Jungheinrich EJE KmS 16, Operating Instructions Manual

Page 1: ...Operating instructions 50114146 EJE KmS 16 G 02 01 02 01 ...

Page 2: ...t 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 ri...

Page 3: ...0108 GB ...

Page 4: ...egulations 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 E Operation 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 ...

Page 5: ...or 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...

Page 6: ...lf 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 ...

Page 7: ...0600 GB A 2 ...

Page 8: ...esigned 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 distanc...

Page 9: ...aster 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 ...

Page 10: ...ned 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 b...

Page 11: ...l 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 Qmax 160...

Page 12: ...m 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 ...

Page 13: ...0201 GB B 6 ...

Page 14: ...ear 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 ba...

Page 15: ...n OFF Set the key switch to position OFF 0 and remove the key Unlock the cover locks 2 open and set down the front hood 3 Slacken the lock nuts 4 and tighten the screws 5 The brake has now been released and the truck can be moved f After arriving at the repair bay ensure that the brake is put back to its initial state The truck must on no account be parked with the brake in the released condition ...

Page 16: ...d 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 na tional environmental protection regulations or waste disposal provisions The manu facturer s specifications for the disposal must be heeded m ...

Page 17: ... not permitted without prior approval by the manufacturer 3 Exposing the battery f Park the truck and render it safe Refer to chapter E Release the cover by depressing the lock 1 fold the battery cover 2 forward and release the cover safety mechanism 3 r The truck is equipped with a PzS battery The battery is now exposed and the re quired operations may be performed Battery type Battery compartmen...

Page 18: ...e battery cells must be exposed to ensure adequate ventilation No metal objects must be placed on the battery Prior to starting the recharging opera tion check all cable connections and plugged connections for visible damage Connect the charging cable of the battery charger to the battery connector Recharge the battery observing the instructions provided by the battery supplier and by the battery ...

Page 19: ...y identifi cation plate located at the battery trough The battery must be lifted vertically to pre vent crushing of the battery trough Lifting hooks must be applied in such a way that with the lifting gear slack they will not drop on to the battery cells Secure the lifting gear Lift out the battery f When replacing batteries ensure that a battery of the same type is fitted Additional weights must ...

Page 20: ...andard batteries and 50 in the case of maintenance free batteries Battery recharging is now advisable The advance Caution symbol 7 will go out and a flashing STOP symbol 8 will appear at a re sidual battery capacity of 20 in the case of standard batteries and 40 in the case of maintenance free batteries After a period of 5 minutes the STOP symbol 8 will remain permanently lit Battery recharging is...

Page 21: ...0201 GB D 6 ...

Page 22: ...ruck or on the attach ments must immediately be brought to the notice of the person in charge Fork lift trucks that cannot be safely operated e g due to worn tyres or defective brakes must not be used until they have been properly repaired Repairs Without specific training and express authorisation the driver is not allowed to perform any repairs or modifications on the fork lift truck Under no ci...

Page 23: ...not be operated by un authorized persons 4 Operating key Lowering t Lowering the fork at a fixed speed 5 Operating key Lifting t Raising the fork at a fixed speed 6 Operating key Horn t Giving audible warning signal 7 Operating key t Without function 8 Controller t Controlling the direction of travel as well as the travelling speed refer to section 4 2 9 Master switch t Switching the current suppl...

Page 24: ...E 3 0201 GB 1 3 5 4 13 14 11 12 6 9 10 2 7 8 V R ...

Page 25: ...aft adjusting lever 10 o swivel the control shaft to the desired position and release the control shaft adjusting lever again Pull out the master switch 9 Insert the key in the key switch 3 and turn the key clockwise towards the I posi tion until reaching the stop Check the warning signal horn 6 for correct functioning Check the controller 8 for correct functioning refer to section 4 2 The truck i...

Page 26: ...E 5 0201 GB 6 10 9 1 3 7 8 ...

Page 27: ...t always be carried at that end of the truck facing uphill U turns cutting obliquely over slopes or inclines and parking of the fork lift truck on slopes or inclines is not permitted Inclines must only be negotiated at slow speed with the driv er ready to brake at any moment Use of lifts and driving on loading platforms Lifts and loading platforms must only be used if they are of adequate load bea...

Page 28: ...A Operating key Slow travel 13 not operated slow speed operated normal travelling speed Swivel the control shaft 2 into the travelling range F Rotate the controller 8 to the required travelling direction V or R Lockable control shaft o Depress the deadman switch 14 Rotate the controller 8 to the required travelling direction V or R A The more the controller is turned the more the travelling speed ...

Page 29: ...current Swivelling control shaft Braking by means of the service brake Swivel the control shaft 2 into one of the braking ranges B or release the control shaft altogether The drive motor will then be braked by means of the motor brake A When the control shaft is released it will automatically swivel into the upper braking range B When the truck is parked the motor brake will act as a parking brake...

Page 30: ...g system is pointing straight ahead and that the operator cannot get caught be tween the truck and an obstacle Key controlled operation Backrest o A The truck can be controlled in the key operated mode with the operator walking on either side of the truck The max travelling speed is then reduced slow speed Depress operating key 11 The truck will move in direction V Depress operating key 12 The tru...

