Jungheinrich ERE 120n, Operating Instructions Manual

Page 1: ...Operating instructions G Operating instructions 51159400 ERE 07 09 11 13 ERE 120n ...

Page 2: ...t 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 material damage Z Used before notices and explanations t Used to indicate standard equipment o Used to indicate optional equipment Our trucks are subject to ongoing development Jungheinrich reserves the ri...

Page 3: ...0108 GB ...

Page 4: ...ansport and Commissioning 1 Lifting by crane C 1 2 Commissioning C 1 3 Removing the Transport Lock C 2 4 Operating the truck without its own drive system C 3 5 Securing the truck during transport C 4 D Battery Maintenance Charging Replacement 1 Safety regulations for handling acid batteries D 1 2 Battery types D 2 3 Exposing the battery D 2 4 Charging the battery D 3 5 Battery removal and installa...

Page 5: ...est E 27 8 Troubleshooting E 28 F Truck Maintenance 1 Operational safety and environmental protection F 1 2 Maintenance Safety Regulations F 1 3 Servicing and inspection F 3 4 Maintenance Checklist F 4 5 Maintenance Schedule F 6 5 1 Fuels coolants and lubricants F 7 6 Maintenance and Repairs F 8 6 1 Preparing the truck for maintenance and repairs F 8 6 2 Opening the battery panel F 8 6 3 Opening t...

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

Page 8: ...s the 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 the owner and user of the industrial truck is charged with operational duties The proprietor must ensure that the truck is used only for the purpose it is intended for and that danger to life and ...

Page 9: ...0505 D A 2 ...

Page 10: ...and side arms A fixed operator platform is optionally available The truck is designed for lifting and transporting goods on a level surface The truck can pick up outside the load wheel area open bottom or diagonal board pallets as well as roll cages The capacity of the truck is shown on the data plate or the data capacity plate Qmax ...

Page 11: ...el 3 o Display instrument CanDis 10 t Folding operator platform 4 t Key switch 11 t Ram protection 5 o Keypad CanCode 12 t Side arm 6 t Battery discharge indicator 13 o Fixed operator platform 7 t Battery connector 14 o Pressure sensitive mat t Standard Equipment o Optional Equipment 13 14 3 6 4 5 1 2 7 8 8 11 12 10 9 ...

Page 12: ...alk along mode w w o load 4 2 km h Travel speed operator position mode w w o load 7 5 8 5 km h Lift time w w o load 2 3 1 8 s Lowering speed w w o load 2 4 2 4 s Max gradeability above 5 mins w w o load 8 0 16 0 Description h14 Tiller height in min max travel position 1130 1450 mm h13 Lowered fork height 85 mm h3 Lift 122 mm b1 Truck width 700 mm b5 Width across forks 532 672 mm e Fork width 162 m...

Page 13: ...0709 GB B 4 Dimensions sheet with folding platform b 2 1 h 3 1 m2 s h3 b5 b 1 1 b3 b1 h14 0 0 5 l6 l1 l2 1 6 4 0 5 8 1006 l y Q c x A t s W a e a 2 a 2 ...

Page 14: ...B 5 0709 GB Dimensions sheet with fixed platform ...

Page 15: ...de 462 mm 3 Battery XL version for battery long version l2 682 mm 72 mm l I1 3 y1 3 x 1 I6 b12 Wa 1 2 3 Ast 2 3 1000 1754 1326 759 1000 800 1537 1978 1150 1904 1476 909 1200 800 1687 2178 1200 1954 1526 959 1200 800 1737 2178 1400 2154 1726 1159 1400 700 1937 2378 1600 2354 1926 1359 1600 1200 2137 2578 1950 2704 1902 1335 2000 800 2113 2978 2150 2904 2102 1535 2100 700 2313 3078 2400 3154 2352 17...

Page 16: ...n the vertical direction It is calculated when travelling over bumps at constant speed Electromagnetic compatibility EMC The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with EN 12895 including the normative procedures contained therein Z No changes to electric or elect...

Page 17: ...The truck data plate 15 is visible when the load section is raised The battery data plate 18 can be seen on the battery see Chapter D Item Description 15 Truck data plate 16 Rated capacity 17 Strap point for crane lifting 18 Battery data plate 16 17 18 15 ...

