Operating instructions
10003627
EMC 110/B 10
G
06.96-
07.08
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 consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important 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 material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment.
o 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.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
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 consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important 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 material damage.
A
Used before notices and explanations.
t Used to indicate standard equipment.
o 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.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
0108.GB
I 1
0708.GB
Table of contents
A Correct use and application of the truck ......................................... A 1
B Description of the truck ................................................................... B 1
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 and motor output ............................................................................... B 6
3.4 EN standards .................................................................................................... B 6
4 Labels ............................................................................................................... B 7
4.1 Truck identification plate ................................................................................... B 8
4.2 Load capacity label, load capacity / load centre / fork ...................................... B 8
C Transportation and commissioning ................................................. C 1
1 Transportation by crane .................................................................................... C 1
2 Commissioning ................................................................................................. 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 battery using the integrated charger ........................................... D 2
4 Replacing the batteries ..................................................................................... D 3
5 Battery discharge indicator ............................................................................... D 4
E Operation ........................................................................................ E 1
1 Safety regulations governing the operation of the fork-lift truck ........................ E 1
2 Description of the operating controls and indicators ......................................... E 2
3 Starting up the truck .......................................................................................... E 4
4 Operation of the fork-lift truck ........................................................................... E 5
4.1 Safety regulations applicable when operating the truck ................................... E 5
4.2 Driving, steering, braking .................................................................................. E 6
4.3 Picking up and setting down loads ................................................................... E 8
4.4 EMB wheel arm ajustment ................................................................................ E 9
4.5 Parking the truck and rendering it safe ............................................................. E 9
I 1
0708.GB
Table of contents
A Correct use and application of the truck ......................................... A 1
B Description of the truck ................................................................... B 1
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 and motor output ............................................................................... B 6
3.4 EN standards .................................................................................................... B 6
4 Labels ............................................................................................................... B 7
4.1 Truck identification plate ................................................................................... B 8
4.2 Load capacity label, load capacity / load centre / fork ...................................... B 8
C Transportation and commissioning ................................................. C 1
1 Transportation by crane .................................................................................... C 1
2 Commissioning ................................................................................................. 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 battery using the integrated charger ........................................... D 2
4 Replacing the batteries ..................................................................................... D 3
5 Battery discharge indicator ............................................................................... D 4
E Operation ........................................................................................ E 1
1 Safety regulations governing the operation of the fork-lift truck ........................ E 1
2 Description of the operating controls and indicators ......................................... E 2
3 Starting up the truck .......................................................................................... E 4
4 Operation of the fork-lift truck ........................................................................... E 5
4.1 Safety regulations applicable when operating the truck ................................... E 5
4.2 Driving, steering, braking .................................................................................. E 6
4.3 Picking up and setting down loads ................................................................... E 8
4.4 EMB wheel arm ajustment ................................................................................ E 9
4.5 Parking the truck and rendering it safe ............................................................. E 9
I 2
0708.GB
F Maintenance of the fork-lift truck ..................................................... F 1
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 the truck for maintenance work ........................................................ F 5
6.2 Removing the front hood .................................................................................. F 5
6.3 Checking the electric fuses ............................................................................... F 5
6.4 Recommissioning the truck ............................................................................... F 6
7 Decommissioning the truck ............................................................................... F 6
7.1 Measures required during decommissioning .................................................... F 6
7.2 Recommissioning the truck after decommissioning .......................................... F 7
8 Safety checks to be performed at regular intervals and
following any unusual incidents ......................................................................... F 7
9 Final de-commissioning, disposal...................................................................... F 7
10 Fault localisation and identification ................................................................... 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 Technical data of the EMB with crane hook ..................................................... G 2
1.3 Performance data of the EMB with crane hook ................................................ G 2
1.4 Dimensions of the EMB with crane hook .......................................................... G 2
1.5 Labels ............................................................................................................... G 4
1.6 Operating the EMB with crane hook ................................................................. G 5
2 Platform ............................................................................................................ G 6
