Jungheinrich EFG 213 Operating Instructions Manual
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Jungheinrich EFG 213 Operating Instructions Manual

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EFG 213-320
06.08-
G
Operating Instructions
51099986
07.11

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Summary of Contents for Jungheinrich EFG 213

  • Page 1 EFG 213-320 06.08- Operating Instructions 51099986 07.11...
  • Page 2 Declaration of Conformity Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or his authorized representative in the Community Type Option Serial No. Year of construc- tion EFG 213 EFG 215 EFG 216k EFG 216 EFG 218k EFG 218 EFG 220...
  • Page 4 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 6: Table Of Contents

    Assemblies and Functional Description ..........B 2 Truck ....................B 3 Standard Version Specifications ............B 4 EFG 213-220 performance data ............B 4 EFG 316-320 performance data ............B 5 EFG 213-220 dimensions ..............B 6 EFG 316-320 dimensions ..............B 8 EFG 213-220 weights .................
  • Page 7 Battery Maintenance, Charging & Replacement Safety regulations for handling acid batteries ........D 1 Battery types ..................D 2 Battery removal and installation ............D 3 Removal and installation using a multi-adapter (o) ......D 3 Removal and installation using a worktable for crane loading (o) ..D 5 Removal and installation using a fork shoe (o) ........
  • Page 8 Industrial Truck Maintenance Operational Safety and Environmental Protection .......F 1 Maintenance Safety Regulations ............F 1 Servicing and Inspection ..............F 3 Maintenance checklist ................F 4 Lubrication Schedule ................F 6 Consumables ..................F 7 Maintenance Instructions ..............F 8 Preparing the truck for maintenance and repairs .........F 8 Opening the rear panel ................F 8 Checking the wheel attachments.
  • Page 10 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. If using a battery with closed EPzV and EPzV ironclad plates, this must first be...

  • Page 12: A Correct Use And Application

    A Correct Use and 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 14: B Truck Description

    Closed bottom pallets can also be lifted. Truck models and maximum capacity: Type Max. capacity Load centre of gravity EFG 213 1,300 kg 500 mm EFG 215 1500 kg 500 mm...

  • Page 15: Assemblies And Functional Description

    Assemblies and Functional Description Item Description Item Description 1 t Driver's seat t Load handler 2 t Overhead guard t Fork carriage 3 t Mast 10 t Drive axle 4 t Steering wheel 11 t Battery door On-board charger o Multifunction steering wheel 12 o (in battery compartment) 5 t SOLOPILOT...

  • Page 16: Truck

    Truck Safety mechanisms: The overhead guard (2) protects the driver from falling objects. Pressing the EMERGENCY DISCONNECT switch rapidly disconnects all electrical functions in hazardous situations. Travelling and lifting can only be activated when the driver is seated. The dashboard control panel (6) displays the truck information. Steering: The travel speed reduces as a function of the steering angle (“CurveControl”).

  • Page 17: Standard Version Specifications

    Standard Version Specifications Technical specification details in accordance with VDI 2198. Technical modifications and additions reserved. EFG 213-220 performance data Description 216k 218k Capacity 1300 1500 1600 1800 2000 (where C = 500 mm) *) Load centre of gravity distance...

  • Page 18: Efg 316-320 Performance Data

    EFG 316-320 performance data Description 316k 318k Capacity (where C = 1600 1600 1800 1800 2000 500 mm) *) Load centre of gravity distance Travel speed 17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 km/h with / without load Raise lift speed 0.49/0.60 0.49/0.60 0.44/0.55 0.44/0.55 0.40/0.55 with / without load Lower lift speed 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55...

  • Page 19: Efg 213-220 Dimensions

    EFG 213-220 dimensions All dimensions in mm Description 216k 218k Mast height retracted 2000 2000 2000 2000 2000 Free lift Lift 3000 3000 3000 3000 3000 Mast height extended 3560 3560 3560 3587 3587 Overhead guard height 2040 2040 2040...

