Jungheinrich EFG 216kn Operator Manual

EFG 216kn

04.09-

Operating Instructions

51159405

04.09

G

I 1

0409.GB

Table of contents

A Correct Use and Application

B Truck Description

1 Application ........................................................................................... B 1

2 Assemblies and Functional Description .............................................. B 2

2.1 Truck ................................................................................................... B 3

3 Standard Version Specifications ......................................................... B 4

3.1 Dimensions ......................................................................................... B 4

3.2 Mast versions ...................................................................................... B 6

3.3 Performance data ............................................................................... B 6

3.4 Weights (all measurements in kg) ....................................................... B 7

3.5 Tyre type ............................................................................................. B 7

3.6 EN norms ............................................................................................ B 8

3.7 Conditions of use ................................................................................ B 8

4 Identification points and data plates .................................................... B 9

4.1 Truck data plate .................................................................................. B 10

4.2 Truck load chart .................................................................................. B 11

4.3 Fork load chart (basic model) .............................................................. B 11

4.4 Attachment load chart ......................................................................... B 12

C Transport and Commissioning

1 Lifting by crane .................................................................................... C 1

2 Securing the truck during transport ..................................................... C 2

3 Using the truck for the first time .......................................................... C 3

4 Operating the Truck without its own Drive System ............................. C 4

D Battery - Servicing, Recharging, Replacement

1 Safety Regulations Governing the Handling of Lead-Acid

Batteries .............................................................................................. D 1

2 Battery types ....................................................................................... D 2

3 Exposing the battery ........................................................................... D 3

4 Charging the battery ............................................................................ D 4

5 Battery removal and installation .......................................................... D 5

6 Closing the battery cover .................................................................... D 6

7 Battery Discharge Indicator, Battery Discharge Monitor,

Hourmeter ........................................................................................... D 6

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0409.GB

Table of contents

A Correct Use and Application

B Truck Description

1 Application ........................................................................................... B 1

2 Assemblies and Functional Description .............................................. B 2

2.1 Truck ................................................................................................... B 3

3 Standard Version Specifications ......................................................... B 4

3.1 Dimensions ......................................................................................... B 4

3.2 Mast versions ...................................................................................... B 6

3.3 Performance data ............................................................................... B 6

3.4 Weights (all measurements in kg) ....................................................... B 7

3.5 Tyre type ............................................................................................. B 7

3.6 EN norms ............................................................................................ B 8

3.7 Conditions of use ................................................................................ B 8

4 Identification points and data plates .................................................... B 9

4.1 Truck data plate .................................................................................. B 10

4.2 Truck load chart .................................................................................. B 11

4.3 Fork load chart (basic model) .............................................................. B 11

4.4 Attachment load chart ......................................................................... B 12

C Transport and Commissioning

1 Lifting by crane .................................................................................... C 1

2 Securing the truck during transport ..................................................... C 2

3 Using the truck for the first time .......................................................... C 3

4 Operating the Truck without its own Drive System ............................. C 4

D Battery - Servicing, Recharging, Replacement

1 Safety Regulations Governing the Handling of Lead-Acid

Batteries .............................................................................................. D 1

2 Battery types ....................................................................................... D 2

3 Exposing the battery ........................................................................... D 3

4 Charging the battery ............................................................................ D 4

5 Battery removal and installation .......................................................... D 5

6 Closing the battery cover .................................................................... D 6

7 Battery Discharge Indicator, Battery Discharge Monitor,

Hourmeter ........................................................................................... D 6

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E Operation

1 Safety regulations for the operation of forklift trucks ........................... E 1

2 Controls and Displays ......................................................................... E 2

2.1 Instrument panel switches ................................................................... E 4

2.2 Control panel switches ........................................................................ E 4

2.3 Multitask display .................................................................................. E 5

2.4 Warning displays, buttons and switches ............................................. E 6

2.5 Displays ............................................................................................... E 7

2.6 Setting the time ................................................................................... E 7

2.7 Driver’s Display Warning Messages ................................................... E 8

3 Starting up the Truck ........................................................................... E 9

3.1 Checks and operations to be performed before starting

daily operation ..................................................................................... E 9

