Jungheinrich Electric Lift Truck EFG-Series Service & Repair Manual

tUNGHEINRICH EFG-DHac 10-15 / EFG 110-115 04.10 0.1 (S§) CHAPTER OVERVIEW Operating Manual 1 9 Technical Description of Components 2 10 General Truck Test and Setting Data 3 11 Truck Maintenance 4 12 Service Manual Items 5 ACS 2410 Drive Controller 6 Electrical Diagrams 7 Hydraulic Diagrams 8

tUNGHEINRICH EFG-DHac 10-15 01.03 1.1 (5b) Operating Manual Language SAP Order No. © 52 001 550 CD 52 001 529 (DK) 52 001 528 CD 52 001 547 CD 52 001 553 © 52 001 557 CD 52 001 574 © 52 001 558 CD 52 001 563 (PL) 52 001 564 © 52 001 544 © 52 001 546

*ЦЛТЩШЫЧТОЧЭШ Operating instructions 52001557 EFG-DH ac 10/10L/12,5/15 G 01.03- 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 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

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 ............................................................................ B6 3.2 Performance data ............................................................................... B8 3.3 Weights ............................................................................................... B9 3.4 Tyre equipment ................................................................................... B9 3.5 EN standards ...................................................................................... B 10 3.6 Conditions for application .................................................................... B 10 4 Location of instruction labels and identification plates ........................ B 11 4.1 Truck identification plate ..................................................................... B 12 4.2 Capacity label Truck ............................................................................ B 12 4.3 Capacity label Fork tines (basic device) .............................................. B 13 4.4 Capacity label Attachment .................................................................. B 13 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, replacement 1 Safety regulations governing the handling of lead-acid batteries ........ D1 2 Battery types ....................................................................................... D2 3 Exposing the battery ........................................................................... D3 4 Charging the battery ............................................................................ D4 5 Removing and installing the battery .................................................... D5 6 Closing battery cover .......................................................................... D6 7 Battery discharge indicator, battery discharge monitor, operating hour meter ........................................................................................... D6 1203. GB

I 2 E Operation 1 Safety regulations governing the operation of the fork lift truck .......... E1 2 Description of the operating controls and indicators ........................... E2 2.1 Auxiliary electrical system o ............................................................... E5 2.1.1 Dashboard switches o ....................................................................... E5 2.1.2 Operating console switches o ............................................................ E5 3 Multi function display t ...................................................................... E6 3.1 LED warning indicators ....................................................................... E7 3.2 Displays ............................................................................................... E7 4 Enhanced multi function display o ..................................................... E8 4.1 Warning indicators, push buttons, and switches ................................. E9 4.2 Displays ............................................................................................... E 10 5 Commissioning the truck ..................................................................... E 11 5.1 Checks and actions before routine start-up ........................................ E 11 5.2 Adjustment of driver's seat .................................................................. E 11 5.3 Adjusting the steering column ............................................................. E 12 5.4 Provide operatability ............................................................................ E 12 5.5 Safety belt ........................................................................................... E 13 6 Operation of the fork lift truck .............................................................. E 15 6.1 Safety regulations applicable when operating the truck ...................... E 15 6.2 Driving ................................................................................................. E 17 6.3 Steering ............................................................................................... E 20 6.4 Braking ................................................................................................ E 20 6.5 Operating the lifting device and attachments (control lever t) ........... E 22 6.6 Operating the lifting device and attachments (Multi Pilot o) ............... E 23 6.7 Operating the lifting device and the attachments (operating pattern N o) ....................................................................... E 25 6.8 Picking up, transporting and setting down of loads ............................. E 27 6.9 Safe parking of the truck ..................................................................... E 30 6.10 Trailer towing ....................................................................................... E 30 6.11 Trailer loads ........................................................................................ E 31 7 Fault location ....................................................................................... E 31 7.1 Temperature monitoring ...................................................................... E 31 1203. GB

I 3 F Maintenance of the fork lift truck 1 Operational safety and environmental protection ................................ F1 2 Safety regulations applicable to truck maintenance ............................ F1 3 Servicing and inspection ..................................................................... F3 4 Maintenance check list for EFG-DH ac 10/10 L/12,5/15 .................... F4 5 Lubrication plan for EFG-DH ac 10/10 L/12,5/15 ................................ F6 5.1 Fuels, coolants and lubricants ............................................................. F7 6 Description of servicing operations ..................................................... F8 6.1 Preparation of the truck for servicing and maintenance operation ...... F8 6.2 Check fixing of the wheels .................................................................. F8 6.3 Check hydraulic oil level ...................................................................... F9 6.4 Check the transmission oil level .......................................................... F 10 6.5 Let off oil .............................................................................................. F 10 6.6 Refill oil ................................................................................................ F 10 6.7 Top up brake fluid ............................................................................... F 11 6.8 Changing of hydraulic oil filter ............................................................. F 11 6.9 Safety belt maintenance ...................................................................... F 12 6.10 Checking the electric fuses ................................................................. F 13 6.11 Recommissioning the truck ................................................................. F 15 7 Decommissioning the fork lift truck ..................................................... F 15 7.1 Operations to be performed prior to decommissioning ....................... F 15 7.2 Measures to be taken during decommissioning .................................. F 15 7.3 Recommissioning the truck ................................................................. F 16 8 Safety checks to be performed at regular intervals and following any untoward incidents (D: Accident prevention check according to BGV D27) ............................................................................................ F 16 1203. GB

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 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 operating 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 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 work is carried out on 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. 1203. GB

B 1 B Truck description 1 Description of application The EFG-DH ac 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-DH ac 10 1,000 kg 500 mm EFG-DH ac 10 L 1,000 kg 500 mm EFG-DH ac 12,5 1,250 kg 500 mm EFG-DH ac 15 1,500 kg 500 mm 1203. GB

B 2 2 Description of assemblies and functions Item Designation 1 t Steering system 2 t Hoist frame 3 t Drive axle 4 t Batteries 5 t Fork carrier 6 t Counterweight 7 t Driver's seat 8 t Overhead guard -vj 00 1203. GB

Jungheinrich Electric Lift Truck EFG-Series Service & Repair Manual

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