  • Page 21: Efg 316-320 Dimensions

    EFG 316-320 dimensions All dimensions in mm Description 316k 318k Mast height retracted 2000 2000 2000 2000 2000 Free lift Lift 3000 3000 3000 3000 3000 Mast height extended 3560 33560 3587 3587 3587 Overhead guard height 2040 2040 2040 2040 2040 Seat height...

  • Page 23: Efg 213-220 Weights

    EFG 213-220 weights All dimensions in kg Description 216k 218k Truck weight 3000 3256 2733 2978 3382 (including battery) 3057 3207 1411 1409 Front axle load 1326 1310 1501 (without lifting load) 1496 1520 4052 4380 Front axle load 3545...

  • Page 24: Efg 213-220 Tyres

    15 x 4.5 - 8 Pneumatic Diagonal, not available 12 PR; 7 bar Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries please contact your Jungheinrich customer adviser. EFG 316-320 tyres Description EFG 316 EFG 318 EFG 320...

  • Page 25: Efg 213-320 Mast Versions

    EFG 213-320 mast versions All dimensions in mm VDI 3596 Lift Free lift Height Height extended retracted Description EFG 213/ EFG 218k/ EFG 213/ EFG 218k/ 215/216k/ 218/220/ 215/216k/ 218/220/ 216/316/ 318/318k/ 216/316/ 318/318k/ 316k 316k 2300 1650 2850 2885...

  • Page 26: Norms

    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. EFG 213-220 vibration: 0.53 m/s EFG 316-320 vibration: 0.51 m/s...

  • Page 27: Identification Points And Data Plates

    Identification points and data plates Warnings and notices such as load charts, strap points and data plates must be legible at all times. Replace if necessary. (mm) Q (kg) D (mm) B 14...
  • Page 28 Item Description Do not travel with raised load or mast forward tilt with raised load Wear seatbelt Strap points Tipover caution, no passengers Lift limit Do not step onto or beneath the load, risk of trapping Read the operating instructions Capacity Risk of trapping, in chassis behind the battery door Data plate...

  • Page 29: Truck Data Plate

    Truck data plate Item Description Item Description Type Manufacturer Serial no. Min./max. battery weight (kg) Rated capacity (kg) 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 ordering spare parts always quote the truck serial number (31).

  • Page 30: Fork Load Diagram (Basic Model)

    The arrow shape markings (42 and 43) on the inner and outer masts show the driver when the prescribed lift limits have been reached. Fork load diagram (basic model) The fork load diagram give the truck’s capacity Q in kg. The maximum capacity for the various load centres of gravity (D in mm) is shown in chart form.
  • Page 31 B 18...

  • Page 32: C Transport And Commissioning

    C Transport and Commissioning Transport Transport can be carried out in two different ways, depending on the height of the mast and the local conditions: – Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all hydraulic lines between the basic truck and the mast separated.

  • Page 33: Securing The Truck During Transport

    Securing the truck during transport The truck must be securely fastened when transported on a lorry or a trailer. The lorry / trailer must have fastening rings and a wooden floor. – To fasten the truck attach the tensioning belt (3) to the upper cross member of the mast (1) or over the mudguard (5) and attach it to the trailer hitch (2).

  • Page 34: Using The Truck For The First Time

    – Place the auxiliary tool (6) on the lever (8) with the notches (7) (Jungheinrich symbol can be read from the left hand side of the truck). – Pull the lever (6) forward (forks direc- tion) or backward (towards the opera- tor position) and lock it in position.

  • Page 35: Moving The Truck When The Electric/Hydraulic Steering Has Failed

    Moving the truck when the electric/hydraulic steering has failed The truck cannot be steered if the steering hydraulic system or the truck electronics are damaged. To steer the truck without power, apply the steering as follows. – Turn the EMERGENCY DISCONNECT switch and key switch off.

  • Page 36: D Battery Maintenance, Charging & Replacement

    D Battery Maintenance, Charging & Replacement Safety regulations for handling acid batteries Park the 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 37: Battery Types

    Battery types The truck will be equipped with different battery types, depending on the application. The following table shows which combinations can be included as standard: EFG 213 48 V - 4PzS 460 Ah battery EFG 215 48 V - 4PzS 460 Ah battery...

