Jungheinrich EKS 308 Operating Instructions Manual
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Jungheinrich EKS 308 Operating Instructions Manual

Jungheinrich EKS 308 Operating Instructions Manual

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EKS 308
03.06 -
G
Operating instructions
51009741
07.08

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Summary of Contents for Jungheinrich EKS 308

  • Page 1 EKS 308 03.06 - Operating instructions 51009741 07.08...
  • Page 2 Used to indicate standard equipment. Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions.

  • Page 4: Table Of Contents

    Index Correct Application Truck Description Application ................... B 1 Assemblies and Functional Description ..........B 2 Truck ....................B 3 Standard Version Specifications ............B 5 Performance Data ................B 5 Dimensions (as per data plate) ............B 7 Mast version ..................B 7 EN norms ....................
  • Page 5 Operation Safety Regulations for the Operation of Forklift Trucks ...... E 1 Controls and Displays ................. E 2 Operating and display equipment on control panel ......E 2 Display unit controls and displays ............E 3 Truck operational status symbols ............E 7 Starting up the truck ................
  • Page 6 Operational safety and environmental protection ........ F 1 Maintenance Safety Regulations ............F 1 Servicing and inspection ..............F 3 EKS 308 maintenance checklist ............F 4 Lubrication Schedule ................F 7 Consumables ..................F 8 Maintenance and Repairs ..............F 9 Prepare the truck for maintenance and repairs ........
  • Page 8 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.

  • Page 10: A Correct Application

    A Correct Application The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full. The truck described in the present operating instructions is an industrial truck designed for lifting and transporting loads.

  • Page 12: B Truck Description

    B Truck Description Application The EKS 308 is an electric stockpicker. It is designed to transport and pick goods on level surfaces in accordance with DIN 15185. The truck can lift open bottom or diagonal board pallets as well as roll cages outside the load wheel area.

  • Page 13: Assemblies And Functional Description

    Assemblies and Functional Description Item Description Mast Overhead guard Safety gates in load direction Side safety gates Handle for two-hand operation in narrow aisles Control panel Safety belt Height-adjustable driver’s position Chassis Foot button / deadman button Pallet sensing device Pallet clamp t = Standard equipment o = Optional Equipment...

  • Page 14: Truck

    Truck Safety mechanisms: Safey gates positioned in load direction (option) and laterally (3,4). The overhead guard (2) protects the driver from falling objects. The driver can be optionally secured by a safety belt (7). The Emergency Disconnect immediately disconnects all truck movement in hazardous situations.

  • Page 15: Controls And Displays

    Controls and Displays The functions are activated via ergonomic thumb and finger movement to ensure fatigue-free operation without straining the wrists; sensitive application of travel and hydraulic movements to spare and position the goods exactly. The display unit shows all the important driver information such as steer wheel position, overall lift, truck status reports (e.

  • Page 16: Standard Version Specifications

    Standard Version Specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved. Performance Data Description EKS 308 Capacity (where D = 600 mm) 1,360 kg Load centre of gravity 600 mm Travel speed without load (RG) 10.5 km/h...

  • Page 18: Dimensions (As Per Data Plate)

    4,120 kg DZ mast - performance data measured for 500 DZ Rail guidance Wire guidance Mast version Description EKS 308 (DZ) EKS 308 (ZT) Mast height (retracted) 2510 - 3950 mm 3310 - 4870 mm Lift 5000 - 9250 mm...

  • Page 19: En Norms

    EN norms Noise level: 64 dB(A) in accordance with EN 12053 as harmonized with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear on a level surface in accordance with DIN 15185.

  • Page 20: Identification Points, Warning Decals And Data Plates

    Identification points, warning decals and data plates Warnings and notices such as load charts, strap points and data plates must be legible at all times. Replace if necessary. h3 (mm) Q (kg) D (mm) 1,5 V Item Description “Read operating instructions" notice Truck data plate Capacity plate “Wear safety belt”...
  • Page 21 h3 (mm) Q (kg) D (mm) 1,5 V Item Description Strap points for crane lifting “Add hydraulic oil” notice “Emergency drain” decal “Caution: Low voltage electronics system" decal “Emergency drain key” decal “Do not step onto or beneath the load, risk of trapping” decal B 10...

