frame in vertical p...

Page 24: ...act point decal 29 indi cates where the truck may be lifted and jacked up refer to chapter F X 20 29 B 11 0205 GB 4 3 Load diagram capacity lateral traversing device The load diagram 20 shows the redu ced capacity Q in kg with the lateral tra versing device extended 4 4 Pick up points for lifting jack The Jack contact point decal 29 indi cates where the truck may be lifted and jacked up refer to c...

Page 25: ...0205 GB B 12 0205 GB B 12 ...

Page 26: ...er D Charge the battery refer to chapter D Commission the truck as prescribed refer to chapter E 1 2 C 1 0205 GB C Transportation and commissioning 1 Loading and unloading of trucks by crane F Ensure that the lifting gear is of adequate capacity Transportation weight net weight battery weight see truck identification plate To load the truck with lifting gear lay the loop of the rope around the str...

Page 27: ...ng pace Z As the power steering is not operative the truck can only be steered with increased effort 0205 GB C 2 3 Moving a defective truck Secure the towing device to the recovery vehicle and to the truck to be towed away Disconnect the battery connector Release the parking brake F The towed truck must be steered by a person seated on the truck seat Tow the truck at a walking pace Z As the power ...

Page 28: ...om the manufacturer Capacity Designation 48 V 4PzS Battery 560 Ah 560L 48 V 5PzS Battery 700 Ah 700L D 1 0205 GB D Battery servicing recharging replacement 1 Safety regulations governing the handling of lead acid batteries The truck must be parked and rendered safe before any operations on batteries are to be undertaken refer to chapter E Servicing staff Recharging servicing and replacing of batte...

Page 29: ... position to uncouple the battery trolley and the mast holder The LED 2 must have gone out 1 2 5 4 3 0205 GB D 2 3 Exposing the battery Sit on the driver s seat Render the truck ready for operation refer to chapter E Tilt the control lever 1 in direction of arrow U drive mast holder to its limit stop position towards the battery and release control lever 1 mast is in final position Tilt the contro...

Page 30: ...tions as provided by the battery supplier and battery charger supplier must be strictly observed 6 7 D 3 0205 GB 3 1 Bypassing the drive current interruption Switch on the switch Cut back speed 3 F If the battery is protruding the truck may only be driven at cut back speed in the bat tery charging station 3 2 Battery trolley emergency unlocking system Render the truck ready for operation refer to ...

Page 31: ... plugged connections for any visible damage Covers and side doors must be safely locked 10 11 9 8 12 0205 GB D 4 5 Removing and installing the battery Expose the battery refer to section 3 F Batteries with open poles or open cell bridges must be covered with a rubber mat to prevent short circuiting When using a crane in battery replacing operations ensure that the crane is of adequate capacity ref...

Page 32: ...er indicates the overall time of the driving and the lifting move ments BATT T 0 0 4 4 71 h 13 14 15 D 5 0205 GB 6 Battery discharge indicator battery discharge monitor and hour meter Battery discharge indicator The charging state of the battery 13 is indicated in 10 steps in the LISA display M The standard setting of the battery discharge indicator discharge monitor is made using standard batteri...

Page 33: ...0205 GB D 6 0205 GB D 6 ...

Page 34: ...rning labels and warning notes described in the present operating instructions must always be heeded E 1 1005 GB E Operation 1 Safety regulations governing the operation of the truck Driving permission The truck must only be operated by persons who have been trained in the operation of trucks who have demonstrated to the user or his represen tative their capability of moving and handling loads and...

Page 35: ...Switch cut back speed t Switches cut back speed on and off t Standard equipment o Optional equipment 1005 GB E 2 2 Description of the operating controls and indicators Item Operating control indicator Function 1 Control lever Inclining of mast t Operates the following function Tilting the hoist frame forward backward 2 Control lever Inclining of fork t Operates the following function Pushing forwa...

Page 36: ...E 3 1005 GB 6 5 4 8 12 13 14 15 16 17 11 7 1 2 3 9 10 E 3 1005 GB 6 5 4 8 12 13 14 15 16 17 11 7 1 2 3 9 10 ...

Page 37: ...ever ZH 2 o Controls the second auxiliary hydraulic system t Standard equipment o Optional equipment 1005 GB E 4 Item Operating control indicator Function 15 Master switch emergency stop t The power circuit is interrupted and all electrical functions are switched off 16 Information and ser vice display LISA t Display of essential driving parameters lifting para meters warning signals operating err...

Page 38: ...E 5 1005 GB 6 5 4 8 12 13 14 15 16 17 11 7 1 2 3 9 10 E 5 1005 GB 6 5 4 8 12 13 14 15 16 17 11 7 1 2 3 9 10 ...

