Jungheinrich ETV 110, Operating Instructions Manual

Page 1: ...ating Instructions Operating Instructions 50468482 50468482 ETV 110 116 ETV 110 116 G G 07 12 07 12 12 05 12 05 ETV 112 ETV 112 ETV 114 ETV 114 ETV 116 ETV 116 ETV 110 ETV 110 https www besttruckmanuals com ...

Page 2: ...rial truck conforms to the EU Directive 2006 42 EC Machine Directive and 2004 108 EEC Electro Magne the EU Directive 2006 42 EC Machine Directive and 2004 108 EEC Electro Magne tic Compatibility EMC including their amendments as translated into national legisla tic Compatibility EMC including their amendments as translated into national legisla tion of the member countries The signatories are indi...

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Page 4: ... trucks with medium overall height Hydraulic line for the lifting function is interrup lifting function is interrup ted ted Standing with the lifting mast dismounted for trucks with large overall height Standing with the lifting mast dismounted for trucks with large overall height Safety Instructions for Assembly and Commissioning Safety Instructions for Assembly and Commissioning f f The assembly...

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Page 6: ...F Used before safety instructions which must be observed to avoid danger to Used before safety instructions which must be observed to avoid danger to personnel personnel M M Used before notices which must be observed to avoid material damage Used before notices which must be observed to avoid material damage Z Z Used before notices and explanations Used before notices and explanations t t Used to ...

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Page 8: ...3 5 Wheels Wheels tyres tyres B B 11 11 3 6 3 6 Batter Battery y B B 12 12 3 7 3 7 Hydrau Hydraulics lics B B 12 12 3 8 3 8 Mast Mast weight weights s B B 13 13 3 9 3 9 EN EN norms norms B B 15 15 3 10 3 10 Conditions Conditions of of use use B B 15 15 3 11 3 11 Electrical Electrical requirements requirements B B 16 16 4 4 Identi Identificati fication on points points and and data data plates plat...

Page 9: ...scon Disconnect nect E E 18 18 4 4 4 4 Travel Travel steeri steering ng brakin braking g E E 19 19 4 5 4 5 Adjust Adjusting ing the the forks forks E E 23 23 4 6 4 6 Liftin Lifting g and and deposi depositing ting loads loads E E 24 24 4 7 4 7 Mast Mast Suppor Support t Reach Reach E E 26 26 4 8 4 8 Emerge Emergency ncy loweri lowering ng E E 29 29 4 9 4 9 Operat Operating ing Attachm Attachments ...

Page 10: ...enance nance Instru Instructions ctions F F 13 13 6 1 6 1 Prepar Preparing ing the the truck truck for for mainte maintenance nance and and repair repairs s F F 13 13 6 2 6 2 Check Check fixing fixing of of the the wheels wheels F F 13 13 6 3 6 3 Removi Removing ng the the seat seat panel panel F F 14 14 6 4 6 4 Check Checking ing the the hydrau hydraulic lic oil oil level level F F 14 14 6 5 6 5 ...

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Page 12: ...ructions Z Z These operating instructions apply only to Jungheinrich battery models If using These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instructions another brand refer to the manufacturer s operating instructions https www besttruckmanuals com ...

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Page 14: ...y distance under local operating conditions must be obtained from of sufficient safety distance under local operating conditions must be obtained from a specialist assessor a specialist assessor Carrying and lifting passengers Carrying and lifting passengers Pushing or pulling load units Pushing or pulling load units 3 3 A Ap pp pr ro ov ve ed d a ap pp pl li ic ca at ti io on n c co on nd di it t...

Page 15: ... guidelines must be servicing and repair guidelines must be followed followed The attachment must only be operated by trained and authorised personnel The attachment must only be operated by trained and authorised personnel The The proprietor must ensure proprietor must ensure that all users that all users have read and have read and understood these operating understood these operating instructio...

Page 16: ...f the load pallets with transverse boards can be lifted inside or outside the area of the load wheels or roll cage Loads can be stacked or unstacked and transported over long wheels or roll cage Loads can be stacked or unstacked and transported over long distances distances The capacity can be obtained from the data plate The capacity can be obtained from the data plate T Ty yp pe e C Ca ap pa ac ...

Page 17: ...rolley lock pedal Battery trolley lock pedal 4 4 t t S So ol lo o P Pi il lo ot t 1 12 2 t t Driver s display Driver s display o o M Mu ul lt ti i P Pi il lo ot t 1 13 3 t t Two stage switch key with Two stage switch key with spare key service spare key service 5 5 t t Load wheels Load wheels o o CANCODE CANCODE 6 6 t t Outriggers Outriggers o o ISM Access Module ISM Access Module 7 7 t t D Dr ri ...

Page 18: ...ydraulic system failure of a hydraulic system failure Displays Displays Driver s display 12 with widescreen LCD display Driver s display 12 with widescreen LCD display t t including residual including residual time display battery discharge indicator lift and travel profile settings time display battery discharge indicator lift and travel profile settings and steer angle and steer angle mode displ...

Page 19: ...tive stop if the functionality test is positive Steering Steering Electrical steering system which turns Electrical steering system which turns the drive unit via a spur gear the drive unit via a spur gear Choice Choice of 2 operating modes in service mode on the driver s display of 2 operating modes in service mode on the driver s display 180 180 t t 360 360 o o endless endless The adjustable ste...

Page 20: ...So ol lo o P Pi il lo ot t 1 12 2 t t Driver s display Driver s display o o M Mu ul lt ti i P Pi il lo ot t 1 13 3 t t Two stage switch key with Two stage switch key with spare key service spare key service 5 5 t t Load wheels Load wheels o o CANCODE CANCODE 6 6 t t Outriggers Outriggers o o ISM Access Module ISM Access Module 7 7 t t D Dr ri iv ve e w wh he ee el l 1 14 4 t t EMERGENCY DISCONNECT...

Page 21: ...o be shown on the driver s display driver s display 2 2 2 2 L Lo oa ad d h ha an nd dl li in ng g Mast support Mast support The mast support is mounted on support rollers A single telescopic The mast support is mounted on support rollers A single telescopic reach cylinder extends and retracts the support The mast support rails for the reach cylinder extends and retracts the support The mast suppor...

Page 22: ...vi it ty y 6 60 00 0 6 60 00 0 m mm m Travel speed Travel speed Drive fork direction Drive fork direction 1 11 1 0 0 1 10 0 0 0 1 11 1 0 0 1 10 0 0 0 k km m h h Lift speed Lift speed w w o load w w o load 0 0 4 48 8 0 0 7 70 0 0 0 4 43 3 0 0 7 70 0 m m s s 10 10 Lowering speed Lowering speed w w o load w w o load 0 0 5 50 0 0 0 5 50 0 0 0 5 50 0 0 0 5 50 0 m m s s 15 15 Reach speed Reach speed w w...

