Jungheinrich EKS 310, Operating Instructions Manual

Page 1: ...Operating Instructions 52025067 EKS 310k 310 G 07 04 07 08 ...

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

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Page 4: ... 5 Check the battery condition the acid level and acid density D 5 6 Battery discharge indicator D 5 I 1 0708 GB Table of contents A Correct use and application of the truck B Truck Description 1 Application B 1 2 Assemblies and Operational Description B 2 2 1 Truck B 3 3 Standard Version Specifications B 4 3 1 Performance data B 4 3 2 Dimensions as per data plate B 6 3 3 Mast version B 6 3 4 EN n...

Page 5: ... operation E 27 6 9 Recovering the truck from a narrow aisle Moving the truck without a battery E 29 0708 GB I 2 E Operation 1 Safety Regulations for the Operation of Forklift Trucks E 1 2 Control Panel Layout Variants E 2 3 Operating and Display Equipment E 4 3 1 Operating and display equipment on control panel E 4 3 2 Display unit controls and displays E 5 3 3 Truck operational status symbols E ...

Page 6: ...at regular intervals and following any unusual incidents F 17 8 Final de commissioning disposal F 17 I 3 0708 GB F Maintenance of the forklift truck 1 Operational safety and environmental protection F 1 2 Maintenance Safety Regulations F 1 3 Servicing and inspection F 3 4 EKS 310 maintenance checklist F 4 4 1 Fuels coolants and lubricants F 8 5 Maintenance and Repairs F 9 5 1 Preparing the truck f...

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Page 8: ...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 ...

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Page 10: ...e required Approval of the local authorities however does not constitute the manufacturer s approval A 1 0504 GB A Correct use and application of the truck Z The Guidelines for the Correct Use and Application of Industrial Trucks VDMA are supplied with the truck The guidelines form part of these operating instructions and must be observed National regulations apply in full The truck described in t...

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Page 12: ... of gravity EKS 310k 1000 kg 400 mm EKS 310 1000 kg 600 mm Left Right Drive direction Load direction B 1 0708 GB B Truck Description 1 Application The EKS 310 is an electric powered stockpicker It is designed to be used on level surfaces in accordance with DIN 15185 to transport and pick goods Open or cross board pallets can be lifted outside the contour of the load wheels or trolley Loads can be ...

Page 13: ...Aux lift 3 t Control panel 4 t Battery 5 t Chassis t Series Equipment o Optional Equipment 3 2 1 4 5 0708 GB B 2 2 Assemblies and Operational Description Pos Bezeichnung 1 t Mast 2 t Aux lift 3 t Control panel 4 t Battery 5 t Chassis t Series Equipment o Optional Equipment 3 2 1 4 5 ...

Page 14: ...h then acts as a generator regenerative lowering The energy produced is then fed back to the battery B 3 0708 GB 2 1 Truck Safety devices An enclosed truck contour with rounded edges ensures safe hand ling of the truck The overhead guard protects the driver from falling objects The Emergency Disconnect switch immediately cuts out all truck movements in ha zardous situations Safety gates on either ...

Page 15: ...h load 0 18 0 32 m s Lowering speed with load 0 32 0 37 m s Lowering speed without load 0 3 0 34 m s 0708 GB B 4 Electrical System Service laptop connection interface Configures all key truck data lift limit damping lift cutout retardation and acceleration patterns cut outs etc rapidly and reliably Reads off the error log to analyse fault causes Simulates and analyses program operations Simple fun...

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Page 17: ...40 mm h10 Overall lift height 3840 5090 3840 9340 mm h15 Stockpicking height 4890 6140 4890 10390 mm 0708 GB B 6 3 2 Dimensions as per data plate 3 3 Mast version Description EKS 310k EKS 310 h1 Mast height retracted 3005 3830 mm h3 Lift 4250 5500 mm h4 Mast height extended 6550 7820 mm h7 Seat height standing height 290 290 mm h9 Aux lift 840 840 mm h10 Overall lift 5090 6340 mm h15 Stockpicking ...

