Page 1 EFG 213-320 09.09 - Operating instructions 51151902 03.13 EFG 213 EFG 215 EFG 216k EFG 216 EFG 218k EFG 218 EFG 220 EFG 316k EFG 316 EFG 318k EFG 318 EFG 320...
Page 2 Declaration of Conformity Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union Type Option Serial no. Year of manufacture EFG 213 EFG 215 EFG 216k EFG 216 EFG 218k EFG 218 EFG 220 EFG 316k...
Page 4: Safety Instructions, Warning Indications And Other Notes
Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions.
Page 5 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 6: Table Of Contents
Contents Correct Use and Application ........... General....................Correct application................... Approved application conditions .............. Proprietor responsibilities ................ Adding attachments and/or optional equipment ........Truck Description ..............Application ....................Truck models and rated capacity............. Assemblies and Functional Description........... Travel direction definition................. Assembly Overview ................. Functional Description ................
Page 7 Battery - Servicing, Recharging, Replacement ....... Safety Regulations Governing the Handling of Lead-Acid Batteries ..General notes on handling batteries............Battery types.................... Battery dimensions .................. Exposing the battery................Charging the battery ................Charging the battery with a stationary charger........Charging the battery with an on-board charger ........Battery removal and installation ..............
Page 8 4.15 Operating additional attachments for the Multi Pilot ........ 131 4.16 Fitting additional attachments..............133 Towing trailers ..................135 Optional equipment ................. 137 CanCode keypad..................137 Assistance systems ................. 141 Steel cab....................143 Sliding windows ..................144 Automatic / mechanical folding gate............145 Panel door ....................
Page 9 Safety tests to be performed at intervals and after unusual incidents ..194 Final de-commissioning, disposal............195 Human vibration measurement ............... 195 Servicing and Inspection ................. 196 Maintenance checklist EFG 213-220............197 10.1 Operating company ................. 197 10.2 Customer service..................200 Maintenance checklist EFG 316-320............208 11.1 Operating company .................
Page 10 Appendix JH Traction Battery Operating Instructions These operating instructions apply only to Jungheinrich battery models. If using another brand, refer to the manufacturer's operating instructions.
Page 12: A Correct Use And Application
A Correct Use and Application General The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property. Correct application NOTE The maximum load and load distance are indicated on the capacity plate and must...
Page 13: Approved Application Conditions
Approved application conditions – Operation in industrial and commercial environments. – Permissible temperature range -20°C to 40°C. – Operation only on secure, level surfaces with sufficient capacity. – Do not exceed the permissible surface and spot load limits on the travel routes. –...
Page 14: Proprietor Responsibilities
Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.
Page 16: B Truck Description
B Truck Description Application The EFG 213-320 is a three- or four-wheel electric sit-down counterbalanced truck. It is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attached in front. Closed bottom pallets can also be lifted.
Page 17: Assemblies And Functional Description
Assemblies and Functional Description Travel direction definition The following determinations have been made for travel direction specification: The following conventions have been agreed for travel direction specification: Item Travel direction Links Reverse Forward Right...
Page 18: Assembly Overview
Assembly Overview Item Component Item Component t Driver's seat t Fork tines t Overhead guard t Fork carriage t Mast t Drive system t Steering wheel t Battery door t Lifting mechanism control t Steer axle t Control and display unit t Trailer coupling t Emergency Disconnect t Counterweight...
Page 19: Functional Description
Functional Description Chassis The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components. Operator position and overhead guard The overhead guard comes in a range of models and protects the operator from falling objects and other external influences.
Page 20: Technical Specifications
Emergency Stop safety feature If the system recognises a fault in the steering, an emergency stop is automatically introduced. The truck brakes to a halt, the travel direction does not change. An event message is shown in the control and display unit. The truck performs a self- test whenever it is switched on.
Page 21: Performance Data
Performance data EFG 213-220 Description 216k 218k Q Rated capacity (where 1300 1500 1600 1800 2000 C = 500 mm) C Load centre Travel speed 16/16 16/16 16/16 16/16 16/16 Lift speed 0.48/0.60 0.46/0.60 0.49/0.60 0.44/0.55 0.40/0.55 m/s with / without load Lowering speed 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 m/s...
Page 22 EFG 316-320 Description 316k 318k Q Rated capacity (where 1600 1600 1800 1800 2000 C = 500 mm)1) C Load centre Travel Speed * 17/17 17/17 17/17 17/17 17/17 Lift speed 0.49/0.60 0.49/0.60 0.44/0.55 0.44/0.55 0.40/0.55 m/s w / w.o. load Lowering speed 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 m/s w / w.o.
Page 23: Dimensions
Dimensions EFG 213-220 Description 216k 218k a/2 Safety distance Mast height 2000 2000 2000 2000 2000 retracted Free lift Lift 3000 3000 3000 3000 3000 Mast height 3560 3560 3560 3587 3587 extended Overhead guard 2040 2040 2040 2040 2040...
Page 25 EFG 213-220 Description 216k 218k Overall width 1060 1060 1060 1120 1120 Fork width Ground clearance with load below mast Centre wheel base ground clearance Ast Working aisle 3339 3339 width for 3226 3226 3446 pallet 800x1200 3446 3446 longit.
Page 27 EFG 316-320 Description 316k 318k a/2 Safety distance Mast height 2000 2000 2000 2000 2000 retracted Free lift Lift 3000 3000 3000 3000 3000 Mast height 3560 3560 3587 3587 3587 extended Overhead guard 2040 2040 2040 2040 2040 height Seat height Coupling height 410/580...
Page 29: Weights
Weights All dimensions in kg. EFG 213-220 Description 216k 218k Net weight 3000 3256 2733 2978 3382 (including battery) 3057 3207 Front axle load (without lifting 1411 1409 1326 1310 1501 load) 1496 1520 Front axle load (with lifting 4052...
Page 30: Mast Versions
Mast versions All dimensions in mm. EFG 216-220 and 316-320 VDI 3596 Lift h Free lift h Retracted Extended height h Description height h 213/215/ 218k/218/ 213/215/ 218k/218/ 216k/216/ 220/318/ 216k/216/ 220/318/ 316/316k 318k/320 316/316k 318k/320 2300 1650 2850 2885 3000 2000 3550...
Page 31: Tyre Type
When replacing tyres/rims fitted at the factory, always use original spare parts or tyres approved by the manufacturer. Otherwise the manufacturer's specification cannot be guaranteed. If you have any queries please contact the manufacturer's customer service department. EFG 213-220 Description 213/215 218k 216k/216...
Page 32: Engine Data
EFG 316-320 Description 316k 318k SE *) 18x7-8 200/50-10 200/50-10 Full rubber*) 18x7x12 18x7x12 18x7x12 Pneumatic*) 180/70-8 - LI125 Front tyres not available not available (PR 16) Tyre pressure bar 10,0 Torque (Nm) SE *) 16x6-8 16x6-8 16x6-8 Full rubber*) 15x5x11¼...
Page 33: Norms
EN norms Noise emission level – EFG 213-220: 68 dB(A) – EFG 316-320: 67 dB(A) *+/- 3 dB(A) depending on the truck's equipment in accordance with EN 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle.
Page 34: Conditions Of Use
Conditions of use Ambient temperature – operating at -20°C to 40°C Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations. Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used according to its purpose.
