Jungheinrich EZS 350 XL Operating Instructions Manual Download Page 38 | Manualshive

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4

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Procedure

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Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly.

CAUTION!

After installing the battery make sure the battery lock (35) is in place to prevent
it from sliding out.

37

11

.1

4

E

N

Procedure

Z

Installation is the reverse order. When reinstalling the battery, note the proper
installation position and make sure the battery is connected correctly.

CAUTION!

After installing the battery make sure the battery lock (35) is in place to prevent
it from sliding out.

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Summary of Contents for EZS 350 XL

Page 1: ...08 09 11 14 51133023 EZS 350 350 XL C40 Operating instructions G EZS 350 XL EZS C40 EZS 350 ...

Page 2: ...at the powered industrial truck described below in detail complies with the European Directives 2006 42 EC Machinery Directive and 2004 108 EEC Electromagnetic Compatibility EMC including amendments as well as the legislative decree to incorporate the directives in national law The signatories are in each case individually authorized to compile the technical documents Type Option Serial no Year of...

Page 3: ...11 14 EN 4 ...

Page 4: ...guarantee of particular 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 following graphics DANGER Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death WARNING Indicates an...

Page 5: ...11 14 EN 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com ...

Page 6: ...hts 19 3 4 Tyre type 19 3 5 EN norms 20 3 6 Conditions of use 21 4 Identification points and data plates 22 4 1 Data plate 23 C Transport and Commissioning 25 1 Lifting by crane 25 2 Transport 26 3 Using the Truck for the First Time 27 D Battery Servicing Recharging Replacement 29 1 Safety Regulations Governing the Handling of Lead Acid Batteries 29 2 Battery types 30 3 Exposing the battery 32 4 C...

Page 7: ...69 F Industrial Truck Maintenance 77 1 Operational Safety and Environmental Protection 77 2 Maintenance Safety Regulations 77 3 Servicing and Inspection 83 4 Maintenance checklist 84 4 1 Owner 84 4 2 Customer Service 86 5 Lubricants and Lubrication Schedule 90 5 1 Handling consumables safely 90 5 2 Lubrication Schedule 92 5 3 Consumables 93 6 Maintenance and repairs 94 6 1 Preparing the truck for ...

Page 8: ...506 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 9: ...0506 GB 2 ...

Page 10: ... may only be pushed with the trailer coupling 3 Approved application conditions Operation in industrial and commercial environments Permissible temperature range 5 C to 40 C Operation only on secure level surfaces with sufficient capacity Operation only on routes that are visible and approved by the proprietor Negotiating inclines up to a maximum of 15 Do not negotiate inclines crosswise or at an ...

Page 11: ...hird parties Furthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The proprietor must ensure that all users have read and understood these operating instructions NOTE Failure to comply with the operating instructions shall invalidate the warranty The same applies if improper work is carried out on the truck by the customer or...

Page 12: ...on 1 Application The truck is a three wheel electric tow truck with an operator platform equipped with a Jet Pilot It is designed for transporting goods on level surfaces in buildings The drawbar pull is indicated on the data plate ...

Page 13: ...p button 2 t Battery cover 10 o Forward pedestrian operation button 3 t JetPilot 11 o Trailer coupling 4 t Emergency Disconnect main switch 12 t Storage compartment 5 t Travel switch 13 t Drive wheel on EZS C40 CSE wheel 6 o Control keypad CanCode o Headlight not shown 7 t Key switch o Strobe not shown 1 2 3 4 5 6 7 8 9 10 12 11 13 ...

Page 14: ...13 11 14 EN 8 o Reverse pedestrian operation button o Rear view mirror t Standard version o Option ...

Page 15: ...reephase motor actuates the drive wheel via a bevel spur gearbox The electronic traction controller ensures smooth drive motor speed control and hence smooth travel powerful acceleration and electrically controlled braking with energy regeneration The driver can choose from 3 travel programs depending on the load and the environment from maximum performance to energy saving Curve Control Automatic...

Page 16: ... see CanCode keypad on page 62 Service hours are counted while the truck is operational and the operator is standing on the platform 2 2 2 Hourmeter in Pedestrian Mode Z Prepare the truck for operation see Preparing the truck for operation on page 45 or see CanCode keypad on page 62 Service hours are counted while the truck is operational and one of the following controls is applied Pedestrian dri...

Page 17: ...ull 1000 1000 N Travel speed w w o rated load 1 7 0 12 5 7 0 12 5 km h Traction motor output S2 60 min 2 8 2 8 kW Max drawbar pull S2 5 min 3200 3200 N Battery voltage nominal capacity K5 24 420 24 560 V Ah EZS C40 F Nominal drawbar pull 800 N Travel speed w w o rated load 1 8 2 12 5 km h Traction motor output S2 60 min 2 8 kW Max drawbar pull S2 5 min 2600 N Battery voltage nominal capacity K5 24...

Page 18: ...17 11 14 EN 3 2 Dimensions ...

