Jungheinrich EFG 213 Operating Instructions Manual Download

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09.09 -

03.13

51151902

EFG 213-320

Operating instructions

EFG 316

EFG 215

EFG 216k

EFG 216

EFG 218k

EFG 218

EFG 220

EFG 316k

EFG 318k

EFG 318

EFG 320

EFG 213

Summary of Contents for EFG 213

Page 1: ...09 09 03 13 51151902 EFG 213 320 Operating instructions G EFG 316 EFG 215 EFG 216k EFG 216 EFG 218k EFG 218 EFG 220 EFG 316k EFG 318k EFG 318 EFG 320 EFG 213...

Page 2: ...ibed below in detail complies with the European Directives 2006 42 EC Machinery Directive and 2004 108 EEC Electromagnetic Compatibility EMC including amendments as well as the legislative decree to i...

Page 3: ...03 13 EN 4...

Page 4: ...uarantee of particular features of the truck should therefore be assumed from the present operating instructions Safety notices and text mark ups Safety instructions and important explanations are ind...

Page 5: ...3 13 EN 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com...

Page 6: ...al Specifications 19 3 1 Performance data 20 3 2 Dimensions 22 3 3 Weights 28 3 4 Mast versions 29 3 5 Tyre type 30 3 6 Engine Data 31 3 7 EN norms 32 3 8 Conditions of use 33 3 9 Electrical requireme...

Page 7: ...y door removal and installation o 74 E Operation 75 1 Safety Regulations for the Operation of the Forklift Truck 75 2 Displays and Controls 77 2 1 Control panel with display unit 81 2 2 Armrest contro...

Page 8: ...system 156 7 3 Emergency lowering 159 F Industrial Truck Maintenance 161 1 Operational Safety and Environmental Protection 161 2 Maintenance Safety Regulations 162 2 1 Consumables and used parts 163 2...

Page 9: ...ruck to service after decommissioning 193 6 Safety tests to be performed at intervals and after unusual incidents 194 7 Final de commissioning disposal 195 8 Human vibration measurement 195 9 Servicin...

Page 10: ...06 GB Appendix JH Traction Battery Operating Instructions Z These operating instructions apply only to Jungheinrich battery models If using another brand refer to the manufacturer s operating instruct...

Page 11: ...0506 GB 2...

Page 12: ...e capacity plate and must not be exceeded The load must rest on the load handler or be lifted by an attachment approved by the manufacturer The load must be fully raised see Lifting transporting and d...

Page 13: ...o a maximum of 15 Do not travel across or at an angle on inclines Travel with the load facing uphill Operation in partially public traffic WARNING Use under extreme conditions Using the truck under ex...

Page 14: ...ies are excluded Furthermore accident prevention regulations safety regulations and operating servicing and repair guidelines must be followed The operating company must ensure that all users have rea...

Page 15: ...03 13 EN 14...

Page 16: ...sing the load handler attached in front Closed bottom pallets can also be lifted 1 1 Truck models and rated capacity The rated capacity depends on the model The rated capacity can be derived from the...

Page 17: ...1 Travel direction definition The following determinations have been made for travel direction specification The following conventions have been agreed for travel direction specification Item Travel...

Page 18: ...Overhead guard 9 t Fork carriage 3 t Mast 10 t Drive system 4 t Steering wheel 11 t Battery door 5 t Lifting mechanism control 12 t Steer axle 6 t Control and display unit 13 t Trailer coupling 7 t E...

Page 19: ...ngle of the steering column are adjustable and can be set to suit all operators The low cross section means the operator has maximum legroom at all times The steering is particularly smooth offering a...

Page 20: ...trolled hydraulic pump ensures a proportionate and efficient supply to the hydraulic functions Mast Two or three stage masts optionally with free lift function narrow mast sections ensure excellent vi...

Page 21: ...m Travel speed 16 16 16 16 16 16 16 16 16 16 km h Lift speed with without load 0 48 0 60 0 46 0 60 0 49 0 60 0 44 0 55 0 40 0 55 m s Lowering speed with without load 0 55 0 55 0 55 0 55 0 55 0 55 0 55...

Page 22: ...500 500 500 500 mm Travel Speed 17 17 17 17 17 17 17 17 17 17 km h Lift speed w w o load 0 49 0 60 0 49 0 60 0 44 0 55 0 44 0 55 0 40 0 55 m s Lowering speed w w o load 0 55 0 55 0 55 0 55 0 55 0 55 0...

Page 23: ...50 150 150 mm h3 Lift 3000 3000 3000 3000 3000 mm h4 Mast height extended 3560 3560 3560 3587 3587 mm h6 Overhead guard height 2040 2040 2040 2040 2040 mm h7 Seat height 920 920 920 920 920 mm h10 Cou...

Page 24: ...23 03 13 EN h6 h7 h y l x 10 m 2 1 m 2 L 2 h 2 h1 h3 h4 L 1 l6 b12 R Wa b a e c Q A st 2 a...

Page 25: ...80 80 80 80 mm m2 Centre wheel base ground clearance 100 100 100 100 100 mm Ast Working aisle width for pallet 800x1200 longit 3226 3226 3339 3339 3446 mm 3446 3446 Ast Aisle width for pallet 1000x120...

Page 26: ...25 03 13 EN h6 h7 h y l x 10 m 2 1 m 2 L 2 h 2 h1 h3 h4 L 1 l6 b12 R Wa b a e c Q A st 2 a...

Page 27: ...0 mm Mast tilt fwd 7 7 7 7 7 Mast tilt back 7 7 7 7 7 L1 Length including forks 3140 3248 3140 3248 3248 mm L2 Headlength 1990 2098 1990 2098 2098 mm b Overall width 1060 1060 1120 1120 1120 mm e Fork...