Page 35: Identification Points And Data Plates
Identification points and data plates Indication Points Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary. (mm) Q (kg) D (mm)
Page 36 Item Component 15 Do not drive, or operate the forward tilt, with the load in the raised position 16 Wear seat belt 17 Strap points for crane lifting 18 Tipover caution, no passengers 19 Lift limit 20 Do not step onto or beneath the load, risk of trapping with moving mast 21 Read operating instructions 22 Capacity (or reduced capacity) 23 Data plate, behind the battery door...
Page 37: Data Plate
Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Description Item Description Type Year of manufacture Serial number Load centre (mm) Rated capacity (kg) Output Battery voltage (V) Min./max.
Page 38: Truck Capacity Plate
Truck capacity plate CAUTION! Accident risk from fork replacement If you replace the forks with ones that differ from the originals, the capacity will change. When replacing the forks you must attach an additional capacity plate to the truck. Trucks supplied without forks are given a capacity plate for standard forks (length: 1150 mm).
Page 39: Attachment Capacity Plate
Attachment capacity plate The attachment capacity plate is next to the truck's capacity plate and gives the truck’s capacity Q (in kg) in conjunction with the respective attachment. The serial number for the attachment indicated on the capacity plate must match the data plate of the attachment.
Page 40: C Transport And Commissioning
C Transport and Commissioning Transport Transport can be carried out in two different ways, depending on the height of the mast and the local conditions. – Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all mechanical connections and hydraulic lines between the basic truck and the mast separated.
Page 41: Lifting The Truck By Crane
Lifting the truck by crane WARNING! All persons involved in loading by crane must be trained Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck. Loading must only be performed by specialist personnel trained for this purpose.
Page 42 Lifting the truck by crane Requirements – Park the truck securely, see "Parking the truck securely" on page 105. Procedure • Secure the crane slings to the attachment points (44) and (45. • Raise and load the truck. • Lower and deposit the truck carefully (see "Parking the truck securely"...
Page 43: Loading With Another Industrial Truck
Loading with another industrial truck WARNING! The truck can be damaged The truck to be loaded can be damaged when loading with another industrial truck. Only trained specialist personnel should load the truck. Use only trucks with sufficient capacity for loading. Only for loading and unloading.
Page 44: Securing The Truck During Transport
Securing the truck during transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. Loading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
Page 45 Securing the industrial truck for transport Requirements – Position the industrial truck securely on a lorry or trailer, see "Parking the truck securely" on page 105. Tools and Material Required – 2 fastening belts with a tensioner – Retaining wedges. Procedure •...
Page 46: Using The Truck For The First Time
Using the Truck for the First Time Safety Instructions for Assembly and Commissioning WARNING! Incorrect assembly can result in accidents The assembly of the truck at the application site, commissioning and operator training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.
Page 48: D Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement Safety Regulations Governing the Handling of Lead-Acid Batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. This operator manual and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. Fire Protection Do not smoke and avoid naked flames when handling batteries.
Page 50: General Notes On Handling Batteries
General notes on handling batteries WARNING! Batteries can be hazardous Batteries contain an acid solution which is poisonous and corrosive. Avoid contact with battery acid at all times. Dispose of used battery acid in accordance with regulations. Always wear protective clothing and goggles when working with batteries. Do not let battery acid come into contact with skin, clothing or eyes.
Page 51: Battery Types
The truck will be equipped with different battery models, depending on the application. The following table shows which combinations are included as standard: Truck model Description Capacity EFG 213 48V - 4PzS 460 Ah EFG 215 48V - 4PzS 460 Ah...
Page 52: Battery Dimensions
Battery dimensions Battery 48 V Dimension (mm) Rated weight Truck model L max. W max. H1 +/- H2 +/- (-5/+8%)in kg EFG 213/215 EFG 216k/ 218k/ 316k/318k EFG 216/ 218/220/ 1025 316/318/320...
Page 53: Exposing The Battery
Exposing the battery Requirements – Park the truck securely, see "Parking the truck securely" on page 105. – Load handler lowered. – Key switch set to OFF. – Key removed. – Set the Emergency Disconnect OFF. Procedure • Open the battery door (49) as far as the stop. •...
Page 54: Charging The Battery
Charging the battery WARNING! The gases produced during charging can cause explosions The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. Switch the charging station and truck off first before connecting/disconnecting the charging cable of the battery charging station to/from the battery connector.
Page 55: Charging The Battery With An On-Board Charger
The on-board charger consisting of a battery charger and battery controller must not be opened. If faulty, contact the manufacturer’s customer service department. The charger must only be used for batteries supplied by Jungheinrich or other approved batteries provided it has been adapted by the manufacturer's customer service department.
Page 56 When charging, the battery door must be exposed by at least 200 mm to provide sufficient ventilation. Charge the battery Requirements – Park the truck securely, see "Parking the truck securely" on page 105. – Battery exposed. – Charger switched off. –...
Page 57 Battery charger LED displays Green LED Meaning Flashing Charging Charging complete Red LED Meaning Flashing Error Battery controller LED displays White LED Meaning Flashing Radio network activated Blue LED Meaning Electrolyte level too low (measured after each charge) Yellow LED Meaning Flashing rolling Charging...
Page 58 Float charge: The compensation charge starts automatically when charging is complete. Partial charging: The charger is designed to automatically adapt to partially charged batteries. This keeps battery wear to a minimum. If a charging operation has to be interrupted, press the button (54). Only remove the mains connector when the green LED goes out.
Page 59: Battery Removal And Installation
Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. Note the "Safety regulations for handling acid batteries" section in this chapter. Wear safety shoes when removing and installing the battery.
Page 60: Battery Holder Assembly
Battery holder assembly CAUTION! The battery holder can only be fitted to Jungheinrich AG pallet trucks (EJE) or hand pallet trucks with notice signs. Requirements – EJE or hand pallet truck available with holes in accordance with assembly instructions, see "Assembly instructions" on page 60.
Page 61 5.1.1 Assembly instructions Ø Procedure • Drill 4 holes with a 16 mm diameter into the EJE or hand pallet truck according to the drill patterns. • Make sure there is sufficient distance between the connecting rod and the bottom of the forks.
Page 62: Removal And Installation Using An Eje Pallet Truck With Snapfit Battery Holder (O)
Removal and installation using an EJE pallet truck with Snapfit battery holder (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. When replacing the battery do not reach between the battery and the chassis. Wear safety shoes. Removing the battery Requirements –...
Page 63 • • Engage the safety catch (55) on the battery trolley. • Make sure the safety catch (55) is firmly engaged in the battery trolley. Do not raise the fork tines. • Undo the battery lock (63). • • Remove the the battery with the EJE pallet truck at crawl speed as far as the stop (64).
Page 64 Battery installation Procedure • • Drive the EJE pallet truck and battery to the truck. • Deposit the battery replacement trolley with the rollers (65) on the rails of the truck base. • Lower the forks of the EJE pallet truck until the battery is horizontal.
Page 65: Removal And Installation Using A Hand Pallet Truck With Snapfit Battery Holder (O)
Removal and installation using a hand pallet truck with Snapfit battery holder (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. When replacing the battery do not reach between the battery and the chassis. Wear safety shoes. Removing the battery Requirements –...
Page 66 • • Open the battery lock (63). • Raise the hand pallet truck (approx. 20 mm) until the battery can be freely pulled out of the battery compartment. NOTE Risk of material damage Removing the battery can cause material damage to the truck chassis. Raise the forks and avoid striking the top or bottom parts of the chassis when removing the battery.
Page 67 Battery installation Procedure • • Move the hand pallet truck and battery to the truck. • Raise and move the hand pallet truck into the battery compartment until the forks contact the truck chassis. • Deposit the battery trolley with the rollers (65) on the base of the truck.