Page 19: ...0 mm Wa Turning radius 1220 1370 mm 1 JetPilot height 2 Total length excluding coupling as different coupling versions are available EZS C40 y Wheelbase 1229 mm h7 Seat height standing height 182 mm h14 Tiller height in travel position 1 1450 mm h10 Coupling height 140 480 mm l1 Overall length 2 1517 mm b1 Overall width 810 mm b11 Track width rear load section 680 mm m2 Ground clearance centre whe...

Page 20: ...ttery 606 677 715 kg Axle load w o load front rear battery 520 456 590 520 660 525 kg Battery weight 370 470 470 kg EZS 350 EZS 350 XL EZS C40 Tyre size drive 230 x 77 230 x 77 310 x 105 Tyre size load section 250 x 80 250 x 77 301 x 85 Wheels number front rear x driven 1x 2 1x 2 1x 2 ...

Page 21: ... human vibrations of the 2002 44 EC Vibrations operator directive The manufacturer offers a special service to measure these human vibrations see Human vibration measurement on page 102 Electromagnetic compatibility EMC The manufacturer confirms that the truck adheres to the limits for electromagnetic emissions and resistance as well as the static electricity discharge test in accordance with EN 1...

Page 22: ...Conditions of use Ambient temperature operating at 5 C to 40 C Z Special equipment and authorisation are required if the truck is to be constantly used in conditions of extreme temperature or air humidity fluctuations ...

Page 23: ...tem Description 14 Data plate 15 Serial number 16 Warning Caution pushbutton operation 17 Test plaque 18 Warning Risk of trapping when reversing 19 Strap points for crane lifting 20 Model description 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 2000 16 19 15 17 18 20 14 ...

Page 24: ...of the truck shall apply see Performance data on page 16 If the owner has attached trailer couplings adapt the drawbar pull tow loads to the trailer coupling or maximum drawbar pull tow load of the truck 21 22 24 23 25 32 28 31 30 29 27 26 Item Description Item Description 21 Type 27 Year of manufacture 22 Serial number 28 Nominal drawbar pull 5 min in N 23 Nominal drawbar pull 60 min in N 29 Outp...

Page 25: ...11 14 EN 24 ...

Page 26: ...swaying load Do not walk into or stand in a hazardous area Always use lifting gear with sufficient capacity for truck weight see truck data plate Always attach the crane slings to the prescribed strap points and prevent them from slipping Use the lifting gear only in the prescribed load direction Crane slings should be fastened in such a way that they do not come into contact with any attachments ...

Page 27: ...y measures adopted The truck must be securely fastened when transported on a lorry or a trailer The lorry trailer must have fastening rings Use wedges to prevent the truck from moving Use only tension belts or tie down straps or with sufficient strength Securing the truck for transport Tools and Material Required Tension belts tie down straps Procedure Move the truck onto the transporting truck Pa...

Page 28: ...ts Cable connections to the battery tow leads must be less than 6 m long and have a minimum cross section of 50 mm Procedure Check the equipment is complete If necessary install the battery see Battery removal and installation on page 35 Charge the battery see Charging the battery on page 33 The truck can now be started see Starting up the truck on page 44 ...

Page 29: ...11 14 EN 28 ...

Page 30: ...ing there shall be no inflammable material or lubricants capable of creating sparks within 2 m around the truck The room must be ventilated Fire protection equipment must be on hand Battery maintenance The battery cell covers must be kept dry and clean The terminals and cable shoes must be clean secure and have a light coating of dielectric grease CAUTION Before closing the battery panel make sure...

Page 31: ... battery have a considerable effect on the operational safety and capacity of the industrial truck Changing the battery features requires the manufacturer s approval as compensating weights are required if smaller batteries are fitted When replacing installing the battery make sure the battery is securely located in the battery compartment of the truck Park the truck securely before carrying out a...

Page 32: ...kg 24 volt battery 626X286X782 mm LXWXH England tray 3 PzS 450 Ah HX 370 kg 24 volt battery 796X210X782 mm LXWXH 3 PzS 465 Ah 370 kg 24 volt battery 796X210X782 mm LXWXH Maintenance free 3 PzV 360 Ah 411 kg 24 volt battery 796X330X782 mm LXWXH 4 PzS 620 Ah 450 kg 24 volt battery 796X210X784 mm LXWXH 3 PzS 420 Lib Silver 389 kg 24 volt battery 626X286X782 mm LXWXH 3 PzS 420 Lib Silver 395 kg 24 vol...

Page 33: ...y prohibited Always park the truck on a level surface In special cases the truck may need to be secured with wedges Requirements Park the truck on a level surface Park the truck securely see Parking the truck securely on page 46 Procedure Pull the lever 34 upward while at the same time setting the JetPilot vertical Flip the battery latch 35 up pull up the lock and open the battery cover 2 The batt...

Page 34: ...check all cables and plug connections for visible signs of damage Ventilate the room in which the truck is being charged The battery cover must be open and the battery cell surfaces must be exposed during charging to ensure adequate ventilation Do not smoke and avoid naked flames when handling batteries Wherever an industrial truck is parked for charging there shall be no inflammable material or l...

