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EFG 213-320
Operating Manual
109 pgs3.12 Mb1
Operator Manual
243 pgs5.68 Mb0

Jungheinrich EFG 213-320 Operator Manual

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EFG 213-320
09.09 -
Operating instructions G
51151902
03.13
EFG 213 EFG 215
EFG 216k EFG 216 EFG 218k EFG 218 EFG 220 EFG 316k EFG 316 EFG 318k EFG 318 EFG 320
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 213 EFG 215 EFG 216k EFG 216 EFG 218k EFG 218 EFG 220 EFG 316k EFG 316 EFG 318k EFG 318 EFG 320
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
3
4
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
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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
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Contents
A Correct Use and Application ................................................... 11
1 General.................................................................................................... 11
2 Correct application................................................................................... 11
3 Approved application conditions.............................................................. 12
4 Proprietor responsibilities ........................................................................ 13
5 Adding attachments and/or optional equipment ...................................... 13
B Truck Description .................................................................... 15
1 Application ............................................................................................... 15
1.1 Truck models and rated capacity............................................................. 15
2 Assemblies and Functional Description................................................... 16
2.1 Travel direction definition......................................................................... 16
2.2 Assembly Overview ................................................................................. 17
2.3 Functional Description ............................................................................. 18
3 Technical 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 requirements ............................................................................ 33
4 Identification points and data plates ........................................................ 34
4.1 Indication Points ...................................................................................... 34
4.2 Data plate ................................................................................................ 36
4.3 Truck capacity plate................................................................................. 37
4.4 Attachment capacity plate ....................................................................... 38
5 Stability .................................................................................................... 38
C Transport and Commissioning ................................................ 39
1 Transport ................................................................................................. 39
2 Truck laden.............................................................................................. 39
2.1 Centre of gravity of the truck ................................................................... 39
2.2 Lifting the truck by crane ......................................................................... 40
2.3 Loading with another industrial truck ....................................................... 42
3 Securing the truck during transport ......................................................... 43
4 Using the Truck for the First Time ........................................................... 45
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D Battery - Servicing, Recharging, Replacement ....................... 47
1 Safety Regulations Governing the Handling of Lead-Acid Batteries ....... 47
1.1 General notes on handling batteries........................................................ 49
2 Battery types............................................................................................ 50
2.1 Battery dimensions .................................................................................. 51
3 Exposing the battery................................................................................ 52
4 Charging the battery ................................................................................ 53
4.1 Charging the battery with a stationary charger ........................................ 53
4.2 Charging the battery with an on-board charger ....................................... 54
5 Battery removal and installation .............................................................. 58
5.1 Battery holder assembly .......................................................................... 59
5.2 Removal and installation using an EJE pallet truck with Snapfit battery
holder (o)................................................................................................ 61
5.3 Removal and installation using a hand pallet truck with Snapfit battery
holder (o)................................................................................................ 64
5.4 Removal and installation using a multi-adapter (o) ................................ 67
5.5 Removal and installation using a worktable for crane loading (o) .......... 69
5.6 Removal and installation using a fork shoe (o) ...................................... 71
5.7 Removal and installation using a roller conveyor (o).............................. 73
5.8 Hook-on battery 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 control panel switch (o)............................................................. 85
2.3 Side compartment control panel switch (o) ............................................ 86
2.4 Display ..................................................................................................... 87
3 Preparing the Truck for Operation ........................................................... 90
3.1 Checks and operations to be performed before starting daily operation . 90
3.2 Entry and exit........................................................................................... 93
3.3 Trucks with reduced headroom (o)......................................................... 93
3.4 Setting up the operator position............................................................... 94
3.5 Seat Belt .................................................................................................. 98
4 Industrial Truck Operation ....................................................................... 100
4.1 Safety regulations for truck operation ...................................................... 100
4.2 Preparing the truck for operation ............................................................. 103
4.3 Setting the time........................................................................................ 104
4.4 Parking the truck securely ....................................................................... 105
4.5 Emergency Disconnect............................................................................ 106
4.6 Travel....................................................................................................... 107
4.7 Steering ................................................................................................... 109
4.8 Brakes ..................................................................................................... 110
4.9 Adjusting the forks ................................................................................... 114
4.10 Replacing the forks.................................................................................. 115
4.11 Lifting, transporting and depositing loads ................................................ 116
4.12 Operating the lift mechanism and integrated attachments ...................... 118
4.13 Safety instructions for operating additional attachments ......................... 125
4.14 Operating additional attachments for the SOLO-PILOT .......................... 129
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4.15 Operating additional attachments for the Multi Pilot ................................ 131
4.16 Fitting additional attachments.................................................................. 133
5 Towing trailers ......................................................................................... 135
6 Optional equipment ................................................................................. 137
6.1 CanCode keypad ..................................................................................... 137
6.2 Assistance systems ................................................................................. 141
6.3 Steel cab.................................................................................................. 143
6.4 Sliding windows ....................................................................................... 144
6.5 Automatic / mechanical folding gate ........................................................ 145
6.6 Panel door ............................................................................................... 146
6.7 Operator position extension..................................................................... 146
6.8 Adjusting the driver’s seat ....................................................................... 147
6.9 Heating .................................................................................................... 148
6.10 Removable load backrest ........................................................................ 149
6.11 Lift cutout override ................................................................................... 149
6.12 Fire extinguisher ...................................................................................... 150
6.13 Tilt angle display...................................................................................... 150
6.14 Rockinger coupling with hand lever or remote control............................. 151
6.15 Camera system ....................................................................................... 152
6.16 Control layout “N” .................................................................................... 153
7 Troubleshooting....................................................................................... 154
7.1 Troubleshooting ....................................................................................... 154
7.2 Operating the truck without its own drive 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
2.2 Wheels..................................................................................................... 163
2.3 Lift Chains................................................................................................ 164
2.4 Hydraulic system ..................................................................................... 165
3 Lubricants and Lubrication Schedule ...................................................... 166
3.1 Handling consumables safely .................................................................. 166
3.2 Lubrication Schedule ............................................................................... 168
3.3 Consumables........................................................................................... 169
4 Maintenance and repairs ......................................................................... 171
4.1 Preparing the truck for maintenance and repairs .................................... 171
4.2 Lifting and jacking up the truck safely...................................................... 172
4.3 Opening the rear panel ............................................................................ 173
4.4 Checking the wheel attachments............................................................. 174
4.5 Replacing wheels .................................................................................... 175
4.6 Hydraulic system ..................................................................................... 177
4.7 Replacing the hydraulic oil filter ............................................................... 179
4.8 Replacing the ventilation/discharge filter ................................................. 179
4.9 Check the gear oil level ........................................................................... 180
4.10 Heating .................................................................................................... 181
4.11 Adding window washer system fluid........................................................ 181
4.12 Checking electrical fuses......................................................................... 182
4.13 Cleaning .................................................................................................. 186
4.14 Working on the electrical system............................................................. 189
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4.15 Restoring the truck to service after maintenance and repairs ................. 190
5 Decommissioning the industrial truck ...................................................... 191
5.1 Prior to decommissioning ........................................................................ 192
5.2 During decommissioning ......................................................................... 192
5.3 Restoring the truck 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 Servicing and Inspection ......................................................................... 196
10 Maintenance checklist EFG 213-220....................................................... 197
10.1 Operating company ................................................................................. 197
10.2 Customer service..................................................................................... 200
11 Maintenance checklist EFG 316-320....................................................... 208
11.1 Operating company ................................................................................. 208
11.2 Customer service..................................................................................... 211
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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.
