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EFG-110
User Manual [de]
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User Manual
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Jungheinrich EFG 110 User Manual [de]

EFG 110-115
Operating instructions G
10.09 -
51151449
09.12
EFG 110k EFG 110
EFG 113 EFG 115
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union
Type Option Serial no. Year of
EFG 110k EFG 110 EFG 113 EFG 115
Additional information
On behalf of
Date
G EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described 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 incorporate the directives in national law. The signatories are in each case individually authorized to compile the technical documents.
manufacture
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Foreword
Notes on the operating instructions
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 and the pages are numbered continuously.
The operator manual details different industrial truck models. When operating and servicing the industrial truck, make sure that the particular section applies to your truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee 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 indicated by the following graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Z Used before notices and explanations.
t Indicates standard equipment o Indicates optional equipment
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
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Jungheinrich Aktiengesellschaft
Am Stadtrand 35 22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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Contents
A Correct Use and Application ................................................... 11
1General....................................................................................................11
2Correct application...................................................................................11
3Approved application conditions..............................................................12
4Proprietor responsibilities........................................................................13
5Adding attachments and/or accessories..................................................13
BTruck Description....................................................................15
1Application...............................................................................................15
1.1 Truck models and rated capacity............................................................. 15
2Assemblies and Functional Description...................................................16
2.1 Assembly Overview ................................................................................. 16
2.2 Functional Description ............................................................................. 17
3Technical Specifications..........................................................................19
3.1 Performance data .................................................................................... 19
3.2 Dimensions.............................................................................................. 20
3.3 Weights.................................................................................................... 22
3.4 Mast versions .......................................................................................... 22
3.5 Tyre type.................................................................................................. 23
3.6 Engine Data............................................................................................. 23
3.7 EN norms................................................................................................. 24
3.8 Conditions of use..................................................................................... 25
3.9 Electrical requirements ............................................................................ 25
4Identification points and data plates........................................................26
4.1 Indication Points ...................................................................................... 26
4.2 Data plate ................................................................................................ 28
4.3 Truck capacity plate................................................................................. 29
4.4 Attachment capacity plate ....................................................................... 30
5Stability....................................................................................................30
CTransport and Commissioning................................................31
1Transport.................................................................................................31
2Truck laden..............................................................................................31
2.1 Centre of gravity of the truck ................................................................... 31
2.2 Lifting the truck by crane ......................................................................... 32
2.3 Loading with another industrial truck ....................................................... 33
3 Securing the truck during transport ......................................................... 34
4Using the Truck for the First Time...........................................................36
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DBattery - Servicing, Recharging, Replacement.......................37
1Safety Regulations Governing the Handling of Lead-Acid Batteries.......37
1.1 General notes on handling batteries........................................................ 39
2Battery types............................................................................................40
2.1 Battery dimensions .................................................................................. 40
3 Exposing the battery................................................................................ 41
4 Charging the battery ................................................................................ 43
4.1 Charging the battery with a stationary charger........................................ 43
5Battery removal and installation..............................................................44
6Closing the battery cover.........................................................................46
EOperation................................................................................47
1 Safety Regulations for the Operation of the Forklift Truck....................... 47
2Displays and Controls..............................................................................49
2.1 Control panel with display unit................................................................. 53
2.2 Side compartment control panel switch (o)............................................ 55
2.3 Instrument panel switches (o)................................................................ 55
2.4 Display..................................................................................................... 56
3Starting up the truck................................................................................58
3.1 Checks and operations to be performed before starting daily operation . 58
3.2 Entry and exit........................................................................................... 60
3.3 Trucks with reduced headroom X (o)..................................................... 60
