1996-2003 Jungheinrich Electric Forklift Truck EFG-DH Series Service & Repair Manual

tUNGHEINRICH EFG-DH 10/1 2,5/15B 05.02 0.1 (GB) CHAPTERS - OVERVIEW Operating Instructions 1 Legend of technical modifications EFG-DH 10 9 Component Technical Description 2 10 General Truck Data Test and Setting Values 3 11 Truck - Maintenance 4 12 Service Manual Items 5 Drive control system / lifting control system 6 Electrical Wiring Diagrams 7 Hydraulic Wiring Diagrams 8

EFG-DH 12,5/15 B 05.96- Operating instructions Щ 10003616 06.97

Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide suf- ficient 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 gra- phics: f Used before safety instructions which must be observed to avoid danger to person- nel. m Used before notices which must be observed to avoid material damage. A Used before notices and explanations. t Used to indicate standard equipment. o Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to al- ter the design, equipment and technical features of the truck. No guarantee of partic- ular features of the truck should therefore be assumed from the present operating instructions. Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Am Stadtrand 35 D-22047 Hamburg - Germany Telephone: +49 (0) 40/6948-0 www.jungheinrich.com 0507. GB

List of contents I 1 A Correct use and application of the truck.................. A1 B Truck description 1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 4 4.1 4.2 4.3 4.4 4.5 4.6 Application.............................................................................. Description of assemblies and functions.......................... Truck........................................................................................ Load lifting system................................................................ Technical data - Standard version.................................... Output data for standard truck versions equipped with a double lift telescopic mast................................................ Standard mast versions ...................................................... Dimensions............................................................................ EN standards......................................................................... Location of instruction labels and identification plates.. Truck identification plate ..................................................... Load diagram, capacity / load centre / lifting height................................... Label: Order-no., Inventory-no., Service-no..................... Load diagram, capacity / load centre / fork.................................................. Jack location label................................................................ Trailer loads........................................................................... B1 B2 B3 B5 B5 B5 B6 B7 B8 B9 B10 B10 B11 B11 B11 B11 C Transportation and commissioning 1 2 3 Loading and unloading of trucks by crane....................... Commissioning...................................................................... Moving the truck with the drive unit inoperative.............. C1 C1 C2 D Battery- Servicing,recharging, replacement 1 2 3 4 5 6 Safety regulations governing the handling of lead-acid batteries................. Battery types........................................................................... Exposing the battery............................................................. Charging the battery............................................................. Removing and installing the battery.................................. Battery discharge indicator, battery discharge monitor and hour meter...................................................................... D1 D1 D2 D3 D4 D5 E Operation 1 2 3 4 4.1 4.2 4.3 Safety regulations governing the operation of the truck.................................. Description of the operating controls and displays......... Start-up of truck..................................................................... Truck operation...................................................................... Safety regulations applicable when operating the truck................................................................................... Driving, steering, braking..................................................... Adjusting the fork tines......................................................... E1 E2 E4 E6 E6 E7 E9 189.001. GB 1-2 0396

4.4 4.5 4.6 4.7 5 5.1 5.2 5.3 5.4 6 7 7.1 7.2 7.3 7.4 7.5 7.6 Picking up and setting down loads.................................... Picking up, lifting and transporting of loads..................... Operating an attachment..................................................... Rendering vehicle safe when parking............................... Information and service display (LISA)............................. LED warning lamps.............................................................. Key assignment..................................................................... Displays.................................................................................. Changing truck parameters................................................. Fault locating operations..................................................... Options - additional electrical systems.............................. Lighting................................................................................... Complete lighting according to German road regulations..................................................... Searchlight............................................................................. 360° warning light................................................................. Inching speed........................................................................ Seat heating........................................................................... E9 E10 E11 E11 E12 E13 E13 E14 E15 E16 E17 E17 E17 E18 E18 E19 E19 F Truck maintenance 1 2 3 4 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 7.3 8 Operational safety and environmental protection........... Safety regulations applicable to truck maintenance...... Servicing and inspection..................................................... Maintenance checklist EFG-DH2....................................... Lubrication schedule EFG-DH2......................................... Fuels and oils....................................................................... Instructions for the servicing operations........................... Preparing the truck for the performance of servicing and maintenance operations.............................................. Opening the rear cover........................................................ Checking the wheels for tightness..................................... Checking the hydraulic oil level......................................... Checking the electric fuses................................................. Checking the electric fuses of the additional electrical systems............................................... Recommissioning of the truck............................................. Decommissioning the truck................................................. Operations to be performed prior to decommissioning.................................................................. Measures to be taken during decommissioning............. Recommissioning of the truck............................................. Safety checks to be performed at regular intervals and following any untoward incidents (Ь: Accident prevention check according to VBG 36)................................................................................... F1 F1 F3 F4 F6 F7 F8 F8 F9 F10 F10 F11 F12 F13 F13 F13 F13 F14 F14 I 2 189.001.GB 2-2 0396