  • Page 38: Battery Removal And Installation

    Battery removal and installation To prevent short circuits, batteries with exposed terminals or connectors must be covered with a rubber mat. When replacing a battery with a crane, make sure the crane has sufficient capacity (see battery weight on the battery data plate on the container).
  • Page 39 – Push the lift truck with the multi- adapter as far as the stop (5) underneath the battery. – Set the multi-adapter to the straight-ahead position using the alignment (6). – Raise the lift truck until the multi- adapter is up to the height stop (7).

  • Page 40: Removal And Installation Using A Worktable For Crane Loading (O)

    Removal and installation using a worktable for crane loading (o) – Open the battery door as far as the stop. – Disconnect the battery connector. See “Removal and installation using a multi-adapter” (o) – Push the lift truck with the worktable as far as the stop (5) underneath the battery.

  • Page 41: Removal And Installation Using A Fork Shoe (O)

    Removal and installation using a fork shoe (o) – Open the battery door as far as the stop. – Disconnect the battery connector. – Undo the battery lock. See “Removal and installation using a multi-adapter” (o) – Place the fork shoe onto the forks of a second lift truck with a minimum 1000 kg capacity and secure it to the fork carriage with a chain (10).

  • Page 42: Removal And Assembly For Maintenance

    Removal and assembly for maintenance – Open the battery door as far as the stop. – Disconnect the battery connector. – Undo the battery lock. See “Removal and installation using a multi-adapter” (o) – Place a standard hand pallet truck (800 mm fork length) under the battery.

  • Page 43: Charging The Battery

    Charging the battery Only connect and disconnect the battery and charger when the charger is switched off. To charge the battery, the truck must be dry and parked in closed and properly ventilated rooms. The battery door must remain at least 200 mm open to ensure adequate ventilation.

  • Page 44: Charging The Battery With An On-Board Charger

    The on-board charger consisting of a battery charger and battery controller must not be opened. If damaged, it must be replaced. The charger must only be used for batteries supplied by Jungheinrich or other approved batteries provided it has been adapted by the manufacturer's service department.
  • Page 45 Battery charger LED displays Green LED Meaning Flashing Charging Charging complete Red LED Meaning Flashing Error Battery controller LED displays White LED Meaning Flashing Radio network activated Blue LED Meaning Electrolyte level too low (measured after each charge) Yellow LED Meaning Flashing rolling Charging Charge status...

  • Page 46: E Operation

    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 47: Controls And Displays

    Controls and Displays Item Control / Display Function t Steers the truck. Steering wheel t Operating the functions: SOLOPILOT – Forward / reverse travel direction MULTIPILOT – Lift/lower load handler – Mast forward / reverse tilt – Horn switch – Side shift left / right (o) –...

  • Page 49: Solopilot / Multipilot

    SOLOPILOT / MULTIPILOT SOLOPILOT (t) SOLOPILOT (o) MULTIPILOT with ZH1-ZH3(o) MULTIPILOT (o) Item Control / Display Function Travel direction switch Selects travel direction / neutral position Horn Activates the horn Travel direction switch – To select forward gear, push the direction switch (13) forward. –...

  • Page 50: Armrest Control Panel Switch (O)

    Armrest control panel switch (o) Function Work lights Front windscreen wipers – Press 1x > intermittent, – 2x > fast, – 3x > off – Hold down on the button > Switch on the windscreen washing system Rear windscreen wiper –...