3.2 Trucks with reduced headroom X (o) ................................................. E 9

3.3 Driver's seat ........................................................................................ E 10

3.4 Adjusting the steering column ............................................................. E 12

3.5 Preparing the truck for operation ......................................................... E 12

3.6 Safety restraint belt ............................................................................. E 13

4 Industrial Truck Operation ................................................................... E 15

4.1 Safety regulations for truck operation ................................................. E 15

4.2 Travel .................................................................................................. E 16

4.3 Steering ............................................................................................... E 17

4.4 Braking ................................................................................................ E 18

4.5 Operating the lift mechanism and attachments (SOLO-PILOT) .......... E 19

4.6 Lifting, transporting and depositing loads ............................................ E 21

4.7 Parking the truck securely ................................................................... E 24

4.8 Towing trailers ..................................................................................... E 25

5 Troubleshooting .................................................................................. E 26

5.1 Temperature control ............................................................................ E 26

F Industrial Truck Maintenance

1 Operational Safety and Environmental Protection ...............................F 1

2 Maintenance Safety Regulations .........................................................F 1

3 Servicing and Inspection ......................................................................F 3

4 EFG216kn Maintenance Checklist .......................................................F 4

5 EFG 216kn lubrication chart .................................................................F 6

5.1 Consumables .......................................................................................F 7

6 Maintenance Instructions .....................................................................F 8

6.1 Preparing the truck for maintenance and repairs .................................F 8

6.2 Opening the rear panel ........................................................................F 8

6.3 Checking the wheel attachments. ........................................................F 8

6.4 Rear wheel rated condition ..................................................................F 8

6.5 Checking the hydraulic oil level ............................................................F 9

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E Operation

1 Safety regulations for the operation of forklift trucks ........................... E 1

2 Controls and Displays ......................................................................... E 2

2.1 Instrument panel switches ................................................................... E 4

2.2 Control panel switches ........................................................................ E 4

2.3 Multitask display .................................................................................. E 5

2.4 Warning displays, buttons and switches ............................................. E 6

2.5 Displays ............................................................................................... E 7

2.6 Setting the time ................................................................................... E 7

2.7 Driver’s Display Warning Messages ................................................... E 8

3 Starting up the Truck ........................................................................... E 9

3.1 Checks and operations to be performed before starting

daily operation ..................................................................................... E 9

3.2 Trucks with reduced headroom X (o) ................................................. E 9

3.3 Driver's seat ........................................................................................ E 10

3.4 Adjusting the steering column ............................................................. E 12

3.5 Preparing the truck for operation ......................................................... E 12

3.6 Safety restraint belt ............................................................................. E 13

4 Industrial Truck Operation ................................................................... E 15

4.1 Safety regulations for truck operation ................................................. E 15

4.2 Travel .................................................................................................. E 16

4.3 Steering ............................................................................................... E 17

4.4 Braking ................................................................................................ E 18

4.5 Operating the lift mechanism and attachments (SOLO-PILOT) .......... E 19

4.6 Lifting, transporting and depositing loads ............................................ E 21

4.7 Parking the truck securely ................................................................... E 24

4.8 Towing trailers ..................................................................................... E 25

5 Troubleshooting .................................................................................. E 26

5.1 Temperature control ............................................................................ E 26

F Industrial Truck Maintenance

1 Operational Safety and Environmental Protection ...............................F 1

2 Maintenance Safety Regulations .........................................................F 1

3 Servicing and Inspection ......................................................................F 3

4 EFG216kn Maintenance Checklist .......................................................F 4

5 EFG 216kn lubrication chart .................................................................F 6

5.1 Consumables .......................................................................................F 7

6 Maintenance Instructions .....................................................................F 8

6.1 Preparing the truck for maintenance and repairs .................................F 8

6.2 Opening the rear panel ........................................................................F 8

6.3 Checking the wheel attachments. ........................................................F 8

6.4 Rear wheel rated condition ..................................................................F 8

6.5 Checking the hydraulic oil level ............................................................F 9

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6.6 Checking the gear oil level ...................................................................F 10

6.7 Draining the oil .....................................................................................F 10

6.8 Adding oil .............................................................................................F 10

6.9 Replacing the hydraulic oil filter ...........................................................F 10

6.10 Checking the brake fluid level ..............................................................F 11

6.11 Seat belt maintenance .........................................................................F 11

6.12 Checking electrical fuses .....................................................................F 12

6.13 Recommissioning .................................................................................F 13

7 Decommissioning the industrial truck ...................................................F 13

7.1 Prior to decommissioning: ....................................................................F 13

7.2 During decommissioning: .....................................................................F 13

7.3 Returning the truck to operation after decommissioning ......................F 14

8 Safety tests to be performed at intervals and

after unusual incidents .........................................................................F 14