Page 18: ...applies Average ambient temperature over 24 hours max 25 C max air humidity inside 70 non condensing B 7 0708 GB 3 4 EN norms Noise emission 65 dB A in accordance with EN 12053 as harmonised with ISO 4871 Z The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling lifting and when idle The noise level is measured at the dri...

Page 19: ...engers 11 Test sticker o 6 17 mV 1 5 V 15 16 13a 14 10a 8 7 18 D mm h3 mm Q kg 13a 13b 9 9 10b 12 11 0708 GB B 8 4 Identification points and data plates F Warning and information labels such as capacity diagrams attachment points and identification plates must be readable at all times or be replaced if necessary Item Description 6 Strapping points for lifting by crane 7 Truck data plate 8 Decal Ca...

Page 20: ...ating Instructions label 6 17 mV 1 5 V 15 16 13a 14 10a 8 7 18 D mm h3 mm Q kg 13a 13b 9 9 10b 12 11 B 9 0708 GB Item Description 12 Decal Do not step onto or beneath the load risk of trapping 13a Jack contact point 13b Serial number engraved in chassis underneath the battery cover 14 Decal Add hydraulic oil 15 Decal Emergency drain 16 Decal Emergency drain key 17 Decal Caution Low voltage electro...

Page 21: ...f manufacture 24 Manufacturer s logo 30 Option 25 24 26 23 27 22 28 21 29 20 30 19 8 D mm h3 mm Q kg 0708 GB B 10 4 1 Truck data plate For queries regarding the truck or spare part orders please quote the serial number 20 4 2 Capacity The plate 8 gives the capacity Q in kg of the truck as a function of the load centre of gravity distance D in mm and lift height H in mm in tabular form Item Descrip...

Page 22: ...d Attach the crane slings to the strap points 1 2 so that it cannot slip under any circumstances 1 2 C 1 0504 GB C Transport and Commissioning 1 Transport The truck can be transported in three different ways depending on the height of the mast and the local conditions Vertically with mast and load lifting device assembled for low heights Vertically with mast and load lifting device disassembled fo...

Page 23: ...ach the crane slings to the strap points 2 3 so that it cannot slip under any cir cumstances 1 1 3 2 0504 GB C 2 Crane loading with collapsed mast When the mast is collapsed the crane lifting gear must be attached to the top and bottom mast cross members If the truck is attached to the crane with the mast collapsed the transport parts must be attached to it M Attach the crane slings to the strap p...

Page 24: ...I 2703 In each case correct measurements shall be determined and appropriate safety measures adopted C 3 0504 GB 2 1 Crane points The crane points 1 are the eyes in the mast Crane points 2 are located on either side of the frame and crane points 3 are located on the top mast bearing respectively Suitable ring screws must be screwed in at this point When lifting by crane use the following crane poi...

Page 25: ...oning belt above the upper chassis section is routed behind the two mast attachment bars 4 4 6 6 5 5 0504 GB C 4 2 4 Basic truck transport safety M The mast must only be disassembled by the manufacturer s authorised service department To ensure secure transport of a disassembled EKS 310 use the prescribed attachment points for fastening quick release belts Z Only use belts with a rated capacity of...

Page 26: ...apacity of 5 to At least 4 belts 2 on the left and 2 on the right 14 15 must be attached to the mast C 5 0504 GB 2 5 Mast transport safety M Secure the driver s position carriage 13 to prevent it from slipping If the mast is stored on a pallet s fasten them securely to the mast 11 Use the lower attachment bracket 10 as the mast bottom strap point for securing to the lorry eyes 12 Route the belt ov...

Page 27: ...am 18 underneath the counterweight at least the chassis width to relieve the drive wheel 18 17 16 16 0504 GB C 6 Safely transporting the truck with the mast collapsed Z Only use belts with a rated capacity of 5 tonnes The fastening belts should be attached to at least 4 different lorry truck eyes 16 F Warning Risking of tipping through high centre of gravity The tensioning belts are tightened over...