Page 39: ...performing the seat adjustments ensure that all operating controls are within easy reach 9 18 8 7 19 1005 GB E 6 3 Start up of truck F The driver must make sure that nobody is within the danger area of the truck before the truck is switched on or operated or before a load is lifted Checks and operations to be performed before starting daily work Visually check the entire truck especially the wheel...

Page 40: ...lers or branches Only original spare parts may be used for upgrading or repairs 15 20 13 10 49 47 48 E 7 1005 GB Adjusting the steering column Loosen the steering column locking 10 and adjust steering wheel 20 to desired position Tighten steering column locking me chanism Switching on the truck Pull up the master switch 15 Insert the key in the key switch 13 and turn clockwise against the stop to ...

Page 41: ...he reel up device Z Drive the floor conveyor carefully out of its slope position and fasten the belt 1005 GB E 8 Behaviour in unusual situations M Proceed as follows if there is danger of the floor conveyor tipping over Press the upper part of your body against the the backrest Keep both hands at the steering wheel and use your feed for additional support Bend your body against the falling directi...

Page 42: ...h a manner that the safe driving and braking of the truck and trailer can be guaranteed at all times E 9 1005 GB 4 Truck operation 4 1 Safety regulations applicable when operating the truck Driving lanes and work areas Only such lanes and routes that are specially alloca ted for truck traffic must be used Unauthorized persons must stay away from work areas Loads must only be stored at places speci...

Page 43: ...actuation di rection When driving both feet are to kept on the pedals R V 15 21 11 4 5 6 R V 47 5 48 1005 GB E 10 4 2 Driving steering braking Emergency cut out Depress the master switch 15 This will switch off all electric functions Functioning of the switch must not be af fected by object placed on it Driving F Do not drive the truck unless the hoods are closed and locked in the stipulated manne...

Page 44: ... The truck is hydraulically braked by means of a drum brake and two load bearing wheel brakes 21 4 5 E 11 1005 GB Steering When the steering wheel is actuated the steering booster is automatically switched on and the position of the drive wheel is set accordingly t Contradirectional steering standard version When travelling forward travel direction switch 21 set to V drive direction turning the st...

Page 45: ... speed M Avoid impacting of the load to prevent damage to the load and to the racking 23 22 24 H S 3 1005 GB E 12 4 3 Adjusting the fork tines F To ensure safe picking up of loads the tines should be apart as far as possible and set centrally to the truck The load centre must be located centrally bet ween the fork tines Swivel the locking lever 22 upwards Push the fork tines 23 along the fork carr...

Page 46: ...control lever 1 in direction V for front inclining and in direction R for back inclining U T 2 R V 1 E 13 1005 GB F The fork must be free before they can be lowered from the rack Do not start before the fork is completely lowered Pushing the mast holder forward F Do not reach between the mast and the battery hood Tilt the control lever 2 in the T direc tion to push the mast holder forward and in t...

Page 47: ...irection to set down the load Pull the control lever 2 in the U direction to retract the mast holder 1005 GB E 14 4 5 Picking up lifting and transporting of loads Tilt the control lever 1 in the V or the R direction to bring the fork tines into a hori zontal position Move the truck up to the load Tilt the control lever 2 in the T direction to push the mast holder forward Pull the solo pilot 3 in t...

Page 48: ...sible signs of damage at least once a shift Report any signs of damage immediately 21 17 Y1 Y2 X1 X2 E 15 1005 GB 4 6 Operating an attachment o Lateral traversing device Z The directions to the left and to the right refer to the load lifting device as seen from the operator s position Moving the lateral traversing device to the left Press the switch 21 in the X1 direc tion Moving the lateral trave...

Page 49: ...tion OFF Switch the key switch 13 to the posi tion 0 and remove the key from the key switch 15 13 11 1005 GB E 16 4 7 Rendering truck safe when parking When the truck is parked and left unattended it has to be rendered safe even if it is left unattended for only a short period of time F Never park the truck on a slope or incline The load lifting device must always be com pletely lowered Press the ...

Page 50: ...y be performed by authorized service per sonnel of the manufacturer 26 27 28 29 30 31 32 33 34 35 25 E 17 1005 GB 5 Information and service display LISA The display 25 of the LCD information and service display LISA shows the opera tion data the battery charge the service hours as well as service data and diagnosti cal data Below the display there are six LEDs 26 31 The keyboard four keys 32 35 se...

Page 51: ...ng of modified parameters acknowledging a query with YES q display change between service hours time 1005 GB E 18 5 1 LED warning lamps Six red light emitting diodes indicate the following states 5 2 Key assignment Item Function 26 Direction of motion forward drive direction green LED 27 Parking brake applied red LED 28 Direction of motion backward load direction green LED 29 Brake liquid level to...

