Operating instructions
50114146
EJE KmS 16
G
02.01 -
02.01
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
0201.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
2.1 EN standards ...................................................................................... B 3
2.2 Conditions for application .................................................................... B 3
3 Identification locations and identification plates .................................. B 4
3.1 Truck identification plate ..................................................................... B 5
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery ................................................... D 4
6 Combined instrument (o) ................................................................... D 5
EOperation
1 Safety regulations governing the operation of the fork-lift truck .......... E 1
2 Description of the operating controls and indicating instruments ........ E 2
3 Starting up the truck ............................................................................ E 4
4 Operation of the fork-lift truck .............................................................. E 6
4.1 Safety regulations applicable when operating the truck ...................... E 6
4.2 Driving, steering, braking .................................................................... E 7
4.3 Picking up and setting down loads ...................................................... E 10
4.4 Order picking up to the second level (o) ............................................ E 10
4.5 Safe parking of the truck ..................................................................... E 11
5 Fault location ....................................................................................... E 11
I 1
0201.GB
Table of contents
A Correct use and application of the truck
B Truck description
1 Application ........................................................................................... B 1
2 Assemblies ......................................................................................... B 2
2.1 EN standards ...................................................................................... B 3
2.2 Conditions for application .................................................................... B 3
3 Identification locations and identification plates .................................. B 4
3.1 Truck identification plate ..................................................................... B 5
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Commissioning .................................................................................... C 1
3 Moving the truck with the drive unit inoperative .................................. C 2
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Exposing the battery ........................................................................... D 2
4 Charging the battery ............................................................................ D 3
5 Removing and installing the battery ................................................... D 4
6 Combined instrument (o) ................................................................... D 5
EOperation
1 Safety regulations governing the operation of the fork-lift truck .......... E 1
2 Description of the operating controls and indicating instruments ........ E 2
3 Starting up the truck ............................................................................ E 4
4 Operation of the fork-lift truck .............................................................. E 6
4.1 Safety regulations applicable when operating the truck ...................... E 6
4.2 Driving, steering, braking .................................................................... E 7
4.3 Picking up and setting down loads ...................................................... E 10
4.4 Order picking up to the second level (o) ............................................ E 10
4.5 Safe parking of the truck ..................................................................... E 11
5 Fault location ....................................................................................... E 11
0201.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 Servicing and inspection ..................................................................... F 3
4 Maintenance Check - list ..................................................................... F 4
5 Lubrication Schedule ........................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Description of the servicing and maintenance operations ................... F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ...................................................................... F 8
6.2 Opening the battery hood .................................................................... F 8
6.3 Opening the front hood ....................................................................... F 8
6.4 Checking the hydraulic oil level ........................................................... F 9
6.5 Checking the electric fuses ................................................................. F 10
6.6 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and
following any untoward incidents (D: Accident
prevention check according to VBG 36) .............................................. F 12
0201.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 Servicing and inspection ..................................................................... F 3
4 Maintenance Check - list ..................................................................... F 4
5 Lubrication Schedule ........................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Description of the servicing and maintenance operations ................... F 8
6.1 Preparing the truck for the performance of servicing and
maintenance operations ...................................................................... F 8
6.2 Opening the battery hood .................................................................... F 8
6.3 Opening the front hood ....................................................................... F 8
6.4 Checking the hydraulic oil level ........................................................... F 9
6.5 Checking the electric fuses ................................................................. F 10
6.6 Recommissioning the truck ................................................................. F 11
7 Decommissioning the fork lift truck ..................................................... F 11
7.1 Operations to be performed prior to decommissioning ....................... F 11
7.2 Measures to be taken during decommissioning .................................. F 11
7.3 Recommissioning the truck ................................................................. F 12
8 Safety checks to be performed at regular intervals and
following any untoward incidents (D: Accident
prevention check according to VBG 36) .............................................. F 12
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 app-
lies 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
0201.GB
B Truck description
1Application
The truck is an electrically driven, three-wheeled lifting trolley controlled by means of
a control shaft and provided with a driver standing platform. The truck is designed for
use on level surfaces for transporting and order-picking goods and is able to pick up,
outside the load-bearing wheel range, pallets with open bases or lateral boards, as
well as trolleys.
Access to the second order-picking level is available as optional equipment in the
form of a step in the backrest and a step-on battery cover. The capacity of the truck
is 1600 kg at a load centre distance of 600 mm.
B 1
0201.GB
B Truck description
1Application
The truck is an electrically driven, three-wheeled lifting trolley controlled by means of
a control shaft and provided with a driver standing platform. The truck is designed for
use on level surfaces for transporting and order-picking goods and is able to pick up,
outside the load-bearing wheel range, pallets with open bases or lateral boards, as
well as trolleys.
Access to the second order-picking level is available as optional equipment in the
form of a step in the backrest and a step-on battery cover. The capacity of the truck
is 1600 kg at a load centre distance of 600 mm.
0201.GB
B 2
2 Assemblies
Item Designation Item Designation
1 o Combined instrument 9 t Collision guard
2 t Controller 10 t Motor brake
3 t Master switch 11 t Electric system
4 t Hydraulic pump 12 t Lifting linkage
5 t Hydraulic oil reservoir 13 t Load-bearing wheel support
6 t Drive motor 14 t Driver standing platform
7 t Supporting wheel 15 t Lifting cylinder
8 t Driven wheel 16 t Control shaft
t= Standard equipment o = Optional equipment
1
2
3
4
5
6
7
8 9 7
10
11
12
13
14
16
15
0201.GB
B 2
2 Assemblies
Item Designation Item Designation
1 o Combined instrument 9 t Collision guard
2 t Controller 10 t Motor brake
3 t Master switch 11 t Electric system
4 t Hydraulic pump 12 t Lifting linkage
5 t Hydraulic oil reservoir 13 t Load-bearing wheel support
6 t Drive motor 14 t Driver standing platform
7 t Supporting wheel 15 t Lifting cylinder
8 t Driven wheel 16 t Control shaft
t= Standard equipment o = Optional equipment
1
2
3
4
5
6
7
8 9 7
10
11
12
13
14
16
15
B 3
0201.GB
2.1 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 measured at the ear.