Page 23: ...d w w o load w w o load 0 0 3 37 7 0 0 6 65 5 0 0 3 33 3 0 0 6 65 5 m m s s 10 10 Lowering speed Lowering speed w w o load w w o load 0 0 5 50 0 0 0 5 50 0 0 0 5 50 0 0 0 5 50 0 m m s s 15 15 Reach speed Reach speed w w o load w w o load 0 2 0 21 1 up to 5 600 up to 5 600 mm mm 0 2 0 21 1 up to 5 600 up to 5 600 mm mm m s m s G Gr ra ad de ea ab bi il li it ty y w w w w o o l lo oa ad d 7 7 1 10 0...

Page 24: ...Working aisle width 800 x 1200 longitudinal pallets 800 x 1200 longitudinal pallets 2 26 65 59 9 2 25 57 70 0 2 26 66 63 3 2 25 56 65 5 m mm m Ast Ast Working aisle width Working aisle width 1000 x 1200 traverse pallets 1000 x 1200 traverse pallets 2 26 60 03 3 2 23 37 70 0 2 26 62 23 3 2 23 36 65 5 m mm m N Ne et t w we ei ig gh ht t S Se ee e t tr ru uc ck k d da at ta a p pl la at te e D De es ...

Page 25: ...st b b5 5 b b4 4 b b11 11 b b1 1 b b2 2 e e b b3 3 a a 2 2 a a 2 2 W Wa a α α β β α α β β m m2 2 h h6 6 h h8 8 h h7 7 h h1 1 l l4 4 l l h h2 2 h h3 3 h h4 4 s s c c Q Q 210 210 y y l l2 2 x x l l7 7 l l1 1 https www besttruckmanuals com ...

Page 26: ...90 02 20 0 m mm m h h4 4 M Ma ax x h he ei ig gh ht t 3 35 54 44 4 5 50 04 44 4 5 51 19 94 4 9 96 66 64 4 m mm m D De es sc cr ri ip pt ti io on n E ET TV V 1 11 10 0 E ET TV V 1 11 12 2 E ET TV V 1 11 14 4 E ET TV V 1 11 16 6 Net weight incl battery Net weight incl batterya a 2 25 56 60 0 2 25 58 80 0 2 29 95 50 0 3 30 07 70 0 Axle load w o load front Axle load w o load front rear rear 1 15 58 87...

Page 27: ... li ic cs s D De es sc cr ri ip pt ti io on n E ET TV V 1 11 10 0 1 11 12 2 E ET TV V 1 11 14 4 1 11 16 6 Available working pressure for attachments Available working pressure for attachments 1 15 50 0 b ba ar r 1 15 50 0 b ba ar r Oil flow for attachments Oil flow for attachments 2 20 0 l l m mi in n 2 20 0 l l m mi in n https www besttruckmanuals com ...

Page 28: ... Mast weight 0 63 x lift height 42 325 kg Mast weight 0 63 x 740 325 kg 1304 kg Mast weight 0 63 x 740 325 kg 1304 kg 3 8 2 3 8 2 Overvi Overview of f ew of formula ormulae to be a e to be applied pplied tabl table depen e depending on ding on operat operating ins ing instruct tructions ions or truck or truck T Tr ru uc ck k s se er ri ie es s D De es si ig gn n C Ca al lc cu ul la at ti io on n E...

Page 29: ...st st b b5 5 b b4 4 b b11 11 b b1 1 b b2 2 e e b b3 3 a a 2 2 a a 2 2 W Wa a α α β β α α β β m m2 2 h h6 6 h h8 8 h h7 7 h h1 1 l l4 4 l l h h2 2 h h3 3 h h4 4 s s c c Q Q 210 210 y y l l2 2 x x l l7 7 l l1 1 https www besttruckmanuals com ...

Page 30: ...facturer offers a separate service see chapter F 10 human vibrations the manufacturer offers a separate service see chapter F 10 Human vibration measurement Human vibration measurement Electromagnetic compatibility EMC Electromagnetic compatibility EMC The manufacturer confirms the truck adheres to the The manufacturer confirms the truck adheres to the limits limits for electromagnetic emissions a...

Page 31: ...ies compliance with the requirements for the design and manufacture of electrical equipment according to EN 1175 Industrial Truck Safety manufacture of electrical equipment according to EN 1175 Industrial Truck Safety Electrical Requirements provided the truck is Electrical Requirements provided the truck is used according to its purpose used according to its purpose https www besttruckmanuals com...

Page 32: ... paci city ty L Loa oad C d Cen entr tre o e of G f Gra ravi vity ty Li Lift ft He Heig ight ht 23 23 No Noti tice ce N No o st stan andi ding ng un unde der r th the e lo load ad ca carr rria iage ge 24 24 F Fin inal al in insp spec ecti tion on co comp mple lete ted d la labe bel l 2 25 5 S St tr ra ap p p po oi in nt ts s f fo or r c cr ra an ne e l li if ft ti in ng g 26 26 D Do n o not ot re ...

Page 33: ...p pe e 3 37 7 M Ma an nu uf fa ac ct tu ur re er r 3 32 2 S Se er ri ia al l n no o 3 38 8 M Mi in n m ma ax x b ba at tt te er ry y w we ei ig gh ht t k kg g 3 33 3 R Ra at te ed d c ca ap pa ac ci it ty y k kg g 3 39 9 O Ou ut tp pu ut t 3 34 4 B Ba at tt te er ry y v vo ol lt ta ag ge e V V 4 40 0 L Lo oa ad d c ce en nt tr re e o of f g gr ra av vi it ty y m mm m 3 35 5 N Ne et t w we ei ig gh...

Page 34: ...reached The st The standard andard load ce load centre o ntre of grav f gravity di ity distance stance takes i takes into ac nto account t count the wid he width as w th as well ell as the height of the load as the height of the load Example of how to calculate the maximum capacity Example of how to calculate the maximum capacity With a load centre of gravity distance C of 600 mm and a maximum lif...

Page 35: ... centre of gravity Ground clearance e g modification of the support columns Ground clearance e g modification of the support columns Position of the mast holder stops Position of the mast holder stops Changing the components can alter the Changing the components can alter the stability stability 4 4 4 4 1 1 W Wi in nd l d lo oa ad ds s Wind forces can affect the stability of a truck when lifting l...

Page 36: ...ll hydraulic lines between the basic truck and the mast separated the basic truck and the mast separated Safety Instructions for Assembly and Commissioning Safety Instructions for Assembly and Commissioning F F On site assembly of the truck commissioning and driver instruction may only be On site assembly of the truck commissioning and driver instruction may only be carried out by personnel traine...

Page 37: ...ld only be laden by be laden by people who are people who are trained in handling trained in handling lift lift ing slings and tools ing slings and tools Wear safety shoes when lifting the truck by crane Wear safety shoes when lifting the truck by crane Do not stand under a swaying load Do not stand under a swaying load Do not walk into or stand in a hazardous area Do not walk into or stand in a h...

Page 38: ...vided on the outriggers overhead guard 1 Two strap points 2 are provided on the outriggers Park the truck securely see Chapter E Park the truck securely see Chapter E Secure the truck with wedges to prevent it from rolling away Secure the truck with wedges to prevent it from rolling away M M Attach the crane slings to Attach the crane slings to the strap points so the strap points so that the truc...

