Jungheinrich EFG 320n User Manual [de]

EFG 216kn

Operating Instructions

51159405 04.09

04.09- G

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:

FUsed before safety instructions which must be observed to avoid danger to personnel.

MUsed before notices which must be observed to avoid material damage.

ZUsed before notices and explanations.

tUsed to indicate standard equipment.

oUsed 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.

Jungheinrich Aktiengesellschaft

Am Stadtrand 35

22047 Hamburg - GERMANY Telephone: [phone] www.jungheinrich.com

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Table of contents

ACorrect Use and Application

BTruck 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

3.1Checks 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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Appendix

JH Traction Battery Operating Instructions

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

MIf using a battery with closed EPzV and EPzV ironclad plates, this must first be discussed with the manufacturer.

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A Correct Use and Application

ZThe “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.

MFailure 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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B Truck Description

1Application

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:

Type	Max. capacity *)	Load centre of gravity
EFG 216kn	1,600 kg	500 mm

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

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2 Assemblies and Functional Description

1

8

2	7

3

6

5

4

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

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2.1Truck

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.

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3 Standard Version Specifications

3.1Dimensions

	Description	EFG 216kn
h1	Mast height retracted	2000	mm
h2	Free lift	150	mm
h3	Lift	3000	mm
h4	Mast height extended	4220	mm
h6	Overhead guard height	1960	mm
h7	Seat height	890	mm
h10	Hitch height	560	mm
L1	Length including forks	3049	mm
L	Headlength 1)	1899	mm
2
b1	Overall width	1060	mm
e	Fork width	100	mm
m1	Ground clearance with load below mast	80	mm
m2	Centre wheel base ground clearance	90	mm
Ast	Working aisle width	3348	mm
	for pallets 800 x 1200 longit.
Ast	Working aisle width	3224	mm
	for pallets 1000 x 1200 traverse
Wa	Turning radius	1545	mm
x	Load distance 1)	352	mm
y	Wheelbase	1357	mm

1) = +25 mm DZ mast

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3.2Mast versions

(all dimensions in mm)

EFG 216kn mast chart

	VDI 3596	Lift	Free lift	Height	Height
				retr.	extd.
	Description	h3	h2	h1	h4
			EFG216kn		EFG 216kn
		3000	150	2000	4220
		3300	150	2150	4520
	ZT	3600	150	2300	4820
		4000	150	2500	5220
		4500	150	2800	5720
		5000	150	3050	6220
		3300	1545	2105	4520
	ZZ	3600	1695	2255	4820
		4000	1895	2455	5220
		4500	1445	2005	5720
		4800	1545	2105	6020
	DZ	5000	1620	2180	6220
		5500	1795	2355	6720
		6000	1995	2555	7220

3.3Performance data

	Description	EFG 216kn
Q	Capacity	1600	kg
	(where C = 500 mm) *)
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)	7.3/12.3	%
	with / without load
	Max. gradeability (5 min)	20.0/35.0	%
	with / without load
	Acceleration (10 m)	3.8/3.4	s
	w / w.o. load

*) with vertical mast

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3.4Weights (all measurements in kg)

	Description	EFG 216kn
	Truck weight	2990
	(including battery)
	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

3.5Tyre type

Description		EFG 216kn
Tyre size, front	SE	18 x 7 -8, 16PR
Tyre size, rear	SE	140 / 55 - 9

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

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3.6 EN norms
Noise emission:	66 dB(A)
	in accordance with EN 12053 as harmonised with
	ISO 4871.

ZThe 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/s2

in accordance with EN 13059.

ZThe 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.

ZNo changes to electric or electronic components or their arrangement may be made without the written agreement of the manufacturer.

3.7Conditions of use

Ambient temperature

- operating at -20 qC to 40 qC

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

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4 Identification points and data plates

FWarnings 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
	0209.GB	23	Do not step onto or beneath the load, trap point
		24	Maximum body size notice

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4.1Truck data plate

25	41	40
26		39
27		38
28		37
29		36
30		35
31
32	33	34

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

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

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4.2Truck 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:

22

	4250	850	850	600
		1105	1105	850
	3600
		1250	1250	850
	2900
		500	600	700

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.

4.3Fork 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.

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4.4Attachment 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 37 38 driver when the prescribed lift limits have

been reached.

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	C	Transport and Commissioning
	1	Lifting by crane
	M	Only use lifting gear with sufficient
			1
		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.	2

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2 Securing the truck during transport

MThe 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.

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

Securing the truck with an installed mast

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

Securing the truck without a mast

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z

y

Approximate centre of gravity position

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.

MOnly 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).

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4Operating 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.

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

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

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D Battery - Servicing, Recharging,

Replacement

1Safety 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.

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

FBatteries 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.

MOnly batteries with a sealed battery container may be used.

FThe 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.

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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:

EFG 216kn

48 V - 5PzS - 600 Ah battery

The battery weights are indicated on the battery data plate.

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

FThe 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.

		48 volt drive battery					similar to
							DIN 43535
Truck		Dimension inch (mm)				Rated weight
	L max.	W max.	H1		H2	(-5/+8%) in kg
			+/- 2 mm		+/- 2 mm
EFG 216kn	830	630	612		627	856	500 - 630 Ah

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3 Exposing the battery

FPark the truck securely (see chapter E).

–Release the steering column lock (1), push the steering column forward and secure it in this position.

FPay 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.

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

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