2.1 Proper use ........................................................................................................ G 6
2.2 Technical data .................................................................................................. G 6
2.3 Label ................................................................................................................. G 6
2.4 Moving the platform .......................................................................................... G 7
2.5 Safety notes regarding operation with the platform .......................................... G 7
3 Platform with rollers .......................................................................................... G 8
3.1 Proper use ........................................................................................................ G 8
3.2 Technical data ................................................................................................... G 8
3.3 Label ................................................................................................................. G 8
3.4 Moving the platform with rollers ......................................................................... G 9
3.5 Safety notes regarding operation with the platform with rollers ........................ G 9
4 Automatic height positioning unit ...................................................................... G 10
4.1 Correct use and application .............................................................................. G 10
4.2 Technical Data .................................................................................................. G 11
4.3 Working with the automatic height positioning unit ........................................... G 11
4.4 Adjusting the sensor .......................................................................................... G 12
I 2
0708.GB
F Maintenance of the fork-lift truck ..................................................... F 1
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 the truck for maintenance work ........................................................ F 5
6.2 Removing the front hood .................................................................................. F 5
6.3 Checking the electric fuses ............................................................................... F 5
6.4 Recommissioning the truck ............................................................................... F 6
7 Decommissioning the truck ............................................................................... F 6
7.1 Measures required during decommissioning .................................................... F 6
7.2 Recommissioning the truck after decommissioning .......................................... F 7
8 Safety checks to be performed at regular intervals and
following any unusual incidents ......................................................................... F 7
9 Final de-commissioning, disposal...................................................................... F 7
10 Fault localisation and identification ................................................................... 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 Technical data of the EMB with crane hook ..................................................... G 2
1.3 Performance data of the EMB with crane hook ................................................ G 2
1.4 Dimensions of the EMB with crane hook .......................................................... G 2
1.5 Labels ............................................................................................................... G 4
1.6 Operating the EMB with crane hook ................................................................. G 5
2 Platform ............................................................................................................ G 6
2.1 Proper use ........................................................................................................ G 6
2.2 Technical data .................................................................................................. G 6
2.3 Label ................................................................................................................. G 6
2.4 Moving the platform .......................................................................................... G 7
2.5 Safety notes regarding operation with the platform .......................................... G 7
3 Platform with rollers .......................................................................................... G 8
3.1 Proper use ........................................................................................................ G 8
3.2 Technical data ................................................................................................... G 8
3.3 Label ................................................................................................................. G 8
3.4 Moving the platform with rollers ......................................................................... G 9
3.5 Safety notes regarding operation with the platform with rollers ........................ G 9
4 Automatic height positioning unit ...................................................................... G 10
4.1 Correct use and application .............................................................................. G 10
4.2 Technical Data .................................................................................................. G 11
4.3 Working with the automatic height positioning unit ........................................... G 11
4.4 Adjusting the sensor .......................................................................................... G 12
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.
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.
0506.GB 20506.GB
2
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 operating instructions and must always be heeded. National regulations are fully applicable.
The fork-lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admissible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork-lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres prevail.
Duties of the user: A “user” within the meaning of these operating instructions is defined as any natural or legal person who either uses the fork-lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is considered the person, who, in accordance with existing contractual agreements between the
owner and the user of the fork-lift truck, is charged with the observance of the operating duties.
The user must ensure that the truck is not abused and only used within its design limits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The
same applies if improper works are carried out at the device by the customer and/or
third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after written approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained. Any approval 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 fully applica-
ble.
The fork-lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these ope-
rating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The fork-lift truck must not be operated in spaces subject to fire
or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre-
vail.
Duties of the user: A “user” within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork-lift truck himself, 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 fork-lift truck, is charged with the observance of the opera-
ting duties.
The user must ensure that the truck is not abused and only used within its design li-
mits and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
m
If these operating instructions are not observed the warranty becomes void. The
same applies if improper works are carried out at the device by the customer and/or
third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained. Any approval obtained from local authorities does
not, however, make the approval by the manufacturer unnecessary.