Page 39: ...ting by crane are restricted Because of the risk to the window the crane the window the crane lifting gear and rope slings must not pass over the front door lifting gear and rope slings must not pass over the front door Z Z Always Always use use crane crane lifting lifting gear gear with with sufficiently sufficiently wide wide cross cross members members and and attachment attachment slings with ...

Page 40: ...e guide on the on the overhead overhead guard brace 1 and attach it to the fastening rings guard brace 1 and attach it to the fastening rings Tighten the tensioning belt with the tensioner 4 Tighten the tensioning belt with the tensioner 4 M M Loading must be carried out by specially trained staff in accordance with Loading must be carried out by specially trained staff in accordance with recommen...

Page 41: ... transport the following tasks must be carried out be carried out Install battery where required Do not damage battery cable Install battery where required Do not damage battery cable Charge the battery see Chapter D Charge the battery see Chapter D If necessary remove the transport lock from the parking brake If necessary remove the transport lock from the parking brake Visu Visually ally inspe i...

Page 42: ...inals must be covered with a non slip grease Batteries with non insulated terminals must be covered with a non slip insulation mat insulation mat M M Before closing the battery cover make sure that the battery lead cannot be damaged Before closing the battery cover make sure that the battery lead cannot be damaged Battery Disposal Battery Disposal Batteries may only be disposed of in accordance wi...

Page 43: ...rer Battery equipment may only be replaced with the agreement of the manufacturer When replacing installing When replacing installing the battery the battery make sure make sure the battery the battery is securely is securely located in located in the battery compartment of the truck the battery compartment of the truck Do not use batteries that have not been approved by the manufacturer Do not us...

Page 44: ...e the mast mast holder holder when when you you move the mast holder move the mast holder Procedure Procedure Preparing for Operation see Chapter E Preparing for Operation see Chapter E Solo Pilot Solo Pilot Move the Solo Pilot 1 Move the Solo Pilot 1 in the arrow direction in the arrow direction U Move the mast hold U Move the mast holder as far as er as far as the stop in the battery direction a...

Page 45: ...rds towards arrow arrow T T and and extend extend the the mast mast holder holder with with the the coupled battery trolley until the battery coupled battery trolley until the battery is exposed for maintenance is exposed for maintenance Release the battery unlatch pedal 2 Release the battery unlatch pedal 2 Turn the EMERGENCY DISCONNECT switch and key switch off Turn the EMERGENCY DISCONNECT swit...

Page 46: ... 4 4 in in the the direction direction of of arrow arrow U U and and move move the the mast mast support further towards the battery as far as the stop position preparation for support further towards the battery as far as the stop position preparation for unlatching the battery and hold it in this position unlatching the battery and hold it in this position Maintain the Maintain the Multi Pilot M...

Page 47: ...CT switch and key switch off Turn the EMERGENCY DISCONNECT switch and key switch off Z Z The battery unlatch safety switch only allows for travel at crawl speed if the battery The battery unlatch safety switch only allows for travel at crawl speed if the battery trolley is unlocked and the control light 3 is still on Before starting up the truck again trolley is unlocked and the control light 3 is...

Page 48: ...ial truck industrial truck is parked is parked for charging for charging there shall there shall be no be no inflammable inflammable material or lubricants capable of creating sparks within 2 metres around the truck material or lubricants capable of creating sparks within 2 metres around the truck Fire protection equipment must be on hand Fire protection equipment must be on hand Do not lay any me...

Page 49: ...the battery and the truck Do not reach between the battery and the truck Use only batteries with insulated cells and terminal connectors Use only batteries with insulated cells and terminal connectors Cover batteries with open terminals or connectors with a rubber mat Cover batteries with open terminals or connectors with a rubber mat Park the truck on a level surface to prevent the battery from s...

Page 50: ... battery cover If necessary remove the battery cover Strap the crane lifting harness to both sides of the battery container 6 Strap the crane lifting harness to both sides of the battery container 6 Lift the battery clear and move out to the side Lift the battery clear and move out to the side Removal and Installation using a Battery Trolley Removal and Installation using a Battery Trolley o o F F...

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Page 52: ...t be immediately informed of any damage or faults to the forklift truck or attachment Trucks which are unsafe for operation or faults to the forklift truck or attachment Trucks which are unsafe for operation e g e g wheel or brake wheel or brake problems must not problems must not be used until they be used until they have been rectified have been rectified Repairs Repairs The driver must not carr...

Page 53: ...oad handler lift lower Mast support extend retract Mast support extend retract Mast forward or backward tilt fork tilt Mast forward or backward tilt fork tilt Sideshift left right Sideshift left right Horn button Horn button Aux hydraulics HF5 Aux hydraulics HF5 o o 4 4 A Ar rm mr re es st t l lo oc ck k t t Armrest longitudinal adjuster Armrest longitudinal adjuster 5 5 D Dr ri iv ve er r s s s s...

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Page 55: ... and height Sets steering column distance and height 1 13 3 D Dr ri iv ve er r s s d di is sp pl la ay y t t Displays important travel and lift parameters Displays important travel and lift parameters selection and display of steering modes selection and display of steering modes warnings incorrect operation notes and warnings incorrect operation notes and service displays see Section 6 service di...

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Page 57: ...damage damage and and make make sure sure they are secure they are secure Check the battery connector is secure Check the battery connector is secure Check Check the load the load handler for handler for visible signs visible signs of damage of damage such as such as cracks bent cracks bent or severely or severely worn forks worn forks Check the forks Check the forks Check the drive wheel and load...

Page 58: ...e applied without having to strain that all the controls are within reach and can be applied without having to strain Adjusting the driver s seat Adjusting the driver s seat Z Z To achieve optimal seat cushioning the driver s seat must be adapted to the driver s To achieve optimal seat cushioning the driver s seat must be adapted to the driver s weight weight The driver s seat must be vacant when ...

Page 59: ...are within easy reach Set the seat heating Set the seat heating M M Avoid prolonged contact of uncovered unprotected skin with the heated seat Avoid prolonged contact of uncovered unprotected skin with the heated seat Procedure Procedure Press the seat heating button C once Press the seat heating button C once The heating changes to heat mode level 3 highest level all LEDs D are The heating change...

Page 60: ...in or max weight setting is reached when you can feel a return stroke on the lever lever After adjusting the weight move the lever back fully until it engages After adjusting the weight move the lever back fully until it engages To adjust the backrest To adjust the backrest F F The backrest must be securely engaged in The backrest must be securely engaged in the set position The backrest setting m...

Page 61: ...e starting the industrial truck starting the industrial truck Change Change the the belt belt height height setting setting 22 22 according to your body size according to your body size Do not alter the belt setting Do not alter the belt setting Frozen belt locks Frozen belt locks 20 or pulleys must 20 or pulleys must be thawed out and dried be thawed out and dried The The warm warm air air temper...