Page 28: ...re the tilt safety device 19 is present Check that all safety devices are present and operational 19 C 7 0504 GB 3 Commissioning 3 1 Moving the truck without a battery M This operation must only be performed by suitably trained maintenance personnel M This operation is forbidden on slopes and inclines no brakes See also Chapter E Section 6 9 3 2 Installing and Removing Assembling and Folding the M...

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Page 30: ...afety of the truck Battery equipment changes may only be made with the agreement of the manufacturer D 1 0504 GB D Battery Maintenance Charging Replacement 1 Safety Regulations for handling acid batteries Before any work is carried out on the batteries the truck must be safely parked see Chapter E Maintenance personnel Batteries may only be charged serviced or replaced by trained personnel Observe...

Page 31: ...ger station manufacturers Battery type Truck type 48 V 3 E PzS 420 EKS 310k 48 V 4 E PzS 560 EKS 310 0504 GB D 2 2 Battery types The EKS 310 can be fitted with a range of battery types All the batteries correspond to DIN 43531 A The following table indicates the capacities to show which combinations can be used as standard The battery weights can be taken from the battery data plate F The weight a...

Page 32: ...Y DISCONNECT switch 2 Open the battery covers 4 Disconnect the battery 4 Remove the battery covers 3 D 3 0504 GB 4 Battery removal and installation F Only batteries with insulated cells and terminal connectors may be used When replacing the battery always use the same battery type Extra weights must not be removed and must remain in the same position F The truck must be horizontral to prevent the ...

Page 33: ...check that the battery retainers are inserted and secured the battery cover is properly closed 6 5 7 0504 GB D 4 Undo and remove the battery retainers 5 7 Pull the battery 6 onto the side of the prepared battery transporter Assembly is the reverse order F After installing again check all cables and connectors for signs of visible damage and before using the truck again check that the battery retai...

Page 34: ...ies the display and cutout points can be adjusted by authorised personnel by assigning parameters 50 D 5 0504 GB 5 Check the battery condition the acid level and acid density The battery manufacturer s maintenance instructions apply Check the battery housing for cracks and any spilled acid Remove any oxydation residue from the battery terminals and apply an acid free grease to the battery terminal...

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Page 36: ...s and Warning Signs Safety devices warning signs and warning instructions shall be strictly observed E 1 0206 GB E Operation 1 Safety Regulations for the Operation of Forklift Trucks Driver authorisation The forklift truck may only be used by suitably trained personnel who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to ope...

Page 37: ...nit is located on the load side below the overhead guard The aux lift is operated from the load side 0206 GB E 2 2 Control Panel Layout Variants Variant I The control panels are arranged as standard at the front i e before the aux lift Accordingly the display unit is below the overhead guard also in the load direction Variant II The control panels and information display are arranged on the mast s...

Page 38: ...s arranged on either the load or mast side The aux lift is operated from the load and the mast sides E 3 0206 GB Variant IV Load side and diagonal arrangement of controls The driver looks directly in the load direction or diagonally to the left in the load direction The Steering control panel module is also present on the mast side The display unit is located on the load side below the overhead gu...

Page 39: ...irms the function related to the symbol displayed above it t Standard equipment o Optional Equipment 0206 GB E 4 3 Operating and Display Equipment 3 1 Operating and display equipment on control panel Item Operating Display Equipment Function 1 EMERGENCY DISCONNECT switch t Interrupts the main supply all truck movements are disabled 2 Steering wheel t Steers the truck in the required direction 3 Su...

Page 40: ...eviates without guidance from the guidance wire and automatic guidance 11 12 13 14 15 16 17 18 19 20 E 5 0206 GB 3 2 Display unit controls and displays Upper range symbols Item Symbol Operating Display Equipment Function 11 Displays possible travel speeds Turtle Rabbit t Creep mode Max travel speed 12 Guidance wire recognition display WG Sensors which have detected the guidance wire have a dark ba...