Page 35: ...er lead 37 of the battery charger station with the battery connector 36 Switch on the charger charging begins automatically The battery is now charged Completing the battery charge restoring the truck to operation NOTE If charging has been interrupted the full battery capacity will not be available Requirements Battery charging is complete Procedure Switch off the charger Disconnect the battery fr...

Page 36: ...olley etc Make sure the battery is securely located in the truck s battery compartment Removing the battery from the top Battery removal Requirements Park the truck securely see Parking the truck securely on page 46 Expose the battery see Exposing the battery on page 32 Procedure Disconnect the battery connector from the truck connector Z Place the battery cable on the tray so that it cannot be se...

Page 37: ...Exposing the battery on page 32 Tools and Material Required Battery replacement station trolley Procedure Disconnect the battery connector 36 from the truck connector Undo the battery lock 35 Move the battery replacement station trolley up to the side of the truck Carefully push the battery from off the truck onto the battery replacement station trolley The battery is now removed Battery installat...

Page 38: ...he reverse order When reinstalling the battery note the proper installation position and make sure the battery is connected correctly CAUTION After installing the battery make sure the battery lock 35 is in place to prevent it from sliding out ...

Page 39: ...11 14 EN 38 ...

Page 40: ...ions The driver shall be afforded all due rights Safety shoes must be worn for pedestrian operated trucks Unauthorised use of truck The driver is responsible for the truck during the time it is in use The driver must prevent unauthorised persons from driving or operating the truck Do not carry passengers or lift other people Damage and faults The supervisor must be immediately informed of any dama...

Page 41: ... can be reached by falling loads Instruct unauthorised people to leave the hazardous area Give a warning signal with plenty of time for people to leave If unauthorised personnel are still within the hazardous area stop the truck immediately Safety devices and warning labels Safety devices warning signs see Identification points and data plates on page 22 and warning instructions in the present ope...

Page 42: ...41 11 14 EN 2 Displays and Controls 44 4 3 45 41 8 9 7 6 10 41 8 11 43 5 10 42 ...

Page 43: ...travel direction and speed 8 Forward pedestrian operation button Forward o Travel starts in pedestrian mode in the forward direction V slow travel 9 Stop button t The truck decelerates at the maximum rate until it comes to a halt 10 Forward pedestrian operation button Reverse o Travel starts in pedestrian mode in the reverse direction R slow travel 11 Trailer coupling o For towed load 41 Pedestria...

Page 44: ...avel speed is reduced to half the setting The full travel speed is only released again when the battery connected is at least 70 charged If the LED flashes red and the truck is not ready for operation inform the manufacturer s service department Red flashing is a truck controller code The flashing sequence indicates the type of fault LED colour Residual capacity Green 40 100 Orange 30 40 Flashing ...

Page 45: ...ny defects immediately to your supervisor Tag out and decommission a faulty lift truck Only return the truck to service when you have identified and rectified the fault Pre start inspections Procedure Check the whole of the outside of the truck for signs of damage and leaks Damaged hoses must be replaced immediately Check the battery attachment and wire connections for damage and make sure they ar...

Page 46: ...lease the Jet pilot adjuster again Pull out the Emergency Disconnect switch 4 Switch on the truck to do this Insert the key in the key switch 47 and turn it to the right as far as it will go position I or for CANCODE 6 o enter the activation code see CanCode keypad on page 62 Test the warning signal button 44 Test the travel switch 5 Test the steering The truck is operational WARNING Do not press ...

Page 47: ...The truck is parked 3 4 Battery discharge monitor Z The standard setting for the battery discharge indicator discharge monitor is based on standard batteries When using maintenance free or special batteries the display and cutout points of the battery discharge monitor must be set by authorised specialist personnel If this adjustment is not made the battery may become damaged through excessive dep...

Page 48: ...braking distance between the forklift truck and the vehicle in front and must be in control of the truck at all times Abrupt stopping except in emergencies rapid U turns and overtaking at dangerous or blind spots are not permitted Do not lean out or reach beyond the working and operating area Travel visibility The driver must look in the direction of travel and must always have a clear view of the...

Page 49: ...ome loose during loading unloading Towing trailers Do not exceed the maximum trailer load specified for the industrial truck for trailers with or without brakes The trailer load must be secured in accordance with regulations and must not exceed the dimensions permitted for that roadway After coupling and before starting the driver shall ensure that the trailer coupling cannot become detached Indus...

Page 50: ...Do not use the Emergency Disconnect switch 4 as a service brake Press the Emergency Disconnect 4 All electrical functions are deactivated The truck brakes to a halt Releasing the Emergency Disconnect switch Procedure Pull the Emergency Disconnect 4 to unlock it All electrical functions are enabled and the truck is operational again assuming the truck was not operational before the Emergency Discon...