  • Page 22: Capacity

    Truck data plate Item Description Item Description Type Manufacturer Serial no. Min./max. battery weight (kg) Rated capacity (kg) Drive output (kW) Battery voltage (V) Load centre of gravity (mm) Net weight w.o. battery (kg) Year of Manufacture Manufacturer’s logo Option For queries relating to the truck or spare parts orders, please state the truck serial no.
  • Page 23 B 12...

  • Page 24: C Transport And Commissioning

    C Transport and Commissioning Transport Depending on the height of the mast and local conditions, the truck can be transported in three different ways: – Vertically, with mast and load handler assembled (for low heights) – Vertically, with mast and load handler disassembled (for large heights) –...
  • Page 25 Loading by crane with the mast folded – With a folded mast attach the crane slings to the cross member at the top of the mast and the one at the bottom of the mast. – When lifting a truck with a folded mast by crane, always attach the transportation components.

  • Page 26: Crane Points / Strap Points

    Crane points / Strap points The crane points (1) are the eyes in the mast. The crane points (5) are located on the side of the chassis and crane points (4) are located on the top mast bearing respectively. Suitable ring screws must be screwed in at this point.

  • Page 27: Basic Truck Transport Safety

    The mast must only be disassembled by the manufacturer’s authorised service department. To ensure secure transport of a disassembled EKS 308, use the attachment points for fastening/quick release belts. Only use fastening / quick release belts with a rated capacity of >5 tonnes.

  • Page 28: Mast Transport Safety

    Mast transport safety Use a transport retaining device (12) to prevent the driver’s position carriage (13) from sliding. If the mast is stored on a pallet(s), fasten them securely to the mast (18). Use the lower attachment latch (17) as the "mast bottom" strap point for attaching to the lorry eyes (15).

  • Page 29: Using The Truck For The First Time

    Safely transporting the truck with the mast folded If the truck’s battery is supplied in the chassis, disconnect the battery. Only use fastening / quick release belts with a rated capacity of >5 tonnes. The fastening/quick release belts (24) should be attached to at least 4 different lorry / truck eyes.

  • Page 30: Commissioning

    Commissioning 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: – If necessary install and charge the battery (see chapter D, “Battery removal and installation”...

  • Page 32: D Battery Maintenance, Re-Charging, Replacement

    D Battery Maintenance, Re-Charging, Replacement Safety regulations for handling acid batteries Park the industrial truck securely before carrying out any work on the batteries (see Chapter E). Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel. The present operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.

  • Page 33: Battery Types

    Battery types The EKS 308 can be fitted with a variety of battery types. All battery types comply with DIN 43531-A. The following table shows which combinations can be included as standard: Battery type Truck type 48 V 2 PzS 160 L - A *...

  • Page 34: Charging The Battery

    Charging the Battery Park the truck securely (see “Parking the Truck Securely” in Chapter E). – Turn key switch (1) to "0" (zero). – Lift up the battery panels (3) (see arrow direction). Only connect and disconnect the battery connector and the socket when the mains and charger are switched off.

  • Page 35: Battery Removal And Installation

    Battery removal and installation Only batteries with insulated cells and terminal connectors may be used. When replacing a battery always use the same battery type. Extra weights must not be removed and must remain in the same position. The truck must be horizontal in order to prevent the battery from falling out when the battery retainer is removed.
  • Page 36 – Undo the battery retainer (4) by moving the lever (5) and remove the retainer. – Pull the battery (6) onto the side of the prepared battery trolley. Make sure the battery trolley is properly secured. After replacing/fitting the battery (6), make sure that the battery (6) is well secured in the battery compartment.

  • Page 37: Check The Battery Condition, The Acid Level And Acid Density

    Check the battery condition, the acid level and acid density – The battery manufacturer’s maintenance instructions apply. – Check the battery housing for cracks and any spilled acid. – Remove any oxydation remains from the battery terminals and apply an acid-free grease to the battery terminals.

  • Page 38: Safety Regulations For The Operation Of Forklift Trucks

    E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation: The forklift truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.

  • Page 39: Operating And Display Equipment On Control Panel

    Controls and Displays Operating and display equipment on control panel Item Control / Display Function t Controls the travel direction and speed of the Travel control knob truck t Lifting and lowering of main lift. Hydraulic control knob t Switches control current on and off. Removing Key switch the key prevents the truck from being switched on by unauthorised personnel.

