Jungheinrich EME 112, Operating Instructions Manual

Page 1: ...Operating instructions 77800386 EME 112 G 05 00 07 08 ...

Page 2: ...tiengesellschaft Am Stadtrand 35 22047 Hamburg GERMANY Telephone 49 0 40 6948 0 www jungheinrich com 0108 GB Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck The information is provided clearly and concisely The chapters are arranged by letter Each chapter starts with page 1 The page identification co...

Page 3: ...0108 GB 0108 GB ...

Page 4: ...raking E 6 4 3 Picking up and setting down loads E 8 4 4 Parking the truck and rendering it safe E 9 I 1 0708 GB Table of contents A Correct use and application of the truck B Description of the truck 1 Application B 1 2 Description of the assemblies and functions B 2 2 1 Truck B 3 3 Technical data standard version B 4 3 1 Performance data for standard trucks B 4 3 2 Dimensions B 4 3 3 Batteries a...

Page 5: ...lt identification flash codes emitted by the LED on the control board F 10 10 3 Circuit diagram F 11 0708 GB I 2 F Maintenance of the fork lift truck 1 Operational safety and environmental protection F 1 2 Safety regulations applicable to truck maintenance F 1 3 Maintenance checklist F 3 4 Hydraulic oil level F 4 5 Fuels coolants and lubricants F 4 6 Notes regarding maintenance F 5 6 1 Preparing t...

Page 6: ...ungheinrich battery models If using another brand refer to the manufacturer s operating instructions 1 0506 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 instructions ...

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

Page 8: ...l obtained from local authorities does not however make the approval by the manufacturer unnecessary A 1 0600 GB A Correct use and application of the truck A The Guidelines for the Correct Use and Application of Industrial Trucks VDMA are included in the scope of delivery for this truck The guidelines are part of these ope rating instructions and must always be heeded National regulations are full...

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

Page 10: ...ours Truck type load capacity and motor output Type Load capacity Motor output EME 1200 kg 0 3 kW AC B 1 1001 GB B Description of the truck 1 Application The truck is intended for transporting goods on a level floor It can pick up pallets that are open to the ground or trolleys The capacity of the truck can be found on the ca pacity label Qmax m The EME truck has been designed for light duty maxim...

Page 11: ...ing wheel 10 t Front hood 11 t Front wall 12 t Drive wheel t Standard equipment o Optional equipment 1001 GB B 2 2 Description of the assemblies and functions Item Designation 1 t Control shaft 2 t Collision protection button 3 t Controller 4 t Battery charge plug 230 VAC integrated battery charger 24 V 6 5 A 5 t Emergency off switch key switch 6 o Battery charge connection 24 VDC lorry charging 7...

Page 12: ... system 24 Volt system As standard the truck is equipped with electronic three phase current control B 3 1001 GB 2 1 Truck Construction EME is a three wheel truck with steered drive wheel 12 and two load wheels 9 The easy to open hood 10 provides good accessiblity to all units The control elements are located at the control shaft head Safety features The truck chassis protects the feet of the oper...

Page 13: ...h 800x1200 in longitudinal dir 1840 1840 mm EME Battery 2 x 12 V 42 Ah in series Motor output 0 3 kW 1001 GB B 4 3 Technical data standard version A Technical data specified according to VDI 2198 Technical data are subject to alteration and additions 3 1 Performance data for standard trucks 3 2 Dimensions Ast includes a safety distance of 200 mm 3 3 Batteries and motor output Designation EME Q Rat...

Page 14: ...B 5 1001 GB c Q 1264 687 h 13 h 3 y 145 l1 l l2 Wa Ast 100 100 b 1 b 5 e b 11 m 2 s 39 B 5 1001 GB c Q 1264 687 h 13 h 3 y 145 l1 l l2 Wa Ast 100 100 b 1 b 5 e b 11 m 2 s 39 ...

Page 15: ... temperatures below 5 C or in cold stores respectively with extreme temperatures or humidity changes 1001 GB B 6 3 4 EN standards Continuous sound level 66 dB A according to prEN 12053 as stipulated in ISO 4871 A The continuous sound level is a value averaged according to standard regulations taking the sound pressure level into account when driving lifting and idling The sound pressure level is m...

Page 16: ...xxxxxx Xxxxxxxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx Xx mV 1 5 V Qmax 2645lb 13 18 15 16 17 14 17 1 17 1 B 7 1001 GB 4 Labels Item Designation 13 Load capacity Qmax 14 Truck identification plate 15 Eye for crane loading 16 Prohibitive sign Do not ride on the truck 17 Label Application points for lifting jack 17 1 Truck number embossed 18 Warning sign Caution electronics and low voltage Qmax 1200kg X x...