9 Final de-commissioning, disposal ........................................................F 14

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6.6 Checking the gear oil level ...................................................................F 10

6.7 Draining the oil .....................................................................................F 10

6.8 Adding oil .............................................................................................F 10

6.9 Replacing the hydraulic oil filter ...........................................................F 10

6.10 Checking the brake fluid level ..............................................................F 11

6.11 Seat belt maintenance .........................................................................F 11

6.12 Checking electrical fuses .....................................................................F 12

6.13 Recommissioning .................................................................................F 13

7 Decommissioning the industrial truck ...................................................F 13

7.1 Prior to decommissioning: ....................................................................F 13

7.2 During decommissioning: .....................................................................F 13

7.3 Returning the truck to operation after decommissioning ......................F 14

8 Safety tests to be performed at intervals and

after unusual incidents .........................................................................F 14

9 Final de-commissioning, disposal ........................................................F 14

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1

0506.GB

Appendix

JH Traction Battery Operating Instructions

Z

These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

1

0506.GB

Appendix

JH Traction Battery Operating Instructions

Z

These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.

0506.GB 20506.GB

2

A 1

0504.GB

A Correct Use and Application

Z

The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
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:

For the purposes of the present operator manual the
“proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the 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.

M

Failure to comply with the operating instructions shall invalidate the warranty.
The same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer’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.

A 1

0504.GB

A Correct Use and Application

Z

The “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are
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:

For the purposes of the present operator manual the
“proprietor” is defined as any natural or legal person who either uses the industrial
truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting)
the proprietor is considered the person who, in accordance with existing contractual
agreements between the owner and user of the industrial truck, is charged with
operational duties.
The proprietor must ensure that the 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.

M

Failure to comply with the operating instructions shall invalidate the warranty.
The same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer’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.

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0504.GB

A 2

0504.GB

B 1

0209.GB

B Truck Description

1 Application

The EFG is a three-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 racks. Closed bottom pallets can also
be lifted.

Truck models and maximum capacity:

*) The load charts attached to the truck are binding in terms of capacity

Type Max. capacity *) Load centre of gravity

EFG 216kn 1,600 kg 500 mm

B 1

0209.GB

B Truck Description

1 Application

The EFG is a three-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 racks. Closed bottom pallets can also
be lifted.

Truck models and maximum capacity:

*) The load charts attached to the truck are binding in terms of capacity

Type Max. capacity *) Load centre of gravity

EFG 216kn 1,600 kg 500 mm

B 2

0209.GB

2 Assemblies and Functional Description

Item Description

1 t Overhead guard
2 t Driver's seat
3 t Counterweight
4 t Battery behind panel
5 t Power
6 t Load handler
7 t Steering system
8 t Mast

1

2

3

4

5

6

7

8

B 2

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2 Assemblies and Functional Description

Item Description

1 t Overhead guard
2 t Driver's seat
3 t Counterweight
4 t Battery behind panel
5 t Power
6 t Load handler
7 t Steering system
8 t Mast

1

2

3

4

5

6

7

8

B 3

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2.1 Truck

Steering (7): A low steer effort of 15 N as well as a favourable transmission ratio of

5 steering wheel revolutions ensure fast and comfortable steering. The hydraulic rack
and pinion steering keeps wear parts down to a minimum, bringing the advantage of
a compact steer unit. The standard twin tyres reduce the steer effort and increase the
useful life of the wheels.

Driver’s seat (2): The driver's seat is the centre point of any lift truck. Our trucks are
particularly strong in this respect. They feature a comfort seat with an adjustable
steering column as well as storage facilities for papers or the driver's personal
belongings.

Electrical/Electronic System: The latest AC threephase system using a CAN Bus
system to minimise the number of cable leads. This results in less downtime due to
cable breakage and considerably faster troubleshooting. The advanced controller is
simple, safe and flexible. The driver can choose from five travel programs, depending
on the load and the environment: from maximum performance to energy saving. Error
analysis and programming can be performed simply and above all rapidly by PC.

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 there is no loss of
energy.
The hydraulic oil bath multi-plate brakes form the operating brake and are practically
maintenance-free. The gear encapsulation 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. Even on ramps the truck will not simply roll
away.

