Jungheinrich Electric Lift Truck EFG 316, EFG 318, EFG 320 (08.2004-12.2008) Workshop Service Manual

tUNGHEINRICH EFG 2xx / 3xx 03.12 0.1 (S§) Service Manual EFG 2xx 13xx Index Chapter 1 Operating Instructions Chapter 2 Technical Description of Components Chapter 3 Test and Setting Values / General Truck Data EFG 2xx / 3xx Chapter 4 Truck Maintenance Chapter 5 Service Manual Items Chapter 6 AS 4812F and AS 4814H CAN Bus Controllers Chapter 7 LISA and Parameters Chapter 8 Electrical Wiring Diagrams Chapter 9 Hydraulic Diagrams Used before safety instructions which must be observed to avoid danger to personnel. S Used before notices which must be observed to avoid material damage. Used before explanations.

tUNGHEINRICH EFG 2xx / 3xx 05.04 1.1 (SB) 1. Operating Instructions EFG 2xx Order no. Order no. CD 52025576 © 52025602 (GB) 52025577 <TR) 52025603 CD 52025578 (RUS) 52025604 <NL) 52025579 © 52025605 CD 52025580 © 52025606 ÿ 52025591 (USA) 52025607 (DK) 52025592 CD 52025593 (RUS) 52025594 © 52025595 CD 52025596 (GR) 52025597 © 52025598 CD 52025599 (PL) 52025600 © 52025601 EFG 3xx Order no. Order no. © 52025615 © 52025655 (GB) 52025616 (TR) 52025656 © 52025617 (RUS) 52025658 © 52025618 ® 52025660 © 52025619 © 52025663 0 52025620 (USA) 52025664 (DK) 52025641 © 52025645 (RUS) 52025647 © 52025648 © 52025649 (GR) 52025650 © 52025651 © 52025652 (PL) 52025653 © 52025654

EFG 316k/ 316/318k/ 3181320 08. 04- Operating instructions 52025616 07.08 Dungheinrich

Foreword The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter. Each chapter starts with page 1. The page identification consists of a chapter letter and a page number. For example: Page B 2 is the second page in chapter B. The operating instructions detail different truck models. When operating and servicing the truck, make sure that the instructions apply to your truck model. Safety instructions and important explanations are indicated by the following graphics: Used before safety instructions which must be observed to avoid danger to personnel. Used before notices which must be observed to avoid material damage. Used before notices and explanations. • Used to indicate standard equipment. O Used to indicate optional equipment. Our trucks are subject to ongoing development. Jungheinrich reserves the right to alter the design, equipment and technical features of the truck. No guarantee of particular features of the truck should therefore be inferred from the present operating instructions. Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Am Stadtrand 35 22047 Hamburg - GERMANY Telephone: +49 (0) 40/6948-0 www.jungheinrich.com CD CD CO o o

Table of contents A Correct use and application of the truck B Truck description 1 Description of application B1 2 Description of assemblies and functions B 2 2.1 Description of truck B 3 3 Technical data of standard version B4 3.1 Performance data B6 3.2 Weights (all weights in kg) B 6 3.3 Tyres B 7 3.4 EN standards B 8 3.5 Conditions for application B 8 4 Location of instruction labels and identification plates B 9 4.1 Truck identification plate B 10 4.2 Capacity label Truck B 10 4.3 Capacity label Fork tines (basic device) B 11 4.4 Capacity label Attachment B 1 1 C Transportation and commissioning 1 Transportation by crane C 1 2 Securing the truck during transport C 1 3 First commissioning C3 4 Moving of the truck without own drive C 4 D Battery - Servicing, recharging, replacement 1 Safety regulations governing the handling of lead-acid batteries D 1 2 Battery type D 2 3 Opening the battery hood with support system (optional) D 3 4 Open battery hood D 4 5 Charging the battery D 5 5.1 Charger socket (O) D 6 6 Removing and installing the battery D 7 7 Closing battery cover D 8 8 Battery discharge indicator, battery discharge monitor, operating hour meter D 8 h- O I 1