0600.GB
A 2
0600.GB
A 2
B 1
0708.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
capacity label Qmax.
m
The EMC/EMB truck has been designed for light duty, maximum continuous
operation should not exceed 2 hours.
Truck type, load capacity and motor output:
Type Load capacity Motor output
EMC/EMB 1000 kg 0.35 kW
B 1
0708.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
capacity label Qmax.
m
The EMC/EMB truck has been designed for light duty, maximum continuous
operation should not exceed 2 hours.
Truck type, load capacity and motor output:
Type Load capacity Motor output
EMC/EMB 1000 kg 0.35 kW
B 2
0708.GB
2 Description of the assemblies and functions
Item EMC/EMB Designation
1
t
Collision protection button
2
t
Mast covering
3
o
Weighing system
4
t
Battery discharge 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 wheel
12
t
Front hood
13
t
Motor cover
14
t
Key switch
15
t
Control shaft
16
t
Controller
t = Standard equipment
o = Optional equipment
5
1
16
15
14
12
13
11
10
9
8
7
6
4
3
2
B 2
0708.GB
2 Description of the assemblies and functions
Item EMC/EMB Designation
1
t
Collision protection button
2
t
Mast covering
3
o
Weighing system
4
t
Battery discharge 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 wheel
12
t
Front hood
13
t
Motor cover
14
t
Key switch
15
t
Control shaft
16
t
Controller
t = Standard equipment
o = Optional equipment
5
1
16
15
14
12
13
11
10
9
8
7
6
4
3
2
B 3
0708.GB
2.1 Truck
Construction: The EMC/EMB is a four-wheel truck with a steerable drive wheel (11),
a supporting wheel (10) and two load-bearing wheels (9). Hoods that are easy to open
(2, 12 and 13) provide easy access to all units. The operating controls are located in
the control shaft head.
Safety features:
- The truck chassis protects the feet of the operator and, in case of collisions, the
load lying on the pallet.
- The control shaft (15) ensures that the operator is at a safe distance from the truck.
In case of danger, its shape allows the control shaft to move upward in front of the
body of the operator, applying the brake.
- When the control shaft is released, a gas pressure spring causes it to be pushed
into the upper braking position.
- The collision protection button (1) in the control shaft head reacts when touched.
The direction of travel is reversed and the truck moves away from the operator.
- Pulling out the emergency stop plug (7) causes all electrical functions to be
deactivated.
Operating controls and indicators: The operating controls for 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 function when the voltage is low
to prevent exhaustive discharge.
Drive system: The drive system has an asymmetrical structure. The 0.35 kW drive
motor drives the drive wheel (11) via a transmission. Reversing the direction of travel
by using the controller (16) in the control shaft head allows the truck to be braked by
counter-current braking.
Steering system: The truck is steered using the control shaft (15). The steering
range is approx. 90° to either side.
Brake system: A spring pressure brake (service brake) acts directly upon the drive
motor. Tilting the control shaft (15) into the upper or lower braking area causes the
truck to be braked.
Hydraulic system: The lifting and lowering functions are triggered using the control
buttons on the control shaft head. When the lifting function is activated, the pump unit
starts up. Hydraulic oil is pumped from the oil reservoir into the cylinder. The load
lifting device (8) is lifted.
Electrical system: 24 volt system. As a standard feature, the truck is equipped with
an electronic drive current control system.
B 3
0708.GB
2.1 Truck
Construction: The EMC/EMB is a four-wheel truck with a steerable drive wheel (11),
a supporting wheel (10) and two load-bearing wheels (9). Hoods that are easy to open
(2, 12 and 13) provide easy access to all units. The operating controls are located in
the control shaft head.
Safety features:
- The truck chassis protects the feet of the operator and, in case of collisions, the
load lying on the pallet.
- The control shaft (15) ensures that the operator is at a safe distance from the truck.