Page 41: ...wering limit controlled by hydraulic control switch Item Symbol Operating Display Equipment Function 0206 GB E 6 Activates switch 10 under the respective symbols 18 displayed or confirms the related function The symbol will be given a dark background Lower range symbols and keys 14 Display Overall lift Referencing required display Main lift lift Main lift lower Aux lift lift Aux lift lower t Displ...

Page 42: ...pecial attachment controlled via the hydraulic control switch Symbol Operating display unit Function E 7 0206 GB Travel cutout display o Indicates that automatic height dependent travel cutout has been activated Travel cutout bypass switch Bypasses the automatic height dependent travel cutout Aisle end safety device display option o Indicates that the aisle end safety device has been activated The...

Page 43: ...ipment o Optional Equipment RG Rail guidance IG Wire guidance Symbol Operating display unit Function 0206 GB E 8 Attachment fork adjustment Symmetrical fork adjustment display o Indicates that fork adjustment can be operated Symmetrical fork adjustment switch Activates fork adjustment with simultaneous operation of hydraulic control switch Right turn forks turn in Left turn forks turn out Asymmetr...

Page 44: ...wered again This is the only way for the controller to release all the truck movements at full speed E 9 0206 GB 3 3 Truck operational status symbols The operational status of the truck when it has been switched on is indicated by symbols in the display unit Safety gates open Foot switch not pressed Attachment in home position When the following symbols are displayed you must carry out a reference...

Page 45: ... when the mast is extended Pressing the bypass lift cutout switch disables the lift cutout mechanism 0206 GB E 10 Referencing Main lift lift Referencing Main lift lower Referencing Aux lift lift Referencing Aux lift lower Lift cutout during referencing F When disabling the lift cutout the driver must look out for obstacles when the mast is extended Pressing the bypass lift cutout switch disables t...

Page 46: ...ERGENCY DISCONNECT switch immediately if the truck starts to move or lift when it is switched on 1 9 E 11 0206 GB 4 Starting up the truck F Before the truck can be put into operation operated or a load unit lifted the driver must ensure that there is nobody within the danger area Checks and operations to be performed before starting daily work Check the entire truck on the outside for signs of vis...

Page 47: ...ely and carefully Use suitable precautions to prevent parts of the load from tipping or falling down 0206 GB E 12 5 Lift truck operation 5 1 Safety regulations for truck operation Travel routes and work areas Only use lanes and routes specifically designated for truck traffic Unauthorised persons must stay away from work areas Loads must only be stored in places specially designated for this purpo...

Page 48: ... operational display lamp goes on Apply the foot switch 21 Carry out a test run see Seite E9 1 21 21 E 13 0206 GB 5 2 Travelling Steering Braking EMERGENCY DISCONNECT Press the EMERGENCY DISCONNECT switch 1 down All truck movements are inhibited The switch operation must not be affected by any objects placed in its way Travelling The truck can be driven in 3 modes Free travel in apron with wire or...

Page 49: ...comes to a halt M The EMERGENCY DISCONNECT switch must only be used in dangerous situations 8 2 6 13 0206 GB E 14 Fully lower the Aux lift and raise the Main lift with the hydraulic control switch 8 until the forks are clear of the ground Slowly turn the travel selection switch 6 with the right thumb Turn clockwise forward travel Turn anti clockwise reverse travel You can control the travel speed ...

Page 50: ...eft turn Reverse travel Continue to travel along the narrow aisle at your required speed 22 23 22 23 E 15 0206 GB Negotiating narrow aisles M It is forbidden for unauthorised personnel to enter narrow aisles truck lanes in racking systems with safety distances 500 mm or for personnel to cross through them These work areas must be marked and identified accordingly Carry out a daily inspection of th...

Page 51: ...duced speed The tracking on 27 display appears The audible tracking signal is sounded 24 25 26 22 23 0206 GB E 16 Wire guidance trucks F When starting or continuing to travel after disconnecting the wire guidance check the position of the drive wheel as manual steering is now activated again F If an automatically guided wire guidance truck is switched off the wire guidance is no longer active when...