Page 68: Removal And Installation Using A Multi-Adapter (O)
Removal and installation using a multi-adapter (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. When replacing the battery do not reach between the battery and the chassis. Wear safety shoes. Battery removal and installation Requirements – Park the truck securely, see "Parking the truck securely" on page 105. –...
Page 69 Battery assembly is the reverse order. Release the retaining hook (72) using your foot. Insert the rollers of the battery replacement trolley into the battery compartment guides and push the battery into the battery compartment. WARNING! After inserting the battery close the battery lock and then lower the pallet truck.
Page 70: Removal And Installation Using A Worktable For Crane Loading (O)
Removal and installation using a worktable for crane loading (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. When replacing the battery do not reach between the battery and the chassis. Wear safety shoes. Battery removal and installation Requirements –...
Page 71 • • Pull the battery (71) out by its handle. • The battery trolley must engage securely in the safety catch (72). • Strap the crane lifting harness to the battery container. The hooks must be fitted in such a way that when the crane lifting harness is slackened, they do not fall onto the battery cells.
Page 72: Removal And Installation Using A Fork Shoe (O)
Removal and installation using a fork shoe (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. When replacing the battery do not reach between the battery and the chassis. Wear safety shoes. Battery removal and installation Requirements – Truck parked securely, see "Parking the truck securely" on page 105. –...
Page 73 • • Pull out the battery as far as the stop (76) on the truck chassis. • Raise the fork carriage. • Tilt the mast back fully and bring the battery to the charging station to be charged. • • Place the battery carefully on the charging station (60).
Page 74: Removal And Installation Using A Roller Conveyor (O)
Removal and installation using a roller conveyor (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. When replacing the battery do not reach between the battery and the chassis. Wear safety shoes. Battery removal and installation Requirements – Park the truck securely, see "Parking the truck securely" on page 105. –...
Page 75: Hook-On Battery Door Removal And Installation (O)
Hook-on battery door removal and installation (o) CAUTION! Trapping hazard Trapping hazard when removing and installing the battery door. When removing and installing the battery door do not put your hands between the door and the chassis. Wear safety shoes. Only for trucks with a roller conveyor.
Page 76: E Operation
E Operation Safety Regulations for the Operation of the Forklift Truck Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Page 77 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.
Page 78: Displays And Controls
Displays and Controls...
Page 79 Item Control / Function display Steering wheel Steering the industrial truck. Solo-Pilot Controls the following functions: Multi-Pilot – Fwd/rev. travel direction – Load handler lift / lower – Mast forward / reverse tilt – "Horn" button – Sideshifter left / right (o) –...
Page 81 Item Control / Function display t Selects travel direction / neutral position. Travel direction switch (not available with dual pedal control) t Lever for operating the hydraulic functions. Lever t Activates an audible warning. "Horn" button o Activates the additional hydraulic functions Additional hydraulic function release button or hydraulics that require...
Page 82: Control Panel With Display Unit
Control panel with display unit The control panel display unit shows the operating data, the battery charge, the service hours and error details and information. Pictograms in the left top section of the dashboard control panel act as warning indicators. 95 96 53 97 98 99 100 101 102 100 %...
Page 83 Item Control / Function display t Seat switch not closed Seat switch warning indicator – Truck operational, but driver's seat not occupied Time monitoring expired – Restart the truck o – Truck operational, seat belt Seat belt lock warning indicator (flashing lock not closed symbol) t Service interval exceeded (1000...
Page 84 Item Control / Function display t Secure parking of truck. Yellow LEDs under the parking brake button The parking brake is activated when the truck is switched on or Parking brake indicator when the parking brake button (108) is pressed. Yellow LEDs light up simultaneously under the parking brake button (108) and the parking brake...
Page 85 *Five operating programs with different performance levels are available to adapt the travel and operating functions to the application at hand. Starting from operating program 1 (limited acceleration and speed together with sensitive application of the operating functions), the performance levels increase to program 5 (maximum performance for high throughput levels).
Page 86: Armrest Control Panel Switch (O)
Armrest control panel switch (o) Function Work lights Front windscreen wipers – Press 1x > intermittent, – 2x > fast, – 3x > off – Hold down on the button > Switch on the windscreen washing system Rear windscreen wiper –...
Page 87: Side Compartment Control Panel Switch (O)
Side compartment control panel switch (o) Function Rear window heating Beacon Truck lighting Parking light Warning indicator Lift cutout override...
Page 88: Display
Display 111 112 100 % km/h inch lbs m kg eff code Item Function – Remaining time in the format hours : minutes – Remaining charge time (o) Time display (hours : minutes) Operating program display – Displays the travel program in use Error display: –...
Page 89 2.4.1 Battery discharge indicator NOTE Full discharge can damage the battery The standard setting for the battery discharge indicator is based on standard batteries. When using maintenance-free batteries (gel batteries), the display must be reset. This adjustment should only be made by the manufacturer’s customer service department.
Page 90 2.4.3 Residual time display 100 % km/h inch lbs m kg eff code Setting the residual time display Procedure • Press the toggle switch (102) for 3 seconds. This toggles the display between the time and the residual time or the remaining charge time for an on-board charger (o).
Page 91: Preparing The Truck For Operation
Preparing the Truck for Operation Checks and operations to be performed before starting daily operation WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
Page 92 Checks before daily operation Procedure • Visually inspect the entire truck (in particular wheels, wheel bolts and load handler) for damage. • Check the fork stop (118) and fork retainer (119). • Visually inspect the hydraulic system in the visible area for damage and leaks.
Page 93 • • On trucks with lateral battery removal, check the left and right stops (64) in the battery compartment for damage. • Check the fluid level of the window washer system, see "Preparing the truck for operation" on page 103.
Page 94: Entry And Exit
Entry and exit Procedure • Open the cab door (o). • To enter and exit the cab, hold onto the handle (120). An additional step is provided for the driver position extension (o). Trucks with reduced headroom (o) WARNING! An unsuitable workplace can damage your health Failure to observe the recommended body size can cause stress and endanger...
Page 95: Setting Up The Operator Position
Setting up the operator position WARNING! Accidents can occur if the driver's seat, steering column and armrest are not engaged The driver's seat, steering column and armrest can accidentally adjust during travel and therefore cannot be operated safely. Do not adjust the driver’s seat, steering column or armrest while travelling. Procedure •...
Page 96 Adjusting the driver's weight NOTE To achieve optimal seat cushioning the driver’s seat must be set to the driver’s weight. Set the driver's weight when the seat is occupied. Procedure • Fold out the weight adjustment lever (121) as far as it will go in the arrow 125 126 direction •...
Page 97 Adjusting the seat position CAUTION! An unsecured driver's seat can cause injury An unsecured driver's seat can slide out of its guide during travel, resulting in accidents. The driver's seat must be locked in position. Do not adjust the driver’s seat while travelling.
Page 98 3.4.2 Adjusting the steering column Adjusting the steering column Procedure • Release the steering column stop (127). • Set the steering column to the required position (height and angle). • Fix the steering column stop (127) in position. The steering column is now positioned. 3.4.3 Adjusting the arm rest Adjusting the arm rest Procedure...
Page 99: Seat Belt
Seat Belt WARNING! Travelling without a seat belt increases the risk of injury. Accidents or personal injury can result if the seat belt is not worn or is modified. Always put the seat belt on before starting the industrial truck. Do not modify the seat belt.
