The signatories hereby certify that the specified powered industrial truck conforms to
the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatories are individually empowered in each
case to compile the technical documentation.
tion
09.09 EN
3
09.09 EN
4
Foreword
The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide
sufficient instruction for the safe operation of the industrial truck. The information is
provided clearly and concisely. The chapters are arranged by letter. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model.
Safety instructions and important explanations are indicated by the following
graphics:
Used before safety instructions which must be observed to avoid danger to
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personnel.
Used before notices which must be observed to avoid material damage.
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Used before notices and explanations.
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t Used to indicate standard equipment.
o Used to indicate optional equipment.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating
instructions.
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
0108.GB
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - GERMANY
Telephone: +49 (0) 40/6948-0
www.jungheinrich.com
0108.GB
Table of contents
ACorrect Use and Application
BTruck Description
1Application ........................................................................................... B 1
2Assemblies and Functional Description .............................................. B 2
2.1Truck ................................................................................................... B 3
3Standard Version Specifications ......................................................... B 4
3.1EFG 213-220 performance data ......................................................... B 4
3.2EFG 316-320 performance data ......................................................... B 5
3.3EFG 213-220 dimensions ................................................................... B 6
3.4EFG 316-320 dimensions ................................................................... B 8
3.5EFG 213-220 weights ......................................................................... B 10
3.6EFG 316-320 weights ......................................................................... B 10
3.7EFG 213-220 tyres .............................................................................. B 11
3.8EFG 316-320 tyres .............................................................................. B 11
3.9EFG 213-320 mast versions ............................................................... B 12
3.10 EN norms ............................................................................................ B 13
3.11 Conditions of use ................................................................................ B 13
4Identification points and data plates .................................................... B 14
4.1Truck data plate .................................................................................. B 16
4.2Truck load chart .................................................................................. B 16
4.3Fork load diagram (basic model) ......................................................... B 17
4.4Attachment load chart ......................................................................... B 17
0608.GB
CTransport and Commissioning
1Transport ............................................................................................. C 1
2Lifting by crane .................................................................................... C 1
3Securing the truck during transport ..................................................... C 2
4Using the truck for the first time .......................................................... C 3
5Operating the truck without its own drive system ................................ C 3
6Moving the truck when the electric/hydraulic steering has failed ........ C 4
7Towing the Truck ................................................................................. C 4
I 1
DBattery Maintenance, Charging & Replacement
1Safety regulations for handling acid batteries ..................................... D 1
2Battery types ....................................................................................... D 2
3Battery removal and installation .......................................................... D 3
3.1Removal and installation using a multi-adapter (o) ............................ D 3
3.2Removal and installation using a worktable for crane loading (o) ...... D 5
3.3Removal and installation using a fork shoe (o) .................................. D 6
3.4Removal and assembly for maintenance ............................................ D 7
4Charging the battery ............................................................................ D 8
4.1Charging the battery with a stationary charger ................................... D 8
4.2Charging the battery with an on-board charger ................................... D 9
EOperation
1Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2Controls and Displays ......................................................................... E 2
2.1SOLOPILOT / MULTIPILOT ................................................................ E 4
2.2Armrest control panel switch (o) ........................................................ E 5
2.3Side pocket control panel switch (o) .................................................. E 5
2.4Dashboard control panel and driver’s display ..................................... E 6
2.5Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter .. E 11
3Starting up the truck ............................................................................ E 12
3.1Checks and operations to be performed before starting daily
operation ............................................................................................. E 12
3.2Adjusting the driver’s seat ................................................................... E 12
3.3Safety restraint belt ............................................................................. E 14
3.4Mechanical safety restraint system (o) .............................................. E 15
3.5Adjusting the steering column ............................................................. E 16
3.6To prepare the truck for operation ....................................................... E 16
4Industrial Truck Operation ................................................................... E 17
4.1Safety regulations for truck operation ................................................. E 17
4.2Travel, steering, braking ...................................................................... E 19
4.3Operating the lift mechanism and attachments (SOLOPILOT t) ....... E 22
4.4Operating the lift mechanism and attachments (MULTIPILOT o) ...... E 24
4.5Emergency lowering ............................................................................ E 26
4.6Adjusting the forks ............................................................................... E 26
4.7Collecting, Lifting and Transporting Loads. ......................................... E 27
4.8Parking the truck safely ....................................................................... E 28
4.9Towing trailers ..................................................................................... E 29
5Troubleshooting .................................................................................. E 30
5.1Temperature control ............................................................................ E 30
I 2
0608.GB
FIndustrial Truck Maintenance
1Operational Safety and Environmental Protection ...............................F 1
These operating instructions apply only to Jungheinrich battery models. If using
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another brand, refer to the manufacturer's operating instructions.