In case of danger, its shape allows the control shaft to move upward in front of the
body of the operator, applying the brake.
- When the control shaft is released, a gas pressure spring causes it to be pushed
into the upper braking position.
- The collision protection button (1) in the control shaft head reacts when touched.
The direction of travel is reversed and the truck moves away from the operator.
- Pulling out the emergency stop plug (7) causes all electrical functions to be
deactivated.
Operating controls and indicators: The operating controls for 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 function when the voltage is low
to prevent exhaustive discharge.
Drive system: The drive system has an asymmetrical structure. The 0.35 kW drive
motor drives the drive wheel (11) via a transmission. Reversing the direction of travel
by using the controller (16) in the control shaft head allows the truck to be braked by
counter-current braking.
Steering system: The truck is steered using the control shaft (15). The steering
range is approx. 90° to either side.
Brake system: A spring pressure brake (service brake) acts directly upon the drive
motor. Tilting the control shaft (15) into the upper or lower braking area causes the
truck to be braked.
Hydraulic system: The lifting and lowering functions are triggered using the control
buttons on the control shaft head. When the lifting function is activated, the pump unit
starts up. Hydraulic oil is pumped from the oil reservoir into the cylinder. The load
lifting device (8) is lifted.
Electrical system: 24 volt system. As a standard feature, the truck is equipped with
an electronic drive current control system.
B 4
0708.GB
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
** Can be adjusted in steps of 50 mm
Designation EMC / EMB
Q Rated load capacity 1000 kg
C Load centre 600 mm
Travelling speed with / without load 3.5 / 4 km/h
Lifting speed with / without load 8.0 / 11.0 cm/s
Lowering speed with / without load 20 / 7 cm/s
Designation Standard EMC
Broad version
EMB
h
1
Hoist frame height 1970 1970 mm
h
3
Lifting height 1560/2000 1560/2000 mm
h
13
Load lifting device lowered 90 90 mm
y
Wheel base, load part
lowered
1170 1170 mm
l
1
Truck length 1710 1710 mm
Distance
drive wheel <-> front chass.
150 150 mm
l
2
Front section length 530 530 mm
b
1
Truck width 800 - mm
Wa Turning radius 1405 1405 mm
Ast*
Aisle width
1000x1200 in transversal dir.
2241 2340 mm
Ast*
Aisle width
800x1200 in longitudinal dir.
2178 2190 mm
b4**
Max. distance between
wheel arms, inside
- 970 - 1270 mm
b1/b2**
Max. distance between
wheel arms, outside
- 1170 - 1470 mm
b
5
Distance between the forks,
outside
540 540 or 660 mm
e Fork width 160 160 mm
B 4
0708.GB
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
** Can be adjusted in steps of 50 mm
Designation EMC / EMB
Q Rated load capacity 1000 kg
C Load centre 600 mm
Travelling speed with / without load 3.5 / 4 km/h
Lifting speed with / without load 8.0 / 11.0 cm/s
Lowering speed with / without load 20 / 7 cm/s
Designation Standard EMC
Broad version
EMB
h
1
Hoist frame height 1970 1970 mm
h
3
Lifting height 1560/2000 1560/2000 mm
h
13
Load lifting device lowered 90 90 mm
y
Wheel base, load part
lowered
1170 1170 mm
l
1
Truck length 1710 1710 mm
Distance
drive wheel <-> front chass.
150 150 mm
l
2
Front section length 530 530 mm
b
1
Truck width 800 - mm
Wa Turning radius 1405 1405 mm
Ast*
Aisle width
1000x1200 in transversal dir.
2241 2340 mm
Ast*
Aisle width
800x1200 in longitudinal dir.
