Jungheinrich EMC 110/B 10, Operating Instructions Manual

Page 1: ...Operating instructions 10003627 EMC 110 B 10 G 06 96 07 08...

Page 2: ...explanations are indicated by the following graphics f Used before safety instructions which must be observed to avoid danger to personnel m Used before notices which must be observed to avoid materi...

Page 3: ...0108 GB...

Page 4: ...oning C 1 3 Moving an incapacitated truck emergency operation C 2 D Battery recharging and replacing D 1 1 Safety regulations for handling lead acid batteries D 1 2 Battery types D 1 3 Charging the ba...

Page 5: ...n F 8 10 1 Fault localisation F 8 10 2 Fault identification flash codes emitted by the LED on the control board F 8 10 3 Circuit diagram F 9 G Attachments G1 1 Crane hook G 1 1 1 Proper use G 1 1 2 Te...

Page 6: ...06 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instruct...

Page 7: ...0506 GB 2...

Page 8: ...f or on whose behalf it is used In special cases e g leasing or renting the user is conside red the person who in accordance with existing contractual agreements between the owner and the user of the...

Page 9: ...0600 GB A 2...

Page 10: ...k up pallets that are open to the ground or trolleys The capacity of the truck can be found on the capacity label Qmax m The EMC EMB truck has been designed for light duty maximum continuous operation...

Page 11: ...ge monitor 5 t Charge control lamp 6 t Battery charging plug integrated battery charger 24 V 9 A 7 t Emergency stop plug 8 t Load lifting device 9 t Load bearing wheel 10 t Supporting wheel 11 t Drive...

Page 12: ...lifting lowering inching speed and the horn function are arranged on the control shaft 15 The truck is equipped with a battery discharge monitor 4 A The discharge monitor 4 deactivates the fast speed...

Page 13: ...7 cm s Designation Standard EMC Broad version EMB h1 Hoist frame height 1970 1970 mm h3 Lifting height 1560 2000 1560 2000 mm h13 Load lifting device lowered 90 90 mm y Wheel base load part lowered 11...

Page 14: ...B 5 0708 GB C Q h 1 h 3 h 13 l2 y 150 l1 Ast b 1 Wa b 1 b 2 b 5 e b 4...

Page 15: ...ise level is measured at the driver s ear Electromagnetic compatibility EMC The following limits are observed according to the product standards Electromagnetic Compatibility of Industrial Trucks 9 95...

Page 16: ...Xxxx Xxxxxxx Xxxxxx Xxxxxxxx Xxxxxx Xxxxxx Xxxxxxxxx Xxxxxxxxxx Xxxxxxxxx Xxxxxxxxx Xxxxx Xxxxx Xxxxx Xxxxx Xxxxxxx Xxxxxxxxxx Xxxxxx Xxxxxxxxx Xxxxxx Xxxxxx Xxxxxxx Xxxxxx Xxxxxx Xxxxxxxxxxxxxx Xxxxx...

Page 17: ...35 Net weight without battery in kg 30 Rated load capacity in kg 36 Year of manufacture 31 Battery Voltage V Ampere hours Ah 37 Type no 32 Manufacturer X xx xx xx xx xx Xxx Xxxx Xxxx Xxxx Xxxxxxx Xxx...

Page 18: ...ouch any attachments during lifting 2 Commissioning m The truck must only be operated on battery current Rectified alternating current will damage the electronic components Cables connected to the bat...

Page 19: ...magnetically applied brake must be released Remove the motor cover 2 Turn the screws 3 in clockwise direction until reaching the stop The truck can now be moved m After the truck has been parked at it...

Page 20: ...on skid insulating mat Disposal of the battery Batteries must only be disposed of as stipulated in the national environmental protection regulations or waste disposal provisions The manufacturer s spe...

Page 21: ...is steady on green Pull the plug 1 out of the electric outlet and insert it into the receptacle of the safety circuit on the truck 2 A If the mains plug 1 is not in the receptacle 2 of the safety cut...

Page 22: ...ttery wearing down m Red flashing of LED 3 means that the battery is defective or the charging circuit has been interrupted 4 Replacing the batteries Loosen the screws 4 and remove the front hood 5 Lo...

Page 23: ...ght to left Battery charging is recommended when the capacity has dropped to approx 30 A At a residual capacity of 20 the fast speed function is deactivated The truck can only be moved at inching spee...

Page 24: ...ift truck or on the attachments must immediately be brought to the notice of the person in charge Fork lift trucks that cannot be safely operated e g due to worn tyres or defective brakes must not be...