Page 51: ...vel switch is release it automatically returns to its original position Z For trucks with pedestrian operation o the truck can be operated at reduced speed slow travel without standing on the platform The brakes are released and the truck moves in the selected direction Z Preventing the truck from rolling downhill If the truck rolls backwards on an incline the controller detects the situation and ...

Page 52: ...ance when travelling with an attached load Use the service brake in emergencies The truck can brake in three different ways With the service brake By inversion braking travel switch By regenerative braking coasting CAUTION Use the service brake in emergencies Braking with the service brake Procedure Press the Stop button 9 The truck will decelerate at the maximum rate and the service brake will ap...

Page 53: ...he service brake then applies Z Regenerative braking may not be sufficient on inclines In this case inversion braking must be applied Inversion braking Procedure During travel set the travel switch 5 to the opposite direction The truck brakes regeneratively until it starts to move in the opposite direction Z The brake force can be set by the manufacturer s service department ...

Page 54: ...the operator from either side while walking alongside In this case the truck travels at a significantly reduced speed Travel using the pedestrian button Procedure Press the pedestrian button 8 10 Z The speed can be set via travel parameters see Parameters on page 62 Z When you travel via the pedestrian button 8 10 you can steer between 10 left and right If you steer beyond this range the truck wil...

Page 55: ...Requirements Pull the bolt 48 up fully out of the trailer coupling Procedure Push the tow eye of the trailer into the trailer coupling Push the bolt of the trailer coupling from the top through the holes of the trailer coupling and the tow eye To secure the coupling insert the spring cotter 49 sideways through the hole at the end of the bolt The trailer is now coupled Unhitching the trailer Proced...

Page 56: ...ing away Push the tow eye of the trailer into the trailer coupling Pull the hand lever 51 remote control 50 o up Z The bolt of the trailer coupling closes automatically Slowly reverse the truck until the coupling engages Push the hand lever 51 remote control 50 o down The trailer is now coupled Unhitching the trailer Procedure Prevent the trailer from rolling away Pull the hand lever 51 remote con...

Page 57: ... when transporting loads with large surface areas Light loads must be especially secured when they are subjected to wind forces Stop the truck in both cases CAUTION Cornering with trailers When cornering with long trailers and trailer trains note how the angle is reduced CAUTION Always pull never push a trailer Familiarise yourself with the brake and steering system of the trailer when you start t...

Page 58: ...2 towards you and push it into the required position To adjust the position release the seat so that it falls into the required position The seat is now set Fold the seat back Procedure Pull the seat 52 towards you Push the seat 52 to its highest position and fold it back The seat is now folded back 52 ...

Page 59: ...r s specialist service engineers The manufacturer s customer service department is specially trained to carry out these operations In order for customer services to react quickly and specifically to the fault the following information is essential Truck serial number Error number on the display unit if applicable Error description Current location of truck 5 1 Truck does not start Possible Cause A...

Page 60: ... Material Required Two M5x42 screws Spanner wrench Procedure Turn of the key switch CanCode o Switch off the Emergency Disconnect button Disconnect the battery Prevent the truck from rolling away Open the battery panel see Exposing the battery on page 32 Lift up the front panel 1 and put it to one side see Removing the front panel on page 96 Insert two M5x42 screws 53 as far as the stop and lift u...

Page 61: ... lit steadily the battery must be charged immediately If activated the discharge monitor function is applied in this case see Discharge monitor function on page 61 Z The point at which the Attention 56 and Stop 57 symbols start to light up differs depending on the battery type 54 Battery charge display on board charger only 55 LED bars for battery charge status 56 Warning symbol yellow Battery cha...

Page 62: ...s shown in the display 7 1 3 Event Messages The service hours display is also used to display event messages The event messages overwrite the service hour display Event message start with an E for Event and a four digit error number The event message is displayed as long as the fault persists If there are several event messages they are displayed consecutively Most event messages result in the Eme...

Page 63: ...you use the truck for the first time Z Set different codes for rider and pedestrian trucks Starting the truck Procedure Switching on the Emergency Disconnect LED 65 lights up red Enter the code When you enter the correct operator code the LED 65 turns green If the LED 65 flashes red this means the wrong code has been entered Try again The truck is switched on Z The Set key 64 has no function in op...

Page 64: ...ruck Z Set different codes for rider and pedestrian trucks Changing the truck settings Procedure Press the O key 63 Enter the master code Enter the three digit parameter number Confirm with the SET key 64 Enter the setting as per parameter list Z If the entry is incorrect the LED 65 of the O key 63 turns red Enter the parameter number again Enter the setting again or change it Confirm with the SET...

Page 65: ...rator codes 0000 9999 or 00000 99999 or 000000 999999 7295 LED 60 flashes Confirm current code entry Set 64 LED 61 flashes Enter a new code Set 64 LED 62 flashes repeat new code Set 64 001 Add code max 250 0000 9999 or 00000 99999 or 000000 999999 2580 LED 61 flashes Confirm code entry Set 64 LED 62 flashes repeat code entry Set 64 002 Change code 0000 9999 or 00000 99999 or 000000 999999 LED 60 f...