Page 100 DANGER! A faulty seat belt can cause injury Using a faulty seat belt can result in injury. Only operate the truck with the seat belt intact. A faulty seat belt should be replaced immediately. The truck must remain decommissioned until a functional seat belt has been fitted. Checking the seat belt Procedure •...
Page 101: Industrial Truck Operation
Industrial Truck Operation Safety regulations for truck operation WARNING! Electromagnetic influence can result in accidents Strong magnets can cause electronic components such as Hall sensors to become damaged, resulting in accidents. Do not use magnets in the operating area of the truck. Exceptions to this rule are commercial, weak clamping magnets for attaching notices.
Page 102 Hazardous situations If the truck is about to tip over, do not loosen the seat belt. The operator must not jump off the truck. The operator must lean his upper body over the steering wheel and hold on with both hands. Tilt your body in the opposite direction of fall. Travel visibility The operator must look in the direction of travel and must always have a clear view of the route ahead.
Page 103 Type of loads to be carried The operator must make sure that the load is in a satisfactory condition. Loads must always be positioned safely and carefully. Use suitable precautions to prevent parts of the load from tipping or falling down. Prevent liquid loads from sloshing out. Inflammable liquids (e.g.
Page 104: Preparing The Truck For Operation
Preparing the truck for operation Switching on the truck Requirements – For checks and operations to be performed before starting daily operation, see "Checks and operations to be performed before starting daily operation" on page 90. Procedure • Unlock the Emergency Disconnect switch (83) to do this •...
Page 105: Setting The Time
Setting the time 102 101 100 % km/h inch lbs m kg eff code 109 110 Setting the time Procedure • Press the toggle switch (102) for 3 seconds. This toggles the display between the time and the residual time or the remaining charge time for an on-board charger (o).
Page 106: Parking The Truck Securely
Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load / load handler is dangerous and is strictly prohibited. Always park the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 107: Emergency Disconnect
Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. Do not use the Emergency Disconnect switch as a service brake.
Page 108: Travel
Travel WARNING! Improper travel can result in accidents Do not get up from the driver’s seat during travel. Do not drive the truck unless your are wearing a seat belt and the panels and doors are properly locked. Do not lean out of the truck while travelling. Make sure that the travel area is clear.
Page 109 Dual pedal (optional equipment) Requirements – System prepared operation, "Preparing the truck for operation" on page 103 Procedure For trucks with a dual pedal the travel direction is selected via the accelerator pedals (87;88). When the driver leaves the truck, the truck is automatically set to “Neutral”.
Page 110: Steering
Steering Requirements – Truck ready for operation, see "Preparing the truck for operation" on page 103 Procedure • To negotiate a right-hand bend: • Turn the steering wheel clockwise to match the desired steering radius. • To negotiate a left-hand bend: •...
Page 111: Brakes
Brakes The truck can brake in three different ways: – Service brake – Coasting brake and for secure parking: – Parking brake WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions. The operator must take into account the travel route conditions when braking. Brake with care to prevent the load from slipping.
Page 112 4.8.2 Coasting brake Braking with the coasting brake Procedure • Take your foot off the accelerator pedal (86). The truck decelerates. WARNING! Immediately after the battery has been charged the brake power of the coasting brake may reduce of their own accord after long periods of application, e.g. ramp operation. The operator must instruct people to leave the hazardous area.
Page 113 The parking brake has two functions: – Truck prevented from rolling away (parking brake automatically activated) When the truck stops the parking brake is automatically activated after a set time (1 - 60 sec), prevents the truck from rolling away and the parking brake indicator (95) lights up.
Page 114 Item Control / Function display Parking brake indicator t Comfort feature, displayed when the parking brake indicator (95) lights up. Truck prevented from rolling away but not parked securely. Parking brake is automatically activated after a set time (1 - 60 sec) when the truck stops.
Page 115: Adjusting The Forks
Adjusting the forks WARNING! Unsecured and incorrectly adjusted forks can cause accidents Before adjusting the forks make sure the retaining bolts (119) are fitted. Adjust the forks so that both forks are equidistant from the outside edge of the fork carriage. Engage the locking pin in a groove to prevent forks...
Page 116: Replacing The Forks
4.10 Replacing the forks WARNING! Unsecured forks can cause injury You can injure your legs when replacing the forks. Never pull the forks towards your body. Always push the forks away from your body. Secure heavy forks with lifting slings and a crane before pushing them down from the fork carriage.
Page 117: Lifting, Transporting And Depositing Loads
4.11 Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents. Before lifting a load the operator must make sure that it has been correctly palletised and does not exceed the truck’s capacity. Instruct other people to move out of the hazardous area of the truck. Stop working with the truck if people do not leave the hazardous area.
Page 118 NOTE Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times. Transporting loads Requirements – Load raised correctly. – Load handler lowered for transport (approx. 150 - 200 mm above the ground). –...
Page 119: Operating The Lift Mechanism And Integrated Attachments
4.12 Operating the lift mechanism and integrated attachments WARNING! Operating the lifting device and integrated attachments can be hazardous Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc.
Page 120 4.12.1 Operating the lift mechanism with the SOLO PILOT Lifting and lowering Requirements – To prepare the truck for operation, see "Preparing the truck for operation" on page 103 Procedure • Pull the Solo-Pilot lever (133) in direction H to raise the load.
Page 121 Positioning the integrated sideshift (option) Requirements – Truck prepared for operation, see "Preparing the truck for operation" on page 103. Procedure • Pull the SOLO-PILOT lever (135) in direction R to move the load handler to the right (from the driver’s viewpoint). •...
Page 122 Positioning the forks with an integrated fork positioner (option) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation, see "Preparing the truck for operation" on page 103. Procedure • Press the toggle switch (136) and at the same time pull the SOLO-PILOT (133) in direction Z: the forks will move towards each other.
Page 123 4.12.2 Operating the lift mechanism with the Multi Pilot Lifting and lowering Requirements – To prepare the truck for operation, see "Preparing the truck for operation" on page 103 Procedure • Pull the Multi-Pilot (80) in direction H to raise the load.
Page 124 Positioning the integrated sideshift (option) Requirements – Truck prepared for operation, see "Preparing the truck for operation" on page 103. Procedure • Press the button (137) to the left to move the load handler to the left (from the driver's viewpoint).
Page 125 Synchronising the alignment of the fork tines with an integrated fork positioner (optional equipment) Requirements – Truck prepared for operation, see "Preparing the truck for operation" on page 103. – The fork tines are no longer aligned. Procedure • Press the (138) button whiel at the same time pressing the (93) button, the forks will spread apart.
Page 126: Safety Instructions For Operating Additional Attachments
4.13 Safety instructions for operating additional attachments Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to operate attachments. The auxiliary hydraulics are indicated with ZH1, ZH2 and ZH3. Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement couplings on the fork carriage.
Page 127 Safety instructions for sideshifter and fork positioner attachments WARNING! Restricted visibility and reduced tilt resistance can cause accidents When using sideshifters and fork positioners, the change in centre of gravity can result in reduced lateral tilt resistance and accidents. Note that this affects visibility as well.
Page 128 Safety instructions for telescopic attachments WARNING! Accident risk from increased tipover hazard and reduced residual capacity There is a greater risk of tipover with extended telescopic attachments. Do not exceed the maximum loads specified on the capacity plate. Only use the telescopic function for stacking and retrieving. Retract the telescopic attachment fully during transport.
Page 129 Fork extension safety instructions WARNING! Unsecured and oversized fork extensions can cause accidents. For fork extensions with an open cross sectional area, carry only loads that are resting along the entire length of the fork extension. Use only fork extensions with the same fork cross section and minimum fork length of the truck and which comply with the details on the fork extension data plate.
