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Jungheinrich EZS 330 XL, Operating Instructions Manual, Page: 24 / 85

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Jungheinrich EZS 330 XL Operating Instructions Manual Download Page 24

D 3

0406

.GB

3

Exposing the battery

F

Park the truck securely (see Chapter E).

– Pull lever (1) upward while at the same time setting the tiller vertical.
– Release the lever (1) again.
– Flip up the battery latch (3) and open the battery cover (2). 

F

All covers and connections must be restored to the normal operating condition before
the truck can operate again.

1

2

3

D 3

0406

.GB

3

Exposing the battery

F

Park the truck securely (see Chapter E).

– Pull lever (1) upward while at the same time setting the tiller vertical.
– Release the lever (1) again.
– Flip up the battery latch (3) and open the battery cover (2). 

F

All covers and connections must be restored to the normal operating condition before
the truck can operate again.

1

2

3

Summary of Contents for EZS 330 XL

Page 1: ...Operating instructions 50468397 EZS 330 350 XL G 04 06 04 06...

Page 2: ...explanations are indicated by the following graphics F Used before safety instructions which must be observed to avoid danger to personnel M Used before notices which must be observed to avoid materi...

Page 3: ...0108 GB...

Page 4: ...dentification points and data plates B 6 4 1 Truck data plate B 7 C Transport and Commissioning 1 Lifting by crane C 1 2 Securing the truck during transport C 1 3 Using the truck for the first time C...

Page 5: ...ers E 22 7 Troubleshooting E 27 F Industrial Truck Maintenance 1 Operational safety and environmental protection F 1 2 Maintenance Safety Regulations F 1 3 Servicing and inspection F 3 4 Maintenance c...

Page 6: ...06 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 instruct...

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

Page 8: ...he industrial truck himself or on whose behalf it is used In special cases e g leasing or renting the proprietor is considered the person who in accordance with existing contractual agreements between...

Page 9: ......

Page 10: ...ption 1 Application The truck is a three wheel electric tow truck with a driver s platform equipped with a Jet Pilot It is designed for transporting goods on level surfaces in buildings The tow force...

Page 11: ...utton 3 t Jet Pilot 10 o Forward pedestrian walk along operation button 4 t Main switch isolator emergency disconnect 11 o Trailer coupling 5 t Controller 12 t Storage compartment 6 o CANCODE keypad 1...

Page 12: ...he vertical direction It is calculated when travelling over bumps at constant speed Electromagnetic Compatibility The manufacturer confirms that equipment complies with tolerance levels for electromag...

Page 13: ...front rear 514 552 514 552 635 566 635 566 kg h7 Height 132 132 142 142 mm h14 Tiller height in travel position 2 1342 1342 1387 1387 mm h10 Coupling height 158 158 158 158 mm l1 Overall length3 1260...

Page 14: ...B 5 0406 GB 4 Rated tow force a 2 a 2 Wa y 1335 l1 b 11 b 1 h 14 m 2 h 10 h 7...

Page 15: ...ent point of hooks for transportation by crane inside Read operating instructions warning XXXXXXXXX XXXXXXXXX XXXXXXXXX XXXXXXXXX XXXXXXXXXXX XXXXXXXXXXX XXXXXXXXXXXX XXXXXXXXXXXX XXXXXXXXX XXXXXXXXX...

Page 16: ...d tow force 5 min in N 26 Output kW 27 Order no 28 Battery Voltage V 29 Rated tow force 60 min in N 30 Serial no 31 Type 32 Manufacturer s logo XXXXXXXXX XXXXXXXXX XXXXXXXXX XXXXXXXXX XXXXXXXXXXX XXXX...

Page 17: ...0406 GB B 8...

Page 18: ...chment points in such a manner that it cannot slip under any circumstances and cannot come into contact with any attachments when the truck is lifted 2 Securing the truck during transport The truck mu...

Page 19: ...the truck after delivery or after transport proceed as follows Check the truck for completion and satisfactory condition of the equipment Install battery where required Do not damage battery cables s...

Page 20: ...the key Prevent the truck from rolling away Open battery cover refer to chapter D Open the front cover 7 and put it to one side see chapter F Slacken the lock nuts 8 and tighten the screws 9 The brake...

Page 21: ...0406 GB C 4...

Page 22: ...a light coating of dielectric grease Batteries with non insulated terminals must be covered with a non slip insulation mat Battery Disposal Batteries may only be disposed of in accordance with nationa...

Page 23: ...odels with enhanced performance or maintenance free batteries M When replacing installing the battery make sure the battery is securely located in the battery compartment of the truck LxWxH 798x212x78...

Page 24: ...Pull lever 1 upward while at the same time setting the tiller vertical Release the lever 1 again Flip up the battery latch 3 and open the battery cover 2 F All covers and connections must be restored...