0506.GB
1
0506.GB
2
A Correct Use and Application
1 General
The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property.
2 Correct application
NOTE
The maximum load and load distance are indicated on the 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 depositing loads" on page 116.
– 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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3 Approved application conditions
– Operation in industrial and commercial environments. – Permissible temperature range -20°C to 40°C. – Operation only on secure, level surfaces with sufficient capacity. – Do not exceed the permissible surface and spot load limits on the travel routes. – Operation only on routes that are visible and approved by the operating company. – Negotiating inclines up to 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 extreme conditions can result in malfunctions and accidents. 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 cannot be used 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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4 Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” 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 it is intended for and that danger to life and limb of the user and third parties 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 read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions invalidates 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.
5 Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained. Local authority approval however does not constitute the manufacturer’s approval.
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14
B Truck Description
1 Application
The EFG 213-320 is a three- or four-wheel electric sit-down counterbalanced 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 name.
EFG213
EFG Model name
2Series
13 Rated capacity x 100 kg
The rated capacity is not generally the same as the permissible capacity. The capacity can be found on the capacity plate attached to the truck.
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2 Assemblies and Functional Description
2.1 Travel direction definition
The following determinations have been made for travel direction specification:
1
2
4
The following conventions have been agreed for travel direction specification:
Item Travel direction
1Links 2 Reverse 3Forward 4 Right
3
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2.2 Assembly Overview
12
12
13
14
3
4
5
6
7
8
9
10
11
Item Component Item Component
1 t Driver's seat 8 t Fork tines 2 t 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 Emergency Disconnect
14 t Counterweight
switch
t Standard equipment
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2.3 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 comes in a range of models and protects the operator 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 enable the system to be monitored during operation, thereby ensuring a very high level of safety.
Steering
The electric steering offers a high level of efficiency and ergonomics. The height and tilt angle 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 high level of efficiency. As a result the overall energy consumption is reduced significantly. The steer angle is shown in the display.
Wheels
There is a choice of super elastic or fully rubber tyres as well as optional pneumatic tyres.
Drive and brake system
The 2 motor front drive provides maximum traction to the drive wheels at all times. When cornering, the exact speed required for the wheel on the inside or outside of the bend respectively is set in proportion to the steer angle.
The service brake is a maintenance-free disk brake. The truck also brakes regeneratively via the drive motors. The energy recovered in the process is fed back to the battery.
The parking brake operates both automatically and manually.
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Emergency Stop safety feature
If the system recognises a fault in the steering, an emergency stop is automatically introduced. The truck brakes to a halt, the travel direction does not change. An event message is shown in the control and display unit. The truck performs a self­test whenever it is switched on. Travel is only enabled again when the truck is operational and the parking brake (= emergency stop) released.
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.
3 Technical 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 The technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines. Technical modifications and additions reserved.
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3.1 Performance data
EFG 213-220
Description EFG
213 215
Q Rated capacity
(where C = 500 mm)
1
1300 1500 1600 1800 2000 kg
)
C Load centre 500 500 500 500 500 mm
Travel speed
Lift speed with / without load
Lowering speed with / without load
16/16 16/16 16/16 16/16 16/16
0.48/0.60 0.46/0.60 0.49/0.60 0.44/0.55 0.40/0.55 m/s
0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 m/s
Gradeability (30 min)
7.6/12.5 7.3/12.3
with / without load
Max. gradeability
2
) (5 min)
28.0/35.0 27.0/35.0 27.0/35.0
with / without load
Acceleration (10 m)
3.6/3.2 3.8/3.4 3.8/3.4 3.9/3.5 4.0/3.5 s
with / without load
Max. operating pressure
Oil flow for attachments
1)
for vertical mast.
2)
The values shown represent the maximum gradeability to overcome short
200 200 200 200 200 bar
25 25 25 25 25
differences in height and surface unevenness (surface edges). The truck must not operate on inclines of more than 15%.
216k 218k
216 218
7.3/12.3 6.2/10.7
7.0/11.5 5.9/10.5
26.0/35.0
25.0/35.0
220
km/
h
5.7/10.4 %
24.0/35.0 %
l/
min
20
EFG 316-320
Description EFG
316k 316 318k 318 320
Q Rated
capacity (where
1600 1600 1800 1800 2000 kg
C = 500 mm)1)
C Load centre 500 500 500 500 500 mm
Travel Speed *
Lift speed w / w.o. load
Lowering speed w / w.o. load
17/17 17/17 17/17 17/17 17/17
0.49/0.60 0.49/0.60 0.44/0.55 0.44/0.55 0.40/0.55 m/s
0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 m/s
km/
h
Gradeability (30 min)
7.3/12.3 7.0/11.5 6.2/10.7 5.9/10.5 5.7/10.4 %
w./w.o. load
Max. gradeability
2) (5 min)
27.0/35.0 27.0/35.0 26.0/35.0 25.0/35.0 24.0/35.0 %
w./w.o. load
Acceleration (10 m)
3.8/3.4 3.8/3.4 3.9/3.5 3.9/3.5 4.0/3.5 s
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
200 200 200 200 200 bar
25 25 25 25 25
l/
min
differences in height and surface unevenness (surface edges). The truck must not operate on inclines of more than 15%.
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3.2 Dimensions
EFG 213-220
Description EFG
213 215
a/2 Safety distance 100 100 100 100 100 mm
h1Mast height
retracted
2000 2000 2000 2000 2000 mm
h2Free lift 150 150 150 150 150 mm
h3Lift 3000 3000 3000 3000 3000 mm
h4Mast height
extended
h6Overhead guard
height
3560 3560 3560 3587 3587 mm
2040 2040 2040 2040 2040 mm
h7Seat height 920 920 920 920 920 mm
h10Coupling height 560 560 560 560 560 mm
Į Mast tilt, fwd. 7 7 7 7 7 °
ȕ Mast tilt, back 7 7 7 7 7 °
L1Length including
forks
L2Headlength
2924 2924
1774 1774
216k 218k
216 218
3037 3037
3145 3145 mm
1887 1887
1995 1995
220
3145
mm
1995 mm
22
c
h
4
h
3
h
Q
h
1
h
2
h
10
m
m
x
1
l
L
1
y
L
2
2
6
h
7
a 2
l
6
a
2
e
b
12
W
R
A
st
a
b
23
EFG 213-220
Description EFG
213 215
216k 218k
216 218
220
b Overall width 1060 1060 1060 1120 1120 mm
e Fork width 100 100 100 100 100 mm
m1Ground clearance
with load below
80 80 80 80 80 mm
mast
m2Centre wheel
base ground
100 100 100 100 100 mm
clearance
Ast Working aisle
width for pallet 800x1200
3226 3226
3339 3339
3446 3446
3446 mm
longit.