Vibration: 0.62m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical
plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit values for electromagnetic emission and interference immunity as well as testing of static electricity discharge according to prEN 12895 and the references to other
standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
2.2 Conditions for application
Ambient temperature
- during operation: 5°C to 40°C
A
Industrial trucks must be specially equipped and approved for continuous use in environments with temperatures below 5°C or in cold stores respectively with extreme
temperatures or humidity changes.
B 3
0201.GB
2.1 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 measured at the ear.
Vibration: 0.62m/s
2
according to prEN 13059
A
The swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical
plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms compliance with the limit val-
ues for electromagnetic emission and interference immu-
nity as well as testing of static electricity discharge ac-
cording to prEN 12895 and the references to other
standards contained therein.
A
Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
2.2 Conditions for application
Ambient temperature
- during operation: 5°C to 40°C
A
Industrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5°C or in cold stores respectively with extreme
temperatures or humidity changes.
0201.GB
B 4
3 Identification locations and identification plates
A
The capacity label (18) indicates the maximum capacity of the truck as Qmax. The
rated capacity as shown must not be exceeded. The load distribution label (19) stipulates that the load on the fork is to be approximately uniform.
Item Designation
17 Label “CAUTION: Low-voltage electronics”
18 Capacity Qmax
19 Load distribution
20 Label “Caution, pushbutton operation”
21 Truck identification plate
22 Identification label, battery
23 Accident prevention inspection label (
D
only)
24 Attachment point of hooks for transportation by crane
22
18
17
24
19
20
Q
max
1600
kg
mV
1,5 V
21
23
0201.GB
B 4
3 Identification locations and identification plates
A
The capacity label (18) indicates the maximum capacity of the truck as Qmax. The
rated capacity as shown must not be exceeded. The load distribution label (19) stip-
ulates that the load on the fork is to be approximately uniform.
Item Designation
17 Label “CAUTION: Low-voltage electronics”
18 Capacity Qmax
19 Load distribution
20 Label “Caution, pushbutton operation”
21 Truck identification plate
22 Identification label, battery
23 Accident prevention inspection label (
D
only)
24 Attachment point of hooks for transportation by crane
22
18
17
24
19
20
Q
max
1600
kg
mV
1,5 V
21
23
B 5
0201.GB
3.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial
no. (26) of the truck.
Item Designation Item Designation
25 Type 32 Drive power in kW
26 Serial No. 33 Customer no.
27 Rated capacity in kg 34 Min./max. battery weight in kg
28 Battery: Voltage V
Ampere hours Ah
35 Empty weight without battery in kg
29 Manufacturer 36 Year of manufacture
30 Order no. 37 Manufacturer logo
31 Load centre distance in mm
25
26
27
28
29
30
32
36
35
34
33
31
37
B 5
0201.GB
3.1 Truck identification plate
A
In the event of queries relating to the truck or spare part orders, please state the serial
no. (26) of the truck.
Item Designation Item Designation
25 Type 32 Drive power in kW
26 Serial No. 33 Customer no.
27 Rated capacity in kg 34 Min./max. battery weight in kg
28 Battery: Voltage V
Ampere hours Ah
35 Empty weight without battery in kg
29 Manufacturer 36 Year of manufacture
30 Order no. 37 Manufacturer logo
31 Load centre distance in mm
25
26
27
28
29
30
32
36
35
34
33
31
37
0201.GB
B 6
0201.GB
B 6
C 1
0201.GB
C Transportation and commissioning
1 Transportation by crane
f
Ensure that only lifting gear of adequate capacity is used
(for weight of the truck refer to the truck identification label).
– Park the truck and render it safe (refer to chapter E).
A
The truck chassis and the fork are
provided with hoisting points (1) to
be used when the truck is to be lifted
and transported by crane.
m
Secure the hoisting gear to the
hoisting points (1) ensuring that the
hoisting gear will not slip.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will
damage the electronics. Cables connected to the battery (trailing cables) must be
less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following
operations must be performed:
– If necessary, install the battery. Do not damage the battery cable.
(refer to chapter D).
– Charge the battery (refer to chapter D).
– Commission the truck as detailed
(refer to chapter E).
A
When the truck is parked, the running surface of the tyres will flatten. The flattening
will disappear after a short operating time of the truck.
1 1
C 1
0201.GB
C Transportation and commissioning
1 Transportation by crane
f
Ensure that only lifting gear of adequate capacity is used
(for weight of the truck refer to the truck identification label).
– Park the truck and render it safe (refer to chapter E).
A
The truck chassis and the fork are
provided with hoisting points (1) to
be used when the truck is to be lifted
and transported by crane.
m
Secure the hoisting gear to the
hoisting points (1) ensuring that the
hoisting gear will not slip.
2 Commissioning
m
The truck must only be operated on battery current. Rectified alternate current will
damage the electronics. Cables connected to the battery (trailing cables) must be
less than 6 meters in length.
In order to prepare the truck for work following delivery or transportation, the following
operations must be performed:
– If necessary, install the battery. Do not damage the battery cable.
(refer to chapter D).
– Charge the battery (refer to chapter D).
– Commission the truck as detailed
(refer to chapter E).
A
When the truck is parked, the running surface of the tyres will flatten. The flattening
will disappear after a short operating time of the truck.
1 1
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