Hydraulic System: All operations can be performed sensitively, proportionally and
simultaneously (insofar as they do not affect safety). To ensure greater efficiency,
a hydraulic unit and steering booster motor operate independently of each other.
The micro pressure filter can be replaced from the top (without spilling hydraulic oil).

Mast (8): The aim is to optimise visibility. The cold rolled maximum strength steel
sections are extremely narrow, allowing for good fork visibility in particular with
the three-stage mast. The same standard has been achieved for the fork carriage.
The lift rails and the fork carriage run on permanently-lubricated and hence
maintenance-free angled rollers.

B 3

0209.GB

2.1 Truck

Steering (7): A low steer effort of 15 N as well as a favourable transmission ratio of

5 steering wheel revolutions ensure fast and comfortable steering. The hydraulic rack
and pinion steering keeps wear parts down to a minimum, bringing the advantage of
a compact steer unit. The standard twin tyres reduce the steer effort and increase the
useful life of the wheels.

Driver’s seat (2): The driver's seat is the centre point of any lift truck. Our trucks are
particularly strong in this respect. They feature a comfort seat with an adjustable
steering column as well as storage facilities for papers or the driver's personal
belongings.

Electrical/Electronic System: The latest AC threephase system using a CAN Bus
system to minimise the number of cable leads. This results in less downtime due to
cable breakage and considerably faster troubleshooting. The advanced controller is
simple, safe and flexible. The driver can choose from five travel programs, depending
on the load and the environment: from maximum performance to energy saving. Error
analysis and programming can be performed simply and above all rapidly by PC.

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 there is no loss of
energy.
The hydraulic oil bath multi-plate brakes form the operating brake and are practically
maintenance-free. The gear encapsulation 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. Even on ramps the truck will not simply roll
away.

Hydraulic System: All operations can be performed sensitively, proportionally and
simultaneously (insofar as they do not affect safety). To ensure greater efficiency,
a hydraulic unit and steering booster motor operate independently of each other.
The micro pressure filter can be replaced from the top (without spilling hydraulic oil).

Mast (8): The aim is to optimise visibility. The cold rolled maximum strength steel
sections are extremely narrow, allowing for good fork visibility in particular with
the three-stage mast. The same standard has been achieved for the fork carriage.
The lift rails and the fork carriage run on permanently-lubricated and hence
maintenance-free angled rollers.

B 4

0209.GB

3 Standard Version Specifications

3.1 Dimensions

1)

= +25 mm DZ mast

Description EFG 216kn

h1Mast height retracted 2000 mm

h2Free lift 150 mm

h3Lift 3000 mm

h4Mast height extended 4220 mm

h6Overhead guard height 1960 mm

h7Seat height 890 mm

h10Hitch height 560 mm

L1Length including forks 3049 mm

L2Headlength

1)

1899 mm

b1 Overall width 1060 mm

e Fork width 100 mm

m1Ground clearance with load below mast 80 mm

m2Centre wheel base ground clearance 90 mm

Ast

Working aisle width
for pallets 800 x 1200 longit.

3348 mm

Ast

Working aisle width
for pallets 1000 x 1200 traverse

3224 mm

WaTurning radius 1545 mm

x Load distance

1)

352 mm

y Wheelbase 1357 mm

B 4

0209.GB

3 Standard Version Specifications

3.1 Dimensions

1)

= +25 mm DZ mast

Description EFG 216kn

h1Mast height retracted 2000 mm

h2Free lift 150 mm

h3Lift 3000 mm

h4Mast height extended 4220 mm

h6Overhead guard height 1960 mm

h7Seat height 890 mm

h10Hitch height 560 mm

L1Length including forks 3049 mm

L2Headlength

1)

1899 mm

b1 Overall width 1060 mm

e Fork width 100 mm

m1Ground clearance with load below mast 80 mm

m2Centre wheel base ground clearance 90 mm

Ast

Working aisle width
for pallets 800 x 1200 longit.