Page 52: ... C U T B A C K R E V E R S L B U Z Z E R O N O F F O F F L R E L O A D L C H A N G E T I M E 1 2 2 2 E 19 1005 GB 5 3 Displays The display shows operating data and fault messages The user menu permits the setting of the following driving parameters Here the time between maximum actua tion of the driving pedal and 100 com pensation of the electronics is set When releasing the driving pedal the brak...

Page 53: ...h 3 BATT xxx xx xx 4 Default setting Travel default values Default setting Travel default values 5 6 1005 GB E 20 5 4 Changing truck parameters F Changing of truck parameters will also change the driving behaviour of the truck This must be taken into account when commissioning the truck Parameters may only be changed while the truck is at a standstill and no lifting movements are performed Commiss...

Page 54: ...recharge if required Defective fuse Check fuses Load too high Comply with maximum load see nameplate E 21 1005 GB 6 Fault locating operations This chapter enables the user to locate and to remedy simple faults or the conse quences of operating errors Fault locating operations should be performed in the or der as set out in the table below Z If the fault could not be eliminated after performing the...

Page 55: ...ch seat heating ON OFF Item Designation 39 o Floodlight 40 o Switch floodlight ON OFF 36 37 38 39 40 1005 GB E 22 7 Auxiliary electrical systems 7 1 Seat heating Z All auxiliary electrical systems are activated regardless of the key switch position The battery master switch must have been switched on see section 3 Switching on the truck To prevent discharge of the battery after the truck has been ...

Page 56: ...3 o Flash lamp 44 o Switch flash lamp ON OFF Item Designation 45 o Switch DC DC transformer 43 44 45 E 23 1005 GB 7 3 360 warning light 7 4 Flash lamp 7 5 DC DC transformer on off switch Switches the DC DC transformer 48 24V or 48 12V respectively on or off Item Designation 41 o 360 warning light 42 o Switch 360 warning light ON OFF Item Designation 43 o Flash lamp 44 o Switch flash lamp ON OFF It...

Page 57: ...e load carriage is lifted above the safety height Item Designation 46 o Override switch 46 2 30 21 3 1005 GB E 24 7 6 Override switch ESA Electrical lifting limitation o Bridge switch Lateral traversing device If the load carriage is below the safety height in front of the wheel arms the mast hol der retraction motion is blocked by the limit switches When the lateral traversing device is between t...

Page 58: ...ompletion of cleaning work the operations detailed in the section Recommis sioning must be performed F 1 1207 GB F Maintenance of the fork lift truck 1 Operational safety and environmental protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists F Modifications of fork lift truck assemblies ...

Page 59: ...ed every six years When replacing hydraulic components also renew the hoses in this hydraulic system 1207 GB F 2 Work on the electric system Work on the electric system of the truck must only be performed by personnel specially trained for such operations Before commencing any work on the electric system all measures required to prevent electric shocks have to be taken For battery operated fork li...

Page 60: ...ce hours or after repair work the own er must check the wheel nuts bolts and re tighten if necessary F 3 1207 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 61: ...k the pressure relief valves for correct functioning k t 6 8 Replace the pressure filter cartridge t 1207 GB F 4 4 Maintenance Check Maintenance intervals standard t W A B C cold store k Chassis and superstruct 1 1 Check all load bearing elements for damage t 1 2 Check all bolted connections t 1 3 Check driver s protective roof and load guard for secure fastening k t Drive unit 2 1 Check the trans...

Page 62: ...t 14 2 Upon completion of servicing operations demonstrate the vehicle to the person responsible k t F 5 1207 GB Maintenance intervals standard t W A B C cold store k Electrical system 7 1 Performance check t 7 2 Check all cables for secure connection and damage t 7 3 Check the fuses for correct amperage t 7 4 Check switches and trip cams for secure attachment and correct functioning t 7 5 Check t...

Page 63: ...e fluid Cold store usage 1 Compound cold store 1 1 2 Filling level refer to the table on section 5 2 1207 GB F 6 5 Lubrication Schedule g A c D 0 2 l t s G G g E F E F J Min 16l Max 23l b B B C 1 ETV C16 4 5l ETV C20 5 3l E F 205 Nm 1 2 3 2 a 2 g Gliding surfaces s Grease nipples Filter plug hydraulic oil c Drain plug hydraulik oil b Filter plug gear oil a Drain plug gear oil t Filter plug brake f...