If using a battery with closed EPzV and EPzV ironclad plates, this must first be
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discussed with the manufacturer.
0506.GB
1
0506.GB
2
ACorrect Use and Application
The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
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supplied with the truck. The guidelines form part of these operating instructions and
must be observed. National regulations apply in full.
The truck described in the present operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be used, operated and serviced in accordance with the present instructions.
All other types of use lie beyond the scope of application and can result in damage to
personnel, the truck or property. In particular, avoid overloading the truck with loads
which are too heavy or placed on one side. The data plate attached to the truck and
the load diagram are binding with regard to the maximum load capacity. The owner
must ensure that any damaged and/or illegible load diagrams are replaced.
The industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust.
Proprietor responsibilities:
“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 truck is only used for the purpose it is designed
for and that any danger to life and limb of the user and third parties is avoided.
Furthermore, accident prevention regulations, safety regulations and operating,
servicing and repair guidelines must be followed. The proprietor must ensure that all
truck users have read and understood this operator manual.
Failure to comply with the operating instructions shall invalidate the warranty.
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The same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer’s customer service department.
Attaching accessories: The mounting or installation of additional equipment which
affects or enhances the performance of the industrial truck requires the written
permission of the manufacturer. In some cases, local authority approval shall be
required.
Approval of the local authorities however does not constitute the manufacturer’s
approval.
Trailing and towed loads: The truck may only be used for trailing or towed loads for
which the truck has been approved.
For the purposes of the present operator manual the
0504.GB
A 1
A 2
0504.GB
BTruck Description
1Application
The EFG is a three- or four-wheel electric sit-down counterbalanced truck. It is
cantilevered and the load handler mounted on the front of the truck can unload lorries
without hindrance and deposit the load on ramps or in aisles. Closed bottom pallets
can also be lifted.
Truck models and maximum capacity:
TypeMax. capacityLoad centre of gravity
EFG 2131,300 kg500 mm
EFG 2151500 kg500 mm
EFG 216k1600 kg500 mm
EFG 2161600 kg500 mm
EFG 218k1800 kg500 mm
EFG 2181800 kg500 mm
EFG 2202000 kg500 mm
EFG 316k1600 kg500 mm
EFG 3161600 kg500 mm
EFG 318k1800 kg500 mm
EFG 3181800 kg500 mm
EFG 3202000 kg500 mm
0708.GB
B 1
2Assemblies and Functional Description
2
3
4
B 2
1
15
14
11
12
13
Item DescriptionItem Description
1 t Driver's seat8 t Load handler
2 t Overhead guard9 t Fork carriage
3 t Mast10 t Drive axle
4 t Steering wheel11 t Battery door
o Multifunction steering wheel12 o
On-board charger
(in battery compartment)
5 t SOLOPILOT 13 t Steering axle
o MULTIPILOT14 t Trailer coupling
6 t Dashboard control panel15 t Counterweight
7 t EMERGENCY DISCONNECT
switch
t = Standard equipment o = Optional equipment
5
6
7
8
9
10
0708.GB
2.1Truck
Safety mechanisms: The overhead guard (2) protects the driver from falling objects.
Pressing the EMERGENCY DISCONNECT switch rapidly disconnects all electrical
functions in hazardous situations. Travelling and lifting can only be activated when
the driver is seated. The dashboard control panel (6) displays the truck information.
Steering: The travel speed reduces as a function of the steering angle
(“CurveControl”). The steering angle is shown in the display.