Page 130: Operating Additional Attachments For The Solo-Pilot
4.14 Operating additional attachments for the SOLO-PILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. Mark the controls with symbols that indicate their function. Specify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
Page 131 4.14.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (133, 135, 136) is assigned the function of the attachment. Unused levers have no function. For connections see "Fitting additional attachments" on page 133. Procedure •...
Page 132: Operating Additional Attachments For The Multi Pilot
4.15 Operating additional attachments for the Multi Pilot WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. Mark the controls with symbols that indicate their function. Specify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
Page 133 4.15.2 Multi Pilot with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (137,138,93) is assigned the function of the attachment. Unused levers have no function. connections "Fitting additional attachments" on page 133. Procedure •...
Page 134: Fitting Additional Attachments
4.16 Fitting additional attachments WARNING! Incorrectly connected attachments can cause accidents. Attachments with incorrectly connected hydraulic attachments can result in accidents. Attachments must only be assembled and commissioned by trained, specialist personnel. Observe the manufacturer’s operating instructions. Before starting, check the fasteners are positioned correctly and securely and make sure they are complete.
Page 135 Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance with environmental regulations. If hydraulic oil comes into contact with the skin, wash it off immediately with soap and water. If it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor.
Page 136: Towing Trailers
Towing trailers DANGER! Inappropriate speeds and excessive trailer loads can be dangerous If you do not adapt your speed and / or use an excessive trailer load, the truck can pull apart when cornering and braking. The truck should only be used occasionally to tow trailers. The overall weight of the trailer should not exceed the capacity indicated on the capacity plate, see "Identification points and data plates"...
Page 137 Attaching the trailer CAUTION! Trapping hazard There is a trapping risk when you attach a trailer. Follow the instructions of the coupling manufacturer if using special trailer couplings. Secure the trailer to prevent it from rolling away before coupling it. Do not get caught between the truck and the tiller when coupling the trailer.
Page 138: Optional Equipment
Optional equipment CanCode keypad CanCode keypad The keypad consists of 10 digit keys, a Set key and a o key. The O key indicates the follow operating statuses via a red / green LED: – Code lock function (starting up the truck). –...
Page 139 Switching the truck off Procedure • Press the O key. Truck is switched off. The truck can switch off automatically after a set time. To do this the relevant code lock parameters must be entered, see "Parameter Settings" on page 138. This additional safety mechanism in no way discharges the owner from his obligation to prevent the truck from being used by unauthorized parties before leaving the truck.
Page 140 Parameter list Function Setting range Standard Procedure setting Change master code: 0000 - 9999 7295 – (LED 141 flashes) The length (4-6 digits) of Enter current the master code also 00000 - 99999 code determines the length of – confirm the operator code (4-6 000000 - 999999 (Set 101)
Page 141 Function Setting range Standard Procedure setting Delete code log (deletes 3265 – 3265 = delete all codes) – other entries = do not delete Automatic timeout 00-31 – 00 = No timeout – 01 - 30 = Timeout in minutes –...
Page 142: Assistance Systems
Assistance systems The Access, Drive and Lift Control systems help the driver operate the truck with regard to safety regulations, see "Safety regulations for truck operation" on page 100 of the present operating instructions. Travel conduct The operator must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots.
Page 143 6.2.2 Drive Control This option restricts the travel speed of the truck irrespective of the steer angle. From a factory-set lift height the maximum travel speed is reduced to walking pace (approx. 3 km/h) and the slow travel indicator is activated. When the forks fall below this height, the truck accelerates at reduced levels to the speed prescribed by the accelerator pedal to prevent sudden acceleration when changing from slow travel to normal travel.
Page 144: Steel Cab
Steel cab For trucks fitted with a steel cabin, both doors can be closed. CAUTION! An open door can cause accidents (146) Do not travel with an open door (146). When opening the door make sure there is nobody in the door’s swing range. Always close the door tightly and make sure it is locked.
Page 145: Sliding Windows
Sliding windows CAUTION! An unlocked sliding window can cause accidents The sliding windows must be locked at all times. Opening and closing the windows Procedure • Push the lock (149) up. • Move the window forward or back. • Insert the lock in the stop (148).
Page 146: Automatic / Mechanical Folding Gate
Automatic / mechanical folding gate CAUTION! A faulty folding gate can cause accidents Never use the truck with a non- functional folding gate. Have the folding gate checked by authorised specialist personnel after an accident. Do not modify the folding gate. Closing the folding gate does not release the driver from his responsibility to wear a seat belt, see "Seat Belt"...
Page 147: Panel Door
Panel door CAUTION! An open door can cause accidents (146) Do not travel with an open door (146). When opening the door make sure there is nobody in the door’s swing range. Always close the door tightly and make sure it is locked. Closing the door does not release the driver from his responsibility to wear a seat belt, see "Seat Belt"...
Page 148: Adjusting The Driver's Seat
Adjusting the driver’s seat Adjusting the backrest extension CAUTION! Accident risk when adjusting the backrest during travel Do not adjust the backrest extension while travelling. Procedure • The backrest extension height can be adjusted by changing the detent. • Pull the backrest up and lock it in place to extend the backrest. •...
Page 149: Heating
• Turn the temperature controller (154) to the left to decrease the cab temperature. Regular servicing is required to ensure the heating can work at a consistently high level, see "Maintenance checklist EFG 213-220" on page 197 or see "Maintenance checklist EFG 316-320" on page 208.
Page 150: Removable Load Backrest
6.10 Removable load backrest CAUTION! Trapping hazard and heavy load backrest weight Wear safety gloves and safety shoes when carrying out this operation. Two people are required to remove and attach the load backrest. Load backrest disassembly Procedure • Loosen the screws (158). •...
Page 151: Fire Extinguisher
6.12 Fire extinguisher Procedure • Open the fasteners (159) • Pull the fire extinguish out of its bracket To operate, refer to the illustrations on the fire extinguisher 6.13 Tilt angle display NOTE The current tilt angle is shown in an additional display that is attached on the right of the dashboard.
Page 152: Rockinger Coupling With Hand Lever Or Remote Control
6.14 Rockinger coupling with hand lever or remote control Refer to the instructions for towing trailers, see "Towing trailers" on page 135. CAUTION! Incorrectly coupled trailers can cause accidents Make sure the coupling is engaged securely before starting the truck. The contro pin (163) must be flush with the control sleeve (164).
Page 153: Camera System
6.15 Camera system CAUTION! Accident risk from hidden work areas The camera system acts as an aid to assist safe operation. Practice travelling and working with the camera system. Align the camera so that the hidden work area can be seen. When using the camera to reverse, the monitor automatically switches on when you engage reverse gear.
Page 154: Control Layout "N
6.16 Control layout “N” WARNING! Persons standing under or on a raised load handler are at risk of accidents Do not allow anyone to stand under or on a raised load. Do not stand on the load handler. Do not lift any persons on the load handler. Instruct other people to move out of the hazardous area of the truck.
Page 155: Troubleshooting
Troubleshooting Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
Page 156 Fault Possible Cause Action Truck does not start – Battery connector not – Check battery connector plugged in. and plug in if necessary. – Emergency Disconnect – Unlock the Emergency switch pressed. Disconnect button. – Key switch set to O. –...
Page 157: Operating The Truck Without Its Own Drive System
Operating the truck without its own drive system 7.2.1 Towing the truck WARNING! Accident risk Other people can be injured if the truck is towed incorrectly. Only use vehicles to tow the truck which have sufficient tow and brake forces for the trailer load without its own braking system.