Ast Aisle width for
pallet 1000x1200 diag.
Wa Turning radius
3104 3104
1440 1440
3216 3216
3323 3323
1548 1548
1655 1655
3323 mm
1655 mm
x Load distance 335 335 340 340 340 mm
y Wheel distance
1249 1249
1357 1357
1465 1465
1465 mm
24
c
h
4
h
3
h
Q
h
1
h
2
h
10
m
m
x
1
l
L
1
y
L
2
2
6
h
7
a 2
l
6
a
2
e
b
12
W
R
A
st
a
b
25
EFG 316-320
Description EFG
316k 316 318k 318 320
a/2 Safety distance 100 100 100 100 100 mm
h1Mast height
retracted
Free lift 150 150 150 150 150 mm
h
2
h
Lift 3000 3000 3000 3000 3000 mm
3
h4Mast height
extended
h6Overhead guard
height
2000 2000 2000 2000 2000 mm
3560 3560 3587 3587 3587 mm
2040 2040 2040 2040 2040 mm
h7Seat height 920 920 920 920 920 mm
h10Coupling height 410/580 410/580 410/580 410/580 410/580 mm
Į Mast tilt, fwd. 7 7 7 7 7 °
ȕ Mast tilt, back 7 7 7 7 7 °
L1Length including
forks
3140 3248 3140 3248 3248 mm
L2Headlength 1990 2098 1990 2098 2098 mm
b Overall width 1060 1060 1120 1120 1120 mm
e Fork width 100 100 100 100 100 mm
m1Ground clearance
with load below
80 80 80 80 80 mm
mast
m2Centre wheel
base ground
100 100 100 100 100 mm
clearance
Ast Working aisle
width for pallet 800x1200
3599 3725 3599 3725 3725 mm
longit.
Ast Aisle width for
pallet 1000x1200
3403 3526 3403 3526 3526 mm
transv.
Wa Turning radius 1859 1985 1859 1985 1985 mm
x Load distance 340 340 340 340 340 mm
y Wheel distance 1400 1508 1400 1508 1508 mm
26
c
h
4
h
3
h
Q
h
1
h
2
h
10
6
h
7
s
m
x
1
l
L
a 2
l
6
L
1
m
y
2
2
a 2
e
b
12
b
13
R
A
st
W
a
b
27
3.3 Weights
Z All dimensions in kg.
EFG 213-220
Description EFG
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)
EFG 316-320
Description EFG
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)
213 215
2733 2978
1326 1310
3545 3870
1407 1668
488 608
316k 316 318k 318 320
3035 3001 3175 3141 3306
1380 1493 1385 1499 1489
4004 4043 4336 4367 4676
1655 1508 1790 1642 1817
631 558 638 574 630
216k 218k
216 218
3000 3256
3057 3207
1411 1409
1496 1520
4052 4380
4060 4405
1589 1846
1561 1686
548 675
597 602
220
3382
1501
4706
1881
676
28
3.4 Mast versions
Z All dimensions in mm.
EFG 216-220 and 316-320
VDI 3596 Description
ZT
ZZ 2300 1055 990 1605 2850 2915
DZ 4350 1405 1340 1955 4900 4965
Lift h
3
Free lift h
2
Retracted
height h
Extended height h
1
EFG
213/215/ 216k/216/ 316/316k
2300
218k/218/ 220/318/ 318k/320
213/215/ 216k/216/ 316/316k
218k/218/ 220/318/ 318k/320
1650 2850 2885 3000 2000 3550 3585 3100 2050 3650 3685 3300 2150 3850 3885 3600 2300 4150 4185
150 4000 2500 4550 4585 4500 2800 5050 5085 5000 3050 5550 5585 5500 3400 6050 6085
3000 1405 1340 1955 3550 3615 3100 1455 1390 2005 3650 3715 3300 1555 1490 2105 3850 3915 3600 1705 1640 2255 4150 4215 4000 1905 1840 2455 4550 4615
4500 1455 1390 2005 5050 5115 4800 1555 1490 2105 5350 5415 5000 1630 1565 2180 5550 5615 5500 1805 1740 2355 6050 6115 6000 2005 1940 2555 6550 6615 6500 2255 2190 2805 7050 7115
4
Special trucks are not included in this overview.
29
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.
EFG 213-220
Description EFG
213/215
216k/216
SE *) 18x7-8 200/50-10 200/50-10
Full rubber*) 18x7x12ǩ
Front tyres
Pneumatic*) 180/70-8 - LI125 not available not available
Tyre pressure bar 10,0 - -
Torque (Nm) 240 240 240
SE *) 140/55-9 140/55-9 140/55-9
Full rubber*) 15x5x11¼ 15x5x11¼ 15x5x11¼
Rear tyres
Pneumatic*) 125/75-8 - LI100 not available not available
Tyre pressure bar 10,0 - -
Torque (Nm) 240 240 240
*) The models listed in the table correspond to the standard version. Other tyres can be used depending on the truck's equipment.
218k
218
220
30
EFG 316-320
Description EFG
316k
316
318k
318
SE *) 18x7-8 200/50-10 200/50-10
Full rubber*) 18x7x12ǩ 18x7x12ǩ 18x7x12ǩ
Front tyres
Pneumatic*) 180/70-8 - LI125
(PR 16)
not available not available
Tyre pressure bar 10,0 - -
Torque (Nm) 240 240 240
SE *) 16x6-8 16x6-8 16x6-8
Full rubber*) 15x5x11¼ 15x5x11¼ 15x5x11¼
Rear tyres
Pneumatic*) 150/75-8 - LI113
(PR 16)
not available not available
Tyre pressure bar 10,0 - -
Torque (Nm) 240 240 240
*) The models listed in the table correspond to the standard version. Other tyres can be used depending on the truck's equipment.
3.6 Engine Data
EFG 216-220 and 316-320
Description EFG
213 / 215 / 216k / 216
218k / 218 / 220
Drive motor 2 x 4.5kW 2 x 4.5kW Lift motor 11.5kW 11.5kW Steer motor 0.9kW 0.9kW
316k / 316 / 318k / 318
320
320
31
3.7 EN norms
Noise emission level
– EFG 213-220: 68 dB(A) – EFG 316-320: 67 dB(A)
*+/- 3 dB(A) depending on the truck's equipment
in accordance with EN 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 213-220: 0,53m/s² – EFG 316-320: 0,51 m/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 195.