Operator position: The driver’s seat (1) is a “comfort” seat, the steering column is
adjustable. There are storage facilities for paper and the driver's personal items.
The control and warning displays on the dashboard control panel (6) enable the
system to be monitored during operation, thereby ensuring a very high level of safety.
Electrical/Electronic System: The driver can choose from five travel programs,
depending on the load and the environment: from maximum performance to energy
saving. The latest threephase system using a CAN Bus allows for rapid
troubleshooting. The advanced controller is simple, safe and flexible.
Drive System and Brakes: The 2-motor front drive provides maximum traction to the
drive wheels at all times. Each motor receives the exact power it requires in
proportion to the steering angle. The wheels do not spin and energy is converted
efficiently.
The mechanical disk brake which acts as a service brake is maintenance-free.
Encapsulated, it allows the truck to be used even in hostile environments. The truck
also brakes to a halt regeneratively via the traction motors. This minimizes energy
consumption.
The parking brake is electrically actuated. It is also used for emergency braking.
A warning indicator appears when the parking brake is applied.
Brake system faults are shown on the driver’s display.
Emergency Stop Safety Feature: The emergency stop is controlled by the steering
and traction controllers. If an error is detected the truck automatically brakes to a halt.
Control displays on the driver’s display indicate the emergency stop. Every time the
truck is switched on, the system performs a self-diagnosis which only releases the
parking brake (emergency stop) if the functionality test is positive.
Hydraulic System: All functions must be performed sensitively. To ensure greater
efficiency, a hydraulic unit and a steering motor operate independently of each other.
The micro pressure filter can be replaced from the top (without spilling hydraulic oil).
Mast: The maximum strength steel sections are narrow, allowing for good fork
visibility in particular with the three-stage mast. The lift rails and the fork carriage run
on permanently-lubricated and hence maintenance-free angled rollers.
0708.GB
B 3
3Standard Version Specifications
Technical specification details in accordance with VDI 2198. Technical modifications
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and additions reserved.
3.1EFG 213-220 performance data
DescriptionEFG
213215216k218k220
216218
Capacity
Q
(where C = 500 mm) *)
Load centre of gravity
C
distance
Travel speed
with / without load
Raise lift speed
with / without load
Lower lift speed
with / without load
Gradeability
(30 min)
with / without load
Max. gradeability
(5 min)
with / without load
Acceleration (10m)
with / without load
13001500160018002000kg
500500500500500mm
16/1616/1616/1616/1616/16 km/h
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
7.6/12.5 7.3/12.3
28.0/35.0 27.0/35.0 27.0/35.0
3.6/3.23.8/3.43.8/3.43.9/3.54.0 / 3.5s
7.3/12.36.2/10.7
7.0/11.55.9/10.5
26.0/35.0
25.0/35.0
5.7/10.4 %
24.0/35.0 %
*) with vertical mast
B 4
0708.GB
3.2EFG 316-320 performance data
DescriptionEFG
316k316318k318320
Capacity
Q
(where C =
16001600180018002000kg
500 mm) *)
Load centre of
C
gravity distance
Travel speed
with / without load
Raise lift speed
with / without load
Lower lift speed
with / without load
500500500500500mm
17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 km/h
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
Gradeability
(30 min)
7.3/12.37/11.56.2/10.7 5.9/10.5 5.7/10.4 %
with / without load
Max. gradeability
(5 min rating)
27/3527/3526/3525/3524/35 %
with / without load
Acceleration (10m)
with / without load
3.8/3.43.8/3.43.9/3.53.9/3.54/3.5s