Page 18: ...ype 29 Manufacturer s logo 21 Name 30 Max battery weight in kg 22 Battery Voltage V 31 Min battery weight in kg 23 Rated capacity kg 32 Output kW 24 Net weight w o battery kg 33 Load centre mm 25 Net weight with battery kg 34 Year of manufacture 26 Manufacturer 35 Serial No 27 Production 36 Option 28 Production address 31 30 24 32 23 33 22 34 21 20 36 35 25 26 27 28 29 ...

Page 19: ...0709 GB B 10 ...

Page 20: ...a manner that it cannot slip under any circum stances and cannot come into contact with any attachments of the truck when the truck is lifted 2 Commissioning M Only operate the truck with battery current Rectified AC current will damage the electronic components The battery leads tow cable must be less than 6m long To prepare the truck after delivery or after transport proceed as follows Check the...

Page 21: ...move the cable binder latch 3 loosen the nut 2 and remove the transport lock Leave the transport retainer on the truck for later transportation without a battery Z The transport lock ensures that the truck is braked without the mass of the battery Commission the truck in accordance with instructions see Chapter E Z When the truck is parked the surface of the tyres will flatten The flattening will ...

Page 22: ...e key Disconnect the battery Prevent the truck from rolling away Open and put away the front cover refer to chapter F Pull up the anchor plate 4 by screwing in two M5x16 screws as far as the stop The brake has now been released and the truck can be moved F On reaching your destination ensure that the brake is restored to its initial state The truck must never be parked with the brake released Remo...

Page 23: ... To secure the truck hook the tensioning belt 6 with the integrated load hook into the load handling points 5 and attach it to the fastening rings Tighten the tensioning belt with the tensioner 7 Carry out this process on both sides of the truck Loading must be carried out by staff specially trained for that purpose in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 I...

Page 24: ...t 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 national environmental protection regulations or disposal laws The manufacturer s disposal instructions must be followed M Before closing the battery cover make sure that the battery lead cannot be damaged F Batte...

Page 25: ...ree batteries can be used F When replacing or installing batteries ensure that the battery is correctly secured in the battery compartment of the truck 3 Exposing the battery F Park the truck securely see Chapter E Remove the battery connector 3 Lift up the battery panel 1 using the grip mould 2 and fold it back Battery type Battery compartment approx 227 mm Weight Battery compartment approx 299 m...

Page 26: ...ide sufficient ventilation Do not place any metal objects on the battery Before charging check all cables and plug connections for visible signs of damage M It is essential to follow the safety regulations of the battery and charging station manufacturers Expose the battery see Section 3 Connect the battery plug 4 with the charging lead of the stationary charger 5 and turn on the charger 4 5 ...

Page 27: ...ry container The crane lifting gear must exert a vertical pull The hooks of the lifting gear must never fall into the battery cells Expose the battery see Section 3 Remove the battery connector 3 Undo the screw 6 of the battery retainer and remove the battery retainer 7 Strap the crane lifting gear to the eyes 8 Pull the battery up out of the container M Installation is the reverse order When rein...

Page 28: ...l Expose the battery see Section 3 Remove the battery connector 3 Turn the battery lock 9 as far as the stop Pull the battery out from the side Battery installation M Installation is the reverse order When reinstalling the battery note the proper installation position and make sure the battery is connected correctly After installing the battery again check all cables and plug connections for visib...

Page 29: ...0709 GB D 6 ...

Page 30: ...l Damage and Faults The supervisor must be immediately informed of any damage or faults to the forklift truck Trucks not safe for operation e g wheel or brake problems must not be used until they have been rectified Repairs The driver must not carry out any repairs or alterations to the forklift truck without the necessary training and authorisation to do so The driver must never disable or adjust...

Page 31: ...forces the truck to reverse for approx 3 seconds and then cuts out until the controller is briefly restored to neutral Rider mode No function optionally with the same function as pedestrian mode 4 Controller t Controls travel direction and speed see Section 4 2 5 Tiller t Moving tiller Steering and braking Set to brake zone B see page E9 Truck decelerates mechanically Set to travel zone F see page...

Page 32: ...E 3 1113 GB 14 15 5 9 10 11 12 3 4 13 2 1 R V 8 8 7 7 6 ...