3.4 Setting up the operator position............................................................... 61
3.5 Seat Belt .................................................................................................. 65
4 Industrial Truck Operation ....................................................................... 66
4.1 Safety regulations for truck operation...................................................... 66
4.2 Preparing the truck for operation ............................................................. 68
4.3 Setting the time........................................................................................ 69
4.4 Parking the truck securely ....................................................................... 70
4.5 Emergency Disconnect............................................................................ 71
4.6 Travel....................................................................................................... 72
4.7 Steering ................................................................................................... 73
4.8 Brakes ..................................................................................................... 74
4.9 Adjusting the forks ................................................................................... 76
4.10 Replacing the forks.................................................................................. 77
4.11 Lifting, transporting and depositing loads ................................................ 78
4.12 Operating the lift mechanism and integrated attachments ...................... 80
4.13 Safety instructions for operating additional attachments ......................... 87
4.14 Operating additional attachments for the SOLO-PILOT .......................... 91
4.15 Operating additional attachments for the Multi Pilot ................................ 93
4.16 Fitting additional attachments.................................................................. 94
5Towing trailers.........................................................................................96
6Optional equipment.................................................................................98
6.1 Assistance systems ................................................................................. 98
6.2 BODYGUARD ......................................................................................... 100
6.3 Panel door ............................................................................................... 100
6.4 Adjusting the driver’s seat ....................................................................... 101
6.5 Removable load backrest ........................................................................ 101
6.6 Lift cutout override ................................................................................... 102
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6.7 Fire extinguisher ...................................................................................... 102
6.8 Tilt angle display...................................................................................... 103
6.9 Rockinger coupling with hand lever or remote control............................. 103
6.10 Camera system ....................................................................................... 104
6.11 Control layout “N” .................................................................................... 105
7Troubleshooting.......................................................................................106
7.1 Troubleshooting....................................................................................... 106
7.2 Operating the truck without its own drive system .................................... 108
7.3 Emergency lowering ................................................................................ 109
FIndustrial Truck Maintenance..................................................111
1 Operational Safety and Environmental Protection................................... 111
2Maintenance Safety Regulations.............................................................112
3Servicing and Inspection.........................................................................117
4Maintenance checklist.............................................................................118
4.1 Owner ...................................................................................................... 118
4.2 Customer service..................................................................................... 121
5Lubricants and Lubrication Schedule......................................................129
5.1 Handling consumables safely.................................................................. 129
5.2 Lubrication Schedule ............................................................................... 131
5.3 Consumables........................................................................................... 132
6Maintenance and repairs.........................................................................134
6.1 Preparing the truck for maintenance and repairs .................................... 134
6.2 Opening the battery panel ....................................................................... 135
6.3 Checking the wheel attachments............................................................. 137
6.4 Hydraulic system ..................................................................................... 138
6.5 Check the gear oil level ........................................................................... 140
6.6 Adding window washer system fluid........................................................ 141
6.7 Checking electrical fuses......................................................................... 142
6.8 Seat belt maintenance............................................................................. 145
6.9 Restoring the truck to service after maintenance and repairs ................. 146
7Decommissioning the industrial truck......................................................147
7.1 Prior to decommissioning ........................................................................ 148
7.2 During decommissioning ......................................................................... 148
7.3 Restoring the truck to service after decommissioning ............................. 149
8 Safety tests to be performed at intervals and after unusual incidents ..... 150
9Final de-commissioning, disposal............................................................151
10 Human vibration measurement ............................................................... 151
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Appendix
JH Traction Battery Operating Instructions
These operating instructions apply only to Jungheinrich battery models. If using
Z
another brand, refer to the manufacturer's operating instructions.
If using a battery with closed EPzV and EPzV ironclad plates, this must first be
M
discussed with the manufacturer.
0506.GB
1
0506.GB
2
A Correct Use and Application
1General
The industrial truck described in the present operating instructions is designed for lifting, lowering and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the industrial truck or property.
2Correct application
NOTE
The maximum load and load distance are indicated on the load chart 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 rest on the back of the fork carriage and centrally between the forks.