Page 25: ...ndicates the weight of the load that has been picked up 7 LED Charging state t Indicates the charging state of the battery see chapter D section 3 8 Integrated charger incl safety cut out t The batter...

Page 26: ...E 3 0600 GB 5 2 1 10 11 6 8 9 4 3 7...

Page 27: ...heels and the load lifting device for damage Switching on the truck Check that the battery plug 8 and the emergency stop plug 9 are plugged Insert the key into the key switch 10 and turn it clockwise...

Page 28: ...always be carried at that end of the truck facing uphill U turns cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted Inclines must only...

Page 29: ...he braking position more slowly than normal the cause must be determined and eliminated If necessary the gas pressure spring must be replaced Driving m Only drive with the hoods closed and properly lo...

Page 30: ...e of emergency the service brake must be used to brake the truck Braking using the service brake Tilt the control shaft 12 upwards or downwards into one of the braking ranges B Accelerating on slopes...

Page 31: ...ing up long loads crosswise is not permitted Move the truck so that the load lifting device passes completely below the load A The lifting and lowering speeds are preset Lifting Press the Lift load li...

Page 32: ...washer 16 Adjust the wheel arm 14 to the desired width The thread must align with the bore Screw in the screw with the washer 15 16 and tighten it using a torque wrench torque 195 Nm Lower the liftin...

Page 33: ......

Page 34: ...ined especially for these assignments We thus recommend signing a maintenance contract with the relevant service location of the manufacturer Lifting and jacking up When a fork lift truck is to be lif...

Page 35: ...k lift truck before any welding operations are undertaken Settings When repairing or replacing hydraulic electric or electronic compo nents or assemblies all truck specific settings have to be retaine...

Page 36: ...re firmly seated tighten if necessary Steering brake system Check the steering bearing play Performance and adjustment check Check the braking function of the gas pressure spring check the gas pressur...

Page 37: ...t come into contact with hot components or open fire When filling in consumption type materials use clean containers only Mixing consumption type materials of different grades or qualities is prohibit...

Page 38: ...mmobilise the truck in such a way that it cannot tip over or slip away When lifting the truck the safety instructions in the chapter Transportation and commissioning must also be observed 6 2 Removing...

Page 39: ...are clear off the ground Only this measure will ensure that wheels and wheel bearings do not suffer damage Recharge the battery see chapter D section 3 Disconnect and clean the battery Apply pole grea...

Page 40: ...a safety viewpoint without regard to operational or economic circumstances The inspector shall be sufficiently instructed and experienced to be able to assess the condition of the truck and the effect...

Page 41: ...if necessary connect the battery plug Move the key in clockwise direction until reaching the stop Check the battery charging condition and if necessary recharge the battery Check fuses F1 and F2 Inse...

Page 42: ...eck the motor connections if necessary connect the motor Short circuit between motor and housing Check whether a short circuit has occured if necessary eliminate the cause properly 4x Controller poten...

Page 43: ...Lowering 6 Key operated switch 18 Pump contactor 7 Accidental starting protection 19 Lowering valve 8 Control shaft switch 20 Control system 9 Battery monitor 21 Horn 10 Magnetic brake 22 Battery 11...

Page 44: ...perly secured Loads may only be lifted and transported if they do not exceed the permitted load centres and the pertaining load capacities Qmax see load diagram Load capacity load centre crane hook Th...

Page 45: ...kg C Load centre 500 mm Travelling speed with without load 3 5 4 km h Lifting speed speed with without load 8 0 11 0 cm s Lowering speed with without load 20 7 cm s Designation EMB h1 Hoist frame heig...

Page 46: ...m The maximum height of the completely lifted crane hook is 3490 mm Observe the height of passageways Ast 100 W a h3 h1 500 600 800 986 1173 1350 340 150 Q 750 Kg 700 Kg 600 Kg 350 Kg 250 Kg 175 Kg y...

Page 47: ...1 Type 7 Load centre in mm 2 Serial no truck no 8 Battery weight min max in kg 3 Order no 9 Net weight without battery in kg 4 Rated load capacity in kg 10 Year of manufacture 5 Battery Voltage V Ampe...

Page 48: ...approved lifting gear to the load Fasten the lifting gear to the crane hook Lift the load m Lift the load only as far as necessary until it is clear off the ground f Do not step under the load and kee...