Page 66: ... blocked or 1 released 2nd digit travel program 2 release 0 blocked or 1 released 3rd digit travel program 3 release 0 blocked or 1 released 4th digit start travel program 0 1 2 or 3 003 Delete code 0000 9999 or 00000 99999 or 000000 999999 LED 61 flashes Confirm new code entry Set 64 LED 62 flashes repeat code entry Set 64 004 Delete code log deletes all codes 3265 3265 delete other inputs do not...

Page 67: ...nfirm with SET Enter the configuration 4 digit again and confirm with SET Repeat the procedure for other codes Then press the O key The travel programs are assigned to the codes Keypad event messages The LED 65 flashes red to indicate the following events New master code is already in use New code is already the master code Code to be changed does not exist Attempt to change the code to one that a...

Page 68: ...meter 0256 Acceleration example Procedure Enter four digit parameter number 0256 and confirm with the SET key 64 Enter sub index enter 2 and confirm with the SET key 64 Z The parameter and sub index are displayed alternately with the current reading 0256 2 0000 3 Enter the parameter according to the parameter list and confirm with the Set key 64 Z The LED 65 of the O key 63 switches briefly to ste...

Page 69: ...e truck is now in travel mode and can be checked Z To continue setting confirm with the Set key 64 again Saving travel parameters Requirements Enter all parameters Procedure Run SaveParameters by pressing 1 2 3 Set Confirm with the O key 63 7 4 ISM access module o Z If the truck is equipped with an ISM access module or Can Code refer to the ISM Access Module operator manual ...

Page 70: ...64 Maximum forward speed using travel switch 0 9 3 depending on travel switch 0265 Maximum reverse speed using travel switch 0 9 5 depending on travel switch 0266 Maximum pedestrian forward speed using button 0 9 3 fixed speed 0268 Maximum reverse speed using travel switch 0 9 9 depending on travel switch 0269 Maximum pedestrian reverse speed using travel switch 0 9 5 depending on travel switch 02...

Page 71: ...vel switch 0 125 9 0 km h 90 depending on travel switch 0265 Maximum reverse speed using travel switch 0 40 2 5 km h 25 depending on travel switch 0266 Maximum pedestrian forward speed using button 0 40 2 5 km h 25 adjustable 0268 Maximum reverse speed using travel switch 0 60 6 0 km h 60 depending on travel switch 0269 Maximum pedestrian reverse speed using travel switch 0 25 2 5 km h 25 dependin...

Page 72: ...um forward speed using travel switch 0 9 8 depending on travel switch 0281 Maximum reverse speed using travel switch 0 9 5 depending on travel switch 0282 Maximum pedestrian forward speed using button 0 9 3 fixed speed 0284 Maximum reverse speed using travel switch 0 9 9 depending on travel switch 0285 Maximum pedestrian reverse speed using travel switch 0 9 5 depending on travel switch 0286 Maxim...

Page 73: ...vel switch 0 125 12 5 km h 125 depending on travel switch 0281 Maximum reverse speed using travel switch 0 40 2 5 km h 25 depending on travel switch 0282 Maximum pedestrian forward speed using button 0 40 2 5 km h 25 adjustable 0284 Maximum reverse speed using travel switch 0 60 6 0 km h 60 depending on travel switch 0285 Maximum pedestrian reverse speed using travel switch 0 25 2 5 km h 25 depend...

Page 74: ...um forward speed using travel switch 0 9 8 depending on travel switch 0297 Maximum reverse speed using travel switch 0 9 5 depending on travel switch 0298 Maximum pedestrian forward speed using button 0 9 3 fixed speed 0300 Maximum reverse speed using travel switch 0 9 9 depending on travel switch 0301 Maximum pedestrian reverse speed using travel switch 0 9 5 depending on travel switch 0302 Maxim...

Page 75: ...l switch 0 40 2 5 km h 25 depending on travel switch 0298 Maximum pedestrian forward speed using button 0 40 2 5 km h 25 adjustable 0300 Maximum reverse speed using travel switch 0 60 6 0 km h 60 depending on travel switch 0301 Maximum pedestrian reverse speed using travel switch 0 25 2 5 km h 25 depending on travel switch 0302 Maximum pedestrian reverse speed using button 0 25 1 0 km h 10 adjusta...

Page 76: ...US Flate Plate type 4 US Pallet Pro type 5 US Tubular Plate dry battery type 6 Banner DB69 dry battery 7 Exide GF12 063 Y dry battery 1389 Discharge monitor function 0 4 1 0 Not active 1 Active 2 Display and lift cutout active except for digital lift input 3 Display and lift cutout active except for MFC05 lift setpoints 4 Display and lift cutout active except for MFC05 lift setpoints and digital l...

Page 77: ...11 14 EN 76 ...

Page 78: ...department To ensure safe and reliable operation of the truck use only the manufacturer s spare parts For safety reasons only components which have been specially agreed by the manufacturer for this truck may be installed near the computer controllers and wire guidance sensors antennae These components computers controllers wire guidance sensors antennae must therefore not be replaced either by si...

