Saving energy. Saving costs. Our energy saving book shows you how to minimise your energy costs with the right service and the right accessories.

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Our cost-saving tips Battery service . . . . . . . . . . . . . . . . . . . . . 4 Charger service. . . . . . . . . . . . . . . . . . . . . 6 Battery replacement . . . . . . . . . . . . . . . . 8 Battery maintenance Ion exchangers. . . . . . . . . . . . . . . . . . 10 Battery water trolley. . . . . . . . . . . . . . 12 Battery water management . . . . . . . 14 BMS – Battery Monitoring System. . 15 Battery level sensors. . . . . . . . . . . . . .16 Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . 18 Chargers . . . . . . . . . . . . . . . . . . . . . . . . . 20 Battery serviceboard . . . . . . . . . . . . . . . 22

Reduce your energy costs with efficient battery management. We have everything you will need in your warehouse.

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We guarantee high availability of our products and spare parts from our depots as well as regional service in your area. When necessary, we can deliver individual cells, replacement batteries and chargers to you in a very short time.

Our own battery team provides you with a flexible, expert and extremely fast-responding service. Our battery professionals ensure smooth operation. This guarantees that you receive fast efficient repairs. Fault analysis is supported by state-of-the-art technology which quickly identifies the defect and the causual problem for the engineer.

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Maximise the service life of your battery. Our battery service offers the best options. The battery is the heart of any electric fork lift truck. Regular care and maintenance play a crucial part in ensuring performance and achieving a long service life. We also offer you the right solution to achieve this.

Before After

Scope of battery service •• Basic cleaning •• Measuring the voltage, cell voltages and electrolyte density •• Checking the electrolyte level •• Checking the connections are secure •• Checking the terminal conductors, battery/truck connector and charging plug/cable •• Visual inspection of the battery tray •• Checking the Aquamakit fitting (also electrolyte recirculation if necessary) for tightness and water flow •• Checking the float plug •• Compilation of a test report •• Issuing of inspection stickers •• Monitoring of the maintenance intervals •• Necessary repairs carried out immediately •• Vacuum cleaning the trough •• Environmentally sound disposal of used materials

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Do you also prefer to err on the side of caution? Then our safety service for battery chargers is just what you require. The Jungheinrich safety service for battery­chargers ensures that you always err on the side of caution when it comes to compliance with occupational health and safety regulations. Even with battery chargers. This is because, in addition to the technical monitoring, we also take responsibility for monitoring and compliance with the inspection intervals and all associated administrative work. Make the most of the advantages: •• Maximum reliability for all operators •• Compliance with all regulations •• Long-term investment security for trucks, batteries and chargers •• Inspection sticker •• Detailed test report

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Easy battery replacement with charging/ changing stations and stands.

Battery replacement with SnapFit* The SnapFit adapter facilitates a fast and uncomplicated battery replacement without great physical effort. Installation is possible with the help of an EJE or hand pallet truck with standard fork length (1,150 mm). * Truck specifications for SnapFit adapters can be obtained from your customer consultant.

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Battery changing stand exclusively for SnapFit adapter for tray sizes up to 660 Ah and from 660 to 840 Ah

Stationary exchange table The use of electric fork lift trucks for multiple shifts requires the exchange of batteries. This work can be carried out quickly, safely and economically using our exchange tables.

Stationary exchange tables

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Battery maintenance. Ion exchangers. The economic way to maximise battery service life. Demineralised water consistently ensures the maximum service life of your truck batteries. You can either buy demineralised water, an expensive process, or produce it yourself efficiently and economically, for as much as 70 % less. It’s quite easy to do with the Jungheinrich ion exchanger. Connect the ion exchanger to a conventional water tap and fully automatic desalination of the water will begin immediately.

Advantages •• No cost-intensive purchase and ­storage of distilled water •• Always fresh water with no danger of algae formation due to storage/exposure to light •• Maintenance-free •• High flow speed, e.g. ion exchanger 450 approx. 65 litres/hour

Cost example with the ion exchanger 1000 Your needs •• Consumption: 2,000 litres/year •• Water price: € 0.70/litre •• Water hardness: 300 µs/cm •• Mineral content: May differ regionally

Total costs for external purchase € 1,400/year (2,000 litres)

Costs with ion exchanger •• Costs with first cartridge in the first six months: € 0.52/litre •• Costs with each replacement cartridge*: € 0.10/litre

Total costs for in-house production** € 200/year (2,000 litres)

You save € 1,200 per year Result: Production volume per cartridge: 1,000 litres of demineralised water. Amortisation: After just 1,000 litres (= 1 cartridge or after six months).