  • Page 40: Display Unit Controls And Displays

    Display unit controls and displays 2.2.1 Upper range symbols Item Symbol Control / Function Display Displays possible travel speeds: Turtle Crawl speed Rabbit Max. travel speed “Guidance wire WG Sensors which have recognised the recognition” display guidance wire have a dark background Steering angle display Indicates the current steering angle with reference to the middle position...
  • Page 41 Item Symbol Control / Function Display t Time display “Time” display “Operating hours” Displays the number of service hours display since the truck was commissioned t Displays the battery charge status Battery dischargeindicator (residual capacity as a percentage) t Displays the height of the forks “Overall lift”...
  • Page 42 2.2.2 Lower range symbols and switches Activate switch (6) under the respective symbols (18) displayed or confirm the related function. The symbol will be given a dark background. Symbol Control or Display Function Warning Labels t Displayed when the slack chain safety “Slack chain safety device”...
  • Page 43 Symbol Control or Display Function Guidance systems “Guidance on” display not active “Guidance on” display Displays automatic guidance in the aisle: active Rail guidance display (drive wheel set to forward position) Indicates that wire guidance is activated “Guidance on” switch Sets the drive wheel to forward position Activates the aligning process (and frequency selection for multi-...

  • Page 44: Truck Operational Status Symbols

    Truck operational status symbols The operational status of the truck when it is switched on is indicated by symbols in the display unit. Safety gates open Foot switch not pressed When the following symbols are displayed you must carry out a reference movement in accordance with the display, i.e.

  • Page 45: Starting Up The Truck

    Starting up the truck Before the truck can be commissioned, operated or a load unit lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily work – Check the whole of the outside of the truck for signs of damage and leaks. –...

  • Page 46: Attaching The Safety Restraint Belt

    o Attaching the safety restraint belt Carry out a daily inspection of the safety restraint belt (32) and the eye (30), safety rope (29), karabiner hooks (28, 31) and attachment rail (27) at the front of the overhead guard, checking for wear and damage. Do not operate the truck under any circumstances if the safety restraint harness (28 - 32) and the attachment rail (27) at the front of the overhead guard are damaged.

  • Page 47: Preparing The Truck For Operation

    t Preparing the truck for operation – Put on the safety restraint harness, see “Attaching the safety restraint belt” in this chapter (option). – Close all safety gates. – Undo the EMERGENCY DISCONNECT (5) by turning it. – Put the key in the key switch (3) and turn it clockwise. –...

  • Page 48: Preparing The Truck For Operation With An Additional Access Code

    o Preparing the truck for operation with an additional access code – Put on the safety restraint harness, see “Attaching the safety restraint belt” in this chapter (option). – Fully close all safety gates. – Undo the EMERGENCY DISCONNECT (5) by turning it. –...

  • Page 49: Setting The Time

    Setting the time Selecting the “Set Time” menu: Press key 8, the display changes to the sub menu. Truck movements are inhibited in this truck menu. Now press key 35 twice; the “Set Time” menu now appears in the display unit. Setting the time: Truck movements are inhibited in this truck menu.

  • Page 50: Operator Specific Settings

    Operator specific settings Selecting the “Operator Specific Settings” menu: Press key 8, the display changes to the sub menu. Truck movements are inhibited in this truck menu. Now press key 38; the “Operator Specific Settings” menu now appears in the display unit. Settings in the “Operator Specific Settings”...

  • Page 51: Industrial Truck Operation

    Industrial truck operation Safety regulations for truck operation Travel routes and work areas: Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose. Travel conduct: The driver must adapt the travel speed to local conditions.

  • Page 52: Travelling, Steering, Braking

    Travelling, Steering, Braking – Press EMERGENCY DISCONNECT (5) down. All truck movement is disabled. The operation of the switch must not be affected by any objects placed in the way. 4.2.1 Travel The truck can be operated in 3 modes: Free ranging, wire guidance (WG) or rail guidance (RG).
  • Page 53 4.2.2 Steering The truck is steered outside of narrow aisles with the steering wheel. The drive wheel position is shown in the display unit (14). 4.2.3 Braking The truck’s brake pattern depends largely on the ground conditions. The driver must take this into consideration when handling the truck.