Page 79: ... up the truck safely proceed as follows Jack up the truck only on a level surface and prevent it from moving accidentally Always use a jack with sufficient capacity When jacking up the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks In order to raise the truck the lifting gear must only be secured to the points specially provided for this purpos...

Page 80: ...the electrical system with water Clean the electrical system with weak suction or compressed air use a compressor with a water trap and not a conductive anti static brush CAUTION Risk of component damage when cleaning the truck If the truck is to be cleaned with a water jet or a high pressure cleaner all electrical and electronic components must be carefully covered beforehand as moisture can caus...

Page 81: ...cy Disconnect Disconnect the battery Remove any rings or metal bracelets etc before working on electrical components Consumables and used parts CAUTION Consumables and used parts are an environmental hazard Used parts oils and fuels must be disposed of in accordance with the relevant environmental protection regulations To change the oil contact the manufacturer s customer service department who h...

Page 82: ... immediately to your supervisor Mark defective truck and take out of service Do not return the industrial truck to service until you have identified and rectified the fault Remove any spilled hydraulic immediately with an appropriate bonding agent The bonding agent consumable mixture must be disposed of in accordance with regulations WARNING Faulty hydraulic hoses can result in injury and infectio...

Page 83: ... hoses Check the hydraulic hoses at least annually and replace if necessary If the operating conditions become more arduous the inspection intervals must be reduced accordingly In normal operating conditions a precautionary replacement of the hydraulic hoses is recommended after 6 The owner must carry out a risk assessment to ensure safe prolonged use The resulting protection measures must be obse...

Page 84: ...ed on single shift operation under normal operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts The following servicing checklist indicates the operations to be performed and the respective intervals to be observed Maintenance intervals are defined as Z W maintenance intervals must be performed by ...

Page 85: ... Disconnect switch t Power Supply W A B C 1 Check battery cable connections are secure grease terminals if necessary t 2 Check battery and battery components t 3 Check acid level and add demineralised water if necessary t 4 Check battery connector for damage test it and make sure it is secure t Travel W A B C 1 Check wheels for wear and damage t Chassis and superstructure W A B C 1 Check doors and...

Page 86: ...85 11 14 EN 4 1 2 Optional equipment Work lights Strobe light beacon Electrical System W A B C 1 Test lighting t Electrical System W A B C 1 Test strobe light beacon and check for damage t ...

Page 87: ...are secure grease terminals if necessary t 2 Check battery and battery components t 3 Check acid density and battery voltage t 4 Check battery connector for damage test it and make sure it is secure t Travel W A B C 1 Test Deadman switch t 2 Checking bedding and attachment of the drive system t 3 Check transmission for noise and leakage t 4 Check wheels for wear and damage t 5 Check wheel suspensi...

Page 88: ... B C 1 Carry out a test run with rated load if necessary with a customer specific load t 2 Lubricate truck according to the lubrication schedule t 3 Demonstration after servicing t Steering W A B C 1 Test electric steering and its components t ...

Page 89: ...heck for damage and make sure it is secure t Chassis and superstructure W A B C 1 Check trailer coupling or tow mechanism stop t Power Supply W A B C 1 Test Aquamatik plug hose connections and float and check for leaks t 2 Test flow indicator and check for leaks t Electrical System W A B C 1 Test lighting t Power Supply W A B C 1 Test battery refill system and check for leaks t Electrical System W...

Page 90: ... clean t 2 Check fuse ratings t 3 Check wiring is secure and check for damage t Power Supply W A B C 1 Replace air filter wadding t 2 Check hose connections and test the pump t Electrical System W A B C 1 Check impact sensor is secure and check for damage t Electrical System W A B C 1 Test access module check for damage and make sure it is secure t Electrical System W A B C 1 Check optional contro...

Page 91: ...agent The bonding agent consumable mixture must be disposed of in accordance with regulations WARNING Oils chain spray hydraulic oil are flammable and poisonous Dispose of used oils in accordance with regulations Store used oil safely until it can be disposed of in accordance with regulations Do not spill oil Spilled fluids must be removed immediately with an appropriate bonding agent The bonding ...

Page 92: ...azard Used parts oils and fuels must be disposed of in accordance with the relevant environmental protection regulations To change the oil contact the manufacturer s customer service department who have been specially trained for this task Note the safety regulations when handling these materials ...

Page 93: ...on Schedule 1 Compound ratio for cold store usage 1 1 g Contact surfaces k Cold Store Application s Grease nipple b Transmission oil filler neck Hydraulic oil filler neck a Transmission oil drain plug a B B C B C 1 4 l 1 4 l E ...

Page 94: ...omponent Used for B 50 380 904 5 0 l HSY 75W 90 Transmission C 29 200 670 5 0 l H LP 46 DIN 51524 E 29 202 050 1 0 kg Grease Polylube GA 352P Lubrication Code Saponification Dew point C Worked penetration at 25 C NLG1 class Application temperature C E Lithium 220 280 310 2 35 120 ...