Page 52: ...hange from automatic to manual steering once the truck has fully left the rack lane 28 8 2 6 3 22 23 E 17 0206 GB Inductive automatic steering takes over the steering and applies it to the guidance wire Tracking is completed once the truck has been set to the guidance wire The display 28 changes to guidance wire applied The tracking signal is no longer sounded The track is now automatically guided...

Page 53: ...ise Lift Anti clockwise Lower The lift and lower speeds are proportional to the amount of turn 8 4 8 0206 GB E 18 5 3 Lifting Lowering outside and inside the rack aisles F Risk of injury when the driver s cab and the load lifting device are lowered There must be nobody in the danger zone Lift Lower Main Lift Apply the foot switch Turn the hydraulic control button 8 simultaneously Clockwise Lift An...

Page 54: ...wivel the locking lever 29 down and move the forks until the locking pin engages in a notch 31 29 30 E 19 0206 GB 5 4 Order picking and stacking Picking up transporting and placing load units M Before picking up a load unit the driver must make sure that it has been correctly palletised and does not exceed the truck s capacity Observe the load diagram Check the fork distance for the pallet and adj...

Page 55: ...ng device Carefully remove the load lifting device from the load Fully lower the load lifting device 0206 GB E 20 Picking up a load from the front Drive the truck at creep speed Slowly insert the forks into the pallet until the fork back touches the load or the pallet Raise the load slightly and reverse the truck slowly creep speed M The ground surface must be in good condition to ensure this work...

Page 56: ...st completely lowered Lower the forks to the ground Set the keyswitch to 0 and remove the safety key E 21 0206 GB 5 5 Park the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time F Do not park the truck on an incline In special cases the truck may need to be secured with wedges Z Select a parking place where nobody will collide wi...

Page 57: ... under Truck does not start Narrow aisle mode switch pressed Switch off narrow aisle travel function 0206 GB E 22 6 Troubleshooting This chapter enables the user to identify and rectify basic faults and the effects of incorrect operation When trying to locate a fault proceed in the order shown in the table Fault Possible cause Action Truck does not start Battery not connected Check battery plug an...

Page 58: ...on again Error 344 Personal safety system PSA scanner contaminated clean Fault Possible cause Action E 23 0206 GB Z If after carrying out the remedial action the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code contact the manufacturer s service department Additional troubleshooting must only be performed by the manufacturer...

Page 59: ...key into the hole 33 Slowly open the drain valve 32 using the Allen key The cabin lowers 43 42 32 33 0206 GB E 24 6 1 Emergency stop device When the automatic emergency stop device is applied e g if the wire guidance is lost or the electrical steering fails the truck automatically comes to a halt Before starting again the cause of the error must be identified and corrected When starting the truck ...

Page 60: ...ating instructions or as instructed Attach the safety belt to the abseil device 39 34 36 35 37 38 39 E 25 0206 GB 6 3 Exiting the driver s cab with the emergency abseil device Industrial trucks with a height adjustable operator position which can exceed 3m from the ground have an emergency lowering mechanism and an emergency abseil device for the driver which he can use if the operator position ev...

Page 61: ...low the lift limit height The respective travel and lift limit keys are located in the control panel 0206 GB E 26 Abseiling F Do not drop into loose rope Watch out for obstacles when abseiling Make the rope 37 taut Exit with your face towards the truck To abseil press the lever 36 on the abseil device down To stop abseiling release the brake lever 36 6 4 Bypassing the chain slack safety device If ...

Page 62: ...ction electronics or power electronics applies the truck safety devices will cause the truck to stop E 27 0206 GB 6 7 Aisle end safety device o Trucks with the aisle end safety device brake before the aisle exit or in the transfer aisle There are two basic versions for this 1 Braking to a halt 2 Braking to 2 5 km h Other variants affecting the subsequent travel speed lift height etc are available ...