2178 2190 mm
b4**
Max. distance between
wheel arms, inside
- 970 - 1270 mm
b1/b2**
Max. distance between
wheel arms, outside
- 1170 - 1470 mm
b
5
Distance between the forks,
outside
540 540 or 660 mm
e Fork width 160 160 mm
B 5
0708.GB
C
Q
h
1
h
3
h
13
l
2
y 150
l
1
Ast
b
1
Wa
b
1
/b
2
b
5
e
b
4
B 5
0708.GB
C
Q
h
1
h
3
h
13
l
2
y 150
l
1
Ast
b
1
Wa
b
1
/b
2
b
5
e
b
4
B 6
0708.GB
3.3 Batteries and motor output
3.4 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871
A
The continous sound level is an average value determined according to standard stipulations and covers the noise level during driving, during lifting and during idling. The
noise 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)”:
- interference emission (EN 50081-1)
- interference immunity (EN 50 082-2)
- electrostatic discharge (EN 61000-4-2)
A
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
EMC/EMB
Battery 2x 12 V / 60 Ah or 55 Ah in series
Motor output 0.35 kW
B 6
0708.GB
3.3 Batteries and motor output
3.4 EN standards
Continuous sound level: 66 dB(A)
according to prEN 12053 as stipulated in ISO 4871
A
The continous sound level is an average value determined according to standard sti-
pulations and covers the noise level during driving, during lifting and during idling. The
noise 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)”:
- interference emission (EN 50081-1)
- interference immunity (EN 50 082-2)
- electrostatic discharge (EN 61000-4-2)
A
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
EMC/EMB
Battery 2x 12 V / 60 Ah or 55 Ah in series
Motor output 0.35 kW
B 7
0708.GB
4 Labels
* EMB with crane hook see chapter G, section 1.3
Item Designation
17 Load capacity label “Load capacity / load centre / fork” *
18 Eye for crane loading
19 Warning sign “Do not step below the load lifting device”
20 Load capacity Qmax *
21 Warning sign “Caution: electronics and low voltage”
22 Label “Application points for lifting jack”
23 Test sticker (o)
24 Truck identification plate *
25 Truck number (embossed)
26 Prohibitive sign “Do not ride on the truck”
X xx xx
xxxx xx
Xxx
Xxxx
Xxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxxxxxx
Xxxxxxxxx
Xxxxxxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxxxx
Xxxxxxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxxxxxxx
Xxxxxxxxxxxxxxx
Xxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xx
18
25
19
26
24
17
Q
max
1000
kg
20
21
mV
1,5 V
22
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
1994
Regelmäßige Prüfung
nach UVV VBG 12 a/ 12 b
§20 durch Sachkundigen
Nächste Prüfung
Ihr Kundendienst-Partner
Kundendienst
JUNGHEINRICH
V
23
B 7
0708.GB
4 Labels
* EMB with crane hook see chapter G, section 1.3
Item Designation
17 Load capacity label “Load capacity / load centre / fork” *
18 Eye for crane loading
19 Warning sign “Do not step below the load lifting device”
20 Load capacity Qmax *
21 Warning sign “Caution: electronics and low voltage”
22 Label “Application points for lifting jack”
23 Test sticker (o)
24 Truck identification plate *
25 Truck number (embossed)
26 Prohibitive sign “Do not ride on the truck”
X xx xx
xxxx xx
Xxx
Xxxx
Xxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxxxxxx
Xxxxxxxxx
Xxxxxxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxxxx
Xxxxxxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxxxxxxx
Xxxxxxxxxxxxxxx
Xxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xx
18
25
19
26
24
17
Q
max
1000
kg
20
21
mV
1,5 V
22
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
1994
Regelmäßige Prüfung
nach UVV VBG 12 a/ 12 b
§20 durch Sachkundigen
Nächste Prüfung
Ihr Kundendienst-Partner
Kundendienst
JUNGHEINRICH
V
23
B 8
0708.GB
4.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial
no. (28) of the truck.
4.2 Load capacity label, load capacity / load centre / fork
The load capacity label (17) indicates the load capacity
Q kg of the fork. A diagram shows the actual load capacity
at different load centres (C in mm).