Page 33: ...ms Entering travel parameters ISM Access Module o Code settings For releasing and selecting of travel programs Entering travel parameters 13 Battery connector emergency disconnect t The supply current is interrupted all electrical functions are deactivated and the truck is automatically braked 14 Rigid side arm Fixed operator platform version o Only rider mode available 15 Pressure sensitive mat a...

Page 34: ...E 5 1113 GB 14 15 5 9 10 11 12 3 4 13 2 1 R V 8 8 7 7 6 ...

Page 35: ...amage Visually inspect the battery attachment and cable connections Switching on the truck Make sure the battery is connected 13 Insert the key in the key switch 11 and turn it to the right as far as it will go position I or for CanCode 12 o enter the release code see Section 5 Test the warning button 6 The truck is now operational o The battery discharge indicator 9 or the CanDis display instrume...

Page 36: ... as a lookout Negotiating slopes and 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 specifications for the truck in question The truck must always be driven with the load unit facing uphill The industrial truck must not be turned operated at an angle or ...

Page 37: ...e arms in fold up the operator platform 1 The truck can only be operated at the reduced travel speed Rider mode Push the side arms out fold down the operator platform 1 The truck can be operated at maximum speed General Set the tiller 5 to the travel zone F Turn the controller 4 to the required direction fwd or rev Z Travelling is inhibited when the operator platform is unladen and the side arms a...

Page 38: ...E 9 1113 GB 4 1 5 13 B B B F R V 0 3 2 R V ...

Page 39: ...controller 8 to the opposite direction The truck brakes regeneratively until it starts to move in the opposite direction Z The rate of braking depends on the position of the controller Braking with the service brake Set the tiller 5 to one of the brake zones B The drive motor brakes regeneratively motor brake Only when this brake fails to achieve the necessary brake force is the mechanical brake m...

Page 40: ...e load unit Z When the operator platform is unfolded it must be occupied by the operator to release lifting lowering similar to trucks with a fixed operator platform Z The lifting and lowering speeds are specified Lift Press the Lift 8 button until you reach the desired lift height M Release the button as soon as you reach the limit position of the load handler Lower Press the Lower button 7 until...

Page 41: ... load forks Set the key switch 11 to the 0 position and remove the key For CanCode 6 press the o key Remove the battery connector 13 Fold in the folding side arm where applicable F Do not reach between the operator platform and the truck panel when you fold up the folding platform where applicable Grab hold of the folding platform where applicable at one of the bevelled edges and fold it up 13 11 ...

Page 42: ...ly in conjunction with the display instrument CanDis o The o switch has top priority and resets the truck from any condition to its default condition without modifying any settings 5 1 Code Lock When the correct code has been entered the machine is ready for use You can allocate an individual code to each truck driver or group of drivers Z When delivered from the factory the operator code factory ...

Page 43: ...he wrong code is entered LED 16 flashes red for two seconds The correct code can then be entered Z The Set key 17 has no function in operating mode Switching off To switch the truck off press the o key 21 Z The truck can switch off automatically after a pre determined time To do this the corre sponding code lock parameter must be set refer to section 5 4 1 2 3 4 5 6 7 8 9 0 Set 18 17 16 21 20 19 ...

Page 44: ...en using the truck for the first time Program 3 Power mode Z The travel programs can be individually adapted see Section 5 5 5 3 Parameters In programming mode the operator keypad enables you to set the code lock functions and adapt travel programs In addition the battery parameters can also be set M For trucks without a display instrument CanDis o the parameters must be adjusted with particular c...

Page 45: ...ou 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 Parameters Setting procedure for trucks without display instrument CanDis o Enter the three digit parameter number confirm with the Set key 17 Enter the setting according to the parameter list or change and confirm with the Set key 17 Z If the entry is incorrect the...

Page 46: ...ction by pressing keys 1 2 3 Set When you have finished entering the parameters press the o button 21 The following parameters may be entered Code Lock Parameter List No Function Range of Setting Standard Setting Comments Procedure Code Lock 000 Change Master Code The length 4 6 digits of the master code also pre determines the length of the operator code 4 6 digits Provided the operator codes are...

Page 47: ...de Confirm Set LED 19 flashes Enter new code Confirm Set LED 20 flashes Repeat code entry confirm 003 Delete Operator Code 0000 9999 or 00000 99999 or 000000 999999 LED 19 flashes Enter code Confirm Set LED 20 flashes Repeat code entry Confirm Set 004 Delete code memory Deletes all user codes 3265 3265 delete other inputs do not delete 010 Automatic time cutout 00 31 00 00 no cutout 01 to 30 Cutou...