3348 mm

Ast

Working aisle width
for pallets 1000 x 1200 traverse

3224 mm

WaTurning radius 1545 mm

x Load distance

1)

352 mm

y Wheelbase 1357 mm

B 5

0209.GB

B 5

0209.GB

B 6

0209.GB

3.2 Mast versions

(all dimensions in mm)

3.3 Performance data

*) with vertical mast

EFG 216kn mast chart

VDI 3596

Description

Lift

h

3

Free lift

h

2

EFG216kn

Height

retr.

h

1

Height

extd.

h

4

EFG 216kn

ZT

3000 150 2000 4220

3300 150 2150 4520

3600 150 2300 4820

4000 150 2500 5220

4500 150 2800 5720

5000 150 3050 6220

ZZ

3300 1545 2105 4520

3600 1695 2255 4820

4000 1895 2455 5220

DZ

4500 1445 2005 5720

4800 1545 2105 6020

5000 1620 2180 6220

5500 1795 2355 6720

6000 1995 2555 7220

Description EFG 216kn

Q Capacity

(where C = 500 mm) *)

1600 kg

C Load centre 500 mm

Travel speed w / w.o. load 16/16 km/h

Lift speed (lift) w / w.o. load 0.38/0.59 m/s

Lift speed (lower) w / w.o. load 0.55/0.55 m/s

Gradeability (30 min)
with / without load

7.3/12.3 %

Max. gradeability (5 min)
with / without load

20.0/35.0 %

Acceleration (10 m)
w / w.o. load

3.8/3.4 s

B 6

0209.GB

3.2 Mast versions

(all dimensions in mm)

3.3 Performance data

*) with vertical mast

EFG 216kn mast chart

VDI 3596

Description

Lift

h

3

Free lift

h

2

EFG216kn

Height

retr.

h

1

Height

extd.

h

4

EFG 216kn

ZT

3000 150 2000 4220

3300 150 2150 4520

3600 150 2300 4820

4000 150 2500 5220

4500 150 2800 5720

5000 150 3050 6220

ZZ

3300 1545 2105 4520

3600 1695 2255 4820

4000 1895 2455 5220

DZ

4500 1445 2005 5720

4800 1545 2105 6020

5000 1620 2180 6220

5500 1795 2355 6720

6000 1995 2555 7220

Description EFG 216kn

Q Capacity

(where C = 500 mm) *)

1600 kg

C Load centre 500 mm

Travel speed w / w.o. load 16/16 km/h

Lift speed (lift) w / w.o. load 0.38/0.59 m/s

Lift speed (lower) w / w.o. load 0.55/0.55 m/s

Gradeability (30 min)
with / without load

7.3/12.3 %

Max. gradeability (5 min)
with / without load

20.0/35.0 %

Acceleration (10 m)
w / w.o. load

3.8/3.4 s

B 7

0209.GB

3.4 Weights (all measurements in kg)

3.5 Tyre type

Z

Permissible tyres: See chapter F “Forklift Truck Maintenance”. If you have any
queries please contact your Jungheinrich customer adviser.

Description EFG 216kn

Truck weight
(including battery)

2990

Front axle load (without lifting load) 1410

Front axle load (with lifting load) 4015

Rear axle load (without lifting load) 1580

Rear axle load (with lifting load) 575

Description EFG 216kn

Tyre size, front SE 18 x 7 -8, 16PR

Tyre size, rear SE 140 / 55 - 9

B 7

0209.GB

3.4 Weights (all measurements in kg)

3.5 Tyre type

Z

Permissible tyres: See chapter F “Forklift Truck Maintenance”. If you have any
queries please contact your Jungheinrich customer adviser.

Description EFG 216kn

Truck weight
(including battery)

2990

Front axle load (without lifting load) 1410

Front axle load (with lifting load) 4015

Rear axle load (without lifting load) 1580

Rear axle load (with lifting load) 575

Description EFG 216kn

Tyre size, front SE 18 x 7 -8, 16PR

Tyre size, rear SE 140 / 55 - 9

B 8

0209.GB

3.6 EN norms

Noise emission: 66 dB(A)

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 (measured with the MSG 65 driver's seat (o)):

0.79 m/s

2

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 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.

Z

No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.

3.7 Conditions of use

Ambient temperature

- operating at -20 °C to 40 °C

Z

Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.

B 8

0209.GB

3.6 EN norms

Noise emission: 66 dB(A)

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 (measured with the MSG 65 driver's seat (o)):

0.79 m/s

2

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 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.

Z

No changes to electric or electronic components or their arrangement may be made
without the written agreement of the manufacturer.

3.7 Conditions of use

Ambient temperature

- operating at -20 °C to 40 °C

Z

Special equipment and authorisation are required if the truck is to be constantly used
in conditions of extreme temperature or air humidity fluctuations.

B 9

0209.GB

4 Identification points and data plates

F

Warnings and notices such as load charts, strap points and data plates must be
legible at all times. Replace if necessary.