E Operation 1 Safety instructions for floor conveyor operation E 1 2 Description of the operating controls and indicators E 2 2.1 Dashboard switches E 4 2.2 Operating console switches E 4 2.3 Multi function display E 5 2.4 Warning indicators, push buttons, and switches E 6 2.5 Displays E 7 2.6 Setting the time E 7 2.7 Driver's display warning messages E 8 3 Commissioning the truck E 9 3.1 Checks and actions before routine start-up E 9 3.2 Trucks with reduced headroom X (O) E 9 3.3 Adjustment of driver's seat E 10 3.4 Adjusting the steering column E 11 3.5 Provide operatability E 1 1 3.6 Trucks with heating (O) E 12 3.7 Safety belt E 13 3.8 Automatic/Mechanical Support System (optional) E 15 4 Working with the floor conveyor E 17 4.1 Safety regulations applicable when operating the truck E 17 4.2 Driving E 19 4.3 Steering E 22 4.4 Braking E 22 4 5 Operating the lifting device and attachments (SOLO-PILOT) E 24 4.6 Operating the lifting device and attachments (Multi Pilot) E 26 4.7 Picking up, transporting and setting down of loads E 28 4.8 Safe parking of the truck E 31 4.9 Trailer towing E 32 5 Fault location E 33 5.1 Temperature monitoring E 33 m O cd o h- o

F Maintenance of the fork lift truck 1 Operational safety and environmental protection F 1 2 Safety regulations applicable to truck maintenance F 1 3 Servicing and inspection F 3 4 Maintenance check list for EFG 316/318/320 F4 5 Lubrication plan for EFG 316/318/320 F6 5.1 Consumption type materials F 7 6 Instructions for the servicing operations F 8 6.1 Preparing the truck for the performance of servicing and maintenance operations F 8 6.2 Open rear cover F 8 6.3 Check fixing of the wheels F 8 6.4 Check hydraulic oil level F 9 6.5 Check the transmission oil level F 10 6.6 Let off oil F 10 6.7 Refill oil F 10 6.8 Changing of hydraulic oil filter F 10 6.9 Checking the brake fluid F 1 1 6.10 Safety belt maintenance F11 6.1 1 Checking the electric fuses F 12 6.12 Recommissioning the truck F 13 7 Decommissioning the fork lift truck F 13 7.1 Operations to be performed prior to decommissioning F 13 7.2 Measures to be taken during decommissioning F 13 7.3 Recommissioning the truck F 14 8 Safety tests to be performed at intervals and after unusual events F 14 9 Final de-commissioning, disposal F 14 CO U CO o N- o

A Correct use and application of the truck |ÿ"| 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 oper¬ ating instructions and must always be heeded. National regulations are fully applica¬ ble. 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 oper¬ ating 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 operator must ensure that damaged and/or poorly readable load diagrams are renewed. 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 prevail. 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 consid¬ ered 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 op¬ erating duties. The user must ensure that the truck is not abused and only used within its design lim¬ its 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 mainte¬ nance guidelines, are observed. The user must also ensure that all persons operating the truck have read and understood these operating instructions. If these operating instructions 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. Trailing and slipping loads: The truck may only be used for trailing or slipping loads for which the truck has been approved. CD A 1

B Truck description 1 Description of application EFG is an electric four-wheel driver-seat fork lift truck. The truck is a cantilever coun¬ terweight stacker which is able to unload trucks by means of the load lifting device mounted to the stacker front and depose the load on ramps or on stacks. Also closed- ground pallets can be picked up. Vehicle types and maximum load capacity. Model max. load capacity*) Load centre EFG 316k 1600 kg 500 mm EFG 316 1600 kg 500 mm EFG 318k 1800 kg 500 mm EFG 318 1800 kg 500 mm EFG 320 2000 kg 500 mm *) The capacity labels fixed to the vehicle are binding for the load capacity h- O B 1

2 Description of assemblies and functions Item Designation 1 • Overhead guard 2 • Driver's seat 3 • Counterweight 4 • Batteries 5 • Drive axle 6 • Fork carrier 7 • Hoist frame 8 • Steering system m O cd o h- o B 2

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Jungheinrich Electric Lift Truck EFG 316, EFG 318, EFG 320 (08.2004-12.2008) Workshop Service Manual

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