Page 63: ...aise Main Lift REF Test run Lower Main Lift REF Test run Raise Main Lift REF Test run Lower Aux Lift 0206 GB E 28 To enable the truck to travel again after an EMERGENCY STOP carry out the following Determine the possible cause of the EMERGENCY STOP Press the EMERGENCY STOP switch and turn it again Apply inductive automatic steering Press the travel lever F If the truck now starts test that it work...

Page 64: ...of the narrow aisle When bring the truck back into operation Check the brake retardation value 41 40 E 29 0206 GB 6 9 Recovering the truck from a narrow aisle Moving the truck without a battery F Before recovering the truck from a narrow aisle disconnect the battery M This operation can only be performed by a specialist service engineer specially trained in operating the truck When the brakes are ...

Page 65: ... switch several times to restore the functionality of the brake system M Check the brake retardation 0206 GB E 30 Dismantling the hydraulic brake Remove the electronic compartment cover at the back Remove the protective cap 43 from the discharge valve Push the hose 44 onto the vent connectino and insert the other end of the hose in the brake fluid container 45 above it F Brake fluid container is p...

Page 66: ...ring motor 46 Z It is advisable to discharge the wheel if setting an angle greater than 4 degrees 46 E 31 0206 GB Adjust the steering angle F The battery must be disconnected when adjusting the steering angle Using an Allen key set the steered wheel to the required direction via the screw in the steering motor 46 Z It is advisable to discharge the wheel if setting an angle greater than 4 degrees 4...

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Page 68: ...not clean with steam jets After cleaning carry out the tasks detailed in the Recommissioning section F 1 0708 GB F Maintenance of the forklift 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 to the forklift truck especiall...

Page 69: ...y will not provide sufficient lubrication Hydraulic hoses The hoses must be replaced every six years 0708 GB F 2 Electrical System Work on the electrical system may only be performed by trained personnel Before commencing work on the electrical system take all precautionary measures to avoid electric shocks For battery operated trucks also de energise the truck by removing the battery connector We...

Page 70: ... 2000 operating hours or at least annually Z W service intervals are to be performed by the customer F 3 0708 GB 3 Servicing and inspection Thorough and expert servicing is one of the most important preconditions for safe operation of the forklift truck Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment M The application condition...

Page 71: ...k brake lines connections and brake fluid level t 5 5 Check brake fluid t 5 6 Replace brake fluide t 0708 GB F 4 4 EKS 310 maintenance checklist Maintenance intervals Standard t W A B C Chassis Super structure 1 1 Check all load bearing items for damage t 1 2 Check screw connections t 1 3 Test the operator s platform and check for damage t 1 4 Check that identification points data plates and warni...

Page 72: ...tions make sure they are firmly secured t 9 4 Check battery cables for damage replace if necessary t F 5 0708 GB p Replace hydraulic hoses after 6 years operation Maintenance intervals Standard t W A B C Hydraulic System 6 1 Test operation t 6 2 Check connections and ports for leaks and damage t 6 3 Check hydraulic cylinder for leaks and damage and make sure it is secure t 6 4 Check oil level t 6 ...

Page 73: ...n with rated load t 14 2 When maintenance is completed present the truck to the responsible person t 0708 GB F 6 e IG inductive guidance trucks Maintenance intervals Standard t W A B C Lift mechanism 10 1 Clean rollers guide rollers and contact surfaces in the mast sections and apply grease M Warning Danger of crashing t 10 2 Check mast attachments bearings and retaining screws t 10 3 Check lift c...

Page 74: ...il drain plug s Grease nipple Hydraulic oil filler neck c Hydraulic oil drain plug G G H E B E G A E F 7 0708 GB Lubrication Schedule g Slide surfaces a Transmission oil drain plug s Grease nipple Hydraulic oil filler neck c Hydraulic oil drain plug G G H E B E G A E ...