Page 28: ...27 03 13 EN h6 h7 h y l x 10 m s 2 1 m 2 L 2 h 2 h1 h3 h4 L 1 l6 b12 b R 13 Wa b a e c Q A st 2 a...

Page 29: ...4380 4706 4060 4405 Rear axle load without lifting load 1407 1668 1589 1846 1881 1561 1686 Rear axle load with lifting load 488 608 548 675 676 597 602 EFG 316 320 Description EFG 316k 316 318k 318 32...

Page 30: ...000 3550 3585 3100 2050 3650 3685 3300 2150 3850 3885 3600 2300 4150 4185 4000 2500 4550 4585 4500 2800 5050 5085 5000 3050 5550 5585 5500 3400 6050 6085 ZZ 2300 1055 990 1605 2850 2915 3000 1405 1340...

Page 31: ...s listed in the table correspond to the standard version Other tyres can be used depending on the truck s equipment EFG 213 220 Description EFG 213 215 216k 216 218k 218 220 Front tyres SE 18x7 8 200...

Page 32: ...8x7x12 18x7x12 Pneumatic 180 70 8 LI125 PR 16 not available not available Tyre pressure bar 10 0 Torque Nm 240 240 240 Rear tyres SE 16x6 8 16x6 8 16x6 8 Full rubber 15x5x11 15x5x11 15x5x11 Pneumatic...

Page 33: ...and must not be confused with the human vibrations of the 2002 44 EC Vibrations operator directive The manufacturer offers a special service to measure these human vibrations see Human vibration meas...

Page 34: ...ed continually in conditions of extreme temperature or condensing air humidity fluctuations 3 9 Electrical requirements The manufacturer certifies compliance with the requirements for the design and m...

Page 35: ...s and data plates 4 1 Indication Points Z Warnings and notices such as capacity charts strap points and data plates must be legible at all times Replace if necessary D mm mm Q kg XXX 17 16 18 19 15 20...

Page 36: ...sengers 19 Lift limit 20 Do not step onto or beneath the load risk of trapping with moving mast 21 Read operating instructions 22 Capacity or reduced capacity 23 Data plate behind the battery door 24...

Page 37: ...truck or ordering spare parts always quote the truck serial number 31 30 31 33 32 34 41 37 40 39 38 36 35 Item Description Item Description 30 Type 36 Year of manufacture 31 Serial number 37 Load cen...

Page 38: ...e maximum capacity is shown as a table with a given load centre of gravity D in mm and the required lift height H in mm The capacity plate 22 of the truck indicates the truck s capacity with the forks...

Page 39: ...e must match the data plate of the attachment 5 Stability The truck s stability has been tested according to latest technological standards These take into account the dynamic and static tipover force...

Page 40: ...lines between the basic truck and the mast separated 2 Truck laden 2 1 Centre of gravity of the truck WARNING An altered centre of gravity can result in tipovers when cornering The overall centre of g...

Page 41: ...s can tear resulting in accidents XOnly use crane lifting gear with sufficient capacity XLoading weight Net weight of truck battery weight for electric trucks XThe mast must be tilted back fully XThe...

Page 42: ...securely on page 105 Procedure Secure the crane slings to the attachment points 44 and 45 Raise and load the truck Lower and deposit the truck carefully see Parking the truck securely on page 105 Secu...

Page 43: ...ntly long XTransporting over long distances prohibited Loading the truck with a second industrial truck Requirements Park the truck securely see Parking the truck securely on page 105 Procedure Raise...

Page 44: ...g loads on road vehicles and handling load securing devices In each case correct measurements must be taken and appropriate safety measures applied XThe truck must be securely fastened when transporte...

Page 45: ...ly on page 105 Tools and Material Required 2 fastening belts with a tensioner Retaining wedges Procedure Secure the truck with the fastening belt 46 at the top cross member of the mast 3 and the trail...

Page 46: ...emblies controllers sensors motors etc of the electronic system Unsuitable cable connections too long insufficient wire cross section to the battery tow cables can overheat setting the truck and batte...

Page 47: ...03 13 EN 46...

Page 48: ...vailable CAUTION The use of unsuitable fire protection equipment can result in scalding Extinguishing fires with water can cause a reaction with the battery acid This can result in scalding from the a...

Page 49: ...03 13 EN 48...

Page 50: ...y the manufacturer can be hazardous The design weight and dimensions of the battery have a considerable effect on the operational safety of the truck in particular its stability and capacity The use o...

Page 51: ...nding on the application The following table shows which combinations are included as standard Truck model Description Capacity EFG 213 48V 4PzS 460 Ah EFG 215 48V 4PzS 460 Ah EFG 216k 48V 5PzS 575 Ah...

Page 52: ...dimensions Battery 48 V Truck model Dimension mm Rated weight 5 8 in kg L max W max H1 2mm H2 2mm EFG 213 215 830 522 612 627 715 EFG 216k 218k 316k 318k 830 630 612 627 855 EFG 216 218 220 316 318 3...

Page 53: ...king the truck securely on page 105 Load handler lowered Key switch set to OFF Key removed Set the Emergency Disconnect OFF Procedure Open the battery door 49 as far as the stop Pull the battery conne...

Page 54: ...o ensure adequate ventilation XDo not smoke and avoid naked flames when handling batteries XWherever an industrial truck is parked for charging there shall be no inflammable material or lubricants cap...

Page 55: ...ent XBatteries must never be swapped from truck to truck XDo not connect the battery to two chargers simultaneously Mains connection The mains lead may vary depending on the size of the on board charg...

Page 56: ...from the truck connector 51 Procedure Connect the on board charger to the mains socket using the mains cable Charging begins automatically When the truck is switched on the charging status and the res...

