Jungheinrich EFG 535 Operating Instructions Manual
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Jungheinrich EFG 535 Operating Instructions Manual

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EFG 535/540/545/550
01.04
G
Operating Instructions
52016502
07.08

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Summary of Contents for Jungheinrich EFG 535

  • Page 1 EFG 535/540/545/550 01.04 Operating Instructions 52016502 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

    Table of Contents Correct Use and Application of the Truck Truck Description Application ................... B 1 Assemblies and Operational Description ..........B 2 Truck ....................B 3 Standard Version Specifications ............B 4 Performance data ................B 4 Weights (all weights in kg) ..............B 6 Tyres ....................
  • Page 5 Operation Safety Regulations for the Operation of Forklift Trucks ...... E 1 Controls and Displays ................. E 2 Instrument panel switches ..............E 6 Operating panel switches ..............E 6 Multi-function display ................E 7 Warning displays, buttons and switches ..........E 8 Displays ....................
  • Page 6 Maintenance of the forklift truck Operational safety and environmental protection ........ F 1 Maintenance Safety Regulations ............F 1 Servicing and inspection ..............F 3 EFG Maintenance Checklist ............... F 4 EFG lubrication schedule ..............F 7 Fuels, coolants and lubricants ............. F 8 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 Use And Application Of The Truck

    A Correct Use and Application of the Truck 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 operator manual is an industrial truck designed for lifting and transporting load units.

  • Page 12: B Truck Description

    It can be used to stack and transport standardised DIN 15142 pallets, DIN 15144 lattice box pallets and other palletised loads. Truck models and maximum capacity: Type Max. capacity *) Load centre of gravity EFG 535 3.500 kg 500 mm EFG 540 4.000 kg 500 mm EFG 545 4.500 kg...

  • Page 13: Assemblies And Operational Description

    Assemblies and Operational Description Item Description t Overhead guard t Driver’s seat t Counterweight t Steering axle t Drive axle t Fork carriage t Mast t Steering...

  • Page 14: Truck

    Truck Steering (8): When the driver’s seat is occupied the steering is set to stand-by. The steering unit operates at a preset speed. Depending on the steering requirements the speed of the steering pump increases, and the travel speed reduces as a function of the steering angle (Curve Control).

  • Page 15: Standard Version Specifications

    2450 2450 Load distance (DZ mast + 32 mm) Wheelbase 1855 2000 2000 2000 Performance data Description EFG 535 EFG 540 EFG 545 EFG 550 Q Capacity/Load 4.99 c Load centre of gravity Travel speed w / w.o. 16/17 15/17 15/16.5...

  • Page 17: Weights (All Weights In Kg)

    28 x 10 x 22 28 x 12 x 22 Tyre size, rear 21 x 8 -9 Rubbe 21 x 7 -15 1/8“ Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries plea- se contact your Jungheinrich customer adviser.

  • Page 18: En Norms

    EN norms Noise emission: 75 dB(A) in accordance with prEN 12053 as harmonised 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.

  • Page 19: Identification Points And Data Plates

    Identification points and data plates Warnings and notices such as load charts, attachment points and data plates must at all times be legible. Replace if necessary. h3 (mm) Q (kg) D (mm) Item Description “Maximum body size” notice Decal: Do not step onto or beneath the load, trap point Risk of crashing Strap points “No passengers”...

  • Page 20: Data Plate, Truck

    Data plate, truck 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 regarding the truck or spare part orders, please indicate the serial number (23) Truck load chart...

  • Page 21: Fork Load Chart (Basic Model)

    Fork load chart (basic model) The fork load chart indicates the capacity Q of the truck in kg. It shows in schematic form the maximum capacity for a range of load centres of gravity D (in mm). Attachment load chart The attachment load chart indicates the capacity Q of the truck in conjunction with the respective attachment in kg.

  • Page 22: C Transport And Commissioning

    C Transport and Commissioning Lifting by crane Only use lifting gear with sufficient capacity (Weight lifted = net weight + battery weight; see truck data plate). – Park the truck securely (See Chapter E). – Attach the crane lifting slings to the mast cross member (1) and the attachment coupling (2).