–Lifting and lowering loads. –Transporting lowered loads over short distances. –Do not travel with a raised load (>30 cm). –Do not carry or lift passengers. –Do push or pull load units. –Occasional towing of trailer loads. –When towing trailer loads the load must be secured on the trailer. –The permissible trailer load must not be exceeded.
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3Approved application conditions
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes. At blind spots get a second person to assist. The driver must ensure that the loading dock / ramp cannot move or come loose during loading / unloading.
–Operation in industrial and commercial environments. –Permissible temperature range -20°C to 40°C. –Operation only on secure, level surfaces with sufficient capacity. –Operation only on routes that are visible and approved by the proprietor. –Negotiating inclines up to a maximum of 15 %. –Do not negotiate inclines crosswise or at an angle. Transporting loads downhill. –Operation in partially public traffic.
WARNING!
Extreme conditions
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck is not authorised for use in areas at risk of explosion. XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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4Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties. The proprietor must ensure that the industrial truck is used only for the purpose for which it is intended and that there is no danger to life and limb of the user and third parties. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer.
5Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the performance of the forklift truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained. Local authority approval does not however constitute the manufacturer’s approval.
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BTruck Description
1Application
The EFG 110 - 115 is a three-wheel electric sit-down forklift truck. It is a cantilever counterbalanced truck which can lift, transport and deposit loads using 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 model description.
EFG110
EFG Model name
1Series
10 Rated capacity x 100 kg
The rated capacity does not generally match the permissible capacity. The capacity can be found on the load chart attached to the rack.
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2Assemblies and Functional Description
2.1 Assembly Overview
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12
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Item Description
1 t Driver's seat 2 t Overhead guard 3 t Mast 4 t Steering wheel 5 t Control / display unit 6 t Lift mechanism control 7 t Emergency Disconnect switch 8 t Fork tines 9 t Fork carriage
10 t Battery cover
11 t Drive 12 t Trailer coupling 13 t Counterweight
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3
4
5
6
7
8
9
10
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2.2 Functional Description
Chassis
The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components.
Operator position and overhead guard
The overhead guard (2) comes in a range of models and protects the driver from falling objects and other external influences. All the controls are ergonomically arranged. The steering column and driver's seat can be adjusted individually.
The controls and warnings on the control and display unit (5) enable the system to be monitored during operation, thereby ensuring a very high level of safety.
Steering
A low steer effort of 15 N as well as a favourable transmission ratio of 5 steering wheel revolutions for an 180° steer angle. A hydraulic steer motor actuates the drive wheel via a gear wheel pair. Efficient energy deployment through the load sensing system. The steering column is adjustable.
Wheels
There is a choice of super elastic or fully rubber tyres as well as optional pneumatic tyres.
Brake System
The hydraulically activated drum servo brake acting on both front wheels provides effective deceleration with minimal pedal force. The truck also brakes to a halt regeneratively via the traction motor. This makes the foot brake virtually redundant, minimising energy consumption and brake wear.
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Drive system
The entire drive unit is enclosed in the counterweight. The steered rear wheel is also the drive wheel. A fixed, low-noise three-phase motor is driven via a transmission. The electronic traction controller ensures the smooth rotation of the drive motor and as a result consistently smooth travel, powerful acceleration and electrically controlled braking with energy recovery. With steer angle detection (o) the system automatically reduces the travel speed as a function of the steer angle.
Hydraulic system
A multi-pilot valve allows for sensitive operation of the functions via the controls. A speed-controlled 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 visibility of the forks and attachments. Fork carriage and mast run on permanently lubricated and hence maintenance-free support rollers.
Attachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.
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3Technical Specifications
All technical details refer to standard trucks. Values indicated with *) may vary, depending on the types of equipment used (e.g. mast, cabin, tyres etc.).
Z Technical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
3.1 Performance data
Model EFG 110k EFG 110 EFG 113 EFG 115
QRated capacity
(where C=500mm)1)
CLoad centre distance 500 500 500 500 mm
Travel speed, w. / w.o. load *)
Lift speed, with / without load *)
Lowering speed with / without load *)
Gradeability (30 min) w. / w.o. load *)
Max. gradeability (5 mins) w / w.o. load *)
Acceleration (10 min) w / w.o. load *)
Max. operating pressure
Oil flow for attachments
1)
for vertical mast.