Page 57: ...Flashing Charging Lit Charging complete Red LED Meaning Flashing Error White LED Meaning Flashing Radio network activated Blue LED Meaning Lit Electrolyte level too low measured after each charge Yel...

Page 58: ...harger is designed to automatically adapt to partially charged batteries This keeps battery wear to a minimum Z If a charging operation has to be interrupted press the button 54 Only remove the mains...

Page 59: ...teries section in this chapter XWear safety shoes when removing and installing the battery XUse only batteries with insulated cells and terminal connectors XPark the truck on a level surface to preven...

Page 60: ...th holes in accordance with assembly instructions see Assembly instructions on page 60 Procedure Open the safety catch 55 To do this press the pedals 56 Insert bent pins 57 into the forks of the EJE o...

Page 61: ...rill 4 holes with a 16 mm diameter into the EJE or hand pallet truck according to the drill patterns Make sure there is sufficient distance between the connecting rod and the bottom of the forks Z Att...

Page 62: ...ttery on page 52 Tools and Material Required Battery trolley with four wheels EJE pallet truck with Snapfit battery holder Charging station intended for the battery type 60 o Procedure Close the safet...

Page 63: ...be pulled clear of the battery compartment NOTE Risk of material damage Risk of material damage to the truck chassis while the battery is being pulled out XRaise the fork tines While pulling out the b...

Page 64: ...the forks of the EJE pallet truck underneath the truck base NOTE Risk of material damage Inserting the battery can cause material damage to the truck chassis XLower the forks and avoid striking the t...

Page 65: ...al Required Battery trolley with four rollers Hand pallet truck with Snapfit battery holder Charging station intended for the battery type 60 o Procedure Close the safety catch 55 To do this press the...

Page 66: ...age Removing the battery can cause material damage to the truck chassis XRaise the forks and avoid striking the top or bottom parts of the chassis when removing the battery Remove the battery Bring th...

Page 67: ...Deposit the battery trolley with the rollers 65 on the base of the truck Lower the forks of the hand pallet truck until the battery is horizontal Insert the battery in the truck Close the battery loc...

Page 68: ...i adapter Battery trolley with six rollers Pallet truck with a fork length of 1150 mm Procedure Push the pallet truck and the multi adapter up to the stop 68 under the battery Set the multi adapter to...

Page 69: ...retaining hook 72 using your foot Insert the rollers of the battery replacement trolley into the battery compartment guides and push the battery into the battery compartment WARNING After inserting th...

Page 70: ...rements Park the truck securely see Parking the truck securely on page 105 Battery exposed see Exposing the battery on page 52 Battery disconnected Tools and Material Required Side table Battery troll...

Page 71: ...tery with the crane The battery replacement trolley remains secured to the worktable via the safety catches 72 The battery is now removed and can be taken to the charging station for charging Z Batter...

Page 72: ...disconnected Battery lock released Tools and Material Required Fork shoe Second fork lift truck with a capacity to match the battery weight The battery weights are indicated on the battery data plate...

Page 73: ...and bring the battery to the charging station to be charged Place the battery carefully on the charging station 60 The battery is now removed and positioned securely for charging Z Battery installati...

Page 74: ...ry exposed see Exposing the battery on page 52 Battery disconnected Battery lock released Tools and Material Required External roller guided replacement device Procedure Z Note the replacement device...

Page 75: ...cedure Open the battery door by moving the handle 77 up Lift the battery door slightly to the outside Pull the battery door up Put the battery door down securely The battery door is now removed Batter...

Page 76: ...d shall be familiar with the operating instructions Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator must prevent unauthorised persons from...

Page 77: ...e truck immediately WARNING Falling objects can cause accidents Falling objects can injure the operator while the truck is being operated XThe operator must remain within the protected area of the ove...

Page 78: ...77 03 13 EN 2 Displays and Controls 4 80 81 82 80 85 86 87 85 88 84 83 89...

Page 79: ...Code lock 82 Dashboard control panel t Displays the battery capacity service hours errors key warning indicators wheel position and travel direction 83 Emergency Disconnect switch Switches power suppl...

Page 80: ...79 03 13 EN 4 80 81 82 80 85 86 87 85 88 84 83 89...

Page 81: ...sition 91 Lever t Lever for operating the hydraulic functions 92 Horn button t Activates an audible warning 93 Additional hydraulic function release button o Activates the additional hydraulic functio...

Page 82: ...displayed when the parking brake indicator 95 lights up Truck prevented from rolling away but not parked securely Parking brake is automatically activated after a set time 1 60 sec when the truck stop...

Page 83: ...flashing indicator 99 Slow travel speed indicator lamp t Slow travel speed activated max travel speed 6 km h 100 Travel direction display indicator lamp o Right left indicator lamps activated 101 Set...

Page 84: ...Travel is not enabled when the accelerator pedal is pressed Travel is enabled by pressing the parking brake button 108 Parking brake indicator light up simultaneously t 109 Program selector t Selects...

Page 85: ...ting from operating program 1 limited acceleration and speed together with sensitive application of the operating functions the performance levels increase to program 5 maximum performance for high th...

Page 86: ...een wipers Press 1x intermittent 2x fast 3x off Hold down on the button Switch on the windscreen washing system Rear windscreen wiper Press 1x intermittent 2x fast 3x off Hold down on the button Switc...

Page 87: ...03 13 EN 86 2 3 Side compartment control panel switch o Function Rear window heating Beacon Truck lighting Parking light Warning indicator Lift cutout override...

Page 88: ...d If several errors occur they are displayed alternately at 1 5 second intervals A warning sounds 115 Battery capacity display Battery discharge status Charge status display for on board charger o 116...

Page 89: ...ge the battery see Charging the battery on page 53 The battery charge status is shown on the truck display via a battery symbol 115 When a battery is discharged to the permissible discharge level the...