  • Page 51: Dashboard Control Panel And Driver's Display

    Dashboard control panel and driver’s display The control panel display shows the operating data, the battery charge, the service hours and error details and information. Pictograms in the left top section of the dashboard control panel act as warning indicators. Pictograms 100 % km/h...
  • Page 52 Item Control / Display Function Service interval exceeded (1000 service Service display hours) or annual UVV test due (flashing indicator). o Function of right/left flashing indicators (o) Flashing indicator t Crawl speed activated Crawl speed indicator t Changes the display Toggle button t Confirms entries SET button...
  • Page 53 Displays 100 % km/h inch lbs m kg eff code Item Function Residual time display with on-board battery (hours : minutes) Residual charging time (o) Time display (hours : minutes) Travel program display – Displays the travel program in use Error display: –...
  • Page 54 Driver’s display information messages The information messages have a four-digit code. The first digits refers to the functional assembly, the remaining three digits designate the error. Function Meaning group General message General message Travel Steering Lift Battery management Display Meaning 1901 Accelerator pedal pressed during power-up 1904...
  • Page 55 Set time: – Press the toggle button (22) for 3 seconds. The display (33) via the battery shows the current time. This allows you to toggle the display between the time and the residual time. – Press toggle button (22) for 8 seconds until the "Set Time" menu is displayed. –...

  • Page 56: Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter

    Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter Battery Discharge Indicator: The charge status of the battery (36) is shown on the driver’s display. The lower section of the battery symbol is shown as being empty. It indicates the residual capacity of the battery which cannot be used to avoid damaging the battery.

  • Page 57: Starting Up The Truck

    Starting up the truck Before the truck can be started, operated or a load lifted, the driver must ensure that there is nobody within the hazardous area. Checks and operations to be performed before starting daily operation – The entire truck (in particular wheels and load handler) must be inspected for damage.
  • Page 58 Adjusting the backrest: The backrest must be securely engaged in the set position. The backrest setting must not be changed during travel! – Lift up the locking lever (41) and adjust the incline of the backrest. – Release locking lever (41) to lock the backrest in position. Adjusting the seat position: Hold the locking lever (42) only in the recess, do not reach through underneath the lever.

  • Page 59: Safety Restraint Belt

    Safety restraint belt Fit the safety restraint belt each time before starting the industrial truck. The belt protects you from 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 60: Mechanical Safety Restraint System (O)

    Mechanical safety restraint system (o) Test the restraint system before starting the truck. • Never use the truck with a non-functional restraint system. • After an accident, have the restraint system system checked by specialist personnel from the manufacturer's service department. •...

  • Page 61: Adjusting The Steering Column

    Adjusting the steering column – Release the steering column lock (12) and set the steering wheel to the required position (height and tilt). – Now fix the steering column lock again. To prepare the truck for operation – Unlock the EMERGENCY DISCONNECT switch (10). To do this: Press the rocker in (s) and pull it up until you feel the EMERGENCY DISCONNECT engaging.

  • 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. Travel conduct: The driver must adapt the travel speed to local conditions.
  • Page 63 Towing trailers or the truck itself being towed are only permitted occasionally, on secure, level routes, with a maximum deviation of +/- 1% and at a max. speed of 5 km/h. The truck must not be permanently used with trailers. There must be no load on the forks when the truck is being pulled.

  • Page 64: Travel, Steering, Braking

    Travel, steering, braking 4.2.1 Emergency Disconnect – Press the EMERGENCY DISCONNECT switch (10) down. All electrical functions are deactivated. The operation of the EMERGENCY DISCONNECT switch must not be affected by any objects placed in its way. 4.2.2 Travel Safety switch, driver’s seat If the driver’s seat is not occupied (seat belt (o) not closed) travel is inhibited by the seat switch.
  • Page 65 Forward travel (twin pedal o) Make sure that the travel area is clear. – Release the parking brake (27) – Slowly apply the accelerator pedal (8) There is no travel direction switch on trucks with a twin pedal. 4.2.3 Steering Very minimal steering effort is required for the electric steering, therefore turn the steering wheel sensitively.
  • Page 66 Coasting brake: – Take your foot off the accelerator pedal (7) (8/9). The truck brakes regeneratively via the traction controller. This method saves energy. Reversing brake (single pedal): – Set the travel direction button (13) to the opposite direction while travelling. The truck brakes regeneratively via the traction controller until the truck starts to travel in the opposite direction.