  • Page 54: Negotiating Narrow Aisles

    Negotiating narrow aisles It is forbidden for unauthorised personnel to enter narrow aisles (truck lanes in racking systems with safety distances < 500 mm) or for personnel to cross through them. These work areas must be marked and identified accordingly. Carry out a daily inspection of the safety mechanisms on the truck or the racking sysem to avoid hazards and protect personnel.
  • Page 55 4.3.1 Rail guidance truck Rail guidance trucks are equipped with sensors which activate aisle sensing when they enter narrow aisles. – Approach the aisle at reduced speed so that the truck is aligned with the narrow aisle and is within the demarcation. Observe the notices attached along the route.
  • Page 56 4.3.2 Wire guidance trucks When starting or continuing the truck after the wire guidance has been deactivated, note the position of the drive wheel as manual steering is now activated again. If an automatically guided truck is switched off, the wire guidance is no longer active when it is switched on again.
  • Page 57 Grab the handle (11) with the hand rest and with the other hand operate the travel control knob (1) and/or the hydraulic control knob (2) (two-hand operation). Turn the travel control knob (1) to change travel speed and direction. Continue to travel along the narrow aisle at your required speed.

  • Page 58: Lifting - Lowering - Outside And Inside Narrow Aisles

    Lifting – Lowering – outside and inside narrow aisles Risk of injury when lowering the driver’s cab and the load handler. Do not allow anyone to stay in the hazardous area. Lifting and lowering inside the narrow aisle requires two-handed operation. 4.4.1 Lift –...

  • Page 59: Order Picking And Stacking

    Order picking and stacking Collecting, transporting and depositing loads Before picking up a load unit the driver must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Observe the load chart. – Check the fork distance for the pallet and adjust if necessary. Adjusting the forks To lift the load securely, the forks must be as far apart as possible and centrally positioned with respect to the fork carriage.
  • Page 60 4.6.1 Lifting a load from the front. Before collecting the load the driver must ensure that the pallet clamp is open (see Chapter E, section 3.2). – Apply the foot switch (45). – Drive the truck slowly. – Slowly insert the forks into the pallet until the fork shank/driver’s platform touches the load or the pallet.

  • Page 61: Parking The Truck Securely

    4.6.3 Depositing a load – Drive the truck carefully up to the storage location Before a load can be deposited, the driver must ensure that the storage location is suitable for storing the load (size and capacity). – Apply the foot switch (45). –...

  • Page 62: Troubleshooting

    Troubleshooting This chapter enables the user to identify and rectify basic faults and the results of incorrect operation. When locating a fault, proceed in the order shown in the table. Fault Probable Cause Action Truck does not – Battery connector not –...
  • Page 63 Fault Probable Cause Action Error 144 – Truck quit – Restore wire guidance guidance wire Error 330 – Travel control button – Do not press travel control button, pressed during power switch truck off and on again up test Error 331 –...

  • Page 64: Emergency Stop Device

    Emergency stop device When the automatic emergency stop mechanism applies (e.g. if the wire guidance is lost, electric steering fails) the truck brakes to a halt. Before starting again, the cause of the error must be identified and corrected. Start the truck again in accordance with manufacturer’s instructions contained in these operating instructions (see “Starting up the Truck”...

  • Page 65: Exiting The Driver's Cab With The Emergency Abseil Device

    Exiting the driver's cab with the emergency abseil device Industrial trucks with a height-adjustable operator position which can exceed 3m from the ground, have an emergency lowering mechanism and an emergency abseil device for the driver which he can use if the operator position ever becomes stuck. If the driver’s cab cannot be lowered due to a fault, not even with the emergency lowering (see “Driver’s Cab Emergency Lowering”...

  • Page 66: Slack Chain Safety Device Override

    Slack chain safety device override If the slack chain safety device has applied, e. g. when positioning the load handler, loosening or braking the lift chain, the “slack chain safety device” symbol (63) illuminates in the display unit. It is possible to raise the Main Lift if the slack chain safety device override switch (39) is depressed and held down while pressing the hydraulic control knob.

  • Page 67: Aisle End Safety Device (O)

    Aisle end safety device (o) Trucks with the aisle end safety device brake before the aisle exit or in the transfer aisle. There are two basic versions for this: 1. Braking to a halt 2. Braking to 2.5 km/h Other variants (affecting the subsequent travel speed, lift height etc.) are available. 1.

  • Page 68: Wire Guidance Emergency Mode (If) (Error 144)

    Wire guidance emergency mode (IF) (Error 144) If in a wire guidance system the guiding antenna extends beyond the pre-determined range of the guidance wire, an emergency stop is immediately performed. If the truck is travelling directly parallel to the guidance wire, travel is not disabled. The “tracking on”...

