Jungheinrich Electric Lift Truck EFG-DF Series: 13, 15, 16, 18, 20, 16L, 18L (07.98-12.03) Operating and Maintenance Instruction

*ЦЛТЩШЫЧТОЧЭШ Operating instructions 50042826 EFG-DF 13-20/16L/18L G 07.98- 12.03

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 particular 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

I 1 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 ............................................. B2 2.1 Description of truck ............................................................................. B3 3 Technical data of standard version ..................................................... B4 3.1 Types of hoist frame ............................................................................ B5 3.2 Performance data ............................................................................... B7 3.3 Weights (all weights in kg) .................................................................. B8 3.4 Tyre equipment ................................................................................... B8 3.5 EN standards ...................................................................................... B9 3.6 Conditions for application .................................................................... B9 4 Location of instruction labels and identification plates ........................ B 10 4.1 Truck identification plate ..................................................................... B 11 4.2 Capacity label Truck ............................................................................ B 11 4.3 Capacity label Fork tines (basic device) .............................................. B 12 4.4 Capacity label Attachment .................................................................. B 12 C Transportation and commissioning 1 Transportation by crane ...................................................................... C1 2 First commissioning ............................................................................ C1 3 Moving of the truck without own drive ................................................. C2 D Battery - Servicing, recharging, replacing 1 Safety regulations governing the handling of lead-acid batteries ........ D1 2 Battery types ....................................................................................... D2 3 Opening the battery hood with support system (optional) ................... D3 4 Open battery hood .............................................................................. D4 5 Charging the battery ............................................................................ D5 6 Removing and installing the battery .................................................... D6 7 Closing battery cover .......................................................................... D7 8 Battery discharge indicator, battery discharge monitor, operating hour meter ........................................................................................... D7

I 2 E Operation 1 Safety instructions for floor conveyor operation .................................. E1 2 Description of the operating controls and indicators ........................... E2 2.1 Dashboard switches ............................................................................ E4 2.2 Operating console switches ................................................................ E4 3 Information and service indication ....................................................... E5 3.1 Information indication .......................................................................... E5 3.2 LED warning indicators ....................................................................... E6 3.3 Keyboard assignment ......................................................................... E6 3.4 Plain text alarm messages in the display ............................................ E7 3.5 Indication of driving programs ............................................................. E7 3.6 Display indicators ................................................................................ E8 3.7 Changing truck parameters ................................................................. E9 4 Commissioning the truck ..................................................................... E 10 4.1 Checks and actions before routine start-up ........................................ E 10 4.2 Adjustment of driver's seat .................................................................. E 10 4.3 Adjusting the steering column ............................................................. E 11 4.4 Provide operatability ............................................................................ E 11 4.5 Setting the time ................................................................................... E 11 4.6 Safety belt ........................................................................................... E 12 4.7 Automatic/Mechanical Support System (optional) .............................. E 14 5 Working with the floor conveyor .......................................................... E 16 5.1 Safety regulations applicable when driving the truck .......................... E 16 5.2 Driving ................................................................................................. E 17 5.3 Steering ............................................................................................... E 20 5.4 Braking ................................................................................................ E 20 5.5 Operating the lifting device and attachments (control lever) ............... E 22 5.6 Operating the lifting device and attachments (Multi Pilot) ................... E 23 5.7 Picking up, transporting and setting down of loads ............................. E 25 5.8 Safe parking of the truck ..................................................................... E 28 5.9 Trailer towing ....................................................................................... E 28 5.10 Trailer loads ........................................................................................ E 29 6 Fault location ....................................................................................... E 30 6.1 Temperature monitoring ...................................................................... E 30

I 3 F Maintenance of the truck 1 Operating safety and environmental protection .................................. F1 2 Safety regulations applicable to truck maintenance ............................ F1 3 Servicing and inspection ..................................................................... F3 4 Maintenance check list for EFG DF 13/15/16(L)/18(L)/20 ................... F4 5 Lubrication plan for EFG 13/15/16(L)/18(L)/20 ................................... F7 5.1 Consumption type materials ................................................................ F8 6 Description of servicing operations ..................................................... F9 6.1 Preparation of the truck for servicing and maintenance operation ...... F9 6.2 Open rear cover .................................................................................. F9 6.3 Check fixing of the wheels .................................................................. F9 6.4 Desired condition of rear wheels ......................................................... F9 6.5 Check hydraulic oil level ...................................................................... F 10 6.6 Check the transmission oil level .......................................................... F 11 6.7 Let off oil .............................................................................................. F 11 6.8 Refill oil ................................................................................................ F 11 6.9 Changing of hydraulic oil filter ............................................................. F 11 6.10 Checking the brake fluid ...................................................................... F 12 6.11 Safety belt maintenance ...................................................................... F 12 6.12 Checking the electric fuses ................................................................. F 13 6.13 Recommissioning the truck ................................................................. F 14 7 Decommissioning the truck ................................................................. F 14 7.1 Operations to be performed prior to decommissioning ....................... F 14 7.2 Measures to be taken during decommissioning .................................. F 14 7.3 Recommissioning the floor conveyor .................................................. F 15 8 Safety checks to be performed at regular intervals and following any untoward incidents (D: UVV according to VBG 36) ......................... F 15

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 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 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 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.