Page 90: ...aining charge time for an on board charger o Press the Shift key 102 for 8 seconds until the residual time display menu is shown Press the set key 102 to return to normal operating mode The time remai...

Page 91: ...can result in accidents If damage or other truck or attachment optional equipment defects are discovered during the following checks the truck must be taken out of service until it has been repaired...

Page 92: ...venly tensioned Test the seat belt The belt should jam when extracted suddenly Test the seat switch when the driver s seat is vacated it should not be possible to activate the hydraulic functions Test...

Page 93: ...n trucks with lateral battery removal check the left and right stops 64 in the battery compartment for damage Check the fluid level of the window washer system see Preparing the truck for operation on...

Page 94: ...place can damage your health Failure to observe the recommended body size can cause stress and endanger the operator and may lead to lasting ill health due to an unhealthy posture and excessive strain...

Page 95: ...that all the controls are within reach and can be applied without having to strain Adjust the visibility aid equipment mirrors camera systems etc so that the working environment can be clearly seen 3...

Page 96: ...he seat to a lower weight Z The driver s weight is correct when the arrow is in the middle of the display window 122 The minimum or maximum weight setting is reached when you can feel a return stroke...

Page 97: ...ds or backwards to the desired position Engage the driver s seat locking lever 123 in position The seat position is now correctly set Switching the seat heating on and off Procedure Press the seat hea...

Page 98: ...the steering column stop 127 in position The steering column is now positioned 3 4 3 Adjusting the arm rest Adjusting the arm rest Procedure Pull up the lock 129 and hold it in this position Move the...

Page 99: ...rs XReport any defects immediately to your supervisor XRemove the truck from service until a functional seat belt has been fitted Z Protect the seat belt from contamination e g cover it when the truck...

Page 100: ...cking the seat belt Procedure Check the attachment points for wear and damage Check the cover for damage Pull the belt out fully from the retractor and check for damage loose seams fraying and nicks T...

Page 101: ...not exceed the permissible surface and point loading on the travel lanes At blind spots get a second person to assist The driver must ensure that the loading dock dock leveller cannot be removed or c...

Page 102: ...and have a non slip surface and providing they can be safely travelled along in accordance with the truck s technical specifications The truck must always be driven with the load facing uphill The in...

Page 103: ...ng down Prevent liquid loads from sloshing out Inflammable liquids e g fused metal etc may only be transported with suitable auxiliary equipment Contact the manufacturer s customer service department...

Page 104: ...g Insert the key in the key switch 81 and turn it clockwise as far as it will go to the I position Test the brake pedal and parking brake 108 and 95 lit simultaneously Truck is operational The display...

Page 105: ...for 8 seconds until the set clock time menu is displayed Set the time with the Up 110 and Down 109 keys Confirm with the SET key 101 Set the minutes with the Up 110 and Down 109 keys Press the set key...

Page 106: ...wedges XAlways fully lower the mast and load handler XTilt the mast forward XAlways apply the parking brake button before parking the truck XChoose a place to park where no other people are at risk of...

Page 107: ...o a halt in time by applying the Emergency Disconnect switch XThe operation of the Emergency Disconnect switch must not be affected by any objects placed in its way XReport any defects on the Emergenc...

Page 108: ...carriage approx 200 mm XMake sure you have sufficient visibility when reversing Travel Requirements Truck prepared for operation see Preparing the truck for operation on page 103 Procedure Release th...

Page 109: ...dler approx 200 mm Tilt the mast back Apply the accelerator pedal 87 to travel forward The travel speed is governed by the accelerator 87 Apply the accelerator pedal 88 to reverse The travel speed is...

Page 110: ...ee Preparing the truck for operation on page 103 Procedure To negotiate a right hand bend Turn the steering wheel clockwise to match the desired steering radius To negotiate a left hand bend Turn the...

Page 111: ...The operator must take into account the travel route conditions when braking XBrake with care to prevent the load from slipping XAllow for increased braking distance when travelling with an attached l...

Page 112: ...mp operation XThe operator must instruct people to leave the hazardous area XThe operator must perform test braking 4 8 3 Parking brake DANGER Accident risk XThe parking brake will hold the truck with...

Page 113: ...When the parking brake button 108 is pressed again the parking brake is released travel is enabled and the yellow LEDs under the parking brake button 108 go out This function of the parking brake ensu...

Page 114: ...king brake is automatically activated after a set time 1 60 sec when the truck stops The parking brake is automatically released when the accelerator pedal is applied 108 95 Yellow LEDs under the park...

Page 115: ...cated centrally between the forks Adjusting the forks Requirements Park the truck securely see Parking the truck securely on page 105 Procedure Lift up the locking lever 130 Push the forks 131 into th...

Page 116: ...before pushing them down from the fork carriage XAfter replacing the forks fit the retaining bolts 119 and make sure the bolts are seated correctly Retaining bolt torque 85 Nm Replacing the forks Req...

Page 117: ...ler XDamaged loads must not be transported XIf the stacked load obscures forward visibility then you must reverse the truck XDo not exceed the maximum loads specified on the capacity plate XCheck the...

Page 118: ...oad you are transporting Watch out for other traffic at crossings and passageways Always travel with a lookout at blind spots On slopes and inclines always carry the load facing uphill never approach...

Page 119: ...ople to move out of the hazardous area of the truck Stop working with the truck if people do not leave the hazardous area XIf people do not leave the hazardous area despite the warning prevent the tru...

Page 120: ...will be a noise from the pressure relief valve release the lever The lever will revert automatically to neutral Tilting the mast forward backward Requirements To prepare the truck for operation see Pr...

Page 121: ...n R to move the load handler to the right from the driver s viewpoint Push the SOLO PILOT lever 135 in direction V to move the load handler to the left from the driver s viewpoint The sideshifter is n...