  • Page 23: Securing The Truck For Transport

    Securing the Truck for Transport. When transported on a lorry or a trailer the truck must be securely wedged and fastened down. The lorry or attachment must have securing rings and a wooden floor. Loading shall be carried out by staff especially trained for that purpose in accordance with recommendations contained in Guidelines VDI 2700 and...

  • Page 24: Commissioning

    Commissioning Commissioning and driver instruction must only be performance by trained personnel. If several trucks are supplied, make sure that only load lifting devices, masts and basic trucks with the same serial number are assembled. Operate the truck only with battery voltage.

  • Page 25: Operating The Truck Without Its Own Drive System

    Operating the truck without its own drive system To operate the truck without power supply, release the spring-loaded accumulator brake as follows: – Set lever (3) to the left position “Release accumulator brake” – Turn the steering wheel right until a pressure builds up in the hydraulic system spring-loaded...

  • Page 26: Moving A Truck With A Rotary Seat (O) Without Its Own Power System

    Moving a truck with a rotary seat (o) without its own power system – Move the lever (4) to the left to the “release spring-loaded accumulator brake” position. – Move the pump lever (5) up and down until the spring loaded piston has extended to the end (approx.

  • Page 28: D Battery Maintenance, Charging & Replacement

    D Battery Maintenance, Charging & Replacement Safety regulations for handling acid batteries Before any work is carried out on the batteries the truck must be safely parked (see Chapter E). Maintenance personnel: Batteries may only be charged, serviced or replaced by trained personnel.

  • Page 29: Battery Types

    The truck will be equipped with different battery types, depending on the application. The following table indicates the capacities to show which combinations can be included as standard, similar to DIN 43536 (80 V). EFG 535 80 V - 5PzS - battery 700 Ah EFG 540 / 545 / 550 80 V - 6PzS - battery 840 Ah The battery weight is indicated on the battery data plate.

  • Page 30: Opening The Battery Cover With A Retaining System (Option)

    Opening the battery cover with a retaining system (option) If the truck is fitted with a retaining system, the battery cover can only be opened if the safety latch is down. – For the automatic retaining system engage the stop button (1) and set the latch down.

  • Page 31: Exposing The Battery

    Exposing the battery Park the truck securely (See Chapter E). – Loosen the steering column stop (2), push the steering column forward and secure it in this position. Pay particular attention when locking and unlocking the control valve cover. With MULTI PILOT –...

  • Page 32: Charging The Battery

    Only connect and disconnect the battery connector and the socket when the mains and charger are switched off. – Disconnect the battery (9). – If necessary, remove the insulating mat from the battery. Charging the battery – Expose the battery (see “Exposing the battery”). Only connect and disconnect the battery and charger when the charger is switched off.

  • Page 33: Charger Socket (O)

    Charger socket (o) – Park the truck securely (see chapter E) Always connect and disconnect the battery and charger when the charger is switched off. – Connect the charger lead of the bat- tery charger station to the charger socket (10). –...

  • Page 34: Battery Removal And Installation

    Battery removal and installation The battery must not be raised above the collision guard at the rear wall, otherwise the fans or the seat cover may be damaged. – Expose the battery (See Chapter D, Section 3). – Remove the side section (12, 13). To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat.

  • Page 35: Closing The Battery Cover

    Closing the battery cover With MULTI PILOT – Push the locking panel back with force to engage the locking bolts (14). With SOLO PILOT – After closing the battery panel move the pilot valve cover (3) back until it locks in place. With rotary seat: –...

  • Page 36: Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter

    Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter Battery Discharge Indicator: The battery charge status is shown on the information and service display panel. The standard setting for the battery discharge indicator / discharge monitor is based on standard batteries. The display must be reset if using maintenance-free batteries. The Service department must carry out the adjustment.
  • Page 37 D 10...