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.
32
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 used
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 manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety ­Electrical Requirements", provided the truck is used according to its purpose.
33
4 Identification 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.
1716 18 1915
XXX
20
21
22
34
28
17
24
27
29
26
25
(mm) Q (kg)
D (mm)
23
24
Item Component
15 Do not drive, or operate the forward tilt, with the load in the raised position 16 Wear seat belt 17 Strap points for crane lifting 18 Tipover caution, no passengers 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 Jack contact points 25 Model description 26 Risk of trapping, in chassis behind the battery door 27 Serial number, on chassis behind the battery door 28 Test plaque (o) 29 Add hydraulic oil
35
4.2 Data plate
Z The illustration shows the standard version for EU member states. The data plate
may differ in other countries.
30 31 3332 34
Item Description Item Description
30 Type 36 Year of manufacture 31 Serial number 37 Load centre (mm) 32 Rated capacity (kg) 38 Output 33 Battery voltage (V) 39 Min./max. battery weight (kg) 34 Net weight w.o. battery (kg) 40 Manufacturer 35 Option 41 Manufacturer’s logo
3635
37
38
39
40
41
Z For queries regarding the truck or ordering spare parts always quote the truck serial
number (31).
36
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 (22) 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 (22) 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
22
For a load centre of gravity D of 600 mm and a max. lift height h3 of 3600 mm the maximum capacity Q is 1105 kg.
Lift height restriction
The arrow shaped markings (42 and 43) on the
42 43
inner and outer masts show the operator when the prescribed lift limits have been reached.
37
4.4 Attachment capacity plate
The attachment capacity plate is next to the truck's capacity plate and gives the truck’s capacity Q (in kg) in conjunction with the respective attachment. The serial number for the attachment indicated on the capacity plate 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 forces that can occur if used correctly.
Stability can also be affected by the following factors: – Tyre type –Mast – Attachment – Transported load (size, weight and centre of gravity)
WARNING!
Loss of stability can cause accidents
Changing the components can alter the stability.
38
C Transport and Commissioning
1 Transport
Transport can be carried out in two different ways, depending on the height of the mast and the local conditions.
– Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all mechanical connections
and hydraulic 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 gravity can vary depending on the truck's equipment (especially the mast version).
For trucks without a mast the centre of gravity will move significantly in the direction of the counterweight.
XDrive carefully and with modified speed to avoid tipping over.
The picture shows the approximate centre of gravity location.
39
2.2 Lifting the truck by crane
WARNING!
All persons involved in loading by crane must be trained
Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck.
XLoading must only be performed by specialist personnel trained for this purpose.
The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices. In each case correct measurements must be taken and appropriate safety measures applied.
DANGER!
Crane slings 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 crane lifting gear on the mast must have a minimum clear length of 2 m. XCrane slings should be fastened in such a way that they do not come into contact
with any attachments or the overhead guard when lifting.
XDo not stand under a swaying load. XThe truck should only be handled by people who are trained in using lifting slings
and tools.
XWear safety shoes when lifting the truck by crane. XDo not walk into or stand in a hazardous area. XAlways attach the crane lifting gear to the prescribed strap points and prevent them
from slipping.
Z Truck net weight: see "Data plate" on page 36.
40
Lifting the truck by crane
Requirements
– Park the truck securely, see "Parking the
truck 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).
• Secure the truck with wedges to prevent it from rolling away.
This concludes the loading by crane.
44
45
41
2.3 Loading with another industrial truck
WARNING!
The truck can be damaged
The truck to be loaded can be damaged when loading with another industrial truck.
XOnly trained specialist personnel should load the truck. XUse only trucks with sufficient capacity for loading. XOnly for loading and unloading. XThe forks of the second industrial truck must be sufficiently 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 the truck with the forks at the side between the axles.
• Raise the truck slightly and make sure it is securely positioned on the forks. If necessary adjust or secure the forks with stops.
• Carefully load/unload the truck, see "Lifting, transporting and depositing loads" on page 116.
• Lower the truck slowly onto the ground and prevent it from rolling away.
The truck is now loaded.
42
3 Securing the truck during transport
WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious accidents.
XLoading must only be performed by specialist personnel trained for this purpose.
The specialist personnel must be instructed in securing 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 transported on a lorry or a trailer. XThe lorry or trailer must have fastening rings. XUse wedges to prevent the truck from moving. XUse only fastening belts with sufficient strength. XUse non-slip materials to securing the load aids (pallet, wedges, ...) e. g. non-slip
mats.
Securing with a mast Securing without a mast
3
46
13
47
46
13
48
47
43
Securing the industrial truck for transport
Requirements
– Position the industrial truck securely on a lorry or trailer, see "Parking the truck
securely" 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 trailer coupling (13) or over the mud guard (48) and the trailer coupling (13).
• Tighten the fastening belt (46) with the tensioner (47).
The truck is now secured for transport.
44
4 Using the Truck for the First Time
Safety Instructions for Assembly and Commissioning
WARNING!
Incorrect assembly can result in accidents
The assembly of the truck at the application site, commissioning and operator training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.
XThe hydraulic lines may only be connected to the basic truck / mast interface when
the mast has been properly assembled.
XOnly then can the truck be started. XIf several trucks have been delivered, make sure that the serial numbers of the load
handlers, masts and basic trucks always match.
WARNING!
The use of unsuitable energy sources can be hazardous
Rectified AC current will damage the assemblies (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 battery on fire.
XThe truck must only be operated with battery current. XCable connections to the battery (tow leads) must be less than 6 m long and have
a minimum cross-section of 50 mm².
Preparing the truck for operation after delivery or transport
Procedure
• Check the equipment is complete.
• Check the hydraulic oil level, see "Hydraulic system" on page 177.
• Check the transmission oil level, see "Check the gear oil level" on page 180.
• Install the battery if necessary, see "Battery removal and installation" on page 58.
• Charge the battery, see "Charging the battery" on page 53.
The truck can now be started, see "Preparing the Truck for Operation" on page 90.
Z To operate the truck without its own drive system, see "Operating the truck without
its own drive system" on page 156.
45
46
D Battery - Servicing, Recharging,
Replacement
1 Safety Regulations Governing the Handling of Lead-Acid
Batteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work.
Fire Protection
Do not smoke and avoid naked flames when handling batteries. Wherever an industrial truck is parked for charging there must be no inflammable material or consumables capable of creating sparks within a minimum distance of 2 m from the truck. The room must be ventilated. Fire protection equipment must be available.
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 acid.
XUse powder extinguishers. XNever extinguish a burning battery with water.
Battery maintenance
The battery cell covers must be kept dry and clean. Terminals and cable shoes must be clean, lightly greased with terminal grease and must be securely tightened. Batteries with non insulated terminals must be covered with a non slip insulating mat.