Page 62: ...at movement in the seat F F Sitting at the front edge of the seat affords less protection as the Sitting at the front edge of the seat affords less protection as the belt is too long belt is too long Z Z The belt must only be used to secure one person The belt must only be used to secure one person After After using using the the belt belt press press the the red red button button and and manually...

Page 63: ...rizontally to the required position required position Now fix the steering column lock again Now fix the steering column lock again Adjusting the armrest Adjusting the armrest Raise the armrest lock 4 and Raise the armrest lock 4 and set the set the armrest 18 to the required position armrest 18 to the required position longitudinally longitudinally Release the armrest bar 4 again Release the armr...

Page 64: ...a via the keypad 1a Test horn Test horn The truck is now operational The battery The truck is now operational The battery discharge monitor shows the available discharge monitor shows the available battery capacity battery capacity Check the Check the operation operation of of the brake the brake and and handbrake handbrake see Section 4 4 see Section 4 4 When When you you start start up up the th...

Page 65: ...afety of the operator the truck will brake in a operator the truck will brake in a controlled manner until it comes to controlled manner until it comes to a halt a halt Emergency stop reset Emergency stop reset Turn the Turn the EMERGENCY DISCONNECT EMERGENCY DISCONNECT switch and switch and the key the key switch off switch off and on and on again again Z Z If the emergency stop is shown on the d...

Page 66: ...lays Test the controls and displays Test the steering Test the steering Check the steer Check the steer angle display turn angle display turn the steering the steering wheel in wheel in both directions both directions as far as as far as the stop and check that the the stop and check that the wheel position is displayed on the wheel position is displayed on the control panel control panel Test the...

Page 67: ...t visibility must be positioned at the a clear view of the route ahead Loads that affect visibility must be positioned at the rear of the truck If this is not possible a second person rear of the truck If this is not possible a second person must walk in front of the truck must walk in front of the truck as a lookout as a lookout Negotiating slopes and inclines Negotiating slopes and inclines Nego...

Page 68: ...thout a load when the mast support is The truck can only be moved with or without a load when the mast support is retracted the mast tilted back and retracted the mast tilted back and the load handler lowered the load handler lowered F F Electromagnetic faults can cause accidents Electromagnetic faults can cause accidents Strong magnets can cause electronic components such as Hall sensors to becom...

Page 69: ...g the the Eme Emerge rgency ncy Dis Discon connec nect t Procedure Procedure Do not use the Emergency Disconnect 2 as a service brake Do not use the Emergency Disconnect 2 as a service brake In hazardous situations press the Emergency Disconnect switch 2 down In hazardous situations press the Emergency Disconnect switch 2 down All electrical functions are deactivated All electrical functions are d...

Page 70: ...direction V Extra caution is required when travelling in the load direction R travelling in the load direction R Z Z You should only travel in the load direction R for shunting and You should only travel in the load direction R for shunting and lifting or depositing a lifting or depositing a load load Prepare the truck for operation see Section 3 3 Prepare the truck for operation see Section 3 3 R...

Page 71: ...e deadman switch 10 and the accelerator pedal 8 Apply the deadman switch 10 and the accelerator pedal 8 The truck will start in the The truck will start in the desired direction desired direction F F The deadman switch 10 ensures that the driver s feet do not jut out over the The deadman switch 10 ensures that the driver s feet do not jut out over the perimeter of the truck If it is not pressed al...

Page 72: ... drive wheel position is indicated in the driver s display driver s display Brakes Brakes Z Z The truck s brake pattern depends largely on the ground conditions The driver must The truck s brake pattern depends largely on the ground conditions The driver must take this into consideration when handling the take this into consideration when handling the truck truck The truck can brake in three diffe...

Page 73: ...direction the truck decelerates via the traction current controller until it starts to move in the opposite direction until it starts to move in the opposite direction Z Z This method reduces energy consumption Energy is recovered which is controlled This method reduces energy consumption Energy is recovered which is controlled by the traction current controller The energy recovery is indicated on...

Page 74: ...d 4 4 5 5 A Ad dj ju us st ti in ng g t th he e f fo or rk ks s F F In order to safely raise a load the forks In order to safely raise a load the forks should be set as far apart from each should be set as far apart from each other as possible and centrally to the other as possible and centrally to the truck The load centre of gravity must be truck The load centre of gravity must be in the centre ...

Page 75: ... must ensure that it is correctly Before raising a load the driver must ensure that it is correctly palletised and that the palletised and that the capacity of the truck is not exceeded capacity of the truck is not exceeded Insert the forks as far as possible underneath the load Insert the forks as far as possible underneath the load https www besttruckmanuals com ...

Page 76: ...afety switch is an active accident The safety switch is an active accident prevention device operating outside the prevention device operating outside the free lift range which prevents the truck free lift range which prevents the truck from accidentally accelerating with a from accidentally accelerating with a raised load raised load Z Z When the safety switch has been When the safety switch has ...

Page 77: ...upport forward and in direction U to retract it support forward and in direction U to retract it Z Z The reach speed is determined by the The reach speed is determined by the inclination of the Solo Pilot or Multi Pilot inclination of the Solo Pilot or Multi Pilot Mast tilt Mast tilt Solo Pilot Solo Pilot t t To To til tilt f t forw orward ard pus push t h the he Solo Solo Pil Pilot ot 3 3 lev lev...

Page 78: ...he tilt back position Pull the Solo Pilot 3 lever 27 To position the load in the tilt back position Pull the Solo Pilot 3 lever 27 Transport load Transport load To place the load in a horizontal position Push the Solo Pilot 3 lever 27 To place the load in a horizontal position Push the Solo Pilot 3 lever 27 To To position position the the load load at at the the correct correct height height Pull ...

Page 79: ...er switch 28 rocker R To position the load in the tilt back position Press rocker switch 28 rocker R Transport load Transport load To place the load in a horizontal position Press rocker switch 28 rocker V To place the load in a horizontal position Press rocker switch 28 rocker V To position the load at the correct height Pull Multi Pilot 3a To position the load at the correct height Pull Multi Pi...

Page 80: ... the EM e EMERG ERGENCY ENCY DISC DISCONN ONNECT ECT switch and key switch off switch and key switch off Disconnect the battery connector Disconnect the battery connector Undo Undo the the rotary rotary shaft shaft bolt bolt 25 25 6 6 mm mm hex hex bo bolt ma lt max x tur turns if nec ns if necess essary ary with a suitable extension The mast with a suitable extension The mast and load handler wil...

Page 81: ...h a CE mark Only use Only use attachments that attachments that have been have been designed by designed by the attachment the attachment manufacturer for manufacturer for use with the respective industrial truck use with the respective industrial truck Only use attachments that have been fitted for the purpose by the owner Only use attachments that have been fitted for the purpose by the owner Ma...

Page 82: ...rts see Assembly and hydraulic ports of additional attachments in chapter E additional attachments in chapter E An auxiliary button for releasing the clamp opening must be used An auxiliary button for releasing the clamp opening must be used Safety instructions for rotary attachments Safety instructions for rotary attachments M M A non centred centre of gravity can result in accidents A non centre...