  • 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: Controls And Displays

    Controls and Displays Item Control / Function Display Steering wheel Steers the truck with 5 full turns from left to right. Information and Service Displays the main travel, lift parameters, warning Display displays, error messages and service displays, as well as battery discharge and service hour display. Parking brake (toggle Only apply manually when operating brakes fail.
  • Page 40 MULTIPILOT trucks 10 9 Dual pedal control SOLOPILOT trucks 14 15 16 17...
  • Page 41 o Truck with electric steering in the left armrest Item Control / Function Display o Same operation as for Solopilot items 16; 17; Fingertip 18; 19 o Displays the main travel, lift parameters, Control panel warning displays, error messages and service displays, as well as battery discharge and elapsed hour display.
  • Page 42 Truck with electric steering in the left armrest (rotary seat only) Truck with multifunction armrest MULTIPILOT / Fingertip 16 17 18 19...

  • Page 43: Instrument Panel Switches

    Instrument panel switches Function Hazard warning switch “Beacon / parking light” switch Windscreen wiper / washer system switch Position 1 “Windscreen wiper on” Position 2 “Washing system on” Operating panel switches Function “Lift cutout” override switch “Inching” switch “Seat heater” switch “Truck lighting”...

  • Page 44: Multi-Function Display

    Multi-function display The multi-function display shows the operating data, the battery charge, the service hours and error details and information. Graphic illustrations on the multi-function display act as warning indicators. Item Display Service hours / time toggle switch Controller overtemperature Pump motor overtemperature Drive motor overtemperature Seat switch...

  • Page 45: Warning Displays, Buttons And Switches

    Warning displays, buttons and switches The following conditions are displayed or switched on: Item Display / Function Hourmeter – Time Toggle Switch – Service hours during which truck key switch is ON – EFF service hours can be switched ON or OFF via a code. –...

  • Page 46: Displays

    Displays Item Function Travel direction and wheel position display – Indicates the pre-selected travel direction (forward or reverse) or the position of the steered wheels. Battery capacity display in % Indicates the available residual capacity. 0% display = battery 80% discharged. For a 10% display the warning indicator flashes (42).

  • Page 47: Control Panel Displays

    Control panel displays Item Display No function No function No function Crawl speed control light No function Travel direction indicator – For lighting with a flashing indicator system Parking brake applied – Truck operational, parking brake applied Truck operational – Key switch ON No function Seat switch –...

  • Page 48: Control Panel Buttons

    Control panel buttons 50 52 54 56 58 60 62 64 51 53 55 57 59 61 63 65 km/h Item Function Select travel program (go up to other modes) Hourmeter / time toggle switch SET button – Selects special functions Selects travel program (go down to other modes) Parking brake Applies / releases parking brake...
  • Page 49 Item Function Switches warning indicator system on and off. Switches front headlights on and off. Switches rear headlights on and off. Switches dipped lights on and off. Switches parking light on and off. Switches rear window heating on and off. Switches seat heating on and off.
  • Page 50 Displays km/h Item Function Battery capacity display – Battery discharge status Profile number (travel / lift profile 1, 2, 3, 4 and 5) Hourmeter display – Time display – Residual time display with on-board battery (hours : minutes) Error display: –...

  • Page 51: Setting The Time

    Setting the time Normal operating mode Press the “h/time” (68) and up (67) keys simultaneously The time appears on the display. The first digit flashes. Use the up (67)/down (70) key to increase or decrease the flashing digit. Use the SET key (69) to jump to the next figure.

  • Page 52: Driver's Display Warning Messages

    2.10 Driver’s display warning messages Display Meaning INFO 02 - no direction selected when truck powered up, no wheel position displayed -Travel direction changed to neutral setting during operation, wheel position display alternates between forward and reverse. INFO 05 (optional setting for travel cutout input) Lift cutout active / independent of other conditions INFO 16 (optional setting for travel cutout input)

  • Page 53: Starting Up The Truck

    Starting up the truck Before commissioning or operating the truck, and before raising a load, the driver must ensure that there is nobody in the hazardous area and that the truck is safe to operate. Checks and operations to be performed before starting daily work –...