CAUTION!
Before closing the battery panel make sure that the battery cable cannot be damaged. There is a risk of short circuits with damaged cables.
Battery disposal
Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be followed.
47
48
1.1 General notes on handling batteries
WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Avoid contact with battery acid at all times.
XDispose of used battery acid in accordance with regulations. XAlways wear protective clothing and goggles when working with batteries. XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XIn the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.
XSpilled battery acid should be neutralised immediately with plenty of water. XOnly batteries with a sealed battery container may be used. XFollow national guidelines and legislation.
WARNING!
Unsuitable batteries that have not been approved for the truck by 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 of unsuitable batteries that have not been approved for the truck by the manufacturer can lead to a deterioration of the braking system during energy recovery operations and also cause considerable damage to the electrical control system. The use of batteries that have not been approved by the manufacturer can therefore affect the health and safety of personnel.
XOnly manufacturer-approved batteries may be used on the truck. XBattery equipment may only be replaced with the agreement of the manufacturer. XWhen replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck.
XDo not use batteries that have not been approved by the manufacturer.
Park the truck securely before carrying out any work on the batteries (see "Parking the truck securely" on page 105).
49
2 Battery types
CAUTION!
Always use batteries with insulated covers or live components.
The battery weights are indicated on the battery data plate.
The truck will be equipped with different battery models, depending 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 EFG 216 48V - 6PzS 690 Ah EFG 218k 48V - 5PzS 575 Ah EFG 218 48V - 6PzS 690 Ah EFG 220 48V - 6PzS 690 Ah
EFG 316k 48V - 5PzS 575 Ah EFG 316 48V - 6PzS 690 Ah EFG 318k 48V - 5PzS 575 Ah EFG 318 48V - 6PzS 690 Ah EFG 320 48V - 6PzS 690 Ah
50
2.1 Battery dimensions
Battery 48 V
Dimension (mm)
Truck model
EFG 213/215 830 522 612 627 715
EFG 216k/
218k/
316k/318k
EFG 216/
218/220/
316/318/320
L max. W max. H1 +/-
2mm
H2 +/-
2mm
830 630 612 627 855
830 738 612 627 1025
Rated weight
(-5/+8%)in kg
51
3 Exposing the battery
49
Requirements
– Park the truck securely, see "Parking 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 connector (50) and let it drop down from the battery.
The battery is now exposed.
50
52
4 Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge
capacity.
XBefore charging, check all cables and plug connections for visible signs of damage. XVentilate the room in which the truck is being charged. XThe battery cell surfaces must be exposed during charging to 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 capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand. XDo not lay any metallic objects on battery. XIt is essential to follow the safety regulations of the battery and charger station
manufacturers.
4.1 Charging the battery with a stationary charger
Z When charging, the battery door must be exposed by at least 200 mm to provide
sufficient ventilation.
Requirements
– Park the truck securely, see "Parking the truck
securely" on page 105.
– Battery exposed. – Charger switched off. – Disconnect the battery connector (50) from the
truck connector (51).
Procedure
• Connect the battery connector (50) to the charging lead (52) of the stationary charger and turn on the charger.
The battery is now charged.
51
50
52
53
4.2 Charging the battery with an on-board charger
NOTE
Improper use of the on-board charger can cause material damage
The on-board charger consisting of a battery charger and battery controller must not be opened. If faulty, contact the manufacturer’s customer service department.
XThe charger must only be used for batteries supplied by Jungheinrich or other
approved batteries provided it has been adapted by the manufacturer's customer service department.
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 charger.
– On-board charger with 65 Ah: 16 A; 230 V; 3 pin – On-board charger with 130 Ah: 16 A; 400 V; 5 pin
DANGER!
Risk of electric shock and burning
Damaged and unsuitable wires can cause electric shocks and can overheat, resulting in fires.
XOnly use mains cables with a maximum length of 30 m. XFully unreel the cable reel when using it. XAlways use original manufacturer’s mains cables. XInsulation safety, acid and caustic ratings must comply with the manufacturer's
mains cable.
54
Z When charging, the battery door must be exposed by at least 200 mm to provide
sufficient ventilation.
Charge the battery
Requirements
– Park the truck securely, see "Parking the truck securely" on page 105. – Battery exposed. – Charger switched off. – Disconnect the battery connector (50) 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 residual capacity are shown on the display unit, see "Display" on page 87.
The battery is now charged.
Z If the battery warning indicator (53) lights up after charging the battery, the battery
must be topped up with water when the truck is switched off.
53
am
100 %
pm
km/h
inch lbs m kg eff code err
55
Battery charger LED displays
Green LED Meaning
Flashing Charging Lit Charging complete
Red LED Meaning
Flashing Error
Battery controller LED displays
White LED Meaning
Flashing Radio network activated
Blue LED Meaning
Lit
Electrolyte level too low (measured after each charge)
Yellow LED Meaning
Flashing rolling Charging Lit Charge status
Red LED Meaning
Flashing Error
56
Float charge:
The compensation charge starts automatically when charging is complete.
Partial charging:
The charger 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 connector when the green LED goes out. Charging starts again when the mains cable is reconnected to the mains socket.
54
57
5 Battery removal and installation
WARNING!
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" 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 prevent the battery from sliding out. XMake sure the crane slings have sufficient capacity to replace the battery. XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.
58
5.1 Battery holder assembly
CAUTION!
The battery holder can only be fitted to Jungheinrich AG pallet trucks (EJE) or hand pallet trucks with notice signs.
Requirements
– EJE or hand pallet truck available with 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 or hand pallet truck.
• Push the battery holder down and fit the bolts (58) in the holes.
• Close the safety catch (55).
• To do this press the pedals (56).
• Secure the locking plate (59) against theft with 4 screws (o).
56 57 58
55
59
59
5.1.1 Assembly instructions
1150
16
Ø
x4
Procedure
• Drill 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.
458
130
90
Z Attach safety notices to the EJE.
60
5.2 Removal and installation using an EJE pallet truck with Snapfit
battery holder (o)
CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
XWhen replacing the battery do not reach between the battery and the chassis. XWear safety shoes.
Removing the battery
Requirements
– Truck parked securely, see "Parking the truck securely" on page 105. – Battery exposed, see "Exposing the battery"
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 safety catch (55).
• To do this press the pedals (56).
• Bring the EJE pallet truck approx. 7,9 in (200 mm) underneath the truck base so that it is central with the battery.
• Raise the fork tines of the EJE pallet truck until they are just under the truck base.
60
•
• Push the ramps (61) into the plate recess and align them with the chassis (62).
• Bring the EJE pallet truck up to the battery at crawl speed.
55 56
61
62 62
61
•
• Engage the safety catch (55) on the battery trolley.
• Make sure the safety catch (55) is firmly
engaged in the battery trolley.