2)
The values shown represent the maximum gradeability to overcome short differences in height and surface unevenness (surface edges). The truck must not operate on inclines of more than 15%.
1000 1000 1250 1500 kg
12/12.5 12/12.5 12/12.5 12/12.5 km/h
0.28/0.50 0.29/0.50 0.25/0.50 0.24/0.50 m/s
0.58/0.60 0.58/0.60 0.58/0.60 0.58/0.60 m/s
8.5/12 8/11.5 7/11 6.5/10.5 %
13/18 12.5/17.5 11/16.5 10/16 %
5.1/4.6 5.1/4.6 5.4/4.7 5.6/4.8 s
160 160 185 210 bar
14 14 14 14 l/min
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3.2 Dimensions
Description EFG 110k EFG 110 EFG 113 EFG 115
a/2 Safety distance 100 100 100 100 mm
h1Mast height retracted *) 2000 2000 2000 2000 mm h2Free lift *) 150 150 150 150 mm
Lift *) 3000 3000 3000 3000 mm
h
3
h
Mast height extended *) 3550 3550 3550 3550 mm
4
h6Overhead guard height *) 2090 2090 2090 2090 mm h7Seat height *) 900 900 900 900 mm
h10Coupling height 635 635 635 635 mm
Į Mast tilt, fwd. 5 5 5 5 °
ȕ Mast tilt, back 6 6 6 6 °
L1Length including forks *) 2719 2773 2881 2935 mm
Headlength*)
L
2
b Overall width *) 990 990 990 990 mm
eFork width *) 100 100 100 100 mm
Ground clearance with
m
1
load below mast Ground clearance centre
m
2
wheelbase Aisle width
Ast
for pallets 800 x 1200 longit.
Aisle width
Ast
for pallets 1200 x 1000 longit.
Wa Turning radius 1239 1293 1401 1455 mm
x Load distance *) 330 330 330 330 mm
yWheelbase 984 1038 1146 1200 mm
1569 1623 1731 1785 mm
90 90 90 90 mm
100 100 100 100 mm
3020 3074 3182 3236 mm
2898 2952 3060 3114 mm
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1
h
4
3
h
1
h
H
6
h
c
2
h
Q
1
m
x
L
1
2
m
y
L
2
7
h
10
h
e
b
Wa
a 2
Ast
a 2
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3.3 Weights
Z All dimensions in kg.
Model EFG 110k EFG 110 EFG 113 EFG 115
Net weight *) (including battery)
Front axle load (without lifting load) *)
Front axle load (with lifting load) *)
Rear axle load (without lifting load) *)
Rear axle load (with lifting load) *) 550 625 620 565
2490 2570 2760 2870
1095 1145 1235 1270
2940 2945 3390 3805
1395 1425 1525 1600
3.4 Mast versions
Z All dimensions in mm
EFG 110k/110/113/115 mast table
VDI 3596
Description
ZT
ZZ
DZ
Lift
Free lift
h
3
2300 150 1650 2850 3000 150 2000 3550 3100 150 2050 3650 3300 150 2150 3850 3600 150 2300 4150 4000 150 2500 4550 4500 150 2800 5050 5000 150 3050 5550 5500 150 3400 6050 2300 1055 1605 2850 3000 1405 1955 3550 3100 1455 2005 3650 3300 1555 2105 3850 3600 1705 2255 4150 4000 1905 2455 4550 4350 1405 1955 4900 4500 1455 2005 5050 4800 1555 2105 5350 5000 1630 2180 5550 5500 1805 2355 6050 6000 2005 2555 6550 6500 2255 2805 7050
h
2
Collapsed height
h
1
Extended height
h
4
Special trucks are not included in this overview.