Page 95: ...battery to prevent the truck from being switched on accidentally When working under a raised lift truck secure it to prevent it from lowering tipping or sliding away WARNING Risk of accidents when working under the driver s cab and lift truck When working under a raised driver s cab or a raised truck secure them to prevent the truck from lowering tipping or sliding away When raising the truck foll...

Page 96: ... the truck for maintenance and repairs see Preparing the truck for maintenance and repairs on page 94 Tools and Material Required Torque wrench Procedure Position the drive wheel 68 so that the wheel nuts 67 can be pulled through the hole 66 Tighten all the wheel nuts 67 in the skirt with the socket wrench through the hole 66 To do this torque the wheel nuts in the prescribed order initially to 10...

Page 97: ...el see Exposing the battery on page 32 Tools and Material Required Allen key Procedure Remove the hex socket screws 69 located under the battery cover using a hex socket wrench Lift off the front panel 1 and put it to one side The front panel is now disassembled Z Assembly is the reverse order 1 69 ...

Page 98: ...ont panel removed see Removing the front panel on page 96 Procedure Check the fuse ratings against the table and replace if necessary The fuses are now checked Item Component To protect Rating A 70 F17 Radio data transmission o 10 71 F13 Brake Options 10 72 1F9 Travel display instrument 10 73 6F1 Battery Discharge Indicator 2 74 1F1 Drive motor controller 300 70 72 71 73 74 ...

Page 99: ...replace if necessary Z The manufacturer s customer service department is specially trained to carry out these operations WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times Report any defects immediately to your supervisor Tag out and decommission a faulty lift truck Only return the truck to service when you have identified and rectified th...

Page 100: ...ates on page 22 When jacking up the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks When the truck is out of service it must be jacked up so that all the wheels are clear of the ground This is the only way of ensuring that the wheels and wheel bearings are not damaged If the truck is to be out of service for more than 6 months agree further meas...

Page 101: ... 7 2 During decommissioning NOTE Full discharge can damage the battery Self discharge can cause the battery to fully discharge Full discharge shortens the useful life of the battery Charge the battery at least every 2 months Z Charge the battery see Charging the battery on page 33 ...

Page 102: ...ace if necessary Z The manufacturer s customer service department is specially trained to carry out these operations WARNING Faulty brakes can cause accidents As soon as the truck has been started test the brakes several times Report any defects immediately to your supervisor Tag out and decommission a faulty lift truck Only return the truck to service when you have identified and rectified the fa...

Page 103: ... shall be provided The test results must be kept for at least the next 2 inspections The owner is responsible for ensuring that faults are rectified immediately Z A test plate is attached to the truck as proof that it has passed the safety inspection This plate indicates the due date for the next inspection 9 Final de commissioning disposal Z Final de commissioning or disposal of the truck in must...

Page 104: ...sealed armour plated cells 9 5 1 Description 9 5 2 Operation 10 5 3 Servicing PzV and PzV BS lead acid batteries with sealed armour plated cells 13 6 Aquamatik water replenishment system 14 6 1 Water replenishment system design 14 6 2 Functional Description 15 6 3 Adding water 15 6 4 Water pressure 15 6 5 Filling time 16 6 6 Water quality 16 6 7 Battery tubing 16 6 8 Operating temperature 16 6 9 C...

Page 105: ...uring operation for batteries in accordance with Ex I and Ex II see relevant certification 2 Data plate 1 2 4 8 10 11 6 3 5 9 7 12 13 14 15 1 Battery name 2 Battery type 3 Production week year manf 4 Serial number 5 Supplier number 6 Rated voltage 7 Rated capacity 9 Battery weight in kg 8 Number of cells 15 Electrolyte volume in litres 10 Battery number 11 Manufacturer 13 Manufacturer s logo 12 CE...

Page 106: ...ing Keep away from naked flames and strong heat sources Always wear protective clothing e g safety goggles and safety gloves when working on cells and batteries batteries Always wash your hands after completing the work Use insulated tools only Do not physically alter the battery strike crush compress notch dent or modify it in any way Hazardous electric voltage The metal parts of the battery cell...

Page 107: ...e adjustment factor is 0 0007 kg l per K e g electrolyte density 1 28 kg l at 45 C corresponds to a density of 1 29 kg l at 30 C The electrolyte must conform to DIN 43530 Part 2 purity regulations 4 1 1 Battery nominal data 1 Product Traction battery 2 Nominal voltage 2 0 V x no of cells 3 Rated capacity C5 See data plate 4 Discharge current C5 5h 5 Nominal electrolyte density1 1 Reached within th...

Page 108: ...ative to negative and check that contacts on the battery terminal conducting system are secure Check the terminal screw torques M10 23 1 Nm of the terminal conductors and connectors Charge up the battery Check the electrolyte level Z The electrolyte level must be above the cell baffle or the top of the separator Add electrolyte with distilled water up to the nominal level Checks completed 4 2 3 Di...