Page 49: ...tion with the EMC EMB f It is not allowed to transport goods on the platform 2 2 Technical data 2 3 Label 1200 600 186 77900041 32 kg 600 mm 1000 kg fach Eigengewicht ESP Tragf higkeit Stapelbar Typ H...

Page 50: ...n the load lifting device Lift the platform f Before moving the platform make sure that the fastening cam 12 engages in the recess for the load bearing wheel Move the platform to its destination and l...

Page 51: ...ion with the EMC EMB f Transporting goods on the platform is only allowed if the stoppers are swung down 3 2 Technical data 3 3 Label 600 1200 246 77900042 66 kg 600 mm 500 kg fach Eigengewicht ESP Tr...

Page 52: ...the load lifting device m Lift the platform f Before moving the platform make sure that the fastening cam 13 engages in the recess for the load bearing wheel Move the platform to its destination and l...

Page 53: ...to move a loading aid to a freely selectable height that can be comfortably accessed Positioning occurs according to one of the two states Loading the load is placed onto the loading aid and the carr...

Page 54: ...with the automatic height positioning unit Pick up the loading aid to be used and park the truck in the work area Position the sensor 14 on the side of the mast according to the desired working height...

Page 55: ...to the height of the sensor switch in position 0 Loosen the screw 18 and remove the cover 17 Watch the LED 16 If necessary correct the sensitivity of the sensor using the adjusting screw 15 until the...

Page 56: ...tive tubular plates type EPzS and EPzB 2 6 Type plate Jungheinrich traction battery 7 Instruction for use Aquamatic BFS III water refilling system 8 12 2 Jungheinrich traction battery Maintenance free...

Page 57: ...d clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 50272 3 DIN 50110 1 No smoking Do not expose batteries to naked flames glowing embers or sparks as...

Page 58: ...ucks is the standard which ap plies to the operation traction batteries in industrial trucks 2 1 Discharging Be sure that all breather holes are not sealed or covered Electrical connections e g plugs...

Page 59: ...The containers for batteries with plate protection packs must not be closed until at least half an hour after charging has past 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 60: ...ound further testing and maintenance by the service department should be requested 3 4 Annually In accordance with DIN VDE 0117 at least once per year the insulation resistance of the truck and the ba...

Page 61: ...be taken into account when considering the life of the battery 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called in without delay The meas...

Page 62: ...l battery capacity 5 Battery tray number 12 Number of battery cells 6 Delivery date 13 Battery weight 7 Battery manufacturer s logo 14 Safety instructions and warnings Typ 1 T ype Nennspannung 5 Nomin...

Page 63: ...sing batteries which comply with I and II it is important to follow the in structions on maintaining the respective protection class during operation see asso ciated certification Cell series Aquamati...

Page 64: ...d by means of a central sealing coupler through the hose connections in the individual Aquamatic BFS plugs 2 Application The Aquamatic BFS battery water refilling system is used in traction batteries...

Page 65: ...surface 5 2 Pressurised water The pressure reducing valve in the Aquamatic System is set from 0 2 bars to 0 6 bars and from 0 3 bars to 1 8 bars in the BFS system 5 3 Water Refill Trolley serviceMobi...

Page 66: ...ve a diagnostics hole with a 6 5 mm diameter Aquamatic plugs or a 7 5 mm diameter BFS plugs 9 2 Float Different floats are used depending on the cell design and type 9 3 Cleaning The plug systems may...

Page 67: ...en tral supply pipe This is connected to the water supply system at the battery charging station by means of a sealing coupler system On the battery side a closing nipple ident no 50219538 is mounted...

Page 68: ...battery Work on batteries to be carried out by skilled personnel only Use protective glasses and clothes when working on batteries Pay attention to the accident prevention rules as well as DIN EN 5027...

Page 69: ...g plugs must only be made or broken in the open circuit condition To achieve the optimum life for the battery operating discharges of more than 60 of the rated capacity should be avoided deep discharg...

Page 70: ...0 0171 Ex I in areas with a firedamp hazard or Ex II in potentially explosive areas The attention pictograms has to be respected 2 3 Equalising charge Equalising charges are used to safeguard the life...

Page 71: ...1000 4 Care of the battery The battery should always be kept clean and dry to prevent tracking currents Clea ning must be done in accordance with the ZVEI code of practice The Cleaning of Vehicle Trac...

Page 72: ...raction battery CE mark is only for batteries with a nominal voltage greater than 75 volt Item Designation Item Designation 1 Logo 8 Recycling symbol 2 Battery designation 9 Dustbin material 3 Battery...

Page 73: ...0506 GB 18...