Page 17: ...xxxxxxx Xxxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxx Xxxxxxxxxxxxxxxxxx 19 20 21 22 23 24 26 30 29 28 27 25 31 1001 GB B 8 4 1 Truck identification plate A In the event of queries relating to the truck or spare part orders please state the serial no 20 of the truck Pos Designation Pos Designation 19 Type 26 Drive power in kW 20 Serial No 27 Customer no 21 Rated capacity in kg 28 Min max battery weight in kg...

Page 18: ... tyres may flatten The flattening will dis appear after the truck has been operated for a short time C 1 0301 GB C Transportation and commissioning 1 Transportation by crane m Only use lifting gear of adequate capacity loading weight dead weight battery weight see truck identification plate A Lifting points 1 are provided or loading the truck by means of crane gear The lifting points are covered b...

Page 19: ...ck at the destination the fastening screws 4 must be re tightened Braking action is restored 2 3 4 2 0301 GB C 2 3 Moving an incapacitated truck emergency operation To move the truck by emergency operation the electromagnetically applied brake must be released Losen screws 2 Remove front wall 3 Losen fastening screws 4 until the truck can be moved no braking action The truck can now be moved m Aft...

Page 20: ... the covers will destroy the battery The battery weight is given on the battery identification plate D 1 1001 GB D Battery Servicing recharging replacement 1 Safety regulations governing the handling of lead acid batteries The truck must be parked and rendered safe before any operations on batteries are undertaken refer to chapter E Servicing staff Recharging servicing and replacing of batteries m...

Page 21: ...connected to mains for at least 41 hours Mains supply Mains voltage 230 V 10 Mains frequency 50 Hz 4 1001 GB D 2 3 Charging the battery using the integrated charger 3 1 Charging the battery with 230 VAC The mains cable of the charger is accessible from outside Pull the mains plug 1 out of the receptacle 2 on the charger and plug it into a suitable electric outlet 230 V 10 A green flash light of th...

Page 22: ... via mains connection 115 V 230 V the mains connection must be equipped with an FI safety switch 4 3 D 3 1001 GB 3 2 Charging battery with 24 VDC lorry Connect the charger cable o with the 24 VDC connection 4 A green flash light of the LED 3 indicates that the battery charger is connected to the mains and the battery is being charged Charge the battery until LED 3 is steady on green Disconnect the...

Page 23: ... battery has been reinstalled check all cable connections and plugged connections for visible damage 1001 GB D 4 4 Replacing the batteries Loosen screws 5 remove front hood 6 and front wall 7 Loosen the terminal screws and remove the battery cables from the terminals m Place the battery cables in such a manner that they do not get caught on the truck when the battery is pulled out Lift out battery...

Page 24: ...cation on green Battery charge 30 flashing green Battery charge 30 20 flashing red Battery charge 20 D 5 1001 GB 5 Discharge LED discharge indicator The LED shows the charging condition of the battery m In case of light applications load 300 kg the battery must already be charged if the green LED flashes When the LED is flashing red the battery must be charged Further operation will damage the bat...

Page 25: ...1001 GB D 6 1001 GB D 6 ...

Page 26: ...rning labels and warning notes described in the present operating instructions must always be heeded E 1 0301 GB E Operation 1 Safety regulations governing the operation of the fork lift truck Driving permission The fork lift truck must only be operated by persons who have been trained in the operation of trucks who have demonstrated to the user or his re presentative their capability of moving an...

Page 27: ...s the charging condition of the battery refer to chapter D t Standard equipment o Optional equipment 0301 GB E 2 2 Description of the operating controls and indicators Item Control or indicator Function 1 Collision protection button t The truck moves away from the ope rator 2 Controller t Controls the direction and speed of travel 3 Button Lift load lifting device t For lifting the load lifting de...

Page 28: ...E 3 0301 GB 5 2 1 4 3 6 7 8 9 10 E 3 0301 GB 5 2 1 4 3 6 7 8 9 10 ...

Page 29: ... is now ready for operation Check the braking function of the control shaft see section 4 2 7 10 8 5 0301 GB E 4 3 Starting up the truck f The driver must make sure that nobody is within the danger area of the truck before the truck is switch on or operated or before a load is lifted Checks and operations to be performed before starting daily work Check the entire truck especially the wheels and t...