  • Page 67: Operating The Lift Mechanism And Attachments (Solopilot T)

    Operating the lift mechanism and attachments (SOLOPILOT t) Do not lift other people with the lifting mechanism and do not allow anyone to stand under a raised load. The SOLOPILOT must only be operated from the driver’s seat. The driver must be trained to handle the lift mechanism and the attachments.
  • Page 68 Operating attachments (o) Note the manufacturer’s operating instructions and the capacity of the attachment. The control levers (49 and 50) are used to operate auxiliary hydraulics I ( X 5 ) and II. Auxiliary hydraulics III are operated by control lever (50) in ( X 6 ) conjunction with button (51).

  • Page 69: Operating The Lift Mechanism And Attachments (Multipilot O)

    Operating the lift mechanism and attachments (MULTIPILOT o) Do not lift other people with the lifting mechanism and do not allow anyone to stand under a raised load. 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! Lifting...
  • Page 70 Operating the integrated sideshift (ISS) The references to left and right are based on the load handler as viewed from the operator’s position. Sideshift left (from driver’s position): – Press the left button (52). Sideshift right (from driver’s position): – Press the right button (52). Aux.

  • Page 71: Emergency Lowering

    – Disconnect the battery connector. – Place the auxiliary tool (56) on the emergency lowering valve (55) with the recess 57 (Jungheinrich symbol visible). – Release the emergency lowering valve (55) in the forks direction.

  • Page 72: Collecting, Lifting And Transporting Loads

    Collecting, Lifting and Transporting Loads. Only move the truck with or without a load when the mast is tilted back and the load handler lowered. Do not exceed the capacity of the truck. Note the load chart! Do not lift other people with the lifting mechanism and do not allow anyone to stand under a raised load.

  • Page 73: Parking The Truck Safely

    Parking the truck safely 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. – Apply the parking brake button (27). –...

  • Page 74: Towing Trailers

    Towing trailers The truck can occasionally be used to tow a light trailer on a dry, level and well maintained surface. 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.

  • Page 75: Troubleshooting

    Troubleshooting This chapter allows the user to identify and rectify basic faults or the effects of incorrect operation. When trying to locate a fault, proceed in the order shown in the table. Fault Probable Cause Action Truck does – Battery connector –...

  • Page 76: F Industrial Truck Maintenance

    F Industrial Truck Maintenance 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 77 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 78: 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 adviser carries out an application analysis on site to work out specific service intervals to prevent damage due to wear.

  • Page 79: Maintenance Checklist

    Maintenance checklist Maintenance Intervals = t W A B C Standard Brakes 1.1 Check air gap 1.2 Test service and parking brakes Electrical 2.1 Test instruments, displays and control switches system 2.2 Test warning and safety device 2.3 Check fuse ratings 2.4 Make sure wire connections are secure and check for damage 2.5 Test micro switch setting...
  • Page 80 Maintenance Intervals = t W A B C Standard Hydraulic 6.1 Check mast bearings. operation 6.2 Check setting of slide pieces and stops, and adjust if necessary 6.3 Visually inspect mast rollers and check contact surface wear level 6.4 Check lateral clearance of mast connections and of fork carriage 6.5 Check load chain setting and tighten if necessary 6.6 Check forks and fork carriage for wear and damage...

  • Page 81: Lubrication Schedule

    Lubrication Schedule b -N Contact surfaces Hydraulic oil drain plug Grease nipple Transmission oil filler neck Hydraulic oil filler neck Transmission oil drain plug...

  • Page 82: 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 when filling up with consumables.

  • Page 83: Maintenance Instructions

    Maintenance Instructions Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: – Park the truck securely (see Chapter E). – Disconnect the battery so that the truck cannot be started by unauthorised persons (refer to chapter D).

  • Page 84: Checking The Hydraulic Oil Level

    Checking the hydraulic oil level Fully lower the load handler. – Park the truck on a horizontal surface. – Prepare the truck for maintenance and repairs (see Sections 6.1 and 6.2). – Visually inspect the hydraulic oil level on the hose (2). If the reservoir is filled sufficiently, the hose will be approx.