*on return of the old cartridge, **exclusive one-off material costs for starter set

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How many litres of demineralised water does a battery need? 24-V traction battery approx. 2 litres/week 48-V traction battery approx. 4 litres/week 80-V traction battery approx. 7 litres/week

All values are guide values and dependent on intensity of use, charging time and ambient/charging temperature.

Ion exchanger 450 Conversion capacity: 450 litre Capacity: •• 450-litre single-use cartridge (replacement cartridge can be reordered) •• Conductance sensor •• Wall fastening •• Hose set (4 m) •• Quick release coupling

Ion exchanger 1000 Conversion capacity: 1,000 litre Capacity: •• 1,000-litre reusable cartridge (single-use cartridge for export, replacement cartridge can be re-ordered) •• Conductance sensor •• Hose set (4 m) •• Quick release coupling

Ion exchanger 2000 (new) Conversion capacity: 2,000 litre Capacity: •• 2,000-litre single-use ­cartridge (replacement cartridge can be re­ ordered) •• Conductance sensor •• Hose set (4 m) •• Quick release coupling

Ion exchanger 4000 Conversion capacity: 4,000 litre Capacity: •• Pressure-resistant 4,000-litre stainless steel container (reusable ­cartridge) •• Conductance sensor •• Universal hose set •• Quick release coupling 11

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Battery maintenance. Battery water trolley. Topping up battery water – where and when you want. The provision of an adequate water ­supply for your batteries is often problematic and expensive.

The battery water trolley is a mobile water carrier with built-in battery operated pump, which provides you with the opportunity to flexibly transport battery water in the warehouse.

Battery water trolley •• Thanks to the large water tank (30 litres), it is economical and can be used anywhere •• Safe and convenient operation •• Robust yet lightweight

Optional Watering gun

Aquamatik quick release coupling

Flow indicator

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Battery maintenance. Battery water management Aquamatik water tank Water container for clean and professional storage of the battery water as well as for manual topping up of batteries •• incl. 4 m hose, shut-off valve and flow indicator •• Capacity 10, 30 or 60 litres

Demineralised water

Distance at least 3 m

Wall bracket (optional) For the secure wall mounting of battery water containers (for 30-litre and 60-litre containers). (Please check the wall ­stability prior to use!)

Topping up the batteries with distilled water shortly after charging is complete.

Battery

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BMS – Battery Monitoring System Gather valuable information to ensure the maximum battery life of your battery. The BMS collects and stores important battery data, such as the number of charging and discharging cycles, temperature, electrolyte level, battery voltage and half voltages, deep discharges and the battery charge state. With the BMS, your knowledge of the battery is always under control. For example, the data can be read off during maintenance by our service engineers.

Three LED displays provide additional direct warnings: •• Green: Displays a normal battery status and the correct functioning of the BMS and all battery parameters. •• Flashing red: The unit warns of a low electrolyte level. •• Flashing yellow: The battery temperature exceeds 50°C.

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Battery maintenance. Battery level sensors. Let your battery tell you when it needs water. Simply and quickly check the battery’s electrolyte level – too low electrolyte levels in the battery may cause permanent damage to cells. With the aid of our battery level sensors, the battery’s electrolyte level is continuously monitored and displayed via a red

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or green LED. This saves unnecessary checks and also guarantees optimum utilisation of the maximum life and performance of the battery. Our battery level sensors are available in different designs.

Smart Blinky with probe •• Suitable for all batteries •• Probe is connected with cell connector cable

Smart Blinky with probe and remote display •• Suitable for all batteries •• Clearly visible from outside

Standard level sensor (O ring) •• Suitable for all batteries •• O ring is connected to cell connector

Standard level sensor (O ring) with external LED •• Suitable for all batteries •• Clearly visible from outside fixed to the battery cable

Standard level sensor (O ring) with external sensor •• Suitable for smaller cells •• O ring is connected to cell connector •• LED is positioned between the cells

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The perfect battery for every truck.

Our batteries perform with their high quality and outstanding durability.