  • Page 54: Adjusting The Driver's Seat

    Adjusting the driver’s seat To achieve optimal seat cushioning the driver’s seat must be adapted to the driver’s weight. Adjusting the driver's weight: – Sit on the driver’s seat. When the weight is set correctly the arrow on the driver’s weight display (94) should be above the calibration line.
  • Page 55 Adjusting the backrest tilt: – Sit on the driver’s seat. – Lift up the backrest tilt adjuster (91) and adjust the incline of the backrest. – Release the backrest tilt adjuster (91) to lock the backrest in position. Adjusting the seat position: –...

  • Page 56: Safety Restraint Belt

    Safety restraint belt Put on the safety restraint belt each time before starting the industrial truck. The belt protects against serious injury. Protect the belt from contamination (e.g. cover it when the truck is idle) and clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to prevent them from freezing up again.
  • Page 57 Restraint belt instructions Before starting the truck pull the belt out of the pulley, pull it tightly across your body and engage it in the lock. The belt must not be twisted when fastened. When operating the truck (e.g. travelling, lifting, lowering, etc.), sit as far back as possible so that your back is against the backrest.

  • Page 58: Automatic/Mechanical Restraint System (Option)

    Automatic/mechanical restraint system (option) Never use the truck with a non-functional restraint system. The restraint system must be checked by authorised specialist personnel after an accident. Do not alter the restraint system. When the driver’s seat is occupied, maintain a 90 mm gap between the gate (98) and the seat to ensure safety.
  • Page 59 Restraint system (automatic) operating instructions Test the restraint system before starting the truck. The stop knob (98) must not be engaged. – Sit down on the seat – Turn the key switch “On”. After releasing the parking brake the two safety gates (LH and RH) close and lock automatically.

  • Page 60: Adjusting The Steering Column

    Adjusting the steering column – Loosen the steering column lock (4) and push the steering column forward or back into the desired position. – Now fix the steering column lock again. To prepare the truck for operation – Unlatch the isolator (10). –...

  • Page 61: Heating (O)

    Heating (o) Covering the heater is prohibited due to severe risk of burning. – Set switch (101) to level I or II to switch on the heating. If the switch (101) is set to the middle position, the heating is off. –...

  • Page 62: 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. Driving code: The driver must adapt the travel speed to local conditions.

  • Page 63: Travel

    Travel Travelling in electromagnetic fields beyond the permitted limits can result in random truck motion. Immediately apply the EMERGENCY DISCONNECT, brake with the service brake and apply the parking brake. Determine the cause of the fault and if necessary inform the manufacturer’s service department.
  • Page 64 the MULTI-PILOT (104). Forward travel (single pedal) Make sure that the travel area is clear – Release the parking brake (3). – Push the travel direction switch (14/ 104) on the SOLO-PILOT or the MULTI-PILOT forward – Slowly apply the accelerator pedal (6) Forward travel (twin pedal) Make sure that the travel area is clear –...
  • Page 65 Forward travel (rotary seat) Make sure that the travel area is clear To ensure comfortable entry and exit pull the rotary stop (24) up and turn the seat to the left until it engages. – Fold the armrest down. – Release the parking brake (3) –...
  • Page 66 Accelerating (single pedal / rotary seat) – Slowly apply the accelerator pedal (6) until the truck starts to move. – Continue to depress the accelerator (6). The motor speed and travel speed increase the more you apply the accelerator. Accelerating (twin pedal) –...

  • Page 67: Steering (T) / Electrical Steering (O)

    Braking The braking pattern depends largely on the ground conditions. The driver must take this into consideration when handling the truck. Brake with care to prevent the load from slipping. If you are travelling with an attached load you must increase the braking distance. –...
  • Page 68 Reversing brake (single pedal) – Set the travel direction switch (14/104) to the opposite direction while travelling. The truck brakes regeneratively via the traction controller until it starts to travel in the opposite direction. Depending on the truck model, the travel direction switch may be fitted to the –...