  • Page 85: Check Transmission Oil Level

    Check transmission oil level Transmission oil must never enter the ground; therefore place a collection tray underneath the gear unit. – Park truck securely (see Chapter E). – Unscrew the oil dipstick (3). – Check transmission oil level, top up if necessary The oil level should reach the bottom mark of the oil check hole (3).

  • Page 86: Seat Belt Maintenance

    6.10 Seat belt maintenance – Pull out the belt completely and check for fraying – Test the belt buckle and make sure the belt returns correctly into the retractor. – Check the cover for damage. Testing the automatic blocking system: –...

  • Page 87: Checking Electrical Fuses

    6.11 Checking electrical fuses – Prepare the truck for maintenance and repairs. – Open the rear panel. – Unscrew the cover. – Check condition and rating of the fuses in accordance with the table. To avoid damaging the electrical system, only use fuses with the correct ratings. 19 - 36 F 12...
  • Page 88 Electrical system fuses Item Description Electric circuit Rating / type 3F10 Steering threephase controller fuse Control fuse 48V Magnetic brake control fuse 7.5A Travel/Lift electronics control fuse Horn control fuse Power on contactor control fuse Overall control circuit fuse EMERGENCY DISCONNECT fuses Item Description Electric circuit...
  • Page 89 Options fuses (o) Item Description Electric circuit Rating / type Windscreen wiper control fuse 9F33 Windscreen washer pump fuse 9F14 Rear windscreen wiper control fuse DC/DC converter control fuse DC/DC converter control fuse Searchlight control fuse 4F14 Strobe control fuse 48 volt heating fuse F14.1 24 volt heating fuse...

  • Page 90: Recommissioning

    6.12 Recommissioning The truck may only be restored to service after cleaning or repair work, once the following operations have been performed: – Test horn. – Test main switch operation. – Test brakes. – Lubricate the truck in accordance with the lubrication chart. Decommissioning the industrial truck If the industrial truck is to be decommissioned for more than two months, e.g.

  • Page 91: Returning The Truck To Operation After Decommissioning

    Safety checks to be performed at intervals and after unusual events Carry out the safety check in accordance with national regulations. Junheinrich recommends checks in accordance with FEM 4.004. Jungheinrich has a special safety department with trained personnel to carry out such checks.
  • Page 92 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 93: Jungheinrich Traction Battery

    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 94 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 95 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 96 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 97 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 98: 7. Type Plate, Jungheinrich Traction Battery

    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 Jungheinrich AG, D-22047 Hamburg, Germany Hersteller...

  • Page 99: Aquamatic/Bfs Iii Water Refilling System

    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 100 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 101 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 102 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 103 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.

  • Page 104: Jungheinrich Traction Battery

    Jungheinrich traction batterie Maintenance free Jungheinrich traction batterie with positive tubular plates type EPzV and EPzV-BS Rating Data 1. Nominal capacity C5: See type plate 2. Nominal voltage: 2,0 Volt x No of cells 3. Discharge current: C5/5h 4. Rated temperature: 30°...
  • Page 105 Ignoring the operation instructions, repair with non-original parts and non authorised interventions 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 106 With the charger switched off connect up the battery, ensuring that the polarity is cor- rect (positive to positive, negative to negative). Now switch on the charger. When charging the temperature of the battery rises by about 15° C, so charging should only begin if the battery temperature is below 35°...
  • Page 107 3.2 Weekly Visual inspection after recharging for signs of dirt and mechanical damage. 3.3 Quarterly After the end of the charge and a rest time of 5 h following should be measured and recorded: • the voltages of the battery •...

  • Page 108: 7. Type Plate, Jungheinrich Traction Battery

    Batteries with this sign must be recycled. Batteries which are not returned for the recycling process must be disposed of as hazardous waste! We reserve the right make technical modification. 7. Type plate, Jungheinrich traction battery Baujahr T ype Year of manufacture Serien-Nr.

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