Item Designation Item Designation
27 Type 33 Load centre in mm
28 Serial no. (truck no.) 34 Min./max. battery weight in kg
29 Order no. 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
xxxx xx
Xxx
Xxxx
Xxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxxxxxx
Xxxxxxxxx
Xxxxxxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxxxx
Xxxxxxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxxxxxxx
Xxxxxxxxxxxxxxx
Xxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xx
27
28
29
30
31
33
37
36
35
34
32
B 8
0708.GB
4.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial
no. (28) of the truck.
4.2 Load capacity label, load capacity / load centre / fork
The load capacity label (17) indicates the load capacity
Q kg of the fork. A diagram shows the actual load capacity
at different load centres (C in mm).
Item Designation Item Designation
27 Type 33 Load centre in mm
28 Serial no. (truck no.) 34 Min./max. battery weight in kg
29 Order no. 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
xxxx xx
Xxx
Xxxx
Xxxx
Xxxx
Xxxxxxx
Xxxxxx
Xxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxxxxxx
Xxxxxxxxx
Xxxxxxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxx
Xxxxxxx
Xxxxxxxxxx
Xxxxxx
Xxxxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxx
Xxxxxx
Xxxxxx
Xxxxxxxxxxxxxx
Xxxxxxxxxxxxxxx
Xxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxxxxxx
Xxxxxxxxxxxxxxxxxx
Xx
27
28
29
30
31
33
37
36
35
34
32
C 1
0600.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
A lifting eye (1) is provided on the fork side of the mast for loading the truck using
crane gear.
- Park the truck and render it safe
(see chapter E, section 4.5).
- Attach the crane gear to the lifting eye (1).
m
The crane gear must be attached to the lifting eye
in such a manner that it cannot slip!
The crane gear must be attached in such a
manner that it does not touch 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 battery (trailing cables) must be less than 6 m
in length.
To prepare the truck for operation after delivery or
transportation, the following operations must be
performed:
- Check the equipment for completeness.
- If necessary, install the battery. Make sure that the battery cable is not damaged.
- Charge the battery (see chapter D, section 3).
- Put the truck into operation in the stipulated manner (see chapter E, section 3).
A
When the truck is parked, the surface of the tyres may flatten. The flattening will
disappear after the truck has been operated for a short time.
1
C 1
0600.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
A lifting eye (1) is provided on the fork side of the mast for loading the truck using
crane gear.
- Park the truck and render it safe
(see chapter E, section 4.5).
- Attach the crane gear to the lifting eye (1).
m
The crane gear must be attached to the lifting eye
in such a manner that it cannot slip!
The crane gear must be attached in such a
manner that it does not touch 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 battery (trailing cables) must be less than 6 m
in length.
To prepare the truck for operation after delivery or
transportation, the following operations must be
performed:
- Check the equipment for completeness.
- If necessary, install the battery. Make sure that the battery cable is not damaged.
- Charge the battery (see chapter D, section 3).
- Put the truck into operation in the stipulated manner (see chapter E, section 3).
A
When the truck is parked, the surface of the tyres may flatten. The flattening will
disappear after the truck has been operated for a short time.
1
C 2
0600.GB
3 Moving an incapacitated truck (emergency operation)
To move the truck by emergency operation, the electromagnetically 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 its destination, the screws (3) must be turned again
anti-clockwise by 1½ revolutions. This restores the braking effect.
2
3
C 2
0600.GB
3 Moving an incapacitated truck (emergency operation)
To move the truck by emergency operation, the electromagnetically 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 its destination, the screws (3) must be turned again
anti-clockwise by 1½ revolutions. This restores the braking effect.
2
3
D 1
0600.GB
D Battery - Servicing, recharging, replace-
ment
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 must only be
performed by qualified personnel. The instructions contained in this operating
manual, and the instructions of the manufacturer of the battery and of the battery
recharging station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery
recharging. The location must be well ventilated and fire fighting equipment must be
kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean.