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3.5 Tyre type
NOTE
When replacing tyres/rims fitted at the factory, always use original spare parts or tyres approved by the manufacturer. Otherwise the manufacturer's specification cannot be guaranteed. If you have any queries please contact the manufacturer's customer service department.
Description EFG 110 EFG 113 EFG 115
SE *) 18 x 7-8 Full rubber*) 18 x 6 x 12 1/8“
Front tyres
Rear tyres
*) The models listed in the table correspond to the standard version. Other tyres can be used depending on the truck's equipment.
Pneumatic*) 180 / 70-8; Diagonal, 16PR; Tyre pressure bar 10 To rq u e (N m ) 1 70 SE*) 18 x 7-8 Full rubber*) 18 x 6 x 12 1/8" Pneumatic*) 180 / 70-8; Diagonal, 16PR; Tyre pressure bar 10 To rq u e (N m ) 1 70
3.6 Engine Data
Model EFG110-115
Drive motor 4 kW Lift motor 6 kW
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3.7 EN norms
Noise emission level
–EFG 110-115: 63 dB(A)
*+/- 3 dB(A) depending on the truck's equipment
in accordance with 12053 as harmonised with ISO 4871.
Z The noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the level of the driver's ear.
Vibration
– EFG 110-115: 0,62m/s²
in accordance with EN 13059.
Z The vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated when travelling over thresholds at constant speed (standard truck version). These recordings were taken on a single occasion 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 measurement" on page 151).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic emissions and resistance as well as the static electricity discharge test in accordance with EN 12895 as well as the standardised instructions contained therein.
Z No changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data transmission) can affect operators' medical equipment (pacemakers, hearing aids etc.) and result in malfunctions. Consult with a doctor or the medical equipment manufacturer to clarify whether it can be used near the industrial truck.
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3.8 Conditions of use
Ambient temperature
–operating at -20°C to 40°C
Z Special equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations.
3.9 Electrical requirements
The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety ­Electrical Requirements", provided the truck is used according to its purpose.
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4Identification points 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.
14
171615 19 2018
(mm) Q (kg)
D (mm)
21
22
26
27
26
19
25
23
24
Item Component
14 Serial number, on chassis below the battery cover 15 Capacity (or reduced capacity) 16 Wear seat belt 17 Do not travel with raised load or mast forward tilt with raised load 18 Tipover warning 19 Strap points for crane lifting 20 Do not step onto or beneath the load, risk of trapping with moving mast 21 Max. body size 22 Test plaque (o) 23 Data plate 24 Jack contact points 25 Model description 26 Do not carry passengers warning 27 Read operating instructions
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4.2 Data plate
28 29 3130 32
Item Description Item Description
28 Type 34 Year of manufacture 29 Serial number 35 Load centre (mm) 30 Rated capacity (kg) 36 Output 31 Battery voltage (V) 37 Min./max. battery weight (kg) 32 Net weight w.o. battery (kg) 38 Manufacturer 33 Option 39 Manufacturer’s logo
3433
35
36
37
38
39
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (29).
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4.3 Truck capacity plate
CAUTION!
Accident risk from fork replacement
If you replace the forks with ones that differ from the originals, the capacity will change.
XWhen replacing the forks you must attach an additional capacity plate to the truck. XTrucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).
The capacity plate (15) gives the capacity (Q in kg) of the truck for a vertical mast. The 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 (15) of the truck indicates the truck's capacity with the forks as originally supplied.
Example of how to calculate the maximum capacity:
h3 (mm)
4250
3600
2900
D (mm) 500 600 700
850 1105 1250
Q (kg)
850
1105
1250
600 850 850
For a load cente of gravity D of 600 mm and a maximum lift height h3 of 3600 mm the maximum capacity is Q 1105 kg.
Lift height restriction
40 41
The arrow shape markings (40 and 41) on the inner and outer masts show the driver when the prescribed lift limits have been reached.
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