Page 30: ...r that safe driving and braking of the truck and the trailer is guaranteed for all driving movements E 5 0301 GB 4 Operation of the fork lift truck 4 1 Safety regulations applicable when operating the truck Driving lanes and work areas Only such lanes and routes that are specially alloca ted for truck traffic must be used Unauthorized persons must stay away from work areas Loads must only be store...

Page 31: ...t 11 to the left or the right m In narrow bends the control shaft protrudes beyond the truck contour 0301 GB E 6 4 2 Driving steering braking f It is not admissible to stay on the vehicle during driving Emergency stop Push the emergency off button 8 All of the electrical functions are switched off Automatic braking Releasing the control shaft causes automatic braking the control shaft automaticall...

Page 32: ...he service brake Tilt the control shaft 11 upwards or downwards into one of the braking ranges B 2 6 E 7 0301 GB Manoeuvering f When using button manoeuvering 6 the driver must be especially careful The truck can be driven with the control shaft in vertical position e g in narrow loca tions elevators Push the manoeuvering button 6 Move the drive control 2 into the desired driving direction F or R ...

Page 33: ...e required lifting height has been reached Lowering Press the Lower load lifting device button 4 3 4 0301 GB E 8 Accelerating on slopes f The load must face uphill The slope to be negotiated must not exceed 10 m in length without load 15 load of 600 kg 6 load of 1200 kg 3 5 m The truck must not be drived on slopes exceeding the specified values Successive slopes may only be negotiated after longer...

Page 34: ... lowered Lower the load lifting device Set the key element 8 to vertical position and remove the key E 9 0301 GB 4 4 Parking the truck and rendering it safe f Always render the truck safe when parking it Do not park the truck on slopes The load lifting device must always be completely lowered Lower the load lifting device Set the key element 8 to vertical position and remove the key ...

Page 35: ...0301 GB E 10 0301 GB E 10 ...

Page 36: ...ompletion of cleaning work the operations detailed in the section Recommis sioning must be performed F 1 0708 GB F Maintenance of the fork lift truck 1 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 f Modifications of fork lift truck assemblies ...

Page 37: ...d every six years When replacing hy draulic components also renew the hoses in this hydraulic system 0708 GB F 2 Work on the electric system Work on the electric system of the truck must only be performed by personnel specially trained for such operations Before commencing any work on the electric system all measures required to prevent electric shocks have to be taken For battery operated fork li...

Page 38: ...minals for secure attachment and apply grease Check the battery cables for damage renew if necessary F 3 0708 GB 3 Maintenance checklist A To ensure safe operation and a long service life of the truck the activities listed in the maintenance checklist must be carried out every 6 months A W1 service intervals are to be performed by the customer In the run in period after approx 100 service hours or...

Page 39: ...ode Designation Used for A H LP 46 DIN 51524 Hydraulic system A 0 25 l Filler plug for hydraulic oil 0708 GB F 4 4 Hydraulic oil level 5 Fuels coolants and lubricants Handling consumption type material Consumption type material must always be handled properly Manufacturer s instructions are to be observed f Improper handling is injurious to health life and environment Consumption type ma terials m...

Page 40: ...ront hood and front wall Losen the fastening screws 2 Carefully remove front hood 3 and front wall 4 F 5 0708 GB 6 Notes regarding maintenance 6 1 Preparing the truck for maintenance work All required safety measures must be taken to prevent any accidents in the course of the servicing and maintenance operations The following preparatory operations must be performed Park the truck and render it sa...

Page 41: ...g Item Designation Type of fuse EME 5 F1 Power fuse 63 A 6 F2 Control fuse 5 A U V W X1 X3 X4 X5 6 5 0708 GB F 6 6 3 Checking the electric fuses Prepare the truck for maintenance work see section 4 1 Remove the front hood see section 4 2 Check all fuses for the correct rating and if necessary replace 6 4 Recommissioning the truck Recommissioning of the truck following the performance of cleaning o...

Page 42: ...e charging it is not necessary to charge the battery every 6 months as a protection against draining F 7 0708 GB 7 Decommissioning the fork lift truck If the fork lift truck is to be decommissioned for more than 6 months it must be parked in a frost free and dry location and all measures to be taken before during and follo wing decommissioning must be performed as detailed below m During decommiss...

Page 43: ...ns go verning the disposal of batteries fuels and electronic and electrical systems must be observed 0708 GB F 8 7 2 Recommissioning the truck Thoroughly clean the fork lift truck Clean the battery Grease the pole screws using pole grease and reconnect the battery Recharge the battery refer to chapter D Check if the hydraulic oil contains condensed water and change if required Start up the fork li...