Page 83: ...ter E also and operations to be performed before starting daily operation in chapter E also check the fork extension lock check the fork extension lock Mark Mark any any fork fork extensions extensions with with an an incomplete incomplete or or faulty faulty lock lock and and take take them them out out of of service service Do not Do not use trucks with use trucks with an incomplete or an incomp...

Page 84: ...ions X2 and Y2 to operate hydraulic attachments HF5 see manufacturer s operator manual hydraulic attachments HF5 see manufacturer s operator manual F F Note the capacity of the attachment Note the capacity of the attachment F F Observe load chart for the truck with attachment and the truck and attachment Observe load chart for the truck with attachment and the truck and attachment operator manuals...

Page 85: ...ctions X2 and Y2 to operate hydraulic attachments HF5 note manufacturer s operator manual HF5 note manufacturer s operator manual F F Note the capacity of the attachment Note the capacity of the attachment F F Observe load chart for the truck with attachment and the truck and attachment Observe load chart for the truck with attachment and the truck and attachment operator manuals operator manuals ...

Page 86: ...k the truck on a slope The load must always be lowered to the ground Activate the Activate the parking brake parking brake by pressing by pressing the parking key 19 the parking key 19 Retract the mast support fully Retract the mast support fully Lower Lower the the load load completely completely and and position it horizontally position it horizontally Set the EMERGENCY DISCONNECT Set the EMERGE...

Page 87: ...ameters battery charge condition and other selected truck parameters Set time Set time Press the shift key 56 for 3 seconds Press the shift key 56 for 3 seconds The display 48 via the battery shows the current time This allows you to toggle the The display 48 via the battery shows the current time This allows you to toggle the display between the time and the residual time display between the time...

Page 88: ...h on n bo boar ard b d bat atte tery ry h hou ours rs m min inut utes es 4 48 8 T Ti im me e d di is sp pl la ay y h ho ou ur rs s m mi in nu ut te es s 49 49 Ba Batt tter ery di y disc scha harg rge st e stat atus a us and e nd ene nerg rgy re y reco cove very d ry dis ispl play ay 5 50 0 D Di is sc ch ha ar rg ge e i in nd di ic ca at to or r 51 51 Se Set sp t spee eed d d dri rive d ve dir irec...

Page 89: ... battery symbol When a battery is discharged to the permissible discharge level the battery symbol is displayed empty is displayed empty Battery Discharge Monitor Battery Discharge Monitor If the residual capacity falls below the required level If the residual capacity falls below the required level lifting is inhibited A message will be indicated on the driver s display unit lifting is inhibited ...

Page 90: ...weight are available display field 2 remains empty field 2 remains empty Energy recovery display during regenerative braking Energy recovery display during regenerative braking During the energy recovery stage the discharge indicator on the driver s display During the energy recovery stage the discharge indicator on the driver s display changes so that the bars in changes so that the bars in the b...

Page 91: ...een icon Slow travel green icon SYMBOL SYMBOL Deadman switch not applied yellow icon Deadman switch not applied yellow icon SYMBOL SYMBOL Service mode active yellow spanner icon Service mode active yellow spanner icon SYMBOL SYMBOL Overtemperature red icon Overtemperature red icon SYMBOL SYMBOL Battery unlocked red icon Battery unlocked red icon SYMBOL SYMBOL Parking brake applied red icon Parking...

Page 92: ...e display to service mode Shift key Change display to service mode Shift key Select travel and lift modes Select travel and lift modes D Di is sp pl la ay y S Sy ym mb bo ol l M Me ea an ni in ng g I IN NF FO O 0 02 2 N No o t tr ra av ve el l d di ir re ec ct ti io on n s se el le ec ct te ed d I IN NF FO O 0 03 3 N No o t tr ra av ve el l r re el le ea as se e I IN NF FO O 0 04 4 N No o s se et ...

Page 93: ...limit reached Lift limit reached I IN NF FO O 1 18 8 F Fl la as sh hi in ng g s sy ym mb bo ol l Safety height not reached Safety height not reached I IN NF FO O 2 22 2 T Tr ra ac ct ti io on n c co on nt tr ro ol ll le er r d do oe es s n no ot t r re ec co og gn ni is se e e el le ec ct tr ri ic c s st te ee er ri in ng g I IN NF FO O 2 23 3 C Co on nt tr ro ol ll le er r s se et t t to o d di i...

Page 94: ...ST TE EM M O Ov ve er rv vo ol lt ta ag ge e S Sw wi it tc ch h o of ff f a an nd d o on n a ag ga ai in n call service department call service department 6 6 A AC CC CE EL LE ER RA AT TO OR R A An na al lo og g r re ea ad di in ng g o ou ut t o of f range or incompatible range or incompatible with digital signal with digital signal Switch off and on again Switch off and on again call service depa...

Page 95: ...a ai in n call service department call service department 4 40 0 T TE EM MP PE ER RA AT T MOTOR MOTOR Mo Moto tor o r ove vert rtem empe pera ratur ture e Al Allo low t w the he mo moto tor t r to c o cool ool down down 4 43 3 A AD DJ JU US ST T B BR RA AK KE E A Ad dj ju us st t b br ra ak ke e C Ca al ll l s se er rv vi ic ce e d de ep pa ar rt tm me en nt t 4 44 4 B BR RA AK KE E D DE EF FE EC ...

Page 96: ... and on again call service department call service department 83 83 EL ELEC ECTR TR SY SYST STEM EM 2 2 id iden enti tica cal l co com mpo pone nent nts s Sw Swit itch ch of off f an and d on on ag agai ain n call service department call service department 8 84 4 R RP PM M S SE EN NS SO OR R F Fa au ul lt ty y s sp pe ee ed d s se en ns so or r S Sw wi it tc ch h o of ff f a an nd d o on n a ag ga...

Page 97: ...T S SU UC CC CE ES SS S A Af ft te er r s so of ft tw wa ar re e f fl la as sh hi in ng g field operation the item field operation the item number of the software is number of the software is improbable and improbable and parameters may also be parameters may also be implausible implausible Switch off and on again Switch off and on again call service department call service department 1 11 18 8 C ...

Page 98: ... digit keys a Set key and a and a o o key key The The o o key indicates operating statuses via a red key indicates operating statuses via a red green LED green LED It contains the following functions It contains the following functions Code lock function starting up the truck Code lock function starting up the truck 6 6 1 1 C Co od de e l lo oc ck k When the correct code has been entered the machi...

Page 99: ...lly after a pre determined time To do this the pre determined time To do this the appropriate code lock parameters must be appropriate code lock parameters must be entered entered see Section 6 3 see Section 6 3 6 6 2 2 P Pa ar ra am me et te er rs s In programming mode you can set the code In programming mode you can set the code lock functions via the keypad lock functions via the keypad Paramet...