Application and technology Light use

Normal use

Heavy use

Standard lead acid batteries Lead acid battery with extended maintenance interval Maintenance-free battery –S  ingle-shift operation per truck –S  till at approx. 50 % battery capacity after around 5 hours of operation –H  eating of the battery to approx. 30°C (at normal ambient temperature) – No boosting charges

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– Single-shift operation per truck – Still at approx. 20 % battery capacity after around 5 hours of operation – Electrolyte temperature approx. 30°C (at normal ambient temperature) – Occasional boosting charges

– Multi-shift operation – Still at approx. 20 % battery capacity after less than 5 hours of operation – Electrolyte temperature approx. 40°C (at normal ambient temperature) – Regular boosting charges

Standard lead acid battery •• 24, 48 and 80 V versions for light to heavy use •• Enclosed battery technology •• Long battery life due to high cycle stability •• Electrolyte recirculation* (optional) •• Manual or automatic water replenishment •• Recyclable •• Battery return and environmentally sound disposal by our service department

Maintenance-free battery •• 24 and 48 V versions for light use •• Closed cells make it unnecessary to replenish the water •• No loss of acid through gel-like ­electrolyte •• Ideal for applications in the foodstuffs, pharmaceuticals and chemicals industries due to its very low emissions during operation •• Recyclable •• Battery return and environmentally sound disposal by our service department

Lead acid battery with extended maintenance intervals •• In 24 V, 48 V and 80 V models for easy to normal tasks •• Up to 120 cycles (charging/discharging) without replenishing water •• Special Jungheinrich charging technology and electrolyte recirculation* required •• Recyclable •• Battery return and environmentally sound disposal by our service department.

* Air pumped into the battery causes the battery acid to mix through. The advantage: Faster charging and lower maintenance costs as less water is used.

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The right charger for every battery. Chargers must fulfil numerous requirements. They should spare the battery, reduce energy costs and offer the lowest possible maintenance costs. Our chargers meet these requirements perfectly. Whether a wet cell battery or maintenance-free battery. One, two or threeshift operation. Three-phase AC or single

phase network. Lightweight or heavy duty. With or without boost charging. We can supply you with the right charger to meet your needs, for practically any charge characteristic, any battery peripherals and any battery type. For maximum battery life and performance.

Cost example with the SLH 090 battery charger Your needs •• Application: EFG with a 550-Ah ­battery •• Energy costs: € 0.11/kWh Costs for 240 conventional charges € 1,271/year

Cost of a battery charger •• An SLH 090 48/80 costs approx. € 2,300.

Costs for 240 charges with high-frequency technology € 761/year

You save € 510 per year on charging Result: With a useful life of six years, the acquisition of a high-frequency charger is already worth it with the first battery. The charger will pay for itself after around five years, and the battery also lasts ten percent longer due to a lower charging temperature and more gentle charging.

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SLH 090 charger •• For all 24, 48 and 80 volt applications •• Pre-configured charging programs for practically all truck battery types (plug and play system) •• Gentle charging due to high-frequency technology with processor control

•• Compact and lightweight devices mean minimum space requirement, also suitable for wall mounting •• Up to 30 % energy saving compared with conventional chargers •• Many options possible (e.g. cold store version) •• Charging times of 5.5 hours possible

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Battery serviceboard. Everything within easy reach for maintenance and emergencies. Did you know that, according to the safety requirements for batteries and battery systems (DIN EN 50272), battery charging stations must be equipped with safety-related components?

Our battery serviceboard ensures that you have everything to hand and clearly laid out for protecting your employees and administering first aid. For the safe handling of all batteries.

Jungheinrich battery serviceboard The serviceboard has a stable and corrosion-proof metal rear wall with the dimensions 65 cm x 65 cm and contains: •• 2 x eye washes with mirror •• Protective goggles •• Acid gloves •• Acid neutralisation spray •• Battery acid tester •• Maintenance instructions in five ­languages •• Additional hooks for other accessories •• Screw set for wall mounting

Optional Acid apron First aid kit

Various safety labels and adhesive safety stickers

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4590.IRL/com.07.2014 · j.r.pdf · Technical modifications reserved. The German production facilities in Norderstedt and Moosburg are certified.

Jungheinrich trucks conform to the European Safety Requirements.

Jungheinrich Lift Truck Ltd. J5 Maynooth Business Campus Maynooth Co. Kildare Tel. 01 651 7100 Fax 01 651 7101 Unit 8/9 Nyhan Industrial Estate Tramore Road Co. Cork Tel. 021 4961010 Fax 01 6517101 [email protected] www.jungheinrich.ie