Page 25: ...charging the tops of the battery cells must be exposed to provide sufficient ventilation Do not place any metal objects on the battery Before charging check all cables and plug connections for visibl...

Page 26: ...lug 10 from the bracket Flip back the battery locking mechanism 9 Using crane lifting gear lift the battery 11 slowly and carefully out of the truck The battery can optionally be removed from the side...

Page 27: ...0406 GB D 6...

Page 28: ...and Faults The supervisor must be immediately informed of any damage or faults to the forklift truck or attachment Trucks which are unsafe for operation e g wheel or brake problems must not be used u...

Page 29: ...o Hourmeter Displays battery capacity Displays travel parameters and service indicators Shows the service hours completed by the truck 9 CANCODE keypad o Code settings Release and select the travel pr...

Page 30: ...E 3 0406 GB 1 2 3 4 5 6 7 8 9 10 11 12 5 6 7 13 14...

Page 31: ...pecially the wheels for visible signs of damage Visually inspect the battery attachment and cable connections M When entering the truck take care not to activate the controller or the pedestrian o but...

Page 32: ...inclines Negotiating slopes or inclines is only permitted if such roads are clean and have a non slip surface and providing such journeys are safely undertaken in accordance with the technical specifi...

Page 33: ...d several times during this period the steering controller reduces the travel speed of the truck to slow travel If such a fault occurs the travel speed is not reset to normal travel by switching the t...

Page 34: ...trucks with pedestrian operation o the truck can be operated at reduced speed without having to stand on the platform Travelling on inclines Preventing the truck from rolling back With the controller...

Page 35: ...y energy recovery Braking with the service brake Apply the brake button 23 The truck brakes at the maximum possible deceleration rate until it comes to a halt Z The truck can only start again when the...

Page 36: ...nd an obstacle Z In pedestrian mode the truck can be operated by the operator from all sides while walking alongside In this case the truck travels at a significantly reduced speed Pedestrian mode is...

Page 37: ...cured by a chain to prevent it from being lost through the hole at the end of the bolt Uncoupling the trailer Make sure that the trailer cannot move accidentally Pull the retaining needle 30 out from...

Page 38: ...33 or Bowden cable handgrip 34 4 5 Travelling with trailers F In difficult application conditions inclines smooth or slippery travel routes the tow load must have to be reduced to ensure braking with...

Page 39: ...into the desired height Lock the seat at the desired height To set a higher position push the seat up and release it in the desired position To fold it in push the seat into the highest position and...

Page 40: ...for error with alternating three digit error number If several errors occurs at the same time they are displayed one after the other The errors are displayed for as long as they remain always in combi...

Page 41: ...ay the setting parameters The first three digits of the display show the parameter numbers the last three digits indicate the parameter value Z Settings of parameter group 0XX code lock are not displa...

Page 42: ...ttery parameters only in conjunction with the display instrument CANDIS o The o key has top priority and restores the truck from any status to its default status without modifying any settings 6 1 Cod...

Page 43: ...the LED 44 turns green If the wrong code is entered LED 44 flashes red for two seconds The correct code can then be entered Z The Set key 45 has no function in operating mode Power Down The truck is s...

Page 44: ...nables you to set the code lock functions and adapt travel programs In addition the battery parameters can also be set Z For trucks without display instrument CANDIS o only the code lock parameters ca...

Page 45: ...changing any parameter will affect the truck s travel pattern you must carry out a test run in a specially designated work area To enter the master code Press the o key Enter master code Code Lock Pa...

Page 46: ...mplete your entry press the o key 43 The following parameters may be entered Code Lock Parameter List No Function Setting range Standard setting Comments Procedure Code Lock 000 Change master code The...

Page 47: ...e Confirm Set LED 41 flashes Enter a new code Confirm Set LED 42 flashes Repeat code entry Confirm 003 Delete user code 0000 9999 or 00000 99999 or 000000 999999 LED 41 flashes Enter a code Confirm Se...

Page 48: ...ing Comments Procedure Code Lock 020 Start travel program 0 3 3 0 There is no start program 1 Travel program 1 Start travel program 2 Travel program 2 Start travel program 3 Travel program 3 Start tra...

Page 49: ...hange the parameter value according to the parameter list Check the LC display of the indicator instrument CANDIS o confirm with the Set key 45 The LED 44 of the o key 43 switches briefly to steady li...

Page 50: ...meter 100 101 Acceleration in Rider mode 0 9 2 102 Coasting brake in rider mode 0 9 2 103 Coasting brake in Pedestrian mode 0 9 2 Value of parameter 103 Parameter 102 104 Maximum speed in drive direct...

Page 51: ...irection via controller 0 9 8 depending on travel switch 205 Pedestrian speed in drive direction via controller 0 9 5 depending on travel switch 206 Pedestrian speed in drive direction via pushbutton...