Page 100: ...dure Truck setting procedure Enter the three digit parameter number confirm with the Set key 68 Enter the three digit parameter number confirm with the Set key 68 Enter the Enter the setting according setting according to the to the parameter list parameter list or change or change and confirm and confirm with the with the Set Set key 68 key 68 Z Z If the entry is incorrect the LED 67 of the If th...

Page 101: ...th can be entered If the can be entered If the code length is to be code length is to be changed all operator changed all operator codes must first be codes must first be deleted deleted 0000 9999 0000 9999 or or 00000 99999 00000 99999 or or 000000 999999 000000 999999 7 72 29 95 5 L LE ED D 6 69 9 f fl la as sh he es s Enter the current Enter the current code code Confirm Set Confirm Set LED 70 ...

Page 102: ...ter the code Re enter the code confirm confirm 0 00 03 3 D De el le et te e u us se er r c co od de e 0 00 00 00 0 9 99 99 99 9 or or 00000 99999 00000 99999 or or 000000 999999 000000 999999 LED 70 flashes LED 70 flashes Enter a code Enter a code Confirm Set Confirm Set LED 71 flashes LED 71 flashes Re enter the code Re enter the code Confirm Set Confirm Set 004 004 Del Delete ete cod code me e m...

Page 103: ...e some truck parameters With the driver s display it is also possible to change some truck parameters acceleration coasting brake reverse braking drive direction speed fork direction acceleration coasting brake reverse braking drive direction speed fork direction speed and lift speed and hence the truck s characteristics speed and lift speed and hence the truck s characteristics t t Trucks with dr...

Page 104: ...ation must only be performed by a suitably trained maintenance engineer This operation must only be performed by a suitably trained maintenance engineer When the brakes are de activated the truck must When the brakes are de activated the truck must be parked on a level surface since be parked on a level surface since the brakes are no longer effective the brakes are no longer effective Preparing t...

Page 105: ...n a correcting moment Procedure Procedure Set the drive wheel to the required Set the drive wheel to the required position to do this position to do this Remove Remove the the protective protective cap cap from from over over the centre screw on the steer motor the centre screw on the steer motor see arrow see arrow Assemble Assemble the the steering steering crank crank in in accordance with the ...

Page 106: ...am Recover Recover the the truck truck carefully carefully and and slowly slowly When When the the truck truck reaches reaches its its destination restore the brake destination restore the brake system to its operating condition system to its operating condition Bleed the magnetic brake Bleed the magnetic brake F F The truck must not be parked with The truck must not be parked with the brakes rele...

Page 107: ... work lights are fitted with a The work lights are fitted with a 360º swivel link 360º swivel link 1 11 1 2 2 B Bea eac co on n s st tr ro ob be e I It te em m D De es sc cr ri ip pt ti io on n 73 73 o o Work lights Work lights 74 74 o o Work lights Work lights 75 75 o o Headlights ON OFF switch for item 73 Headlights ON OFF switch for item 73 76 76 o o Headlights ON OFF switch for item 74 Headlig...

Page 108: ...ollows Only when the mast is fully extended or the fork carriage Only when the mast is fully extended or the fork carriage above the outriggers are above the outriggers are all functions released all functions released Sideshift and Sideshift and lowering are lowering are deactivated if deactivated if the mast the mast is not is not fully extended fully extended and the and the load load is n is n...

Page 109: ...hments such as fork adjusters baling clamps various attachments such as fork adjusters baling clamps masts with integrated sideshift masts with integrated sideshift particularly sensitive loads particularly sensitive loads Only when the mast is extended or the fork carriage above the outriggers are all Only when the mast is extended or the fork carriage above the outriggers are all functions relea...

Page 110: ...ulic function applied simultaneously the clamp function is activated 1 11 1 5 5 S Se ea at h t he ea at ti in ng g 11 11 6 6 12 12 V D V DC 2 C 24 V 4 V DC DC tr tran ansf sfor orme mer r I It te em m D De es sc cr ri ip pt ti io on n 81a 81a o o Clamp function release button Clamp function release button I It te em m D De es sc cr ri ip pt ti io on n 80 80 o o Seat heating switch Seat heating swi...

Page 111: ...ab Comfort 1 without entry door 88 88 o o Weather proof cab Comfort 2 with entry door Weather proof cab Comfort 2 with entry door 89 89 o o Spray water reservoir behind driver s seat Spray water reservoir behind driver s seat 90 90 o o Emergency hammer Emergency hammer 91 91 o o Load side work lights Load side work lights 92 92 o o Not used Not used 93 93 o o Heating Heating 94 94 o o Seat heating...

Page 112: ...ir rr ro or r The parabolic mirror is fitted with a The parabolic mirror is fitted with a side swivel link side swivel link I It te em m D De es sc cr ri ip pt ti io on n 102 102 o o Parabolic mirror adjustable Parabolic mirror adjustable 102 102 https www besttruckmanuals com ...

Page 113: ...uired to remove and attach the load backrest Load backrest disassembly Load backrest disassembly Loosen the screws 104 Loosen the screws 104 Remove the load backrest from the fork carriage and put it down securely Remove the load backrest from the fork carriage and put it down securely Load backrest assembly Load backrest assembly Attach the load backrest to the top rail of the fork carriage 103 A...

Page 114: ...eld in front of the access module to log on When you leave the truck press the red button to log off The truck can only be used again if an authorised press the red button to log off The truck can only be used again if an authorised transponder is held again in front of the access module transponder is held again in front of the access module Z Z If the truck is equipped with an ISM access module ...

Page 115: ...hoses Non pressurised hydraulic hoses The The attachment attachment directions directions of of movement movement must must match match the the controls controls direction direction of of movement movement Procedure Procedure Dep Depressu ressurise rise the the hydra hydraulic ulic hose hoses s by by switc switching hing off off the the truck truck and and waiti waiting ng a a few few minut minute...

Page 116: ...ucks taking safety into account Keep permanent Keep permanent graphic records graphic records of the of the plans tests plans tests and completion and completion of the of the changes changes carry out and have carry out and have authorised the respective changes to authorised the respective changes to the capacity data plates the capacity data plates decals and stickers as well as decals and stic...

Page 117: ...up the truck safely proceed as follows truck safely proceed as follows Jack up the truck only on a level surface and prevent it from moving accidentally Jack up the truck only on a level surface and prevent it from moving accidentally Alwa Always ys use use a a jack jack with with suffic sufficient ient capa capacity city When When jacki jacking ng up up the the truck truck take take appro appropr...

Page 118: ...ause accidents Electric currents can cause accidents Make sure the electrical system is Make sure the electrical system is voltage free before starting work on it voltage free before starting work on it Before starting maintenance on the electrical system Before starting maintenance on the electrical system Park the truck securely see Parking the Truck Securely in Chapter E Park the truck securely...

Page 119: ...ontamination Lift chains and pivot pins must Lift chains and pivot pins must always be clean and well lubricated always be clean and well lubricated Lift Lift chains chains should should only only be be cleaned cleaned with with paraffin paraffin derivatives derivatives e g e g petroleum petroleum or or die diesel sel fue fuels ls Never Never clean clean chains chains with with steam steam jet jet...