Terminals and cable shoes must be clean, lightly greased with pole grease and must
be securely tightened. Batteries with bare terminal posts must be covered using a
non-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 specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be
damaged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid. If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush the affected parts with clean water. Consult a doctor when skin or eyes come into contact with battery acid. Spilled battery acid must
be immediately neutralized.
m
Only batteries with closed tray may be used.
f
Battery weight and dimensions have considerable influence on operational safety of
the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer.
2Battery types
m
The truck is equipped with maintenance-free battery types (refer to chapter B). These
batteries must NOT refilled with distilled water. The covers of the cells are tightly
closed. Opening the covers will destroy the battery!
The battery weight is given on the battery identification plate.
D 1
0600.GB
D Battery - Servicing, recharging, replace-
ment
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 must only be
performed by qualified personnel. The instructions contained in this operating
manual, and the instructions of the manufacturer of the battery and of the battery
recharging station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when
handling batteries. No inflammable substances or spark-generating materials must
be present or stored within a distance of 2 meters of the truck parked for battery
recharging. The location must be well ventilated and fire fighting equipment must be
kept ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean.
Terminals and cable shoes must be clean, lightly greased with pole grease and must
be securely tightened. Batteries with bare terminal posts must be covered using a
non-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 specifications for the disposal must be heeded.
m
Before closing the battery hood, make sure that the battery cable cannot be
damaged.
f
Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid. If clothing, skin or eyes accidentally come into con-
tact with battery acid, liberally flush the affected parts with clean water. Consult a doc-
tor when skin or eyes come into contact with battery acid. Spilled battery acid must
be immediately neutralized.
m
Only batteries with closed tray may be used.
f
Battery weight and dimensions have considerable influence on operational safety of
the truck. Changing the battery equipment is not permitted without prior approval by
the manufacturer.
2Battery types
m
The truck is equipped with maintenance-free battery types (refer to chapter B). These
batteries must NOT refilled with distilled water. The covers of the cells are tightly
closed. Opening the covers will destroy the battery!
The battery weight is given on the battery identification plate.
D 2
0600.GB
3 Charging the battery using the integrated charger
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 (220 - 240V ±10%). When flashing green (possibly yellow
steady on) the LED (3) indicates that the charger is connected to mains.
- Charge the battery until LED (3) 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-out, all electrical
functions are interrupted. In this state, the truck cannot be operated.
Trickle charging
The battery is completely charged when the green LED (3) is continuously lit. The
charger switches to trickle charging. Trickle charging continues until the mains plug
is pulled out of the electric outlet.
Mains supply
Mains voltage: 220 - 240 V ±10%
Mains frequency: 50 Hz ±4%
1
3
2
D 2
0600.GB
3 Charging the battery using the integrated charger
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 (220 - 240V ±10%). When flashing green (possibly yellow
steady on) the LED (3) indicates that the charger is connected to mains.
- Charge the battery until LED (3) 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-out, all electrical
functions are interrupted. In this state, the truck cannot be operated.
Trickle charging
The battery is completely charged when the green LED (3) is continuously lit. The
charger switches to trickle charging. Trickle charging continues until the mains plug
is pulled out of the electric outlet.
Mains supply
Mains voltage: 220 - 240 V ±10%
Mains frequency: 50 Hz ±4%
1
3
2
D 3
0600.GB
Charging times
Depending on the state of discharge, charging the battery can take up to 11 h.
Partial charging
The charger is designed in such a manner that it automatically adapts itself when
charging partially charged batteries. This keeps battery 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).
- Loosen the terminal screws (7) 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 the batteries (6) using the hinged handle.
4
5
6
7
+
+
-
-
1.
2.
D 3
0600.GB
Charging times
Depending on the state of discharge, charging the battery can take up to 11 h.
Partial charging
The charger is designed in such a manner that it automatically adapts itself when
charging partially charged batteries. This keeps battery 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).
- Loosen the terminal screws (7) 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 the batteries (6) using the hinged handle.
4
5
6
7
+
+
-
-
1.
2.
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