Page 52: ...irection via controller 0 9 8 depending on travel switch 305 Pedestrian speed in drive direction via controller 0 9 5 depending on travel switch 306 Pedestrian speed in drive direction via pushbutton...

Page 53: ...ment The parameters are set in the same way as for the travel parameters The following parameters may be entered Setting 0 1 is to be interpreted as 0 off 1 on No Function Setting range Standard setti...

Page 54: ...acturer s service department as any further troubleshooting can only be performed by specially trained and qualified service personnel Fault Possible cause Action Truck does not move Battery connector...

Page 55: ...0406 GB E 28...

Page 56: ...ced and maintained by the manufacturer s trained personnel The manufacturer s service department has field technicians specially trained for these tasks We therefore recommend a maintenance contract w...

Page 57: ...se from the truck before performing welding operations Settings When repairing or replacing hydraulic electric or electronic components or assemblies always note the truck specific settings Tyres The...

Page 58: ...cordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts The following maintenance checklist states the tasks and intervals after which they shoul...

Page 59: ...ering chain and the chain sprocket for wear adjust and grease l t 4 3 Check the mechanical parts of the steering column grease if necessary t Brake system 5 1 Test operation and settings l t 5 2 Check...

Page 60: ...they are secure l t 9 4 Check battery cables for damage replace if necessary t Lubrication 11 1 Lubricate truck in accordance with Lubrication Schedule l t General measure ments 12 1 Check electrical...

Page 61: ...F 6 5 Lubrication Schedule g Contact surfaces s Grease nipple b Transmission oil filler neck a Transmission oil drain plug Cold store application 1 Compound ratio for cold store usage 1 1 G B b a E B...

Page 62: ...ixing is expressively prescribed in the corresponding operating instructions Avoid spillage Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent consumable mi...

Page 63: ...efer to chapter D F When working on the brake system prevent the truck from rolling away 6 2 Tightening the wheel nuts The wheel nuts on the drive wheel must be retightened in accordance with the main...

Page 64: ...chapter D Remove the hex socket screws 5 located under the battery cover using the hex socket wrench 6 Lift up the front panel 4 and put it to one side Z Installation is the reverse order F Do not dr...

Page 65: ...6 3 Referring to the table check all fuses for correct rating and damage replace fuses where required Reinstall the front panel see section 6 3 Item Description To protect Rating 6 6F1 Battery discha...

Page 66: ...e wheels and wheel bearings are not damaged If the truck is to be out of service for more than 6 months further measures must be taken in consultation with the manufacturer s service department 7 1 Pr...

Page 67: ...without regard to operational or economic circumstances The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the saf...

Page 68: ...tive 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 battery Maintenance free...

Page 69: ...d clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 50272 3 DIN 50110 1 No smoking Do not expose batteries to naked flames glowing embers or sparks as...

Page 70: ...ucks is the standard which ap plies to the operation traction batteries in industrial trucks 2 1 Discharging Be sure that all breather holes are not sealed or covered Electrical connections e g plugs...

Page 71: ...The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 72: ...ound further testing and maintenance by the service department should be requested 3 4 Annually In accordance with DIN VDE 0117 at least once per year the insulation resistance of the truck and the ba...

Page 73: ...be taken into account when considering the life of the battery 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called in without delay The meas...

Page 74: ...l battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer s logo 14 Safety instructions and warnings Typ 1 T ype Nennspannung 5 Nomin...

Page 75: ...sing batteries which comply with I and II it is important to follow the in structions on maintaining the respective protection class during operation see asso ciated certification Cell series Aquamati...

Page 76: ...d by means of a central sealing coupler through the hose connections in the individual Aquamatic BFS plugs 2 Application The Aquamatic BFS battery water refilling system is used in traction batteries...

Page 77: ...surface 5 2 Pressurised water The pressure reducing valve in the Aquamatic System is set from 0 2 bars to 0 6 bars and from 0 3 bars to 1 8 bars in the BFS system 5 3 Water Refill Trolley serviceMobi...

Page 78: ...ve a diagnostics hole with a 6 5 mm diameter Aquamatic plugs or a 7 5 mm diameter BFS plugs 9 2 Float Different floats are used depending on the cell design and type 9 3 Cleaning The plug systems may...

Page 79: ...en tral supply pipe This is connected to the water supply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple ident no 50219538 is mounted...

Page 80: ...battery Work on batteries to be carried out by skilled personnel only Use protective glasses and clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 5027...

Page 81: ...g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity should be avoided deep discharg...

Page 82: ...0 0171 Ex I in areas with a firedamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 83: ...1000 4 Care of the battery The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of Vehicle Trac...

Page 84: ...raction 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...

Page 85: ...0506 GB 18...

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