Page 48: ...rm configuration 4 digit SET 1st digit travel program 1 release 0 or 1 2nd digit travel program 2 release 0 or I 3rd digit travel program 3 release 0 or 1 4th digit start travel program 0 I 2 or 3 Error messages on keypad LED 14 flashes red to indicate the following errors New master code is already operator code New operator code is already master code Operator code to be changed does not exist T...

Page 49: ...seconds The parameter and subindex are displayed alternating with the entry 0256 2 0000 5 Z If the entry is incorrect the LED 14 of the o key 19 flashes red If you enter the parameter number again the setting can be entered or changed Repeat the procedure to enter further parameters as soon as the LED 14 of the o key 19 flashes To complete your entry press the o key 19 Z Travel is disabled while t...

Page 50: ...3 6 0 km h 0268 Max speed in forks direction 0 9 4 5 9 0 km h 3 6 0 km h 0257 Acceleration in pedestrian mode no release 0 9 0 09 0 31 m s 8 0 27 m s Platform folded in safety gate folded in 0265 Pedestrian speed in drive direction 0 9 1 5 4 5 km h 8 4 2 km h 0269 Pedestrian speed in forks direction 0 9 1 5 4 5 km h 8 4 2 km h 0267 Special travel speed in drive direction 0 9 1 5 6 0 km h 9 6 0 km ...

Page 51: ... 0 9 4 5 9 0 km h 8 8 5 km h 0273 Acceleration in pedestrian mode no release 0 9 0 09 0 31 m s 8 0 27 m s Platform folded in safety gate folded in 0281 Pedestrian speed in drive direction 0 9 1 5 4 5 km h 8 4 2 km h 0285 Pedestrian speed in forks direction 0 9 1 5 4 5 km h 8 4 2 km h 0283 Special travel speed in drive direction 0 9 1 5 6 0 km h 9 6 0 km h Platform folded out safety gate folded in ...

Page 52: ... 0 9 4 5 9 0 km h 8 8 5 km h 0289 Acceleration in pedestrian mode no release 0 9 0 09 0 31 m s 8 0 27 m s Platform folded in safety gate folded in 0297 Pedestrian speed in drive direction 0 9 1 5 4 5 km h 8 4 2 km h 0301 Pedestrian speed in forks direction 0 9 1 5 4 5 km h 8 4 2 km h 0299 Special travel speed in drive direction 0 9 1 5 6 0 km h 9 6 0 km h Platform folded out safety gate folded in ...

Page 53: ...ies 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 Range of Setting Standard Setting Comments Battery parameters 1377 Battery type normal enhanced dry 0 2 1 0 Normal wet 1 Enhanced wet 2 Dry maintenance free 1389 Discharge monitor function 0 1 1 ...

Page 54: ... of 10 within 3 minutes The displayed status cannot rise again during the present operation The status display is reset to 100 when the battery type is adjusted If the LED flashes red and the truck is not ready for operation inform the manufacturer s service department Red flashing is a fault code of the truck controller The flashing sequence indicates the type of fault LED colour Rating Green Sta...

Page 55: ...rresponds to the minimum available capacity If only one LED bar is lit the battery capacity is almost depleted and the Warning indicator 26 is lit If no more LED bars are illuminated the Stop indicator 23 lights up Lifting is now inhibited The battery must be charged 22 Capacity display bars Battery residual charge 23 Stop symbol lift cutout battery charge required 24 6 digit LCD display hourmeter...

Page 56: ...rrors are displayed until they are rectified Error messages overwrite the service hour display Most errors cause the emergency stop to be activated Errors remain displayed until the control circuit is switched off Code lock If no CanDis is present the error code is displayed by the flashing of the discharge monitor LED Z The manufacturer s service department has detailed component descriptions wit...

Page 57: ...1113 GB E 28 ...

Page 58: ...rsonnel Fault Possible cause Action Truck does not start Battery connector not connected Check the battery connector and connect if necessary Key switch in 0 position Set key switch to I Incorrect CanCode code Check code Battery charge too low Check battery charge charge battery if necessary Faulty fuse Test fuses see chapter F Truck in charge mode Interrupt charging Load cannot be lifted Charge c...