Page 122: ...fork tines with an integrated fork positioner optional equipment Requirements Truck prepared for operation see Preparing the truck for operation on page 103 The fork tines are no longer aligned Proce...

Page 123: ...ill be a noise from the pressure relief valve release the lever The lever will revert automatically to neutral Tilting the mast forward backward Requirements Truck prepared for operation see Preparing...

Page 124: ...ition for the operation has been reached there will be a noise from the pressure relief valve release the lever The lever will revert automatically to neutral Positioning the forks with an integrated...

Page 125: ...r aligned Procedure Press the 138 button whiel at the same time pressing the 93 button the forks will spread apart Pull the 138 button while at the same time pressing the 93 button the forks will move...

Page 126: ...designed by the attachment manufacturer for use with the respective industrial truck XOnly use attachments that have been fitted for the purpose by the owner XMake sure the operator has been instructe...

Page 127: ...se accidents This can result in malfunctions and the load can fall accidentally XClamping attachments may only be added to trucks which have a button to enable additional hydraulic functions XClamping...

Page 128: ...y can result in accidents Transporting hanging loads can reduce the stability of the truck XAdapt the travel speed to the load less than walking pace XSecure swinging loads for example with lifting sl...

Page 129: ...e length of the fork extension XLock the fork extensions onto the basic forks XWhen carrying out the daily checks and operations before starting see Checks and operations to be performed before starti...

Page 130: ...ments direction of movement in accordance with ISO 3691 1 so that they match the controls direction of movement 4 14 1 Solo Pilot with control of ZH1 hydraulic port Z Depending on the attachments used...

Page 131: ...direction The attachment s function is performed 4 14 3 Solo Pilot with control of ZH1 ZH2 and ZH3 hydraulic ports Z Depending on the attachments used the levers buttons 133 135 136 139 are assigned...

Page 132: ...attachments direction of movement in accordance with ISO 3691 1 so that they match the controls direction of movement 4 15 1 Multi Pilot with control of ZH1 hydraulic port Z Depending on the attachmen...

Page 133: ...time pressing the 93 button The attachment performs its operation 4 15 3 Multi Pilot with control of ZH1 ZH2 and ZH3 hydraulic ports Z Depending on the attachments used the levers buttons 137 138 93...

Page 134: ...he exchange ports on the truck are marked ZH1 ZH2 and ZH3 Attachment directions of movement defined to match the controls direction of movement Procedure Non pressurised hydraulic hoses Switch off the...

Page 135: ...agent and disposed of in accordance with environmental regulations If hydraulic oil comes into contact with the skin wash it off immediately with soap and water If it comes into contact with the eyes...

Page 136: ...the capacity indicated on the capacity plate see Identification points and data plates on page 34 If a load is also transported on the load handler the trailer load must be reduced by the same amount...

Page 137: ...between the truck and the tiller when coupling the trailer XThe tiller must be horizontal tilted down by no more than 10 and never facing up Attaching the trailer Requirements Truck and trailer are o...

Page 138: ...up of operators When originally supplied from the factory the code is indicated on a sticker Change the master and operator codes when using the truck for the first time Z When the truck is originally...

Page 139: ...each time the truck is left 6 1 2 Parameter Settings To change the access code you must enter the master code Z The master code factory setting is 7 2 9 5 Change the master code the first time you use...

Page 140: ...Set 101 LED 142 flashes Enter new code confirm Set 101 LED 143 flashes Repeat new code confirm Set 101 001 Add code max 250 0000 9999 or 00000 99999 or 000000 999999 2580 LED 142 flashes Code entry c...

Page 141: ...st Attempt to change the code to one that already exists Attempt to delete a code that does not exist Code memory full 004 Delete code log deletes all codes 3265 3265 delete other entries do not delet...

Page 142: ...ehicle in front and must be in control of the truck at all times Abrupt stopping except in emergencies rapid U turns and overtaking at dangerous or blind spots are not permitted Do not lean out or rea...

Page 143: ...eight and check if the slow travel display lights up Steering when the truck is stationary check if the steering wheel display is working 6 2 3 Lift Control This option includes Drive Control and also...

Page 144: ...elease the driver from his responsibility to wear a seat belt see Seat Belt on page 98 CAUTION Cabin doors can pose a trapping hazard You can trap hands or feet when the cab doors are opened and close...

Page 145: ...TION An unlocked sliding window can cause accidents XThe sliding windows must be locked at all times Opening and closing the windows Procedure Push the lock 149 up Move the window forward or back Inse...

Page 146: ...truck is about to tip over do not loosen the seat belt The operator must not jump off the truck The operator must lean his upper body over the steering wheel and hold on with both hands Tilt your body...

Page 147: ...a door monitoring sensor travel is only enabled when the panel door is closed o Procedure Pull the handle 150 towards the operator position the door swings open Pull the door 146 towards the operator...

Page 148: ...be adjusted by changing the detent Pull the backrest up and lock it in place to extend the backrest Push the backrest down and lock it in place to shorten the backrest Adjusting the swivel seat Proced...

Page 149: ...quired to ensure the heating can work at a consistently high level see Maintenance checklist EFG 213 220 on page 197 or see Maintenance checklist EFG 316 320 on page 208 Replacing the air conditioning...

Page 150: ...ws Load backrest assembly Procedure Attach the load backrest to the top rail of the fork carriage Fit the bolts and tighten them with a torque wrench Z Torque 85 Nm 6 11 Lift cutout override Z A lift...

Page 151: ...sh out of its bracket Z To operate refer to the illustrations on the fire extinguisher 6 13 Tilt angle display NOTE The current tilt angle is shown in an additional display that is attached on the rig...