  • Page 69: Recovering The Truck From A Narrow Aisle / Moving The Truck Without A Battery

    Recovering the truck from a narrow aisle / Moving the truck without a battery Before recovering the truck from a narrow aisle, disconnect the battery. This operation must only be performed by suitably trained maintenance personnel. When the brakes are de-activated the truck must be parked on an even ground as the brakes are no longer effective.
  • Page 70 5.9.2 Adjusting the steering angle The battery must be disconnected when adjusting the steering angle. – Remove the electronic compartment cover at the back. Using an Allen switch set the steered wheel to the required direction via the screw in the steering motor (72). When setting an angle greater than 4 degrees it is advisable to discharge the wheel by raising/jacking up the truck.
  • Page 71 5.9.4 Emergency recovery in load direction – Remove the electronic compartment cover at the back. – Lower the operator position carriage and release the magnetic brake. – Insert the abseil rope (78), tow force > 5 tonnes, to the two mast suspensions (76, 77).

  • Page 72: F Maintenance Of The Forklift Truck

    F Maintenance of the forklift truck Operational safety and environmental protection The servicing and inspection duties contained in this chapter must be performed in accordance with the intervals indicated in the maintenance checklists. Any modification to the forklift truck assemblies, in particular the safety mechanisms, is prohibited.
  • Page 73 Electrical System: Only suitably trained personnel may operate on the truck’s electrical system. Before working on the electrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also de-energise the truck by removing the battery connector. Welding: To avoid damaging electric or electronic components, remove these from the truck before performing welding operations.

  • Page 74: Servicing And Inspection

    The application conditions of an industrial truck considerably affect the wear levels of the service components. We recommend an application analysis carried out on site by a Jungheinrich customer adviser to establish specific maintenance intervals in order to restrict damage caused by wear.

  • Page 75: Eks 308 Maintenance Checklist

    EKS 308 maintenance checklist Maintenance intervals Standard = W A B C Chassis/ 1.1 Check all load bearing components for damage Super- 1.2 Check screw connections structure: 1.3 Test the operator platform and check for damage 1.4 Check that identification points, data plates and warnings are legible and replace if necessary 1.5 Check tilt safety devices are present and secure...
  • Page 76 Maintenance intervals Standard = W A B C Hydraulic 6.1 Test operation System 6.2 Check connections and ports for leaks and damage 6.3 Check hydraulic cylinder for leaks and damage and make sure it is secure 6.4 Check oil level 6.5 Test hose guide and check for damage 6.6 Check ventilation and discharge filter on hydraulic...
  • Page 77 Maintenance intervals Standard = W A B C Lift 10.1 Clean rollers, guide rollers and contact surfaces in the mechanism: mast sections and apply grease. Warning: Danger of crashing! 10.2 Check mast attachments (bearings and retaining screws) 10.3 Check lift chains and chain guide for wear, adjust and lubricate 10.4 Lubricate lift chains 10.5 Visually inspect rollers, slide pieces and stops...

  • Page 78: Lubrication Schedule

    Lubrication Schedule a Transmission oil drain plug Contact surfaces c Hydraulic oil drain plug Grease nipple Hydraulic oil filler neck...

  • Page 79: Consumables

    Consumables Handling Consumables: Consumables must always be handled correctly. Follow the manufacturer’s instructions. Improper handling is hazardous to health, life and the environment. Consumables must only be stored in appropriate containers. They may be flammable and must therefore not come into contact with hot components or naked flames. Only use clean containers for adding consumables.

  • Page 80: Maintenance And Repairs

    Maintenance and Repairs Load bearing parts of the truck, e. g. chassis and mast, may only be welded after consultation with the manufacturer. Prepare the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs.

  • Page 81: Securing The Driver's Position Carriage And Mast

    Securing driver’s position carriage and mast The driver’s position carriage can be secured in the raised position. – Raise the driver’s position carriage until the threads (1,2) for the retaining bolts are free. – Unscrew the retaining bolts from the attachment (3).

  • Page 82: Hydraulic Oil

    Hydraulic oil – Prepare the truck for maintenance and repairs Oil must never be allowed to enter the drainage system or the soil. Used oil must be preserved until it can be disposed of in the correct manner. Only fill or drain hydraulic oil when the mast is completely lowered. Remove the electronic compartment cover at the back.