Page 120: ... and infection Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracks in the hydraulic lines causing severe injury in the hydraulic lines causing severe injury Call for a doctor immediately if you are injured Call for a doctor immediately if you are injured Do not touch pressurise...

Page 121: ...ed on single shift operation under normal operating conditions They must be reduced accordingly if the truck is to be used in operating conditions They must be reduced accordingly if the truck is to be used in conditions of extreme dust temperature fluctuations or multiple shifts conditions of extreme dust temperature fluctuations or multiple shifts The following maintenance checklist states the t...

Page 122: ...1 Check Check steeri steering to ng toothing othing for w for wear a ear and lu nd lubricat bricate e k k t t 4 2 4 2 Che Check mec ck mechan hanica ical part l parts of ste s of steeri ering hea ng head d t t 4 4 3 3 Te Test st st stee eeri ring ng t t Brake Brake system system 5 1 5 1 Test Test ope operat ration ion and and set settin tings gs k k t t 5 5 2 2 Ch Chec eck br k brak ake me e mech ...

Page 123: ...er perati ation on t t 9 3 9 3 Che Check ac ck acid de id densi nsity a ty acid l cid leve evel an l and cel d cell vol l voltag tage e k k t t 9 4 9 4 Che Check te ck termi rminal nals are s s are secur ecurely a ely atta ttache ched an d and app d apply ly grease grease k k t t 9 5 9 5 Cle Clean ba an batte ttery co ry conne nnecti ctions ons mak make sur e sure the e they are t y are tigh ight ...

Page 124: ... electrical ical syste system fo m for fr r frame ame leakag leakage e t t 12 12 2 2 Tes Test trav t travel spe el speed and b ed and brak raking di ing dista stance nce t t 12 12 3 3 Tes Test li t lift a ft and l nd lowe owerin ring sp g speed eeds s t t 12 12 4 4 Tes Test saf t safety d ety devi evices a ces and cu nd cutou touts ts t t Lubrica Lubrica tion tion 13 1 13 1 Lubric Lubricate t ate ...

Page 125: ...when mixing is expressly stipulated in the Operating mixing is expressly stipulated in the Operating Instructions Instructions M M Spilled liquids can cause slipping and endanger Spilled liquids can cause slipping and endanger the environment the environment Risk of slipping from spilled liquids The Risk of slipping from spilled liquids The risk is greater when combined with risk is greater when c...

Page 126: ...draulic oils is not prohibited but may lead to a decline in functionality It is possible to mix the Jungheinrich hydraulic oil with one to a decline in functionality It is possible to mix the Jungheinrich hydraulic oil with one of the named alternative hydraulic oils of the named alternative hydraulic oils Grease guidelines Grease guidelines C Co od de e O Or rd de er r n no o Q Qu ua an nt ti it ...

Page 127: ... 7 71 10 00 0 I IV V 2 21 1 u up p t to o 6 62 20 00 0 I II II I 1 18 8 5 5 u up p t to o 4 45 55 50 0 I II I 1 16 6 u up p t to o 3 37 79 90 0 I I 1 13 3 M Ma ar rk ki in ng g L Li it tr re es s ETV 114 116 ETV 114 116 Lift heights h Lift heights h3 3 Z ZT T D DZ Z Max Max low air cushion low air cushion 3 31 1 6 6 V V 3 30 0 I IV V 2 28 8 u up p t to o 9 90 02 20 0 I II II I 2 25 5 u up p t to o...

Page 128: ... F When working under a raised load fork or a raised truck secure When working under a raised load fork or a raised truck secure them to prevent them them to prevent them from lowering tipping or sliding away When raising the truck also refer to the from lowering tipping or sliding away When raising the truck also refer to the instructions in the Transport and Commissioning section instructions in...

Page 129: ...pa an ne el l Pull seat locking lever 2 up and push seat 3 towards the steering wheel Pull seat locking lever 2 up and push seat 3 towards the steering wheel Disconnect the system Disconnect the system Slacken collar screws 4 and remove panel 5 Slacken collar screws 4 and remove panel 5 Z Z The drive unit and hydraulic unit are now exposed for maintenance The drive unit and hydraulic unit are now ...

Page 130: ...cess recess in in the the panel 7 pull it off with force and put panel 7 pull it off with force and put it to one side it to one side Z Z Fuses are located under the panel Fuses are located under the panel 6 6 6 6 O Op pe en ni in ng t g th he i e in ns st tr ru um me en nt p t pa an ne el l Slacken Slacken the the collar collar screws screws in in mast mast guard Push the steering wheel guard Pus...

Page 131: ...i in n f fu us se e 3 35 55 5 A A 10 10b b 2 2F F1 1 P Pu um mp p m mo ot to or r f fu us se e 2 25 50 0 A A 11 11b b 1 1F F1 1 D Dr ri iv ve e m mo ot to or r f fu us se e 2 25 50 0 A A 12 12c c F F1 1 O Ov ve er ra al ll l c co on nt tr ro ol l f fu us se e 3 30 0 A A 13 13 c c F F1 13 3 V Va al lv ve e b br ra ak ke e f fu us se e 3 30 0 A A 14 14c c 3 3F F1 1 S St te ee er ri in ng g f fu us s...

Page 132: ...ance with the maintenance schedule Lubricate the truck in accordance with the maintenance schedule 7 7 D De ec co om mm mi is ss si io on ni in ng t g th he i e in nd du us st tr ri ia al t l tr ru uc ck k If the industrial truck is to be decommissioned for more than two months e g for If the industrial truck is to be decommissioned for more than two months e g for operational reasons it must be p...

Page 133: ...operating exposed contacts and remove any oxide layers on the contacts of the operating controls by applying them repeatedly controls by applying them repeatedly F F Perform several brake tests immediately after re commissioning the truck Perform several brake tests immediately after re commissioning the truck 8 8 Sa Safe fety ty te test sts t s to b o be p e per erfo form rmed ed at at in inte te...

Page 134: ...rticular regulations accordance with the regulations of the country of use In particular regulations governing the disposal of batteries fuels and electronic and electrical systems must governing the disposal of batteries fuels and electronic and electrical systems must be observed be observed 1 10 0 H Hu um ma an v n vi ib br ra at ti io on m n me ea as su ur re em me en nt t Z Z Vibrations that ...

Page 135: ...F 19 F 19 0 0 2 2 1 1 0 0 G G B B https www besttruckmanuals com ...

Page 136: ... ea al le ed a d ar rm mo ou ur p r pl la at te ed d c ce el ll ls s 9 9 5 5 1 1 De Desc scrip riptio tion n 9 9 5 5 2 2 Op Oper erat atio ion n 10 10 5 3 5 3 Ser Servic vicing P ing PzV a zV and Pz nd PzV B V BS lea S lead a d acid b cid batt atteri eries wi es with se th seale aled arm d armour p our plat lated ed cel cells ls 13 13 6 6 Aq Aqua uam mat atik ik wa wate ter r re rep ple leni nis s...