Page 59: ...1113 GB E 30 ...

Page 60: ...l The manufacturer s service department has field technicians specially trained for these tasks We therefore recommend a maintenance contract with the manufacturer s local service centre Lifting and jacking up When an industrial truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When jacking up the truck take appropriate measures to preven...

Page 61: ...performance of the truck When replacing tyres fitted at the factory only use the manufacturer s original spare parts Otherwise the data sheet specifications of the truck cannot be guaranteed When changing wheels and tyres ensure that the truck does not slew e g when replacing wheels always left and right simultaneously Lift chains Lift chains wear rapidly if not lubricated The intervals stated in ...

Page 62: ...to wear The service intervals stated are based 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 maintenance checklist states the tasks and intervals after which they should be carried out Maintenance intervals are defined as W Every 50 servi...

Page 63: ...r replace if necessary t Power supply 3 1 Visually inspect battery k t 3 2 Check battery cable connections are secure grease terminals if necessary k t 3 3 Check acid density acid level and battery voltage k t Travel 4 1 Check motor suspension t 4 2 Check the transmission for noise and leakage t 4 3 Replace gear oil if service life exceeded 10 000 hours 4 4 Check travel mechanism adjust and lubric...

Page 64: ... their connections are secure check for leaks and damage k t 6 5 Check cylinders and piston rods for damage and leaks and make sure they are secure k t 6 6 Check hydraulic oil level k t 6 7 Replace hydraulic oil filter k t 6 8 Replace hydraulic oil k t 6 9 Check wheels for wear and damage t Agreed performance levels 7 1 Lubricate truck in accordance with Lubrication Schedule k t 7 2 Test run t 7 3...

Page 65: ...old store usage 1 1 s Grease nipples Hydraulic oil filler neck 2 1 25 1 3 litres depending on the type of transmission always up to the lower mark of the filler neck b Transmission oil filler neck a Transmission oil drain plug Cold Store Application B 0 55 l E E E A 0 7l A C 1 ...

Page 66: ...e only exception to this is when mixing is expressly stipulated in the Operating Instructions Avoid spillage Spilled liquids must be removed immediately with suitable bonding agents and the bonding agent consumable mixture must be disposed of in accordance with regulations Grease guidelines Code Order no Quantity Description Used for A 50 449 669 5 0 l H LP 46 DIN 51524 Hydraulic system B 50 380 9...

Page 67: ...cidentally starting When working under a raised lift truck secure it to prevent it from lowering tipping or sliding away F When raising the truck also refer to the instructions in the Transport and Commissioning section see Chapter C 6 2 Opening the battery panel see chapter D 6 3 Opening the front panel Trucks with folding operator platform Fold down the operator platform 5 General Unlock the pan...

Page 68: ...e and repairs see section 6 1 Opening the front panel see Section 6 3 Check hydraulic oil level in hydraulic reservoir 7 Z There are markings 6 on the hydraulic reservoir The oil level should lie between the max and min markings when the forks are lowered If necessary add hydraulic oil of the correct grade up to the max mark for hydraulic oil specification see Section 5 min max 7 6 ...

Page 69: ...6 1 Dismantle the front panel see Section 6 3 Check rating of all fuses in accordance with table replace if necessary Item Description To protect Rating 8 F15 Traction Lift motor 200 A 9 F13 Solenoid magnetic brake 10 A 10 1F9 Travel Lift Controller 5 A 11 6F1 Battery discharge indicator 2 A 11 8 9 10 ...

Page 70: ...maged 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 Prior to decommissioning Thoroughly clean the truck Check the brakes Check the hydraulic oil level and replenish as necessary see Chapter F Apply a thin layer of oil or grease to any non painted mechanical components Lubricate the truck in ...

Page 71: ...east annually refer to national regulations or after any unusual event by a qualified inspector The inspector shall assess the condition of the truck from purely a safety viewpoint 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 safety mechanisms based...

Page 72: ...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 73: ...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 74: ...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 75: ...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 76: ...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 77: ...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 78: ...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 79: ...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 80: ...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 81: ... 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 82: ...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 83: ...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 84: ...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 85: ...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 86: ... 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 87: ...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 88: ... 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 89: ...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 90: ...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 91: ... 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 92: ...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 93: ... 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...