Page 152: ...Procedure Prevent the trailer from rolling away Adjusting the trailer pull rod to the height of the coupling Pull the hand lever 162 remote control 161 o up Z The remote control 161 o is located in t...

Page 153: ...ar Using the camera system Press the button 169 on the monitor to switch the camera system on or off Press the button 168 to lighten or darken the screen day night settings Press the button 165 to ope...

Page 154: ...nd the attachments NOTE XThe lift lower and tilt speeds are determined by the inclination of the Multipilot Do not deposit the load handler suddenly to avoid damaging the load and the racking Lifting...

Page 155: ...ned for these tasks In order for customer services to react quickly and specifically to the fault the following information is essential Truck serial number Error number on the display unit if applica...

Page 156: ...charge battery if necessary Finish charge close battery door Check the fuses Load cannot be lifted Truck not operational Hydraulic oil level too low Battery discharge monitor has switched off Faulty f...

Page 157: ...tow the truck at walking pace XDo not park the truck with the parking brake released XOne person must be seated in the recovery truck to steer it and one person must be seated on the towed truck Towi...

Page 158: ...terial Required Auxiliary tool 172 removed from the document compartment in the backrest of the truck Procedure Place the auxiliary tool 172 on the lever 170 with the recesses 171 chamfer 173 facing t...

Page 159: ...f Disconnect the battery Prevent the truck from rolling away Release the parking brake Tools and Material Required Auxiliary tool 172 removed from the document compartment in the backrest of the truck...

Page 160: ...he truck during emergency lowering XNever stand underneath a raised load handler XOnly operate the emergency lowering valve when standing next to the truck XEmergency lowering of the mast cannot be ap...

Page 161: ...he backrest of the truck Procedure Place the auxiliary tool 172 on the emergency lowering valve 174 with the recess 175 Slowly turn the emergency lowering valve 174 in the forks direction the mast and...

Page 162: ...engineer in industrial trucks taking safety into account keep permanent graphic records of the plans tests and completion of the changes carry out and have authorised the respective changes to the ca...

Page 163: ...Customer Services Customer Services are specially trained in the use of the truck and are able to carry out maintenance and repairs independently Customer Services are aware of the relevant standards...

Page 164: ...n handling these materials 2 2 Wheels WARNING The use of tyres that do not match the manufacturer s specifications can result in accidents The quality of tyres affects the stability and performance of...

Page 165: ...n lift chains with high pressure jets or chemical cleaning agents XImmediately after cleaning dry the lift chain with compressed air and apply a chain spray XAlways lubricate a chain when it is discha...

Page 166: ...ydraulic immediately with an appropriate bonding agent XThe bonding agent consumable mixture must be disposed of in accordance with regulations WARNING Holes or hairline cracks in the hydraulic hoses...

Page 167: ...s in prescribed containers XAlways fill consumables in clean containers XDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the operating...

Page 168: ...parts XDo not smoke when handling oil XAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately XSeek fresh air after breathing in oil fumes or va...

Page 169: ...03 13 EN 168 3 2 Lubrication Schedule g Contact surfaces c Hydraulic oil drain plug s Grease nipple b Transmission oil filler neck Hydraulic oil filler neck a Transmission oil drain plug B E A E G...

Page 170: ...072 20l HLPD 32 1 50 429 647 20l HLPD 22 2 50 124 051 5l HV 68 3 51 082 888 5l Plantosyn 46 HVI BIO hydraulic oil B 51 132 827 5l 2 5 l Jungheinrich hydraulic oil Steering EFG 316 320 50 426 072 20l H...

Page 171: ...f the named alternative hydraulic oils WARNING Industrial trucks are factory equipped with HLP D22 32 hydraulic oil or 2 Plantosyn 46 HVI BIO hydraulic oil You cannot change from Plantosyn 46 HVI BIO...

Page 172: ...measures must be taken to avoid accidents when carrying out maintenance and repairs The following preparations must be made Procedure Park the truck securely see Parking the truck securely on page 10...

Page 173: ...ng the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks Raising and jacking up the truck securely Requirements Prepare the truck for maintenance and...

Page 174: ...aintenance and repairs on page 171 Procedure Undo the two quick release fasteners 176 Pull the rear panel back and remove it The rear panel is now open The fuses and other electrical components can no...

Page 175: ...ure after 10 service hours XAlways use tyres of the same make model and profile Checking the wheel attachment Requirements Prepare the truck for maintenance and repairs see Preparing the truck for mai...

Page 176: ...jury XThe wheels of the truck are very heavy A single wheel can weigh up to 150 kg XAlways replace wheels with a suitable tool and protective equipment Dismantle the wheels Requirements Prepare the tr...

Page 177: ...ry Fit the wheel attachment Remove the hard wooden blocks Lower the truck Torque the wheel attachment 177 crosswise with a torque wrench for torques see Tyre type on page 30 The wheel is now assembled...

Page 178: ...m coming into contact with hot motor parts XDo not smoke when handling hydraulic oil XAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately XSee...

Page 179: ...r panel on page 173 Procedure Visually inspect the hydraulic oil level on the hose Z If the reservoir is filled sufficiently the hose will be full approx 1 cm from the bottom Add hydraulic oil if thro...

Page 180: ...the O ring on assembly Refit the cap with the new filter element in place 4 8 Replacing the ventilation discharge filter Requirements Park the truck on a level surface Prepare the truck for maintenan...

Page 181: ...Oil sump Procedure Place the oil sump underneath the transmission Unscrew the oil dipstick 182 Check gear oil level top up if necessary through the filler hole 181 Z The oil level should reach the bo...

Page 182: ...ews 156 The filter cassette is now replaced Z Regular servicing is required to ensure the heating can work at a consistently high level see Maintenance checklist EFG 213 220 on page 197 or see Mainten...