  • Page 69: Operating The Lift Mechanism And Attachments

    Operating the lift mechanism and attachments (MULTI-PILOT) The Multipilot must only be operated from the driver’s seat. The driver must be instructed in how to handle the lift mechanism and the attachments. Push the Multipilot in the desired direction, depending on the hydraulic function.
  • Page 70 6.5.1 Controlling Attachments (Multipilot) (o) Note the manufacturer’s operating instructions and the capacity of the attachment. Do not lift other people with the lifting device. Auxiliary Controller I (Integrated Sideshift) – Press the button (112) on the Multipilot to push the fork carriage to the left.
  • Page 71 Operating the lift mechanism and attachments (SOLO-PILOT) (Fingertip o) SOLOT-PILOT must only operated from the driver’s seat. The driver must be instructed in how to handle the lift mechanism and the 16 17 18 attachments. Lifting/lowering the fork carriage – Pull the SOLO-PILOT (16) back to raise the fork carriage.
  • Page 72 Integrated Sideshift (o) The fork carriage can be moved sideways using the integrated sideshift. – Pull the auxiliary hydraulics control lever ZH1 (18) back = sideshift right. – Push the auxiliary hydraulics control lever ZH1 (18) forward = sideshift left. Integrated fork positioner (o) The integrated fork positioner allows the distance between the forks to be set.

  • Page 73: Collecting, Transporting And Depositing Loads

    Collecting, transporting and depositing loads Before lifting a load, the driver must ensure that it is correctly palletised and that the capacity of the truck is not exceeded. Note the load chart. Adjusting the forks Adjust the fork tines in such a way that both are equally distanced from the outer edge of the fork carriage and the load centre of gravity lies in the middle of...
  • Page 74 – Drive the truck with forks spread as far apart as possible underneath the load. At least two thirds of their length must extend into the load. – Apply the parking brake (3). Raise the fork carriage until the load rests freely on the forks.
  • Page 75 Transporting a load If the load is stacked so high that it affects forward visibility, then reverse. – Gently accelerate with the accelerator pedal (6) and slowly brake with the brake pedal (7). Be ready to brake at all times. –...

  • Page 76: Parking The Truck Securely

    Parking the truck securely When you leave the truck it must be securely parked even if you only intend to leave it for a short time. – Drive the truck onto a level surface. – Engage the parking brake (3) / brake button (o) (71).

  • Page 77: Trailer Towing

    Trailer towing The truck may be used for occasional towing of trailers on dry, level and smooth sur- faces. The max. tow load is the capacity indicated on the capacity data plate (see decals diagram in chapter B). The tow load consists of the weight of the trailer and the stated capacity. If a load is transported on the forks, the tow load must be reduced by the same amount.

  • Page 78: Troubleshooting

    Troubleshooting This chapter is designed to help the user identify and rectify basic faults or the results of incorrect operation. When locating a fault, proceed in the order shown in the table. Fault Probable Cause Action Truck does – Battery connector –...
  • Page 79 E 42...

  • Page 80: F Maintenance Of The Forklift Truck

    F Maintenance of the forklift truck Operational safety and environmental protection The checks and servicing operations contained in this chapter must be performed in accordance with the intervals as indicated in the servicing checklists. Modifications of forklift truck assemblies, especially of the safety installations, are not permitted.
  • Page 81 Electrical System: Work on the truck’s electrical system may only be performed by trained personnel. Before commencing work on the elctrical system, take all precautionary measures to avoid electric shocks. For battery-operated trucks, also depower the truck by removing the battery connector. Welding: To avoid damaging electrical or electronic components, have them removed from the truck before performing welding operations.

  • Page 82: Servicing And Inspection

    The application conditions of an industrial truck have a considerable impact on the wear of the service components. We recommend that a Jungheinrich customer service adviser carries out an application analysis on site to work out specific service intervals to prevent damage due to wear.