*) with vertical mast
0708.GB
B 5
3.3EFG 213-220 dimensions
All dimensions in mm
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DescriptionEFG
213215216k218k220
216218
h1Mast height retracted20002000200020002000
h2Free lift150150150150150
h3Lift30003000300030003000
h4Mast height extended35603560356035873587
h6Overhead guard height20402040204020402040
h7Seat height920920920920920
h10Tow height560560560560560
L1Length including forks29242924
L2Length incl. fork shank
1)
17741774
30373037
31453145
18871887
19951995
b1 Overall width10601060106011201120
e Fork width100100100100100
Ground clearance
m
1
with load below mast
Centre wheel base ground
m
2
clearance
Working Aisle Width
Ast
800 x 1200 longitudinal pallets
Working Aisle Width
Ast
1000 x 1200 traverse pallets
WaTurning radius14401440
x Load distance
1)
y Wheel base 12491249
8080808080
100100100100100
32263226
31043104
33393339
34463446
32163216
33233323
15481548
16551655
335335340340340
13571357
14651465
3145
1995
3446
3323
1655
1465
B 6
1)
= + 25 mm DZ mast
0708.GB
c
h
4
h
3
h
Q
h
1
h
2
h
10
6
h
7
0708.GB
s
m
x
1
l
L
1
a
2
l
6
m
y
L
2
2
a
2
e
b
12
W
R
A
st
a
b
B 7
3.4EFG 316-320 dimensions
All dimensions in mm
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DescriptionEFG
316k316318k318320
h1Mast height retracted20002000200020002000
h2Free lift150150150150150
h3Lift30003000300030003000
h4Mast height extended356033560358735873587
h6Overhead guard height20402040204020402040
h7Seat height920920920920920
h10Tow height
410/
580
410/
580
410/
580
L1Length including forks31403248314032483248
L2Length including fork shank19902098199020982098
b1Overall width10601060112011201120
e Fork width100100100100100
Ground clearance
m
1
with load below mast
Centre wheel base ground
m
2
clearance
Working Aisle Width
Ast
800 x 1200 longitudinal pallets
Working Aisle Width
Ast
1000 x 1200 traverse pallets
8080808080
100100100100100
35993725359937013701
3403 3526 3403 3526 3526
WaTurning radius18591985185919851985
x Load distance
1)
340340340340340
y Wheel base 14001508140015081508
1)
= + 25 mm DZ mast
410/
580
410/
580
B 8
0708.GB
c
h
4
h
3
h
Q
h
1
h
2
h
10
6
h
7
0708.GB
s
m
x
1
l
L
1
a
2
l
6
m
y
L
2
2
a
2
e
b
12
b
13
R
A
st
W
a
b
B 9
3.5EFG 213-220 weights
All dimensions in kg
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DescriptionEFG
Truck 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)
3.6EFG 316-320 weights
All dimensions in kg
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DescriptionEFG
Truck 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)
213215216k218k220
216218
27332978
13261310
35453870
14071668
488608
316k316318k318320
30353001317531413306
13801493138514991489
40044043433643674676
16551508179016421817
631558638574630
30003256
30573207
14111409
14961520
40524380
40604405
15891846
15611686
548675
597602
3382
1501
4706
1881
676
B 10
0708.GB
3.7EFG 213-220 tyres
DescriptionEFG 213-216EFG 218EFG 220
SE18 x 7 - 8, 16 PR200/50 - 10
Rubber18 x 7 x 12 1/8“
Tyre size, front
Pneumatic
SE140/55 - 9
Rubber15 x 5 x 11 1/4”
Tyre size, rear
Pneumatic
Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries please
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contact your Jungheinrich customer adviser.
3.8EFG 316-320 tyres
DescriptionEFG 316EFG 318EFG 320
SE18 x 7 - 8, 16 PR200/50 - 10
Rubber18 x 7 x 12 1/8”18 x 8 x 12 1/8”
Tyre size, front
Pneumatic
SE16 x 6 - 8
Rubber16 x 5 x 10 1/2”
Tyre size, rear
Pneumatic
180/70 - 8
Diagonal,
16 PR; 7 bar
15 x 4.5 - 8
Diagonal,
12 PR; 7 bar
180/70 - 8
Diagonal,
16 PR; 7 bar
150/75 - 8
Diagonal,
16 PR; 7 bar
not available
not available
not available
not available
0708.GB
Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries please
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contact your Jungheinrich customer adviser.