Page 137: ...h non original spare parts tampering with the battery spare parts tampering with the battery or using electrolyte additives will invalidate the or using electrolyte additives will invalidate the warranty warranty Observe the instructions for maintaining the safety rating during operation for Observe the instructions for maintaining the safety rating during operation for batteries in accordance wit...

Page 138: ... waste waste waste Buy back terms and type of recycling are to be agreed with the Buy back terms and type of recycling are to be agreed with the manufacturer as described in 8 of the battery legislation manufacturer as described in 8 of the battery legislation Do not smoke Do not smoke No naked flames glowing embers or sparks near the battery fire No naked flames glowing embers or sparks near the ...

Page 139: ... charged Higher temperatures will reduce lower temperatures will increase the electrolyte density The adjustment factor is 0 0007 kg l will increase the electrolyte density The adjustment factor is 0 0007 kg l per K e g 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 electrolyte density 1 28 kg l at 45 C corresponds to a density of 1 29 kg l at 30 C Th...

Page 140: ...nd check that contacts on the battery terminal conducting system are secure battery terminal conducting system are secure Chec Check the termi k the terminal scre nal screw torque w torques M10 23 1 Nm of the term s M10 23 1 Nm of the terminal con inal conduct ductors and ors and connectors connectors Ch Char arge u ge up th p the ba e batte ttery ry Che Check t ck the e he elec lectro trolyt lyte...

Page 141: ...cell surfaces must remain exposed during charging in order to ensure Battery cell surfaces must remain exposed during charging in order to ensure sufficient ventilation see truck operating instructions chapter D Charging the sufficient ventilation see truck operating instructions chapter D Charging the Battery Battery Do not smoke and avoid naked flames when Do not smoke and avoid naked flames whe...

Page 142: ...on Deviations are outlined in the truck s operating instructions The plugs remain on the cells or remain the cells or remain closed closed Connect the Connect the battery to battery to the switched the switched off charger off charger ensuring the ensuring the terminals are terminals are connect connect positive to positive and negative to positive to positive and negative to negative negative Sw ...

Page 143: ...urified water up to the rated level after charging ter up to the rated level after charging Z Z The height of the electrolyte level should not be below the cell baffle or above the The height of the electrolyte level should not be below the cell baffle or above the top of the top of the separator or the Min and Max electrolyte markings respectively separator or the Min and Max electrolyte markings...

Page 144: ...void electric the sealed batteries as for batteries with liquid electrolyte This is to avoid electric shock explosion of the electrolyte charging gases or hazardous electrolyte burns if shock explosion of the electrolyte charging gases or hazardous electrolyte burns if the cell vessels are destroyed the cell vessels are destroyed Z Z PzV batteries are low gassing but PzV batteries are low gassing ...

Page 145: ...th the b e bat atte tery ry Check completed Check completed 5 5 2 2 2 2 Di Disc scha harg rgin ing th g the ba e batte ttery ry Z Z To achieve an optimum useful life avoid operational discharges of more To achieve an optimum useful life avoid operational discharges of more than 60 than 60 of nominal capacity of nominal capacity Z Z If the battery is discharged during operation by more than 80 of r...

Page 146: ...istance of material or consumables capable of creating sparks within a minimum distance of 2 m from the truck 2 m from the truck Fire protection equipment must be available Fire protection equipment must be available Do not place any metallic objects on the battery Do not place any metallic objects on the battery Always Always follow follow the the safety safety regulations regulations of of the t...

Page 147: ...of the charger is required The adjustment factor must be applied with 0 004 V C per K factor must be applied with 0 004 V C per K Battery charged Battery charged Z Z Charging is considered to be complete when the electrolyte density and battery Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours voltage remain constant for mo...

Page 148: ...idual voltages idual voltages Compare the results with the previou Compare the results with the previous ones s ones Z Z Carry out the measurements after full charging and subsequent resting for at Carry out the measurements after full charging and subsequent resting for at least least 5 hours 5 hours Z Z If you find significant differences compared with the previous measurements or If you find si...

Page 149: ...r r r re ep pl le en ni is sh hm me en nt s t sy ys st te em m 6 6 1 1 Wa Wate ter r r rep eple leni nish shme ment nt sy syst stem em de desi sign gn 1 15 5 W Wa at te er r c co on nt ta ai in ne er r 15 15 16 16 17 17 18 18 19 19 20 20 3 m 3 m https www besttruckmanuals com ...

Page 150: ... valve is off and the valve is closed securely closed securely The plug systems have an optical level indicator a diagnostic port to measure the The plug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port temperature and electrolyte density and a degassing port 6 6 3 3 A Ad dd di in ng g w wa at te er r Water should be ...

Page 151: ... purified or distilled water Purified water can be produced through distillation or ion distilled water Purified water can be produced through distillation or ion exchangers and is then suitable for the exchangers and is then suitable for the production of electrolyte production of electrolyte 6 6 7 7 B Ba at tt te er ry t y tu ub bi in ng g The tubing of the individual plugs is in accordance with...

Page 152: ...vent based materials or soap or soap 6 6 10 10 Se Serv rvic ice m e mob obil ile v e veh ehic icle le Mobile water filling vehicle with pump and filling gun to fill individual cells The 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 immersion pump in the container generates the necessa...

Page 153: ...of a fault e g if the pressure control system responds for an unknown reason the filters must be reason the filters must be checked and replaced if necessary checked and replaced if necessary Battery connection Battery connection A h A hose ose is is attached attached to the to the pump pump module module which which together together with the with the charge charge leads leads is is routed routed...

Page 154: ... severe temperature fluctuations the electrolyte battery is subjected to severe temperature fluctuations the electrolyte may flow back into the hose system may flow back into the hose system Attach a Attach a separate separate coupling s coupling system to ystem to the air the air inlet line inlet line such a such as s locking c locking coupling o oupling on n the battery side and through coupling...

Page 155: ...ing water the electrolytic rinsing water All health a All health and safety nd safety as well as as well as water and water and waste dispo waste disposal regulations sal regulations are observe are observed d when disposing of used electrolyte or rinsing water when disposing of used electrolyte or rinsing water Protective goggles and clo Protective goggles and clothing are worn thing are worn Cel...

Page 156: ...m behind the outlet nozzle 30cm behind the outlet nozzle Obse Observe th rve the maxi e maximum op mum operatin erating pres g pressure o sure of 50 ba f 50 bar r Obse Observe a min rve a minimum di imum distanc stance of 30 cm fro e of 30 cm from the top o m the top of the batt f the battery ery The bat The battery sho tery should be spr uld be sprayed ov ayed over its entire s er its entire surf...

Page 157: ... 2 23 volts volts x no x no of of cells fo cells for PzS r PzS PzM PzM and and PzB PzB batteries or 2 25 volts x no of cells for PzV batteries batteries or 2 25 volts x no of cells for PzV batteries If the battery is to be taken out of service for a long period If the battery is to be taken out of service for a long period 3 months it should as 3 months it should as far as possible be charged to 5...