Page 75: ...lifting chains H 50157382 1 kg 400 g Lithium saponified grease K3K 20 DIN 51825 Front wheel bearings 0708 GB F 8 4 1 Fuels coolants and lubricants Handling consumables Consumables must always be handled correctly Follow the manufacturer s instructions F Improper handling is hazardous to health life and the environment Consumables must only be stored in appropriate containers They may be flammable ...

Page 76: ...port and Commissioning section When working on the parking brake prevent the truck from rolling away F 9 0708 GB 5 Maintenance and Repairs M Load bearing parts of the truck e g chassis and mast may only be welded after consultation with the manufacturer 5 1 Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents during maintenance and repair w...

Page 77: ... between the chain anchor and the chain must be replaced Only new original parts may be used 1 3 4 2 0708 GB F 10 5 2 Securing the driver s position carriage The driver s position carriage can be secured in the raised position Raise the driver s position carriage until the inner mast 1 is above the carriage 2 of the load lifting safety device Unscrew the attachment screw 4 and remove the retaining...

Page 78: ...and O ring Apply a thin layer of oil to the O ring on installation Screw the sealing cap back on 5 6 F 11 0708 GB 5 5 Cleaning the discharge filter Unscrew the discharge filter and the oil dipstick 5 and clean with compressed air or a cleaning agent M Dispose of used filters in the correct manner 5 6 Replacing the hydraulic oil filter Unscrew the hydraulic oil filter sealing cap 6 Replace filter i...

Page 79: ...n the min and max markings on the dipstick 7 If this is not the case add new hydraulic oil 5 7 8a 8b 0708 GB F 12 5 7 Hydraulic oil Preparing the truck for maintenance and repairs M Oil must never be allowed to enter the drainage system or the soil Used oil must be preserved until it can be disposed of in the correct manner Draining oil Suction off the hydraulic oil with the discharge filter remov...

Page 80: ...elow the lid Only use the prescribed brake fluid Make sure the entire brake system is fully sealed 9 F 13 0708 GB 5 8 Hydraulic hoses Hose lines must be replaced every six years see Safety Regulations for Hydraulic Hose Lines ZH 1 74 5 9 Check brake fluid F The brake fluid is poisonous and should therefore only be kept in sealed original containers Also note that brake fluid will attack the truck ...

Page 81: ...DC DC converter U16 output 24 V 24V 6 3A UL 18 1F3 Drive controller 1A UL 10 11 12 13 14 18 17 16 15 0708 GB F 14 5 10 Checking electrical fuses F Electric fuses must only be checked and replaced by authorized personnel Prepare the truck for maintenance and repairs see Chapter F Check all fuse ratings in accordance with the table replace if necessary F Only use the rating indicated on the controll...

Page 82: ...attery manufacturer s instructions Apply a suitable contact spray to all exposed electrical contacts F 15 0708 GB 5 11 Recommissioning Recommissioning after cleaning or repair work is permitted only after the following operations have been performed Test horn operation Test EMERGENCY DISCONNECT switch Test brake operation Lubricate the truck in accordance with the lubrication chart 6 Decommissioni...

Page 83: ...by applying them repeatedly F Perform several brake tests immediately after starting the truck again 0708 GB F 16 6 2 During decommissioning Every 2 months Charge the battery see Chapter D M Battery powered trucks The battery must be charged at regular intervals to avoid depletion of the battery through self discharge The sulfatisation would destroy the battery 6 3 Recommissioning Thoroughly clean...

Page 84: ...ons governing the disposal of batteries fuels and electronic and electrical systems must be observed F 17 0708 GB 7 Safety checks to be performed at regular intervals and following any unusual incidents Z Carry out a safety check in accordance with national regulations Junheinrich recommends checks in accordance with FEM Guideline 4 004 Jungheinrich has a special safety department with trained per...

Page 85: ...0708 GB F 18 0708 GB F 18 ...

Page 86: ...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 87: ...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 88: ...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 89: ... 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 90: ...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 91: ...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 92: ...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 93: ...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 94: ... 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 95: ...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 96: ...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 97: ...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...