  • Page 83: Efg Maintenance Checklist

    EFG Maintenance Checklist Maintenance intervals Standard= W A B C Chassis/ 1.1 Check all load bearing items for damage Superstructure: 1.2 Check screw connections 1.3 Check trailer coupling 1.4 Check overhead guard for damage and make sure it is secure 1.5 Test seat belt operation and check for damage 1.6 Test retaining system (option) operation and check for damage...
  • Page 84 Maintenance intervals Standard= W A B C Hydraulic 6.1 Check connections and ports for leaks and damage System: 6.2 Check ventilation and discharge filter on hydraulic tank 6.3 Check oil level 6.4 Check hydraulic cylinder for leaks and damage and make sure it is secure 6.5 Test operation of hoses and check for damage 6.6 Replace filter cartridge (hydraulic oil and discharge filter)
  • Page 85 Maintenance intervals Standard= W A B C Mast: 10.1 Apply lubricant to tracks and lateral stopping face of the guide rollers in the mast sections. 10.2 Check lift chains for wear and adjust. 10.3 Grease lift chains and check voltage. 10.4 Check mast attachment 10.5 Check tilt cylinder bearing and attachment 10.6 Check forks and fork carriage for wear and damage...

  • Page 86: Efg Lubrication Schedule

    EFG lubrication schedule t - D g - E g - E b - N g Slide surfaces Transmission oil filler neck Grease nipple Transmission oil drain plug Hydraulic oil filler neck Mineral oil filler neck for brake system Hydraulic oil drain plug Oil level control screw...

  • Page 87: Fuels, Coolants And Lubricants

    Fuels, coolants and lubricants 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.

  • Page 88: Maintenance And Repairs

    Maintenance and Repairs Prepare the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents during maintenance and repair work. The following preparations must be made: – Park the truck securely (See Chapter E). – Disconnect the battery to prevent the truck from being switched on accidentally When working under a raised load fork or a raised truck, secure them to prevent them from lowering, tipping or sliding away.

  • Page 89: Checking The Hydraulic Oil Level

    Checking the hydraulic oil level The load lifting device must be fully lowered. – Prepare the truck for maintenance and repairs (See section 6.1). – Undo the three base plate screws. – Tilt the steering column forward and remove the base plate. –...

  • Page 90: Replacing The Hydraulic Oil Filter

    Replacing the hydraulic oil filter The hydraulic oil filter is located on the left hand side of the tilt cylinder and can be accessed by removing the base plate. – Unscrew the hydraulic oil filter cap (5). – Replace the filter cartridge; if the O-ring is damaged, it must also be replaced.

  • Page 91: Changing The Suction Filter Of The Motor Fan

    Changing the suction filter of the motor fan Loosen the screw (8), take the mesh (9) off from the front and replace the filter. Restraint belt maintenance The driver must check the operation and condition of the restraint belt each day before using the industrial truck.

  • Page 92: Checking Electrical Fuses

    Checking electrical fuses – Prepare the truck for maintenance and repairs (See section 6.1). – Open the battery cover or unscrew the electronics cover. – Unscrew the cap. – Check the fuse rating and condition in accordance with the table. To avoid damaging the electrical system, only use fuses with the appropriate rating.

  • Page 93: Recommissioning

    6.10 Recommissioning Recommissioning after cleaning or repair work is permitted only after the following operations have been performed. – Test horn operation. – Test main switch operation. – Test brake operation. – Lubricate the truck in accordance with the lubrication chart. Decommissioning the forklift truck If the forklift truck is to be decommissioned for more than two months, e.g.

  • Page 94: Recommissioning

    Safety tests to be performed at intervals and after unusual events Perform a safety check in accordance with national regulations. Jungheinrich recom- mends the truck be checked to FEM guideline 4.004. Jungheinrich has a safety de- partment with trained personnel, able to carry out inspections.
  • Page 95 F 16...
  • Page 96 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 97 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 98 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 99 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 100 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 101 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 102 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 103 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 104 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 105 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 106 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 107 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.

This manual is also suitable for:

Efg 540Efg 545Efg 550

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