Z Do not raise the fork tines.
• Undo the battery lock (63).
•
• Remove the the battery with the EJE pallet truck at crawl speed as far as the stop (64).
• Raise the fork tines until the battery can 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 battery, do not allow it to strike the truck chassis on the top or bottom.
• Bring the battery to the charging station for charging.
•
• Place the battery carefully onto the charging station (60).
• Undo the safety catch (55) and remove the EJE pallet truck.
The battery is now removed and positioned securely for charging.
5563
64
60
62
Battery installation
Procedure
•
• Drive the EJE pallet truck and battery to the truck.
• Deposit the battery replacement trolley with the rollers (65) on the rails of the truck base.
• Lower the forks of the EJE pallet truck until the battery is horizontal.
• Align the heights and push 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
top or bottom parts of the chassis when inserting the battery.
• Insert the battery in the truck.
• Close the battery lock (63).
•
• Undo the safety catch (55).
• To do this press the pedals (56).
• Move the EJE pallet truck away from the truck.
• Close the battery door.
The battery is now inserted.
63
65
55 56
63
5.3 Removal and installation using a hand pallet truck with Snapfit
battery holder (o)
CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
XWhen replacing the battery do not reach between the battery and the chassis. XWear safety shoes.
Removing the battery
Requirements
– Truck parked securely, see "Parking the truck securely" on page 105. – Battery exposed, see "Exposing the battery"
on page 52.
Tools and Material 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 pedals (56).
• Fully lower the hand pallet truck.
• Move the hand pallet truck up to the centre of the battery until Snapfit contacts the truck chassis.
60
•
• Raise the forks of the hand pallet truck until the recess (66) is exposed.
• Move the hand pallet truck into the battery compartment until the safety catches lock the battery trolley.
• Make sure both safety catches (55) are
securely engaged in the battery replacement trolley.
64
55
56
66
56
•
• Open the battery lock (63).
• Raise the hand pallet truck (approx. 20 mm) until the battery can be freely pulled out of the battery compartment.
NOTE
Risk of material damage
Removing the battery can cause material
63
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 the battery to the charging station for charging.
•
• Place the battery carefully onto the charging station (60)
60
The battery is now removed and positioned securely for charging.
65
Battery installation
Procedure
•
• Move the hand pallet truck and battery to the truck.
• Raise and move the hand pallet truck into the battery compartment until the forks contact the truck chassis.
• 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 lock (63).
• Lower the hand pallet truck.
•
• Undo the safety catch (55).
• To do this press the pedals (56).
• Move the hand pallet truck away from the truck.
• Close the battery door.
The battery is now inserted.
65 67
63
55
56
66
5.4 Removal and installation using a multi-adapter (o)
CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
XWhen replacing the battery do not reach between the battery and the chassis. XWear safety shoes.
Battery removal and installation
Requirements
– 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
– Multi-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 the straight ahead position using the alignment device (69).
•
• Raise the multi-adapter with the pallet truck as far as the height stop (70).
• Prevent the pallet truck from rolling away.
• Undo the battery lock (63).
•
• Pull the battery (71) out by its handle.
• The battery trolley must engage securely in the safety catch (72).
• Lower the pallet truck slightly to move it.
The battery is now removed and can be taken to the charging station for charging.
68 69
70
63
71
72
67
Z Battery assembly is the reverse order.
Release the 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 the battery close the battery lock and then lower the pallet truck.
68
5.5 Removal and installation using a worktable for crane loading (o)
CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
XWhen replacing the battery do not reach between the battery and the chassis. XWear safety shoes.
Battery removal and installation
Requirements
– 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 trolley with six rollers – Pallet truck with a fork length of 1360 mm – Crane lifting gear
Procedure
•
• Push the hand pallet truck with the worktable as far as the stop (68) underneath the battery.
•
• Raise the worktable and the pallet truck as far as the stop (70).
• Undo the battery lock (63).
68
63
70
69
•
• Pull the battery (71) out by its handle.
• The battery trolley must engage securely in the safety catch (72).
• Strap the crane lifting harness to the battery container. The hooks must be fitted in such
71
a way that when the crane lifting harness is slackened, they do not fall onto the battery cells.
72
• Lift out the battery 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 Battery assembly is the reverse order.
Release the 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 the battery close the battery lock and then lower the pallet truck.
70
5.6 Removal and installation using a fork shoe (o)
CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
XWhen replacing the battery do not reach between the battery and the chassis. XWear safety shoes.
Battery removal and installation
Requirements
– Truck parked securely, see "Parking the truck securely" on page 105. – Battery exposed, see "Exposing the battery"
on page 52.
– Battery 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.
– Battery trolley with two rollers – Battery with cable guard (73) (o) – Charging station intended for the battery type (60) (o)
Procedure
•
• Place the fork shoe onto the forks of a second lift truck and secure it to the fork carriage with a chain (74).
• Tilt the mast forward.
73
60
74
•
• Move the fork shoe up to the stop (75) underneath the battery.
• Raise the fork carriage until the battery is resting on the forks.
75
71
•
• Pull out the battery as far as the stop (76) on the truck chassis.
• Raise the fork carriage.
• Tilt the mast back fully and bring the battery to the charging station to be charged.
•
• Place the battery carefully on the charging
76
station (60).
60
The battery is now removed and positioned securely for charging.
Z Battery installation is the reverse order.
Make sure the battery trolley rollers are inserted into the guides in the battery compartment.
72
5.7 Removal and installation using a roller conveyor (o)
CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
XWhen replacing the battery do not reach between the battery and the chassis. XWear safety shoes.
Battery removal and installation
Requirements
– Park the truck securely, see "Parking the truck securely" on page 105. – Battery 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 manufacturer’s
instructions.
• Bring the external replacement device up to the truck.
•
• Pull the battery out with the external replacement device and transport it to the charging station for charging.
• Deposit the battery securely.
The battery is now removed.
Z Battery assembly is the reverse order.
WARNING!
After inserting the battery close the battery lock.
73
5.8 Hook-on battery door removal and installation (o)
CAUTION!
Trapping hazard
Trapping hazard when removing and installing the battery door. XWhen removing and installing the battery door do not put your hands between the
door and the chassis.
XWear safety shoes.
Z Only for trucks with a roller conveyor.
Battery door removal
Requirements
– Park the truck securely, see "Parking the truck securely" on page 105. – Battery disconnected.
Procedure
•
• 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.
77
Battery door assembly
Requirements
– Park the truck securely, see "Parking the truck
securely" on page 105.
– Battery disconnected.
Procedure
• Insert the battery door in the receptacles (78).
• Push the battery door onto the truck.
• Push the battery door down and engage it in the bracket (79).
The battery door is now assembled.
78 79
Z If the battery door is not closed correctly, the truck will not be released for travel.
Information message (1918) is displayed.