Page 64: ... Approx 23 Up to 4400 Up to 6500 Up to 5600 2 Approx 20 Up to 3800 Up to 5000 Up to 4700 1 Approx 16 F 7 1207 GB 5 1 Fuels coolants and lubricants Handling consumption type material Consumption type material must always be handled properly Manufacturer s instructions to be observed F Improper handling is injurious to health life and environment Consumption type ma terials must be stored in adequat...

Page 65: ...2 Opening the arm rest Swing the arm rest 2 upward Z Service key and hood release are accessible 1 2 1207 GB F 8 6 Instructions for the servicing operations 6 1 Preparing the truck for the performance of servicing and maintenance operati ons All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations The following preparatory operat...

Page 66: ... the arrow Z The drive unit and the hydraulic unit are accessible for servicing purposes 4 3 5 7 6 5 F 9 1207 GB 6 3 Opening the hood Unlock the hood 4 using the service key 3 Swing the hood upward Z Controls and truck fuses are easily accessible for servicing 6 4 Opening the battery doors and the seat hood Unlock the battery door 5 using the service key and remove it Unlock the seat hood 7 using ...

Page 67: ...ts cross wise with a torque wrench Torque Driven wheels MA 195 10 Nm Rear wheels MA 195 10 Nm 8 9 10 1207 GB F 10 6 5 Checking the hydraulic oil level Prepare the truck for servicing and maintenance refer sections 6 1 Open the seat hood see section 6 4 Check the hydraulic oil level in the hydraulic reservoir 8 Z The oil level must be checked at the hydraulic reservoir with the load lifting device ...

Page 68: ...ement F Do not operate the floor conveyor with a defective safety belt have it exchanged immediately F 11 1207 GB 6 8 Safety belt maintenance o It is recommended that the driver checks daily condition and function of the safety belt daily before starting up the floor conveyor Only regular checks ensure that a fault or defective is detected in time Pull out the belt completely and check the fibres ...

Page 69: ...8 Interface control fuse 3 A 22 F1 Overall control fuse 30 A 23 F8 Main fuse 355 A 22 23 21 20 19 18 1207 GB F 12 6 9 Checking electrical fuses Prepare the truck for servicing and maintenance refer section 6 1 Check all fuses for correct value according to table replace if necessary Item Description Rating type 18 9F4 Fuse Options 10 A 19 4F10 Fan fuse 10 A 20 1F9 Travel and lift electronics contr...

Page 70: ... the battery would occur which owing to sulfatiza tion will result in the destruction of the battery F 13 1207 GB 6 10 Recommissioning the truck Recommissioning of the truck following the performance of cleaning or maintenance work is permitted only after the following operations have been performed Check the horn for proper functioning Check the master switch for correct function Check the brake ...

Page 71: ...e will be affixed to it This plaque indicates in which month of which year the next test will be due 1207 GB F 14 7 3 Recommissioning the truck Thoroughly clean the truck Lubricate the truck according to the lubrication chart refer section 5 Clean the battery Grease the pole screws using pole grease and reconnect the battery Recharge the battery refer to chapter D Check if the gear oil contains co...

Page 72: ...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 73: ...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 74: ...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 75: ... 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 76: ...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 77: ...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 78: ...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 79: ...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 80: ... 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 81: ...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 82: ...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 83: ...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...

Page 84: ... Metal parts of the battery are always live Do not place tools or other metal objects on the battery 13 0506 GB 2 Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV BS Rating Data 1 Nominal capacity C5 See type plate 2 Nominal voltage 2 0 Volt x No of cells 3 Discharge current C5 5h 4 Rated temperature 30 C EPzV batteries ...

Page 85: ... container lids and the covers of battery compartments must be opened or re moved steel M 10 23 1 Nm 0506 GB 14 Ignoring the operation instructions repair with non original parts and non authorised interventions 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 certif...

Page 86: ...ured 3 Maintenance Don t refill water 3 1 Daily Charge the battery immediately after every discharge 15 0506 GB With the charger switched off connect up the battery ensuring that the polarity is cor rect positive to positive negative to negative Now switch on the charger When charging the temperature of the battery rises by about 15 C so charging should only begin if the battery temperature is bel...

Page 87: ...ber of cells The storage time should be taken into account when considering the life of the batte ry 0506 GB 16 3 2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage 3 3 Quarterly After the end of the charge and a rest time of 5 h following should be measured and recorded the voltages of the battery the voltages of every cells If significant changes from earlier mea...

Page 88: ...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 17 0506 GB 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called without delay The measurements taken in point 3 3 will facilitate fault fin ding and their elimination A service contract with us will make it easier to detect and correct fault...

Page 89: ...0506 GB 18 0506 GB 18 ...

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