Page 31: ...eep the operating key depressed until the required lifting height has been reached A When the limit stop is contacted at the end of the lifting movement the pressure lim iting valve will respond noise emission Lowering Depress operating key Lowering 4 m Avoid impacting of the load to prevent damage to the load and racking 4 4 Order picking up to the second level o The driver standing platform is d...

Page 32: ... fault by performing the remedial actions indicat ed above please inform the manufacturer s service organisation as more intricate faults can only be rectified by specially trained and qualified service staff Fault Possible cause Remedial action Truck does not move Battery connector not con nected Master switch emergency stop depressed Key switch in position 0 Battery exhausted Fuse defective Chec...

Page 33: ...0201 GB E 12 ...

Page 34: ...ians trained especially for these assign ments We thus recommend signing a maintenance contract with the relevant service location of the manufacturer Lifting and jacking up When a fork lift truck is to be lifted the lifting gear must only be secured to the points specially provided for this purpose When the truck is to be jacked up suitable measures must be taken to prevent the truck from slippin...

Page 35: ...are undertaken Settings When repairing or replacing hydraulic electric or electronic components or assemblies all truck specific settings have to be retained Tyres The quality of the tyres greatly affects the stability and the driving behaviour of the fork lift truck The factory mounted tyres must only be replaced by original spare parts of the manufacturer since otherwise the specification of the...

Page 36: ...vals are defined as follows W1 every 50 operating hours but at least once per week M3 every 500 operating hours but at least every 3 months M6 every 1000 operating hours but at least every 6 months M12 every 2000 operating hours but at least every 12 months A The W1 maintenance intervals must be carried out by the operator customer In the running in phase of the truck the following additional oper...

Page 37: ...rformance and adjustment check t 6 2 Perform sight check of rollers sliding elements and stops l t 6 3 Check fork tines and fork carrier for wear and damage l t Hydraulic system 7 1 Performance check l t 7 2 Check all connections for leakage and damage b l t 7 3 Check hydraulic cylinders for leakage damage and secure attachment l t 7 4 Check the oil level l t 7 5 Change hydraulic oil and filter ca...

Page 38: ...d density acid level and cell voltage l t 10 2 Check the terminals for secure attachment and apply grease l t 10 3 Clean battery connections check for tight seat l t 10 4 Check the battery cables for damage renew if necessary t Lubricati on 11 1 Grease the vehicle in accordance with the lubrication schedule l t General measure ments 12 1 Check the electrical system for a grounding fault t 12 2 Che...

Page 39: ...brication Schedule g Gliding surfaces s Grease nipples Filler plug hydraulic oil b Filler plug gear oil a Drain plug gear oil Cold store usage 1 Compound cold store usage 1 1 B 1 4 l B C 1 A C A 0 7 l 1 E F E F E F E F ...

Page 40: ...des or qualities except if mixing is expressively prescribed in these operating instructions Avoid spilling Spilt liquid must be removed immediately using a suitable binding agent and the mixture of consumption type material and binding agent is to be dis posed of according to the regulations Grease data Code Order No Supply Qty Designation Used for A 29 200 670 5 0 l H LP 46 DIN 51524 Hydraulic s...

Page 41: ...uthorised per sons refer to chapter D f When work has to be performed under the raised fork or under the jacked up truck suitable measures must be taken to prevent any dropping tilting or slipping of the fork or truck When lifting the truck the instructions contained in chapter Transportation and commissioning have to be observed 6 2 Opening the battery hood Refer to chapter D 6 3 Opening the fron...

Page 42: ... at the hydraulic oil reservoir 3 A The hydraulic oil reservoir is provided with markings 4 With the fork in the lowered position the oil level must be between the markings max and min If necessary top up to the max marking using hydraulic oil of the prescribed spec ification refer to hydraulic oil specification section 5 1 Close the front cover remove the key and place the key in the key compartm...

Page 43: ...ion 6 3 Referring to the table check all fuses for correct rating and replace where required Reinstall the front hood refer to chapter E Item Description Protection of Value 5 F1 Total control fuse 10 A 6 1F1 Drive motor in parallel to 1F10 150 A 7 1F10 Drive motor in parallel to 1F1 40 A 8 2F1 Pump motor 150 A 9 6F1 Discharge indicator operating hour meter 10 A 10 9 8 7 6 ...

Page 44: ...r more than 6 months additional meas ures must be discussed with the Service Department of the manufacturer 7 1 Operations to be performed prior to decommissioning Thoroughly clean the fork lift truck Check the brakes for correct function Check the hydraulic oil level and top up if required refer to chapter F Apply a thin film of oil or grease to all parts not protected by a paint coating Grease t...

Page 45: ...k ked by a qualified inspector The inspector must assess the condition of the truck from a standpoint purely concerned with safety aspects uninfluenced by any company or economic circumstances The inspector must be adequately informed and experi enced to be able to assess the condition of the fork lift truck and the effectiveness of the safety installations based on the technical rules and princip...