Page 109: ...ilate the room in which the truck is being charged Battery cell surfaces must remain exposed during charging in order to ensure sufficient ventilation see truck operating instructions chapter D Charging the Battery Do not smoke and avoid naked flames when handling batteries Wherever an industrial truck is parked for charging there must be no inflammable material or consumables capable of creating ...

Page 110: ...f charger ensuring the terminals are connect positive to positive and negative to negative Switch on the charger Battery 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 charging is used to ensure the useful life and maintain capacity after full discharge and repeated insufficie...

Page 111: ...a visual inspection for dirt and physical damage If the battery is charged regularly according to the IU characteristic carry out a compensation charge 4 3 3 Monthly Towards the end of the charging process measure and record the voltages of all the cells with the charger switched on After charging measure and record the electrolyte density and the electrolyte temperature in all the cells Compare t...

Page 112: ...es or hazardous electrolyte burns if the cell vessels are destroyed Z PzV batteries are low gassing but not gassing free Electrolyte The electrolyte is sulphuric acid which is fixed in gel The density of the electrolyte cannot be measured 5 1 1 Battery nominal data 1 Product Traction battery 2 Nominal voltage 2 0 V x no of cells 3 Rated capacity C5 See data plate 4 Discharge current C5 5h 5 Rated ...

Page 113: ... cause explosions The battery gives off a mixture of oxygen and hydrogen electrolytic gas during charging Gassing is a chemical process This gas mixture is highly explosive and must not be ignited Always disconnect the charger and truck before connecting or disconnecting the charger and battery The charger must be adapted to the battery in terms of voltage charge capacity and battery technology Be...

Page 114: ...he cells Always charge the battery with DC current All DIN 41773 charging procedures are permitted in the format approved by the manufacturer Always connect the battery to a charger that is appropriate to the size and type of the battery If necessary have the charger checked by the manufacturer s customer service department for suitability Do not exceed limit currents in the gassing area in accord...

Page 115: ...plied with 0 004 V C per K Battery 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 charging is used to ensure the useful life and maintain capacity after full discharge and repeated insufficient charging Z Compensation charging should be carried out weekly Trickle charging Batt...

Page 116: ...the previous ones Z Carry out the measurements after full charging and subsequent resting for at least 5 hours Z If you find significant differences compared with the previous measurements or differences between the cells contact the manufacturer s customer service department 5 3 4 Annually Measure the truck insulation resistance in accordance with EN 1175 1 Measure the battery insulation resistan...

Page 117: ...ik water replenishment system 6 1 Water replenishment system design 15 Water container 16 Tap connection with ball cock 17 Flow indicator 18 Shut off cock 19 Locking coupling 20 Battery lock connector 15 16 17 18 19 20 3 m ...

Page 118: ... securely The plug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port 6 3 Adding water Water should be added to the batteries just before the battery is fully charged This ensures that the amount of water added is mixed with the electrolyte 6 4 Water pressure The water replenishment system must be operated with a water ...

Page 119: ...er used to fill up electrolyte must correspond to purified or distilled water Purified water can be produced through distillation or ion exchangers and is then suitable for the production of electrolyte 6 7 Battery tubing The tubing of the individual plugs is in accordance with the existing electric circuit No changes should be made 6 8 Operating temperature Batteries with automatic water replenis...

Page 120: ... of the plugs must come into contact with solvent based materials or soap 6 10 Service mobile vehicle Mobile water filling vehicle with pump and filling gun to fill individual cells The immersion pump in the container generates the necessary filling pressure The service mobile must be at exactly the same height as the battery base ...

Page 121: ...onds for an unknown reason the filters must be checked and replaced if necessary Battery connection A hose is attached to the pump module which together with the charge leads is routed from the charger to the charging connector The air is passed on to the battery via the electrolyte circulation coupling ducts in the connector When routing make sure the hose is not bent Pressure monitoring module T...

Page 122: ...ted to severe temperature fluctuations the electrolyte may flow back into the hose system Attach a separate coupling system to the air inlet line such as locking coupling on the battery side and through coupling on the air supply side Schematic illustration Electrolyte circulation on the battery and air supply via the charger ...

Page 123: ... close to a drainage system for processing the electrolytic rinsing water All health and safety as well as water and waste disposal regulations are observed when disposing of used electrolyte or rinsing water Protective goggles and clothing are worn Cell plugs are not removed or opened Clean the plastic components of the battery in particular the cell containers only with water or water based clot...

Page 124: ...at the temperature does not exceed 60 C at a distance of 30cm behind the outlet nozzle Observe the maximum operating pressure of 50 bar Observe a minimum distance of 30 cm from the top of the battery The battery should be sprayed over its entire surface to avoid localised overheating Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the maximum battery surface tempera...

Page 125: ... cells for PzV batteries If the battery is to be taken out of service for a long period 3 months it should as far as possible be charged to 50 of its charge level and stored in a dry room protected from frost 10 Troubleshooting If any faults are found on the battery or charger contact the manufacturer s customer service department immediately Z The operations required must be carried out by the ma...

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