Page 158 7.2.2 Release the parking brake. WARNING! Uncontrolled truck movement When the brakes are released the truck must be parked securely on a level surface, since the brakes are no longer effective. Do not release the parking brake on slopes or inclines. Apply the parking brake again when you reach your destination.
Page 159 7.2.3 Steering the truck when the electric/hydraulic steering has failed The truck cannot be steered if the steering hydraulic system or the truck electronics are damaged. Steering the truck when the electric/hydraulic steering has failed Requirements – Turn the Emergency Disconnect switch and key switch off. –...
Page 160: Emergency Lowering
Emergency lowering The mast can be lowered manually if a fault occurs in the hydraulic system. WARNING! Lowering the mast can result in injuries Instruct other people to move out of the hazardous area of the truck during emergency lowering. Never stand underneath a raised load handler.
Page 161 Mast emergency lowering Requirements – Load handler is not in the rack. – Turn the Emergency Disconnect switch and key switch off. – Disconnect the battery. Tools and Material Required – Auxiliary tool (172) removed from the document compartment in the backrest of the truck.
Page 162: F Industrial Truck Maintenance
F Industrial Truck Maintenance Operational Safety and Environmental Protection The checks and servicing operations contained in this chapter must be performed in accordance with the maintenance checklist service intervals. WARNING! Risk of accidents and component damage Any modification to the truck, in particular the safety mechanisms, is prohibited. Exception: Owners should only make changes or have changes made to powered industrial trucks if the truck manufacturer is no longer operating in the field and there is no successor to the business;...
Page 163: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a service department specially trained for these tasks. A maintenance contract with the manufacturer will ensure trouble-free operation. Truck maintenance and repair work must only be carried out by specially trained personnel.
Page 164: Consumables And Used Parts
Consumables and used parts CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task. Note the safety regulations when handling these materials.
Page 165: Lift Chains
Lift Chains WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated. Lift chains should only be cleaned with paraffin derivatives e.g. petroleum or diesel fuels.
Page 166: Hydraulic System
Hydraulic system WARNING! Brittle hydraulic hose lines can cause accidents The hoses must be replaced every six years. The manufacturer's customer service department is specially trained to carry out these operations. Observe the date of manufacturer on the hydraulic hoses. WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems.
Page 167: Lubricants And Lubrication Schedule
Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. Keep consumables away from hot components and naked flames. Always keep consumables in prescribed containers.
Page 168 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. Dispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. Do not spill oil.
Page 169: Lubrication Schedule
Lubrication Schedule g Contact surfaces c Hydraulic oil drain plug s Grease nipple b Transmission oil filler neck a Transmission oil drain plug Hydraulic oil filler neck...
Page 170: Consumables
Consumables Package Code Order no. Capacity Description Used for quantity Jungheinrich 51 132 827* hydraulic oil 50 426 072 HLPD 32 1) 440AH= 18L Hydraulic 50 429 647 550AH= 20.5L HLPD 22 2) system 660AH= 24L 50 124 051 HV 68 3)
Page 171 *The trucks are factory-equipped with a special manufacturer's hydraulic oil (the Jungheinrich hydraulic oil with a blue colouration) or the Plantosyn 46 HVI bio hydraulic oil. This special hydraulic oil can only be obtained from the manufacturer's customer service department. The use of named alternative hydraulic oils is not prohibited but may lead to a decline in functionality.
Page 172: Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: Procedure • Park the truck securely, see "Parking the truck securely" on page 105. •...
Page 173: Lifting And Jacking Up The Truck Safely
Lifting and jacking up the truck safely WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. Note the weight of the truck on the data plate. Always use a jack with a minimum capacity of 2500 kg kg.
Page 174: Opening The Rear Panel
Opening the rear panel Opening the panel Requirements – Prepare the truck for maintenance and repairs (see "Preparing the truck for maintenance and repairs" on page 171). Procedure • Undo the two quick release fasteners (176). • Pull the rear panel back and remove it. The rear panel is now open.
Page 175: Checking The Wheel Attachments
Checking the wheel attachments. WARNING! Using different tyres can cause accidents The quality of tyres affects the stability and performance of the truck. The diameter of the wheels must differ by no more than 15 mm. Always replace tyres in pairs. After replacing the tyres check the wheel nuts are secure after 10 service hours.
Page 176: Replacing Wheels
Replacing wheels WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. Note the weight of the truck on the data plate. Always use a jack with a minimum capacity of 2500 kg kg. Raise the unladen truck on a level surface.
Page 177 Fitting the wheels Procedure • Assemble the wheel, using a suitable mounting lever if necessary. • Fit the wheel attachment. • Remove the hard wooden blocks. • Lower the truck. • Torque the wheel attachment (177) crosswise with a torque wrench, for torques see "Tyre type" on page 30.
Page 178: Hydraulic System
Hydraulic system CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. Do not touch pressurised hydraulic lines. Dispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
Page 179 4.6.1 Checking the hydraulic oil level Checking the hydraulic oil level and adding hydraulic oil Requirements – Park the truck on a level surface. – Prepare the truck for maintenance and repairs (see "Preparing the truck for maintenance and repairs" on page 171). –...
Page 180: Replacing The Hydraulic Oil Filter
Replacing the hydraulic oil filter Replace oil filter Requirements – Park the truck securely, see "Parking the truck securely" on page 105 Procedure • Unscrew the hydraulic oil filter cap (179). The filter element is located on the cap. • Replace the filter insert; if the O ring is damaged it will also need to be replaced. Apply a thin layer of oil to the O ring on assembly.
Page 181: Check The Gear Oil Level
Check the gear oil level CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations. To change the oil contact the manufacturer's customer service department, who have been specially trained for this task. Note the safety regulations when handling these materials.
Page 182: Heating
The filter cassette is now replaced. Regular servicing is required to ensure the heating can work at a consistently high level, see "Maintenance checklist EFG 213-220" on page 197 or see "Maintenance checklist EFG 316-320" on page 208. 4.11 Adding window washer system fluid Procedure •...
Page 183: Checking Electrical Fuses
4.12 Checking electrical fuses WARNING! Electric currents can cause accidents Make sure the electrical system is voltage-free before starting work on it. Before starting maintenance on the electrical system: Park the truck securely (see "Parking the truck securely" on page 105). Press the Emergency Disconnect.
Page 184 4.12.1 Fuse ratings 191 192 193 Zusatzausstattungen...
Page 185 EMERGENCY DISCONNECT fuses Rating / Item Description Electric circuit type Main contactor control fuse Positive wire main fuse 425 A Electrical system fuses Rating / Item Description Electric circuit type Overall control circuit fuse 63 A 3F10 Steering threephase controller fuse 40 A Control fuse 48 V Magnetic brake control fuse...
Page 186 Options fuses Rating / Item Component Electric circuit type Window wiper control fuse 9F33 Window washer pump fuse 9F14 Rear window wiper control fuse DC/DC converter control fuse DC/DC converter control fuse Search lights control fuse 4F14 Strobe light control fuse 48 volt heater fuse F14.1 24 volt heater fuse...
Page 187: Cleaning
4.13 Cleaning 4.13.1 Cleaning the truck CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. Disconnect the battery before starting cleaning work. Carry out all necessary safety measures to prevent sparking before cleaning (e.g. by short-circuiting). CAUTION! Risk of component damage when cleaning the truck Cleaning with a pressure washer can result in malfunctions due to humidity.