B 11
3.9EFG 213-320 mast versions
All dimensions in mm
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VDI 3596
Description
Lift
h
3
EFG 213/
215/216k/
216/316/
2300150165028502885
3000150200035503585
3100150205036503685
3300150215038503885
ZT
ZZ
DZ
3600150230041504185
4000150250045504585
4500150280050505085
5000150305055505585
5500150340060506085
23001055990160528502915
300014051340195535503615
310014551390200536503715
330015551490210538503915
360017051640225541504215
400019051840245545504615
435014051340195549004965
450014551390200550505115
480015551490210553505415
500016301565218055505615
550018051740235560506115
600020051940255565506615
650022552190280570507115
316k
Free lift
h
2
EFG 218k/
218/220/
318/318k/
320
Height
retracted
h
1
Height extended
h
4
EFG 213/
215/216k/
216/316/
EFG 218k/
218/220/
318/318k/
316k
320
B 12
0708.GB
3.10 EN norms
EFG 213-220
noise emission level: 66 dB(A)
EFG 316-320
noise emission level: 67 dB(A)
in accordance with EN 12053 as harmonised with
ISO 4871.
The noise emission level is calculated in accordance with standard procedures and
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takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the driver’s ear.
EFG 213-220 vibration:0.53 m/s
EFG 316-320 vibration:0.51 m/s
In accordance with EN 13059.
The vibration acceleration acting on the body in the operating position is, in
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accordance with standard procedures, the linearly integrated, weighted acceleration
in the vertical direction. It is calculated when travelling over bumps at constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with
tolerance levels for electromagnetic emissions and
resistance as well as static electricity discharge testing in
accordance with EN 12895 including the normative
procedures contained therein.
No changes to electric or electronic components or their arrangement may be made
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without the written agreement of the manufacturer.
3.11 Conditions of use
Ambient temperature
Special equipment and authorisation are required if the truck is to be constantly used
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in conditions of extreme temperature or air humidity fluctuations.
- operating at -20 °C to 40 °C
2
2
0708.GB
B 13
4Identification points and data plates
Warnings and notices such as load charts, strap points and data plates must be
F
legible at all times. Replace if necessary.
29
16
18
17
27
18
19
XXX
20
21
22
23
(mm)Q (kg)
D (mm)
24
25
26
B 14
28
0708.GB
ItemDescription
16Do not travel with raised load or mast forward tilt with raised load
17Wear seatbelt
18Strap points
19Tipover caution, no passengers
20Lift limit
21Do not step onto or beneath the load, risk of trapping
22Read the operating instructions
23Capacity
24Risk of trapping, in chassis behind the battery door
25Data plate
26Jack contact points
27Serial number, on chassis behind the battery door
28Add hydraulic oil
29Test sticker (o)
0708.GB
B 15
4.1Truck data plate
Item DescriptionItem Description
30Type36Manufacturer
31Serial no.37Min./max. battery weight (kg)
32Rated capacity (kg)38Output (kW)
33Battery: Voltage (V)39Load centre of gravity (mm)
34Net weight w.o. battery (kg)40Year of manufacture
35Manufacturer’s logo41Option
For queries regarding the truck or ordering spare parts always quote the truck serial
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number (31).
4.2Truck load chart
4130
4031
3932
3833
3734
36
35
The capacity plate (23) gives the capacity (Q) of the truck in kg 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).
Example of how to calculate the maximum capacity:
With a load centre of gravity D of 600 mm and a maximum lift height H of 3600 mm.
the max. capacity Q is 1105 kg.
Example:
23
4250
3600
2900
850
1105
1105
12501250
500
850
600
600
850
850
700
B 16
0708.GB
The arrow shape markings (42 and 43)
on the inner and outer masts show the
driver when the prescribed lift limits have
been reached.
4.3Fork load diagram (basic model)
The fork load diagram give the truck’s capacity Q in kg. The maximum capacity for
the various load centres of gravity (D in mm) is shown in chart form.
4243
4.4Attachment load chart
The attachment load chart gives the truck’s capacity Q in combination with the
respective attachment in kg. The serial number specified in the load chart must match
the data plate of the attachment, as the capacity for each truck is specifically indicated
by the manufacturer. It is shown in the same way as the truck’s capacity and can be
determined accordingly.
For loads with a centre of gravity above 500 mm upward, the capacities are reduced
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by the difference of the altered centre of gravity.
0708.GB
B 17
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