Page 44: ...am Check the solenoid valve for correct functioning according to the operating diagram Check fuse F1 F 9 0708 GB 10 Faul localisation and identification 10 1 Fault localisation A If the fault cannot be eliminated decommission the truck and inform the service de partment Fault Possible cause Remedial action Truck does not move Battery is still being charged Key switch in vertical position Battery c...

Page 45: ...defective Let go collision protection switch Replace collision protection switch U V W X1 X3 X4 X5 7 0708 GB F 10 10 2 Fault identification flash codes emitted by the LED on the control board The control board is fitted with an LED 7 for fault identification purposes The type of fault can be identified by the flash signal m The faults described below must only be eliminated by trained personnel or...

Page 46: ...1 4 1 5 1 3 6 4 1 10 6 8 5 2 B 0V A 15V X1 X3 X4 X5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 F 11 0708 GB 10 3 Circuit diagram Legend for the circuit diagram 8 Power stage 17 Backward 9 Control 18 Belly switch 10 Move protection 19 Manoeuvering 11 Sensor bearing 20 Lifting 12 Control shaft switch 21 Lowering 13 Retaining brake 22 Lowering valve 14 Setpoint 1 23 Lift limit switch 15 Setpoin...

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Page 48: ...with positive tubular plates type EPzV and EPzV BS 13 17 Type plate Jungheinrich traction battery 17 1 0506 GB Instructions for use Jungheinrich traction battery Table of contents 1 Jungheinrich traction battery with positive 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 bat...

Page 49: ...Metal parts of the battery are always live Do not place tools or other me tal objects on the battery 0506 GB 2 1 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 1 29 kg l Type EPzB 1 29 kg l 5 Rated temperature 30 C 6 ...

Page 50: ...ent When charging proper provision must be made for venting of the charging gases steel M 10 23 1 Nm 3 0506 GB 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 c...

Page 51: ... S G of 1 29 kg l at 30 C The electrolyte must conform to the purity regulations in DIN 43530 part 2 0506 GB 4 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 positive to positive negative to negative Now swit...

Page 52: ...y corrosion If it is necessary to remove cells it is best to call in our service department for this 5 0506 GB 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 separa...

Page 53: ...ling process must be disposed of as hazardous waste We reserve the right make technical modification 0506 GB 6 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 a monthly equalising charge as in point 2 3 2 float c...

Page 54: ...Year of manufacture Jungheinrich AG D 22047 Hamburg Germany 5 Pb Pb 2 3 6 5 11 13 1 14 4 10 12 7 8 9 7 0506 GB 7 Type plate Jungheinrich traction 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 type 10 Nominal battery voltage 4 Battery number 11 Nominal b...

Page 55: ...ngth stroke length Aquamatic plug with diagnostics hole Aquamatic plug BFS III with diagnostics hole 0506 GB 8 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 The cell series comprise cells with two to ten twelve positive plates e g column EPzS 2 120 10 600 The...

Page 56: ... with five times the buoyant force and consequently interrupt the water supply reliably at least 3 m 9 0506 GB 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 Connection for ...

Page 57: ...ter element optional with a max passage opening of 100 to 300 µm into the battery s main supply pipe 0506 GB 10 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 Conn...

Page 58: ...reatest of care must be employed when prising out the plug to prevent any damage to the plug systems 11 0506 GB 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...

Page 59: ...2 to 0 6 bars in the Aquamatic system and operating pressure range 0 3 to 1 8 bars in the BFS system 0506 GB 12 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...

Page 60: ... Metal parts of the battery are always live Do not place tools or other metal objects on the battery 13 0506 GB 2 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 C EPzV batteries ...

Page 61: ... container lids and the covers of battery compartments must be opened or re moved steel M 10 23 1 Nm 0506 GB 14 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 certif...

Page 62: ...ured 3 Maintenance Don t refill water 3 1 Daily Charge the battery immediately after every discharge 15 0506 GB 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 bel...

Page 63: ...ber of cells The storage time should be taken into account when considering the life of the batte ry 0506 GB 16 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 the voltages of every cells If significant changes from earlier mea...

Page 64: ...Year of manufacture Jungheinrich AG D 22047 Hamburg Germany 5 Pb Pb 2 3 6 5 11 13 1 14 4 10 12 7 8 9 17 0506 GB 6 Malfunctions If malfunctions are found on the battery or the charger our service department should be called without delay The measurements taken in point 3 3 will facilitate fault fin ding and their elimination A service contract with us will make it easier to detect and correct fault...

Page 65: ...0506 GB 18 0506 GB 18 ...