Page 188 Cleaning the truck Requirements – Prepare the truck for maintenance and repairs (see "Preparing the truck for maintenance and repairs" on page 171). Tools and Material Required – Water-based solvents – Sponge or cloth Procedure • Clean the surface of the truck with water-based solvents and water. Use a sponge or cloth to clean.
Page 189 4.13.2 Cleaning the electrical system assemblies CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. Do not clean the electrical system with water. Clean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.
Page 190: Working On The Electrical System
4.14 Working on the electrical system WARNING! Electrical current can cause accidents Make sure the electrical system is voltage-free before starting work on it. The capacitors in the controller must be completely discharged. The capacitors are completely discharged after approximately 10 minutes. Before starting maintenance on the electrical system: Only suitably trained electricians may operate on the truck's electrical system.
Page 191: Restoring The Truck To Service After Maintenance And Repairs
4.15 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see "Cleaning" on page 186. • Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 168. • Clean the battery, grease the terminals and connect the battery. •...
Page 192: Decommissioning The Industrial Truck
Decommissioning the industrial truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.
Page 193: Prior To Decommissioning
Prior to decommissioning Procedure • Thoroughly clean the truck, see "Cleaning" on page 186. • Prevent the truck from rolling away accidentally. • Check the hydraulic oil level and replenish if necessary, see "Checking the hydraulic oil level" on page 178. •...
Page 194: Restoring The Truck To Service After Decommissioning
Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck, see "Cleaning" on page 186. • Lubricate the truck according to the lubrication schedule, see "Lubrication Schedule" on page 168. • Clean the battery, grease the terminals and connect the battery. •...
Page 195: Safety Tests To Be Performed At Intervals And After Unusual Incidents
Safety tests to be performed at intervals and after unusual incidents Perform a safety check in accordance with national regulations. The manufacturer recommends the truck be checked to FEM guideline 4.004. The manufacturer has a service department specially trained for these tasks. The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector.
Page 196: Final De-Commissioning, Disposal
Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed. The truck must only be disassembled by trained personnel in accordance with the procedures as specified by the manufacturer.
Page 197: Servicing And Inspection
Servicing and Inspection WARNING! Risk of accident due to neglected maintenance Failure to perform regular servicing can lead to truck failure and poses a potential hazard to personnel and equipment. Thorough and expert servicing is one of the most important requirements for the safe operation of the industrial truck.
Page 198: Maintenance Checklist Efg 213-220
Maintenance checklist EFG 213-220 10.1 Operating company 10.1.1 Standard equipment Braking W A B C Test brakes. Electrical System W A B C Test warning and safety devices in accordance with operating instructions. Test Emergency Disconnect switch. Power Supply W A B C Check battery cable connections are secure, grease terminals if necessary.
Page 199 10.1.2 Optional equipment Work lights Electrical System W A B C Test lighting. Strobe light/beacon Electrical System W A B C Test strobe light / beacon and check for damage. Heating Chassis and Superstructure W A B C Test the heating. Check heating vent filter for contamination and clean if necessary.
Page 200 Wiper/washer system Chassis and Superstructure W A B C Check wiper water container for leaks and check volume, top up if necessary. Fork adjuster Hydraulic Operations W A B C Check attachment lubrication; clean and lubricate if necessary. Optional equipment Chassis and Superstructure W A B C Check that optional equipment such as mirrors, storage...
Page 201: Customer Service
10.2 Customer service 10.2.1 Standard equipment Brakes W A B C Test brakes. Check magnetic brake air gap. Check brake mechanism, adjust and lubricate if necessary. Electrical System W A B C Test cable and motor attachments. Test warning and safety devices in accordance with operating instructions.
Page 202 Chassis and Superstructure W A B C Check chassis and screw connections for damage. Check doors and/or covers. Check labels are legible and complete. Check attachment and setting function of the driver's seat. Check condition of the driver’s seat. Check attachment of the counterweight. Check mast attachment / mounting.
Page 203 Agreed performance levels W A B C Carry out a test run with rated load, if necessary with a customer- specific load. Lubricate truck according to the lubrication schedule. Demonstration after servicing. Steering W A B C Test electric steering and its components. Check mechanical parts of steering column.
Page 204 Work lights Electrical System W A B C Test lighting. Battery refill system Power Supply W A B C Test battery refill system and check for leaks. Battery replacement system Power Supply W A B C Check safety labels are present. Check lock is present and test it.
Page 205 Electrical optional equipment Electrical System W A B C Test the electrical optional equipment and check for damage. Electrolyte recirculation Power Supply W A B C Replace air filter wadding. Check hose connections and test the pump. Overhead guard cover Chassis and Superstructure W A B C Check overhead guard cover is present, check for damage and...
Page 206 Hydraulic Operations W A B C Check attachment bearing points, guides and stops for wear and damage, grease and clean these components. Check attachment lubrication; clean and lubricate if necessary. Check hydraulic ports and tighten if necessary. Check cylinder seals. Check cylinder piston rods and bushings.
Page 207 Sideshifter Hydraulic Operations W A B C Check axial play of the front and rear rollers and adjust if necessary. Check attachment is properly secured to the truck and the supporting elements. Test attachment, check settings and check for damage. Check sliding blocks are complete.
Page 208 Boom Hydraulic Operations W A B C Check attachment is properly secured to the truck and the supporting elements. Video system System Components W A B C Check wiring is secure and check for damage. Test the camera, make sure it is secured and clean. Test the monitor, make sure it is secured and clean.
Page 209: Maintenance Checklist Efg 316-320
Hydraulic Operations W A B C Check attachment lubrication; clean and lubricate if necessary. Check hydraulic ports and tighten if necessary. Test the fork positioner and check for damage. Check cylinder seals. Check cylinder piston rods and bushings. Access module Electrical System W A B C Test access module, check for damage and make sure it is secure.
Page 210 Travel W A B C Check the wheels for wear and damage. Make sure they are tight and check the compressed air if necessary. Chassis and Superstructure W A B C Check doors and/or covers. Check labels are legible and complete. Check overhead guard and / or cab are secure and check for damage.
Page 211 Sideshifter Hydraulic Operations W A B C Check attachment lubrication; clean and lubricate if necessary. Road traffic approval (StVZO) Electrical System W A B C Test lighting. Telescopic forks Hydraulic Operations W A B C Check attachment lubrication; clean and lubricate if necessary. Weather-proof system Chassis and Superstructure W A B C...
Page 212: Customer Service
11.2 Customer service 11.2.1 Standard equipment Brakes W A B C Test brakes. Check magnetic brake air gap. Check brake mechanism, adjust and lubricate if necessary. Electrical System W A B C Test cable and motor attachments. Test warning and safety devices in accordance with operating instructions.
Page 213 Chassis and Superstructure W A B C Check chassis and screw connections for damage. Check doors and/or covers. Check labels are legible and complete. Check attachment and setting function of the driver's seat. Check condition of the driver’s seat. Check attachment of the counterweight. Check mast attachment / mounting.
Page 214 Agreed performance levels W A B C Carry out a test run with rated load, if necessary with a customer- specific load. Lubricate truck according to the lubrication schedule. Demonstration after servicing. Steering W A B C Check the hydraulic oil level of the hydraulic steering. Test the hydraulic steering for leaks.
Page 215 Work Platform Hydraulic Operations W A B C Check attachment is properly secured to the truck and the supporting elements. Work lights Electrical System W A B C Test lighting. Battery refill system Power Supply W A B C Test battery refill system and check for leaks. Battery replacement system Power Supply W A B C...