  • Page 83: Checking Electrical Fuses

    Checking electrical fuses Electric fuses must only be checked and replaced by authorized personnel. – Prepare the truck for maintenance and repairs (see Chapter F). – Remove the electronic compartment cover at the back. – Check the fuse rating and condition in accordance with the table; replace if necessary.

  • Page 84: Recommissioning The Truck After Cleaning Or Maintenance Work

    Recommissioning the truck after cleaning or maintenance work The truck can only be re-commissioned after cleaning or maintenance once the following procedures have been carried out: – Test the horn. – Test the MAIN SWITCH or the EMERGENCY DISCONNECT to make sure they are operating correctly.

  • Page 85: Action To Be Taken During Decommissioning

    Action to be taken during decommissioning: Every 2 months: – Charge up the battery (see “Charging the Battery” in chapter D). Battery powered trucks: It is important to regularly charge the battery as otherwise automatic discharge will result in battery depletion. This will destroy the battery as a result of sulphurisation. Recommissioning the truck after decommissioning –...

  • Page 86: Safety Checks To Be Performed At Regular Intervals And Following Any Unusual Incidents

    Carry out a safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM Guideline 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.
  • Page 87 F 16...
  • Page 88 Jungheinrich traction battery Table of contents Jungheinrich traction battery ..........2-6 with positive tubular plates type EPzS and EPzB Type plate Jungheinrich traction battery..........7 Instruction for use ............8-12 Aquamatic/BFS III water refilling system Jungheinrich traction battery Maintenance free traction batteries with positive tubular plates type EPzV ....................13-17...
  • Page 89 Jungheinrich traction battery with positive tubular plates type EPzS and EPzB Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 V x No of cells 3. Discharge current:: C5/5h 4. Nominal S.G. of electrolyte* Type EPzS:...
  • Page 90 Ignoring the operation instructions, repair with non-original parts or using additives for the electrolyte will render the warranty void. For batteries in classes I and II the instructions for maintaining the appropriate protection class during operation must be complied with (see relevant certificate). 1.
  • Page 91 Battery container lids and the covers of battery compartments must be opened or re- moved. The vent plugs should stay on the cells and remain closed. With the charger switched off connect up the battery, ensuring that the polarity is cor- rect.
  • Page 92 3. Maintenance 3.1 Daily Charge the battery after every discharge. Towards the end of charge the electrolyte level should be checked and if necessary topped up to the specified level with purified water. The electrolyte level must not fall below the anti-surge baffle or the top of the separator or the electrolyte „min“...
  • Page 93 5. Storage If batteries are taken out of service for a lengthy period they should be stored in the fully charged condition in a dry, frost-free room. To ensure the battery is always ready for use a choice of charging methods can be made: 1.
  • Page 94 7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr. Lieferanten Nr. Serial-Nr. Supplier No. Nennspannung Kapazität Nominal V oltage Capacity Zellenzahl Batteriegewicht min/max Number of Cells Battery mass min/max Hersteller Jungheinrich AG, D-22047 Hamburg, Germany Manufacturer...
  • Page 95 Aquamatic/BFS III water refilling system for Jungheinrich traction battery with EPzS and EPzB cells with tubular positive plates Aquamatic plug arrangement for the Operating Instructions Cell series* Aquamatic plug type (length) EPzS EPzB Frötek (yellow) (black) 2/120 – 10/ 600 2/ 42 –...
  • Page 96 Diagrammatic view Equipment for the water refilling system 1. Water tank 2. Level switch 3. Discharge point with ball valve 4. Discharge point with sole- noid valve 5. Charger 6. Sealing coupler 7. Closing nipple 8. Ion exchange cartridge with conductance meter and solenoid valve 9.
  • Page 97 4. Filling (manual/automatic) The batteries should be filled with battery water as soon as possible before the battery charging comes to an end; this ensures that the refilled water quantity is mixed with the electrolyte. In normal operation it is usually sufficient to fill once a week. 5.
  • Page 98 8. Battery hose connections Hose connections for the individual plugs are laid along the existing electric circuit. No changes may be made. 9. Operating temperature The temperature limit for battery operation is set at 55° C. Exceeding this temperature damages the batteries. The battery filling systems may be operated within a tempe- rature range of >...
  • Page 99 10.2.1 Clamping ring tool The clamping ring tool is used to push on a clamping ring to increase the contact pres- sure of the hose connection on the plugs' hose couplings and to loosen it again. 10.3 Filter element For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte- ry's main supply pipe for supplying battery water.

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