Item Description

9 Strap points
10 Risk of crashing notice
11 Decal: Travelling with raised load, mast forward tilt with raised load forbidden
12 Lift notice
13 Forward / reverse notice
14 “No passengers” notice
15 Lower notice
16 Hydraulic function (Multi-Pilot) notice
17 Max. speed notice
18 Read operating instructions notice
19 Jack contact points
20 Data plate
21 Add hydraulic oil notice
22 Capacity decal
23 Do not step onto or beneath the load, trap point
24 Maximum body size notice

B 9

0209.GB

4 Identification points and data plates

F

Warnings and notices such as load charts, strap points and data plates must be
legible at all times. Replace if necessary.

Item Description

9 Strap points
10 Risk of crashing notice
11 Decal: Travelling with raised load, mast forward tilt with raised load forbidden
12 Lift notice
13 Forward / reverse notice
14 “No passengers” notice
15 Lower notice
16 Hydraulic function (Multi-Pilot) notice
17 Max. speed notice
18 Read operating instructions notice
19 Jack contact points
20 Data plate
21 Add hydraulic oil notice
22 Capacity decal
23 Do not step onto or beneath the load, trap point
24 Maximum body size notice

B 10

0209.GB

4.1 Truck data plate

Z

For queries regarding the truck or ordering spare parts always quote the truck serial
number (26).

Item Description Item Description

25 Type 34 Manufacturer’s logo
26 Name 35 Max. battery weight in kg
27 Battery: Voltage (V) 36 Min. battery weight in kg
28 Rated capacity (kg) 37 Output (kW)
29 Net weight w.o. battery (kg) 38 Load centre (mm)
30 Net weight with battery (kg) 39 Year of manufacture
31 Manufacturer 40 Serial No.
32 Production 41 Option
33 Production address

36

35

29

3728

3827

3926

25

41

40

30

31

32 33 34

B 10

0209.GB

4.1 Truck data plate

Z

For queries regarding the truck or ordering spare parts always quote the truck serial
number (26).

Item Description Item Description

25 Type 34 Manufacturer’s logo
26 Name 35 Max. battery weight in kg
27 Battery: Voltage (V) 36 Min. battery weight in kg
28 Rated capacity (kg) 37 Output (kW)
29 Net weight w.o. battery (kg) 38 Load centre (mm)
30 Net weight with battery (kg) 39 Year of manufacture
31 Manufacturer 40 Serial No.
32 Production 41 Option
33 Production address

36

35

29

3728

3827

3926

25

41

40

30

31

32 33 34

B 11

0209.GB

4.2 Truck load chart

The load chart (22) gives the capacity (Q) of the truck in kg with 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.

4.3 Fork load chart (basic model)

The fork load chart give the truck’s capacity Q in kg. The maximum capacity for the
various load centres of gravity (D in mm) is shown in the form of a chart.

4250

3600

2900

1250 1250

850

500

600 700

1105

1105

850

850

850

600

Example:

22

B 11

0209.GB

4.2 Truck load chart

The load chart (22) gives the capacity (Q) of the truck in kg with 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.

4.3 Fork load chart (basic model)

The fork load chart give the truck’s capacity Q in kg. The maximum capacity for the
various load centres of gravity (D in mm) is shown in the form of a chart.

4250

3600

2900

1250 1250

850

500

600 700

1105

1105

850

850

850

600

Example:

22

B 12

0209.GB

4.4 Attachment load chart

The attachment load chart gives the truck capacity Q in conjunction 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 capacity and
can be determined accordingly.

The arrow shape markings (37 and 38)
on the inner and outer masts show the
driver when the prescribed lift limits have
been reached.

37 38

B 12

0209.GB

4.4 Attachment load chart

The attachment load chart gives the truck capacity Q in conjunction 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 capacity and
can be determined accordingly.

The arrow shape markings (37 and 38)
on the inner and outer masts show the
driver when the prescribed lift limits have
been reached.

37 38

C 1

0409.GB

C Transport and Commissioning

1 Lifting by crane

M

Only use lifting gear with sufficient
capacity
(transport weight = net. weight + battery
weight, see truck data plate).

– Parking the truck securely

(see Chapter E).

– Attach the crane slings to the cross

member of the mast (1) and the trailer
coupling (2).

M

The crane lifting gear couplings must be
fitted in such a way that they do not
touch any attachments or the overhead
guard during lifting.