Page 183: ...e of incorrect fuses can damage the electrical system and result in fire The safety and functionality of the truck cannot be ensured XUse only fuses with the prescribed rated current see Fuse ratings...

Page 184: ...183 03 13 EN 4 12 1 Fuse ratings 187 185 186 188 190 189 191 192 193 194 195 196 197 Zusatzausstattungen...

Page 185: ...ntroller fuse 40 A 189 F23 Control fuse 48 V 5 A 190 7F1 Magnetic brake control fuse 7 5 A 191 1F9 Traction lift electronics control fuse 5 A 192 4F1 Horn control fuse 3 A 193 F18 Power on contactor c...

Page 186: ...ntrol fuse 5A 205 F14 48 volt heater fuse 40A 206 F14 1 24 volt heater fuse 15A 207 5F11 Front LH work lights fuse 5A 57 5F11 1 Front RH work lights fuse 5A 209 5F11 2 Rear LH work lights fuse 5A 5F3...

Page 187: ...e g by short circuiting CAUTION Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity XCover all electronic system assemblies cont...

Page 188: ...h water based solvents and water Use a sponge or cloth to clean In particular clean the following areas Windows All walk on areas Oil filler ports and their surroundings Grease nipples before lubricat...

Page 189: ...intenance and repairs see Preparing the truck for maintenance and repairs on page 171 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure Expose the e...

Page 190: ...The capacitors are completely discharged after approximately 10 minutes Before starting maintenance on the electrical system XOnly suitably trained electricians may operate on the truck s electrical s...

Page 191: ...le on page 168 Clean the battery grease the terminals and connect the battery Charge the battery see Charging the battery on page 53 Replace transmission oil Condensation water could have formed Repla...

Page 192: ...sioning as described hereafter When the truck is out of service it must be jacked up so that all the wheels are clear of the ground This is the only way of ensuring that the wheels and wheel bearings...

Page 193: ...te the truck according to the lubrication schedule see Lubrication Schedule on page 168 Charge the battery see Charging the battery on page 53 Disconnect the battery clean it and grease the terminals...

Page 194: ...page 168 Clean the battery grease the terminals and connect the battery Charge the battery see Charging the battery on page 53 Replace transmission oil Condensation water could have formed Replace hy...

Page 195: ...es The inspector must be sufficiently instructed and experienced to be able to assess the condition of the truck and the effectiveness of the safety mechanisms based on the technical regulations and p...

Page 196: ...sassembled by trained personnel in accordance with the procedures as specified by the manufacturer 8 Human vibration measurement Z Vibrations that affect the operator over the course of the day are kn...

Page 197: ...ust temperature fluctuations or multiple shifts NOTE To prevent damage due to wear the manufacturer recommends an on site application analysis to agree on appropriate service intervals The following m...

Page 198: ...e t Travel W A B C 1 Check the wheels for wear and damage Make sure they are tight and check the compressed air if necessary t Chassis and Superstructure W A B C 1 Check doors and or covers t 2 Check...

Page 199: ...he heating t 2 Check heating vent filter for contamination and clean if necessary t Hydraulic Operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Hydraulic Operations...

Page 200: ...eaks and check volume top up if necessary t Hydraulic Operations W A B C 1 Check attachment lubrication clean and lubricate if necessary t Chassis and Superstructure W A B C 1 Check that optional equi...

Page 201: ...test t 10 Check electric wiring for damage insulation damage connections Make sure wire connections are secure t Power Supply W A B C 1 Check battery cable connections are secure grease terminals if n...

Page 202: ...ks and make sure they are secure t 4 Test hose guide and check for damage t 5 Check settings and wear levels of slide pieces and stops and adjust the slide pieces if necessary t 6 Check load chain set...

Page 203: ...anical parts of steering column t 3 Check steering block for wear and damage t Electrical System W A B C 1 Check anti static discharge strap is present and not damaged t Electrical System W A B C 1 Te...

Page 204: ...t strobe light beacon and check for damage t Electrical System W A B C 1 Check data recorder is secure and check for damage t System Components W A B C 1 Test scanner and terminal check for damage and...

Page 205: ...t is secure t Agreed performance levels W A B C 1 Check fire extinguisher is present secure and Check test interval t Chassis and Superstructure W A B C 1 Test the belt lock control and check for dama...

Page 206: ...ts t Hydraulic Operations W A B C 1 Check the load backrest for damage and make sure it is secure t Electrical System W A B C 1 Check electric wiring for damage insulation damage connections Make sure...

Page 207: ...damage t 9 Check cylinder seals t 10 Check cylinder piston rods and bushings t Electrical System W A B C 1 Check electric wiring for damage insulation damage connections Make sure wire connections are...

Page 208: ...fuse ratings t Chassis and Superstructure W A B C 1 Test the window heating and check for damage t 2 Test the doors and check for damage t Chassis and Superstructure W A B C 1 Check wiper water conta...

Page 209: ...secure t Chassis and Superstructure W A B C 1 Check that optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc are working correctly and check for da...

Page 210: ...ck load chain lubrication and lubricate if necessary t 2 Check running surfaces of the mast for wear and damage and lubricate if necessary t 3 Test hydraulic system t 4 Check cylinders hydraulic ports...

Page 211: ...ricate if necessary t Chassis and Superstructure W A B C 1 Test the windscreen heating and check for damage k 2 Test the doors and check for damage t Chassis and Superstructure W A B C 1 Check wiper w...

Page 212: ...test t 10 Check electric wiring for damage insulation damage connections Make sure wire connections are secure t Power Supply W A B C 1 Check battery cable connections are secure grease terminals if...

Page 213: ...ks and make sure they are secure t 4 Test hose guide and check for damage t 5 Check settings and wear levels of slide pieces and stops and adjust the slide pieces if necessary t 6 Check load chain set...