Page 216 On-board charger Charger W A B C Check mains connector and mains cable. Test the immobiliser on trucks with an on-board charger. Check the wires and electrical connections are secure and not damaged. Carry out potential measurement on chassis while charging is in progress.
Page 217 Clamping device Hydraulic Operations W A B C Test the acknowledgement key. Check axial play of the front and rear rollers and adjust if necessary. Check attachment is properly secured to the truck and the supporting elements. Test attachment, check settings and check for damage. Check sliding blocks are complete.
Page 218 Impact sensor Electrical System W A B C Check impact sensor is secure and check for damage. Sideshifter Hydraulic Operations W A B C Check axial play of the front and rear rollers and adjust if necessary. Check attachment is properly secured to the truck and the supporting elements.
Page 219 Hydraulic Operations W A B C Check attachment lubrication; clean and lubricate if necessary. Check hydraulic ports and tighten if necessary. Check cylinder seals. Check that hydraulic ports, hose and pipe lines are secure, check for leaks and damage. Check piston and piston rod for damage, check setting and adjust if necessary.
Page 220 Fork adjuster Hydraulic Operations W A B C Check axial play of the front and rear rollers and adjust if necessary. Check attachment is properly secured to the truck and the supporting elements. Test attachment, check settings and check for damage. Check sliding blocks are complete.
Page 222 A Traction Battery Appendix Contents Traction Battery Appendix............Correct Use and Application..............Data plate ....................Safety Instructions, Warning Indications and other Notes ....... Lead acid batteries with armour plated cells and liquid electrolyte..Description....................Operation....................Servicing lead-acid batteries with armour plated cells......PzV and PzV-BS lead-acid batteries with sealed armour plated cells..
Page 223: Correct Use And Application
Correct Use and Application Failure to observe the operating instructions, carrying out repairs with non-original spare parts, tampering with the battery or using electrolyte additives will invalidate the warranty. Observe the instructions for maintaining the safety rating during operation for batteries in accordance with Ex I and Ex II (see relevant certification).
Page 224 Safety Instructions, Warning Indications and other Notes Used batteries must be treated as hazardous waste. These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. waste.
Page 225: Lead Acid Batteries With Armour Plated Cells And Liquid Electrolyte
Lead acid batteries with armour plated cells and liquid electrolyte Description Jungheinrich traction batteries are lead acid batteries with armour plated cells and liquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM. Electrolyte The rated density of the electrolyte assumes a temperature of 30°C and the rated electrolyte level is fully charged.
Page 226: Operation
Operation 4.2.1 Commissioning unfilled batteries The operations required must be carried out by the manufacturer's customer service department or a customer service organisation authorised by the manufacturer. 4.2.2 Commissioning filled and charged batteries Checks and operations to be performed before starting daily work Procedure •...
Page 227 4.2.4 Charging the battery WARNING! The gases produced during charging can cause explosions The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited. Always disconnect the charger and truck before connecting or disconnecting the charger and battery.
Page 228 The electrolyte temperature rises by approx. 10 K during charging. Charging should therefore only begin when the electrolyte temperature is below 45°C. The electrolyte temperature of batteries must be at least +10°C before charging. Otherwise the battery will not charge correctly. Below 10°C the battery is insufficiently charged with standard charging systems.
Page 229: Servicing Lead-Acid Batteries With Armour Plated Cells
Servicing lead-acid batteries with armour plated cells Water quality The quality of the water used to fill up electrolyte must correspond to purified or distilled water. Purified water can be produced through distillation or ion exchangers and is then suitable for the production of electrolyte. 4.3.1 Daily –...
Page 230: Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells
PzV and PzV-BS lead-acid batteries with sealed armour plated cells Description PzV batteries are sealed batteries with fixed electrolytes, to which no water can be added over the entire lifespan of the battery. Relief valves are used as plugs which are destroyed when opened.
Page 231: Operation
Operation 5.2.1 Commissioning Checks and operations to be performed before starting daily work Procedure • Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative) and check that contacts on the battery terminal conducting system are secure. •...
Page 232 NOTE Charging the battery incorrectly can result in material damage. Incorrect battery charging can result in overloading of the electric wires and contacts, hazardous gas formation and electrolyte leakage from the cells. Always charge the battery with DC current. All DIN 41773 charging procedures are permitted in the format approved by the manufacturer.
Page 233 Charging the battery Requirements – Electrolyte temperature between +15°C and 35°C Procedure • Open or take off the tray lid or covers from the battery compartment. • Connect the battery to the switched off charger, ensuring the terminals are connect (positive to positive and negative to negative).
Page 234: Servicing Pzv And Pzv-Bs Lead-Acid Batteries With Sealed Armour Plated Cells
Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells Do not add water! 5.3.1 Daily – Charge the battery after each discharge. 5.3.2 Weekly – Visually inspect for dirt and physical damage. 5.3.3 Every three months – Measure and record the overall voltage. –...
Page 235: Aquamatik Water Replenishment System
Aquamatik water replenishment system Water replenishment system design > 3 m Water container Tap connection with ball cock Flow indicator Shut-off cock Locking coupling Battery lock connector...
Page 236: Functional Description
Functional Description The Aquamatik water replenishment system is used to adjust the rated electrolyte level automatically on traction batteries for industrial trucks. The battery cells are interconnected through hoses and are attached to the water supply (e.g. water container) through a plug connection. When the shut-off cock is opened all the cells are filled with water.
Page 237: Filling Time
Filling time The filling time for a battery depends on the electrolyte level, the ambient temperature and the filling pressure. Filling ends automatically. The water supply line must be disconnected from the battery when the water has been filled. Water quality The quality of the water used to fill up electrolyte must correspond to purified or distilled water.
Page 238: Cleaning Measures
Cleaning measures The plug systems must only be cleaned with purified water in accordance with DIN 43530-4. No parts of the plugs must come into contact with solvent-based materials or soap. 6.10 Service mobile vehicle Mobile water filling vehicle with pump and filling gun to fill individual cells. The immersion pump in the container generates the necessary filling pressure.
Page 239: Electrolyte Circulation
Electrolyte circulation Functional Description Electrolyte circulation ensures the supply of air during charging to mix the electrolyte, thereby preventing any acid layer, shortening the charge time (charge factor approx. 1.07) and reducing the formation of gas during charging. The charger must be suitable for the battery and electrolyte circulation.
Page 240 NOTE If an installed electrolyte circulation system is seldom used or not used at all, or if the battery is subjected to severe temperature fluctuations, the electrolyte may flow back into the hose system. Attach a separate coupling system to the air inlet line, such as: locking coupling on the battery side and through-coupling on the air supply side.
Page 241: Cleaning Batteries
Cleaning batteries Batteries and trays must be cleaned in order to – maintain cell insulation and protect cells from ground or external conductive parts. – Avoid damage from corrosion and stray currents. – Avoid excessive and varying automatic discharge of the individual cells or block batteries due to stray currents.
Page 242 Cleaning the battery with a high pressure cleaner Requirements – Cell connectors tight, plugged in securely – Cell plugs closed Procedure • Follow the high pressure cleaner's user instructions. • Do not use any cleaning additives. • Observe the permissible cleaning device temperature setting of 140°C. This generally ensures that the temperature does not exceed 60°C at a distance of 30cm behind the outlet nozzle.
Page 243: Storing The Battery
Storing the battery NOTE The battery should not be stored for longer than 3 months without charging as otherwise it will no longer be functional. If the battery is to be taken out of service for a long period, it should be stored fully charged in a dry room protected from frost.

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Jungheinrich EFG 213 Operating Instructions Manual

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