A 1 A Correct use and application of the truck A The Guidelines for the Correct Use and Application of Industrial Trucks (VDMA) are included in the scope of delivery for this truck. The guidelines are part of these operating instructions and must always be heeded. National regulations are fully applicable. The fork-lift truck described in these operating instructions is a truck that is suitable for lifting and transporting loads. It must be used, operated and maintained according to the information in these operating instructions. Any other uses are outside the design envelope and can lead to injury to persons or damage to equipment and property. Above all, overloading caused by excessively heavy or unbalanced loads must be avoided. The max. admis- sible load to be picked up is indicated on the identification plate or load diagram label shown on the truck. The fork-lift truck must not be operated in spaces subject to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres pre- vail. Duties of the user: A user within the meaning of these operating instructions is de- fined as any natural or legal person who either uses the fork-lift truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting), the user is conside- red the person, who, in accordance with existing contractual agreements between the owner and the user of the fork-lift truck, is charged with the observance of the operating duties. The user must ensure that the truck is not abused and only used within its design li- mits and that all danger to life and limb of the operator, or third parties, is avoided. In addition to this, it must be ensured that the relevant accident prevention regulations and other safety-related provisions, as well as the operating, servicing and maintenance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions. m If these Operating Instruction are not observed the warranty becomes void. The same applies if improper works are carried out at the device by the customer and/or third parties without permission of our Customer Service. Mounting of attachments: The mounting or installation of any attachments which will interfere with, or supplement, the functions of the truck is permitted only after writ- ten approval by the manufacturer has been obtained. If necessary, the approval of local authorities has to be obtained. Any approval obtained from local authorities does not, however, make the approval by the manufacturer unnecessary. 0600.GB

B Truck description B1 1 Application The EFG-DH 12,5/15 B is a rear-end drive, three-wheeled, electrically-driven truck with driver seat. It is a self-supporting counterweight truck whose fork, mounted at the front of the truck, is designed to load and unload trucks and to set down the loads on ramps or in racking. Pallets with closed ground support can also be picked up. Truck types and capacities: *) with the mast in vertical position Type Capacity *) Load centre distance EFG-DH 12,5 B 1250 kg 500 mm EFG-DH 15 B 1500 kg 500 mm B89.001.GB 1-11 0797

B2 2 Description of assemblies and functions h T M M 10 4 3 2 1 7 8 5 6 9 Item Designation 1 Battery discharge indicator/battery discharge monitor/hour meter 2 Steering column adjustment 3 Information and service display (LISA) 4 Hoist frame 5 Travelling direction switch 6 Control lever 7 Master switch 8 Horn 9 Driver seat 10 Overhead guard B89.001.GB 2-1 1 0396

B3 2.1 Truck Safety installations: The enclosed truck contour featuring rounded edges ensures safe handling of the EFG-DH 12,5/15 B truck. The driver is protected by the overhead guard (10). The master switch (7) ensures instant cut-out of all electrical functions in an emergency. Line break safety devices in the lifting cylinders limit the lowering speed of the load in the event of a malfunction in the hydraulic system. Indicating instruments: Information and service display (LISA) (3) with large indications in LCD-technology (option). Hour meter and battery discharge indicator (1) with lifting movement cut-out function. Drive system: The complete drive unit assembly is screwed to the truck chassis. A shunt motor drives the driven wheel through a spur gear. The drive wheel is arranged within the truck envelope. The tyre size is the same for all wheels. The wheels are available with super-elastic or solid rubber tyres. An electronic drive control system, provided as standard equipment, ensures smooth starting, powerful acceleration and electronically controlled braking with energy recovery. Brake system: Two independent brake systems act on the front wheels. The service brake is designed as a hydraulic drum brake with asbestos-free brake linings and is applied by means of the foot pedal. The brake fluid level is monitored by the LISA (option). The parking brake is a manually operated cable brake. Steering system: The hydrostatic steering system with hydraulic swivelling drive is arranged immediately at the bogie of the rear wheel and acts through a chain on the drive unit. A steering lock of 90° to either side permits small turning radii. Driver position: The driver position is ergonomically designed and features generous foot space and a low mounting height. Driver seat (9) and steering column (8) can be adjusted for maximum driver comfort. Travelling direction switch (5) and valve levers (6) are of operator-friendly design. Accelerator and brake pedals are arranged as found in normal vehicles. Hydraulic system: The lifting, tilting and steering functions, as well as the auxiliary functions, are supplied by a low-noise hydraulic pump flanged directly to the electric motor. The pump motor is of high efficiency and offers an output of 7.6 kW (15% ED). An electronic drive control system provided as standard equipment permits sensitive load lifting movements. A pressure limiting valve is provided as protection against overpressure and overloading. B89.001.GB 3-1 1 0396

B4 h T M M 10 4 3 2 1 7 8 5 6 9 Item Designation 1 Battery discharge indicator/battery discharge monitor/hour meter 2 Steering column adjustment 3 Information and service display (LISA) 4 Hoist frame 5 Travelling direction switch 6 Control lever 7 Master switch 8 Horn 9 Driver seat 10 Overhead guard B89.001.GB 4-1 1 0396

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1996-2003 Jungheinrich Electric Forklift Truck EFG-DH Series Service & Repair Manual

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