74
E Operation
1 Safety Regulations for the Operation of the
Forklift Truck
Driver authorisation
The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Operator’s rights, obligations and responsibilities
The operator must be informed of his duties and responsibilities and be instructed in the operation of the truck and 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 driving or operating the truck. Do not carry passengers or lift other people.
Damage and faults
The supervisor must be informed immediately of any damage or faults to the truck or attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems) must not be used until they have been rectified.
Repairs
The operator must not carry out any repairs or alterations to the truck without authorisation and the necessary training to do so. The operator must never disable or adjust safety mechanisms or switches.
75
Hazardous area
WARNING!
Risk of accidents/injury in the hazardous area of the truck
A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.
XInstruct unauthorised persons to leave the hazardous area. XIn case of danger to third parties, give a warning signal in good time. XIf unauthorised persons are still within the hazardous area, stop the 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 overhead guard while
the truck is being operated.
Safety devices, warning signs and warning instructions
Safety devices, warning signs (see "Indication Points" on page 34) and warning instructions in the present operating instructions must be strictly observed.
CAUTION!
Reduced headroom can cause injuries
Trucks with reduced headroom are equipped with a warning label within the operator's line of sight.
XThe max. recommended body size indicated on this warning sign must be
observed.
XThe headroom is also reduced when you wear a protective helmet.
76
2 Displays and Controls
4808182
80
83
84
89
85
86
87
85
88
77
Item Control /
display
4 Steering wheel t Steering the industrial truck. 80 Solo-Pilot t Controls the following functions:
Multi-Pilot o
81 Key switch t Switches control current on and off.
ISM Access Module o Switches the truck on. Code lock
82 Dashboard control panel t Displays the battery capacity, service hours,
83 Emergency Disconnect
switch
84 Armrest / side pocket
control panel
85 Brake pedal t Provides infinitely variable braking control. 86 Accelerator pedal t Provides infinitely variable travel speed
87 Twin pedal control
“Reverse” accelerator pedal
88 Twin pedal control
“Forward” accelerator pedal
89 On-board charger o Charges the truck
Function
– Fwd/rev. travel direction – Load handler lift / lower – Mast forward / reverse tilt – "Horn" button – Sideshifter left / right (o) – Auxiliary hydraulics (o)
Removing the key prevents the truck from being switched on by unauthorized personnel.
errors, key warning indicators, wheel position and travel direction.
Switches power supply on and off.
t Switches electric options on and off
control
o The truck travels forward when the
accelerator pedal is applied. Provides infinitely variable travel speed.
o The truck reverses when the accelerator
pedal is applied. Provides infinitely variable travel speed.
Z *If the truck is equipped with an ISM access module refer to the “ISM Access
Module” operator manual.
78
4808182
80
83
84
85
89
86
87
85
88
79
Item Control /
Function
display
90 Travel direction switch
t Selects travel direction / neutral position.
(not available with dual pedal control)
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 functions
or hydraulics that require acknowledgement.
94 Button o Hydraulic auxiliary function control button.
92
9190 92
90
91
91 9290
93
94
90
93
92
80
2.1 Control panel with display unit
The control panel display unit shows the operating data, the battery charge, the service hours and error details and information. Pictograms in the left top section of the dashboard control panel act as warning indicators.
95 96 53 97 98 99 100 101 102
103
km/h
inch lbs m kg eff code err
am
100 %
pm
104 105 106 107 108 109 110
Item Control /
Function
display
95 Parking brake display t Comfort feature, 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 stops. The parking brake is automatically released when the accelerator pedal is applied.
96 WARNING t WARNING
– Flashes for faults, an audible
warning sounds.
– Flashes when battery capacity
is less than 10 %
53 Battery warning
t Not used
indicator
81
Item Control /
Function
display
97 Seat switch warning
indicator
t Seat switch not closed
– Truck operational, but driver's
seat not occupied
Time monitoring expired – Restart the truck
Seat belt lock warning indicator (flashing
o – Truck operational, seat belt
lock not closed
symbol)
98 Service display t Service interval exceeded (1000
operating hours) or annual FEM test due (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 key t Confirms the entries
102 Toggle button t Changes the display between
“Time / Residual Run Time”
103 Display t Displays the operating data (see
"Display" on page 87 )
104 Not used
105 Not used
106 Slow travel button t Switches slow travel on and off
107 Warning indicator
t Not used
Controller and motor overtemperature
82
Item Control /
Function
display
108
95
Yellow LEDs under the parking brake button and
Parking brake indicator
light up simultaneously
t Secure parking of truck.
The parking brake is activated when the truck is switched on or
t
when the parking brake button (108) is pressed. Yellow LEDs under the parking brake button (108) and the parking brake indicator (95) light up simultaneously. Travel is not enabled when the accelerator pedal is pressed. Travel is enabled by pressing the parking brake button (108).
109 Program selector t Selects the operating program
(moves down a level in the operating program list.)
110 Program selector t Selects the operating program
(moves up a level in the operating program list.)
95 96 53 97 98 99 100 101 102
104 105 106 107 108 109 110
103
km/h
inch lbs m kg eff code err
am
100 %
pm
83
Z *Five operating programs with different performance levels are available to adapt
the travel and operating functions to the application at hand. Starting 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 throughput levels). If necessary the operating programs can also be adapted or restricted to suit the customer. Contact the manufacturer's customer service department.
84
2.2 Armrest control panel switch (o)
Function
Work lights
Front windscreen 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 > Switch on the windscreen
washing system Sideshift centre position
Lift cutout override
85
2.3 Side compartment control panel switch (o)
Function
Rear window heating
Beacon
Truck lighting
Parking light
Warning indicator
Lift cutout override
86
2.4 Display
111 112
am
100 %
pm
km/h
117
inch lbs m kg eff code err
116
115
114
Item Function
111 – Remaining time in the format hours : minutes
– Remaining charge time (o)
112 Time display (hours : minutes) 113 Operating program display
– Displays the travel program in use
114 Error display:
– If an error (Err) or a warning (Inf) occurs, the error or info
code is displayed.
– 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 Hourmeter display 117 Travel direction, speed and wheel position display
– Indicates the pre-selected travel direction (forward or
reverse) or the position of the steered wheels.
– Flashing direction arrow = no travel direction selected
113
87
2.4.1 Battery discharge indicator
NOTE
Full discharge can damage the battery
The standard setting for the battery discharge indicator is based on standard batteries. When using maintenance-free batteries (gel batteries), the display must be reset.
XThis adjustment should only be made by the manufacturer’s customer service
department.
XThe battery discharge indicator shows the battery’s residual capacity. XCharge 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 battery symbol (115) is displayed empty.
2.4.2 Battery discharge monitor
If the residual capacity falls below the required level, lifting is inhibited and the travel speed is reduced. An message appears in the display. Lifting is only released when the battery connected is at least 40% charged.