Page 214: ...ing hoses and lines t 4 Check steering axle and steering knuckle for wear and damage t 5 Check stub axle and adjust if necessary t 6 Test electric hydraulic steering and its components t 7 Check mecha...

Page 215: ...ly W A B C 1 Test battery refill system and check for leaks t Power Supply W A B C 1 Check safety labels are present t 2 Check lock is present and test it t Electrical System W A B C 1 Test strobe lig...

Page 216: ...ctrical System W A B C 1 Test the electrical optional equipment and check for damage t Power Supply W A B C 1 Replace air filter wadding t 2 Check hose connections and test the pump t Chassis and Supe...

Page 217: ...ic ports and tighten if necessary t 9 Check cylinder seals t 10 Check cylinder piston rods and bushings t Hydraulic Operations W A B C 1 Check attachment is properly secured to the truck and the suppo...

Page 218: ...ease and clean these components t 6 Check attachment lubrication clean and lubricate if necessary t 7 Check hydraulic ports and tighten if necessary t 8 Test the sideshifter check settings and check f...

Page 219: ...he truck and the supporting elements t System Components W A B C 1 Check wiring is secure and check for damage t 2 Test the camera make sure it is secured and clean t 3 Test the monitor make sure it i...

Page 220: ...s guides and stops for wear and damage grease and clean these components t 6 Check attachment lubrication clean and lubricate if necessary t 7 Check hydraulic ports and tighten if necessary t 8 Test t...

Page 221: ......

Page 222: ...ealed armour plated cells 9 5 1 Description 9 5 2 Operation 10 5 3 Servicing PzV and PzV BS lead acid batteries with sealed armour plated cells 13 6 Aquamatik water replenishment system 14 6 1 Water r...

Page 223: ...ring operation for batteries in accordance with Ex I and Ex II see relevant certification 2 Data plate 1 2 4 8 10 11 6 3 5 9 7 12 13 14 15 1 Battery name 2 Battery type 3 Production week year manf 4 S...

Page 224: ...ng Keep away from naked flames and strong heat sources Always wear protective clothing e g safety goggles and safety gloves when working on cells and batteries batteries Always wash your hands after c...

Page 225: ...adjustment factor is 0 0007 kg l per K e g electrolyte density 1 28 kg l at 45 C corresponds to a density of 1 29 kg l at 30 C The electrolyte must conform to DIN 43530 Part 2 purity regulations 4 1...

Page 226: ...tive to negative and check that contacts on the battery terminal conducting system are secure Check the terminal screw torques M10 23 1 Nm of the terminal conductors and connectors Charge up the batte...

Page 227: ...ate the room in which the truck is being charged XBattery cell surfaces must remain exposed during charging in order to ensure sufficient ventilation see truck operating instructions chapter D Chargin...

Page 228: ...charger ensuring the terminals are connect positive to positive and negative to negative Switch on the charger Battery charged Z Charging is considered to be complete when the electrolyte density and...

Page 229: ...a visual inspection for dirt and physical damage If the battery is charged regularly according to the IU characteristic carry out a compensation charge 4 3 3 Monthly Towards the end of the charging pr...

Page 230: ...s or hazardous electrolyte burns if the cell vessels are destroyed Z PzV batteries are low gassing but not gassing free Electrolyte The electrolyte is sulphuric acid which is fixed in gel The density...

Page 231: ...explosions The battery gives off a mixture of oxygen and hydrogen electrolytic gas during charging Gassing is a chemical process This gas mixture is highly explosive and must not be ignited XAlways d...

Page 232: ...ells XAlways charge the battery with DC current XAll DIN 41773 charging procedures are permitted in the format approved by the manufacturer XAlways connect the battery to a charger that is appropriate...

Page 233: ...lied with 0 004 V C per K Battery charged Z Charging is considered to be complete when the electrolyte density and battery voltage remain constant for more than 2 hours Compensation charging Compensat...

Page 234: ...the previous ones Z Carry out the measurements after full charging and subsequent resting for at least 5 hours Z If you find significant differences compared with the previous measurements or differen...

Page 235: ...k water replenishment system 6 1 Water replenishment system design 15 Water container 16 Tap connection with ball cock 17 Flow indicator 18 Shut off cock 19 Locking coupling 20 Battery lock connector...

Page 236: ...securely The plug systems have an optical level indicator a diagnostic port to measure the temperature and electrolyte density and a degassing port 6 3 Adding water Water should be added to the batter...

Page 237: ...r used to fill up electrolyte must correspond to purified or distilled water Purified water can be produced through distillation or ion exchangers and is then suitable for the production of electrolyt...

Page 238: ...of the plugs must come into contact with solvent based materials or soap 6 10 Service mobile vehicle Mobile water filling vehicle with pump and filling gun to fill individual cells The immersion pump...

Page 239: ...nds for an unknown reason the filters must be checked and replaced if necessary Battery connection A hose is attached to the pump module which together with the charge leads is routed from the charger...

Page 240: ...d to severe temperature fluctuations the electrolyte may flow back into the hose system XAttach a separate coupling system to the air inlet line such as locking coupling on the battery side and throug...

Page 241: ...close to a drainage system for processing the electrolytic rinsing water All health and safety as well as water and waste disposal regulations are observed when disposing of used electrolyte or rinsin...

Page 242: ...t the temperature does not exceed 60 C at a distance of 30cm behind the outlet nozzle Observe the maximum operating pressure of 50 bar Observe a minimum distance of 30 cm from the top of the battery T...

Page 243: ...cells for PzV batteries If the battery is to be taken out of service for a long period 3 months it should as far as possible be charged to 50 of its charge level and stored in a dry room protected fro...

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Jungheinrich EFG 213, Operating Instructions Manual

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