1

2

C 1

0409.GB

C Transport and Commissioning

1 Lifting by crane

M

Only use lifting gear with sufficient
capacity
(transport weight = net. weight + battery
weight, see truck data plate).

– Parking the truck securely

(see Chapter E).

– Attach the crane slings to the cross

member of the mast (1) and the trailer
coupling (2).

M

The crane lifting gear couplings must be
fitted in such a way that they do not
touch any attachments or the overhead
guard during lifting.

1

2

C 2

0409.GB

2 Securing the truck during transport

M

The truck must be securely fastened when transported on a lorry or a trailer.
The lorry / trailer must have fastening rings. Loading must be carried out by specially
trained staff in accordance with recommendations contained in Guidelines VDI 2700
and VDI 2703. In each case correct measurements must be made and appropriate
safety measures adopted.

Z

To secure the truck with the mast assembled, use the eyes on the upper cross
member of the mast and the trailer pins.

Z

If the truck is to be transported without a mast, it must be tied down at the front over
the overhead guard.

Securing the truck with an installed mast

Securing the truck without a mast

C 2

0409.GB

2 Securing the truck during transport

M

The truck must be securely fastened when transported on a lorry or a trailer.
The lorry / trailer must have fastening rings. Loading must be carried out by specially
trained staff in accordance with recommendations contained in Guidelines VDI 2700
and VDI 2703. In each case correct measurements must be made and appropriate
safety measures adopted.

Z

To secure the truck with the mast assembled, use the eyes on the upper cross
member of the mast and the trailer pins.

Z

If the truck is to be transported without a mast, it must be tied down at the front over
the overhead guard.

Securing the truck with an installed mast

Securing the truck without a mast

C 3

0409.GB

3 Using the truck for the first time

F

Commissioning and driver instruction must be performed by trained personnel.
If several trucks are supplied, make sure that only load pickup devices, masts and
basic trucks with the same serial number are assembled.

M

Only operate the truck with battery
current. Rectified AC current will
damage the electronic components.
The battery leads (tow cables) must be
less than 6m long.

To prepare the truck after delivery or
after transport, proceed as follows:

– Check the equipment is complete.
– Test the battery connections.
– Start up the truck as indicated.

(see Chapter E).

Approximate centre of gravity position

y

z

C 3

0409.GB

3 Using the truck for the first time

F

Commissioning and driver instruction must be performed by trained personnel.
If several trucks are supplied, make sure that only load pickup devices, masts and
basic trucks with the same serial number are assembled.

M

Only operate the truck with battery
current. Rectified AC current will
damage the electronic components.
The battery leads (tow cables) must be
less than 6m long.

To prepare the truck after delivery or
after transport, proceed as follows:

– Check the equipment is complete.
– Test the battery connections.
– Start up the truck as indicated.

(see Chapter E).

Approximate centre of gravity position

y

z

C 4

0409.GB

4 Operating the Truck without its own Drive System

If the truck needs to be towed, proceed as follows:

– Attach the tow bar / rope to the trailer coupling of the recovery vehicle and the truck

to be recovered.
– Disconnect the battery (see chapter D).
– Release the parking brake.

F

One person must be seated in the towed truck to steer it. Tow the truck at walking
speed.

Z

As the power steering system is not switched on, extra effort is required to steer
the truck.

C 4

0409.GB

4 Operating the Truck without its own Drive System

If the truck needs to be towed, proceed as follows:

– Attach the tow bar / rope to the trailer coupling of the recovery vehicle and the truck

to be recovered.
– Disconnect the battery (see chapter D).
– Release the parking brake.

F

One person must be seated in the towed truck to steer it. Tow the truck at walking
speed.

Z

As the power steering system is not switched on, extra effort is required to steer
the truck.

D 1

0409.GB

D Battery - Servicing, Recharging,

Replacement

1 Safety Regulations Governing the Handling of Lead-Acid Batteries

Park the truck securely before carrying out any work on the batteries (see Chapter E).

Maintenance personnel: Recharging, servicing and replacing of batteries must only
be performed by qualified personnel. This operator manual and the manufacturer’s
instructions concerning batteries and charging stations must be observed when
carrying out the work.

Fire protection: Smoking and open flames are not permitted when handling
batteries. Wherever a truck is parked for charging there shall be no inflammable
material or consumables capable of creating sparks within a 2-meter area of
the truck. The room must be ventilated. Fire protection equipment must be on hand.

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.

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.

M

Before closing the battery panel make sure that the battery lead cannot be damaged.