Z In order to complete the lift cycle, the key switch must be turned off and on again.
Lifting is then enabled for 30 to 40 seconds.
88
2.4.3 Residual time display
102
am
100 %
pm
km/h
inch lbs m kg eff code err
Setting the residual time display
Procedure
• Press the toggle switch (102) for 3 seconds. This toggles the display between the time and the residual time or the remaining 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 remaining to reach the residual capacity is displayed.
2.4.4 Hourmeter
The service hours are counted when the truck is switched on and the seat switch is closed.
89
3 Preparing the Truck for Operation
3.1 Checks and operations to be performed before starting daily operation
WARNING!
Damage and other truck or attachment (optional equipment) defects 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.
XReport any defects immediately to your supervisor. XMark defective truck and take out of service. XDo not return the industrial truck to service until you have identified and rectified the
fault.
90
Checks before daily operation
km/
95
108
Procedure
• Visually inspect the entire truck (in particular wheels,
wheel bolts and load handler) for damage.
• Check the fork stop (118) and fork retainer (119).
• Visually inspect the hydraulic system in the visible
118
area for damage and leaks.
• Make sure the driver’s seat is locked in position.
119
• Test the horn and reversing buzzer (o) where
applicable.
• Check that the capacity plate and warning labels are
legible.
• Test the controls and displays.
• Test the steering.
• Check the steer angle display (o), turn the steering wheel in both directions as far
as the stop and check that the wheel position is displayed on the control panel.
• Make sure the load chains are evenly 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 the restraint system (o).
• Test the Drive Control (o).
• Raise the fork carriage without load beyond the reference point on the mast. The slow travel symbol lights up on the display.
• Slowly apply the accelerator pedal on a clear route with good visibility. The maximum speed should be reduced to walking pace (3 km/h).
• Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.
• Check the accelerator pedal can move freely while the parking brake is applied (108 and 95 lit simultaneously) and the truck is idling, by pressing it several times.
•
• Visually inspect the battery attachment and cable connections.
• Check the battery lock is present and working.
91
•
• On 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 103.
64
92
3.2 Entry and exit
Procedure
• Open the cab door (o).
• To enter and exit the cab, hold onto the handle (120).
Z An additional step is provided for the driver position extension (o).
3.3 Trucks with reduced headroom (o)
WARNING!
An unsuitable workplace 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 on the operator.
XThe operating company must ensure
that truck operators do not exceed the maximum body size indicated.
XThe operating company must check that
the operators can sit in a normal and upright position without having to strain.
120
93
3.4 Setting up the operator position
WARNING!
Accidents can occur if the driver's seat, steering column and armrest are not engaged
The driver's seat, steering column and armrest can accidentally adjust during travel and therefore cannot be operated safely.
XDo not adjust the driver’s seat, steering column or armrest while travelling.
Procedure
• Before starting to travel, adjust the driver’s seat, steering column and armrest (if necessary) so 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.
3.4.1 Adjusting the driver’s seat
WARNING!
Risk of accidents and damage to health
An incorrectly adjusted driver’s seat can result in accidents and damage to health.
XDo not adjust the driver’s seat while travelling. XThe driver’s seat should lock in position after adjustment. XCheck and adjust the individual driver's seat setting before starting up the truck. XHold the weight setting lever only by the recess, do not reach through underneath
the lever.
94
Adjusting the driver's weight
NOTE
To achieve optimal seat cushioning the driver’s seat must be set to the driver’s weight. Set the driver's weight when the seat is occupied.
Procedure
• Fold out the weight adjustment lever (121) as far as it will go in the arrow direction
• Move the weight adjustment lever (121) up and down to set the seat to a higher weight.
• Move the weight adjustment lever (121) up and down to set the seat to a lower weight.
122
121
125 126
124123
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 on the lever.
• After setting the weight, move the lever (121) back in full.
The driver’s weight is now set.
Adjusting the backrest
Procedure
• Sit on the driver’s seat.
• Pull the lever (124) to adjust the backrest.
• Adjust the backrest tilt.
• Release the lever (124) again. The backrest is locked.
The backrest is now set.
Z Hold the weight setting lever (121) only by the recess, never reach through
underneath the lever.
95
Adjusting the seat position
121
CAUTION!
122
An unsecured driver's seat can cause injury
An unsecured driver's seat can slide out of its guide during travel, resulting in accidents.
XThe driver's seat must be locked in
position.
XDo not adjust the driver’s seat while
travelling.
124123
Procedure
• Sit on the driver’s seat.
• Pull up the driver’s seat locking lever123 in the direction of the arrow.
• Push the driver’s seat forwards 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 heating switch (125). Switch setting 1 = Seat heating on. Switch setting 0 = Seat heating off.
125 126
Adjusting the lumbar vertebrae support (o)
Procedure
• Turn the hand wheel (126) to the required position. Position 0 = no warping in lumbar vertebrae area. Position 1 = increasing warping in upper lumbar vertebrae area. Position 2 = increasing warping in lower lumbar vertebrae area.
The lumbar vertebrae support is now set.
96
3.4.2 Adjusting the steering column
127
Adjusting the steering column
Procedure
• Release the steering column stop (127).
• Set the steering column to the required position (height and angle).
• Fix the steering column stop (127) in position.
The steering column is now positioned.
3.4.3 Adjusting the arm rest
128 129
Adjusting the arm rest
Procedure
• Pull up the lock (129) and hold it in this position.
• Move the armrest (128) vertically and horizontally.
• Release the lock (129) at the desired position.
• Push the armrest slightly forward or back until it locks in position.
The armrest is now positioned.
97
3.5 Seat Belt
WARNING!
Travelling without a seat belt increases the risk of injury.
Accidents or personal injury can result if the seat belt is not worn or is modified.
XAlways put the seat belt on before starting the industrial truck. XDo not modify the seat belt. XDamaged or non-operational seat belts must be replaced by trained personnel. XSeat belts must always be replaced after an accident. XOnly original spare parts must be used for retrofits or repairs. 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 is idle) and
clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to prevent them from freezing up again. The temperature of the warm air should not exceed +60 °C!
Starting the industrial truck on steep slopes
The automatic blocking system locks the belt in the retractor when the truck is positioned on a steep slope. This prevents the belt from being pulled out of the retractor.
Z Carefully drive the truck off the slope and then put on the belt.
98
DANGER!
A faulty seat belt can cause injury
Using a faulty seat belt can result in injury. XOnly operate the truck with the seat belt intact. A faulty seat belt should be replaced
immediately.
XThe truck must remain decommissioned until a functional seat belt has been fitted.
Checking 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).
• Test the belt buckle and make sure the belt returns correctly into the retractor.
Check the automatic locking system
Procedure
• Park the truck on a level surface.
• Jerk the seat belt out suddenly.
Z The locking system should prevent the belt from coming out.
The seat belt has now been checked.
99
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