B 1 B Truck description 1 Description of application The EFG DF is a three-wheel type electric fork-lift truck that is provided with a driver's seat. The truck is a cantilever counterweight 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: *) The capacity labels fixed to the vehicle are binding for the load capacity Model max. load capacity *) Load centre EFG DF 13 1300 kg 500 mm EFG DF 15 1500 kg 500 mm EFG DF 16 1600 kg 500 mm EFG DF 16 L 1600 kg 500 mm EFG DF 18 1800 kg 500 mm EFG DF 18 L 1800 kg 500 mm EFG DF 20 2000 kg 500 mm

B 2 2 Description of assemblies and functions Item Designation 1 t Overhead guard 2 t Driver's seat 3 t Counterweight 4 t Batteries 5 t Drive axle 6 t Fork carrier 7 t Hoist frame 8 t Steering system 1 2 3 4 5 6 7 8

B 3 2.1 Description of truck Steering system (8): Low steering forces of 15 N and a good transmission ratio with 5 revolutions of the steering wheel enable comfortable and quick steering. The number of wearing parts has been minimised by means of the rack steering offering the advantage of a compact steering unit. The standard dual twin-tyre equipment reduces the steering forces and increases the service life of the wheels. Driver`s seat (2): The driver`s seat is the centre of the fork-lift truck. This is where you find the particular advantages of our vehicles. The Multi-Pilot (option) offers very comfortable operation since it combines all hydraulic functions and even the drive sel- ection switch in just one lever. The truck is equipped with a comfortable seat, an ad- justable steering column and places of deposit for the papers and personal things of the driver. The overhead guard (2) is prepared for a driver`s cabin which can be re- trofitted quickly. Electrical system/electronics: State-of-the-art shunt technology via CAN bus redu- cing the number of required looms of cables. Thereby we achieve a lower suscepti- bility to cable parting and a much quicker fault localisation. The complex control system is simple, safe and built up in a flexible way. Depending on the load and the environment, the driver can select between 5 driving programmes: from heavy duty to energy saving. A very comfortable and especially quick fault analysis and pro- gramming can be carried out via PC. Drive and brake: The 2-motor front wheel drive assures optimum traction results at the driven wheels. Each motor is exactly supplied with the power it requires. The power supply is carried out proportionally to the steering angle. The wheels do not skid and no energy is wasted. The hydraulically operated oil bath multiple plate brake is virtually maintenance-free as service brake. The encapsulation of the transmission allows operation even in har- sh environments. Furthermore the speed of the stacker is reduced by means of the generator drive motors until standstill. Thereby the energy consumption is minimised. The fork-lift truck does not start to move even when standing on a ramp. Hydraulic system: All functions are to be carried out sensitively, proportionally and simultaneously (if not limiting the safety). In order to achieve higher efficiency one hydraulic aggregate and one steering booster motor work separately. The micro pres- sure filter can be changed from the upper side (without loss of hydraulic oil). Hoist frame (7): Our aim is visibility optimisation. The cold-milled, high-strength steel profiles are extraordinary thin with the result of very good visibility on the forks, especially in case of the three-level hoist frame. The same positive results were achieved for the fork carrier. The hoist rails and the fork carrier run on constantly lubricated and hence maintenance-free angular rollers.

B 4 3 Technical data of standard version (all dimensions in mm) 1) = + 25mm TZ mast 2) = EFG DF16/18; +108 mm = EFG DF16L/18 L Designation EFG-DF 13 EFG-DF 15 EFG-DF 16(L) EFG-DF 18(L) EFG-DF 20 h 1 Height with hoist frame retrac- ted 2000 2150 2000 2000 2000 h 2 Free lift 150 150 150 150 150 h 3 Length of lift 3000 3300 3000 3000 3000 h 4 Height with hoist frame extended 3550 3850 3550 3585 3585 h 6 Height above protective roof 1960 1960 1960 1960 1960 h 7 Height of seat 890 890 890 890 890 h 10 Height of clutch 560 560 560 560 560 L 1 Length including fork 2786 2786 2899 2) 2899 2) 3007 L 2 Length including fork backing 1) 1786 1786 1899 2) 1899 2) 2007 b 1 Total width 1060 1060 1060 1120 1120 e Fork width 100 100 100 100 100 m 1 Road clearance with load be- low hoist frame 90 90 90 90 90 m 2 Road clearance centre wheel base 100 100 100 100 100 Ast Width of corridors for pallets 800 x 1200 longitudinal axis 3243 3243 EFG- DF16: 3345 EFG- DF16L: 3455 EFG-DF 18: 3345 EFG- DF18L: 3455 3455 Ast Width of corridors for pallets 1000 x 1200 transversely 3115 3115 EFG- DF16: 3225 EFG- DF16L: 3330 EFG- DF18: 3225 EFG- DF18L: 3330 3330 W a Turning circle 1) 1440 1440 EFG- DF16: 1545 EFG- DF16L: 1655 EFG- DF18: 1545 EFG- DF18L: 1655 1655 x Load spacing 1) 347 347 352 352 352 y Wheel base 1249 1249 1357 2) 1357 2) 1465

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Jungheinrich Electric Lift Truck EFG-DF Series: 13, 15, 16, 18, 20, 16L, 18L (07.98-12.03) Operating and Maintenance Instruction

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