F

Batteries contain dissolved acid which is toxic and caustic. For this reason protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water - where the skin or eyes are affected
call a doctor immediately. Neutralise any spilled battery acid immediately.

M

Only batteries with a sealed battery container may be used.

F

The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.

D 1

0409.GB

D Battery - Servicing, Recharging,

Replacement

1 Safety Regulations Governing the Handling of Lead-Acid Batteries

Park the truck securely before carrying out any work on the batteries (see Chapter E).

Maintenance personnel: Recharging, servicing and replacing of batteries must only
be performed by qualified personnel. This operator manual and the manufacturer’s
instructions concerning batteries and charging stations must be observed when
carrying out the work.

Fire protection: Smoking and open flames are not permitted when handling
batteries. Wherever a truck is parked for charging there shall be no inflammable
material or consumables capable of creating sparks within a 2-meter area of
the truck. The room must be ventilated. Fire protection equipment must be on hand.

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.

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.

M

Before closing the battery panel make sure that the battery lead cannot be damaged.

F

Batteries contain dissolved acid which is toxic and caustic. For this reason protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
Nevertheless, should clothing, skin or eyes come in contact with acid the affected
parts should be rinsed with plenty of clean water - where the skin or eyes are affected
call a doctor immediately. Neutralise any spilled battery acid immediately.

M

Only batteries with a sealed battery container may be used.

F

The weight and dimensions of the battery have considerable affect on the operational
safety of the truck. Battery equipment may only be replaced with the agreement of the
manufacturer.

D 2

0409.GB

2Battery types

The truck will be equipped with different battery types, depending on the application.
The following table shows which combinations can be included as standard with
reference to capacity:

The battery weights are indicated on the battery data plate.

F

When replacing/installing the battery make sure the battery is securely located in the
battery compartment of the truck.

F

The weight and size of the battery have a considerable affect on the operational
safety of the truck. The size and weight of the batteries must therefore comply with
the following table and diagram. The use of different batteries on the truck requires
the manufacturer’s authorisation.

EFG 216kn 48 V - 5PzS - 600 Ah battery

48 volt drive battery

similar to

DIN 43535

Truck

Dimension inch (mm)

Rated weight

(-5/+8%) in kg

L max. W max.

H1

+/- 2 mm

H2

+/- 2 mm

EFG 216kn 830 630 612 627 856 500 - 630 Ah

D 2

0409.GB

2Battery types

The truck will be equipped with different battery types, depending on the application.
The following table shows which combinations can be included as standard with
reference to capacity:

The battery weights are indicated on the battery data plate.

F

When replacing/installing the battery make sure the battery is securely located in the
battery compartment of the truck.

F

The weight and size of the battery have a considerable affect on the operational
safety of the truck. The size and weight of the batteries must therefore comply with
the following table and diagram. The use of different batteries on the truck requires
the manufacturer’s authorisation.

EFG 216kn 48 V - 5PzS - 600 Ah battery

48 volt drive battery

similar to

DIN 43535

Truck

Dimension inch (mm)

Rated weight

(-5/+8%) in kg

L max. W max.

H1

+/- 2 mm

H2

+/- 2 mm

EFG 216kn 830 630 612 627 856 500 - 630 Ah

D 3

0409.GB

3 Exposing the battery

F

Park the truck securely (see chapter E).

– Release the steering column lock (1),

push the steering column forward and

secure it in this position.

F

Pay extra attention when unlocking and
locking the pilot valve cover.

– Press the lever (4) to unlock the pilot

valve cover (2) and move it forward.
– Carefully lift back the battery panel (3)

with the driver’s seat.

– Remove the battery connector (5).
– Where necessary remove the

insulating mat from the battery.

F

The battery plug and socket may only
withdrawn or connected when the main
switch and the charging equipment are
switched off.

1

3

4

2

5

D 3

0409.GB

3 Exposing the battery

F

Park the truck securely (see chapter E).

– Release the steering column lock (1),

push the steering column forward and

secure it in this position.

F

Pay extra attention when unlocking and
locking the pilot valve cover.

– Press the lever (4) to unlock the pilot

valve cover (2) and move it forward.
– Carefully lift back the battery panel (3)

with the driver’s seat.

– Remove the battery connector (5).
– Where necessary remove the

insulating mat from the battery.

F

The battery plug and socket may only
withdrawn or connected when the main
switch and the charging equipment are
switched off.

1

3

4

2

5