ÖËÒÙØÛ×ÒÎ×ÝØ Operating Instructions 52016502 EFG 535/540/545/550 07.08 01.04
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
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:
F Used before safety instructions which must be observed to avoid danger to personnel.
M
Used before notices which must be observed to avoid material damage.
Z 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 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
I 1
ACorrect Use and Application of the Truck BTruck Description 1Application ...........................................................................................B 1 2Assemblies and Operational Description ............................................B 2 2.1Truck ...................................................................................................B 3 3Standard Version Specifications .........................................................B 4 3.1 Performance data ................................................................................B 4 3.2 Weights (all weights in kg) ..................................................................B 6 3.3 Tyres ...................................................................................................B 6 3.4EN norms ............................................................................................B 7 3.5 Conditions of use ................................................................................B 7 4Identification points and data plates ....................................................B 8 4.1Data plate, truck ..................................................................................B 9 4.2 Truck load chart ..................................................................................B 9 4.3Fork load chart (basic model) ..............................................................B 10 4.4 Attachment load chart .........................................................................B 10 CTransport and Commissioning 1Lifting by crane ....................................................................................C 1 2Securing the Truck for Transport. .......................................................C 2 3Commissioning ....................................................................................C 3 4Operating the truck without its own drive system ................................C 4 4.1Moving a truck with a rotary seat (o) without its own power system ..C 5 5Towing the truck ..................................................................................C 5 DBattery Maintenance, Charging & Replacement 1Safety regulations for handling acid batteries .....................................D 1 2Battery types .......................................................................................D 2 3Opening the battery cover with a retaining system (option) ................D 3 4Exposing the battery .......... .........D 4 5Charging the battery ............................................................................D 5 5.1Charger socket (o) .............................................................................D 6 6Battery removal and installation ........... ..................D 7 7Closing the battery cover ....................................................................D 8 8Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter ...........................................................................................D 9
Table of Contents
EOperation
I 2
1Safety Regulations for the Operation of Forklift Trucks ......................E 1 2Controls and Displays .......... .......E 2 2.1Instrument panel switches ................ .........E 6 2.2 Operating panel switches ... .........E 6 2.3Multi-function display .......... .........E 7 2.4Warning displays, buttons and switches .. ...........E 8 2.5Displays ......... .........E 9 2.6 Control panel ................. .........E 9 2.7 Control panel displays ........ .........E 10 2.8 Control panel buttons ......... .........E 11 2.9 Setting the time .... .........E 14 2.10Driver’s display warning messages ...... ..................E 15 3Starting up the truck ........ .........E 16 3.1 Checks and operations to be performed before starting daily work ....E 16 3.2 Trucks with reduced headroom X (o) ................ ..................E 16 3.3Adjusting the driver’s seat .........E 17 4Safety restraint belt .. .........E 19 4.1Automatic/mechanical restraint system (option) .................................E 21 4.2Adjusting the steering column ...........E 23 4.3 To prepare the truck for operation ............. .........E 23 5Heating (o) .............. .........E 24 6Industrial Truck Operation .. .........E 25 6.1 Safety regulations for truck operation ......... .........E 25 6.2Travel ............ .........E 26 6.3 Steering (t) / electrical steering (o) ................. ..................E 30 6.4 Braking ................. .........E 30 6.5Operating the lift mechanism and attachments (MULTI-PILOT) .........E 32 6.6Operating the lift mechanism and attachments (SOLO-PILOT) + (Fingertip o) ................... .........E 34 6.7Collecting, transporting and depositing loads ........... .........E 36 6.8Parking the truck securely .. .........E 39 6.9Trailer towing ................. .........E 40 7Troubleshooting .......... .........E 41
I 3 FMaintenance of the forklift truck 1Operational safety and environmental protection ................................F 1 2Maintenance Safety Regulations .........F 1 3Servicing and inspection ...... .......F 3 4EFG Maintenance Checklist .......F 4 5EFG lubrication schedule ....... ...........F 7 5.1Fuels, coolants and lubricants .............. .......F 8 6Maintenance and Repairs ......... .........F 9 6.1 Prepare the truck for maintenance and repairs ......... .........F 9 6.2 Checking the wheel attachments. ........ .......F 9 6.3 Tyre pressure ....... .........F 9 6.4Checking the hydraulic oil level ................. .........F 10 6.5 Replacing the hydraulic oil filter ......... .......F 11 6.6 Checking the brake system oil level .......... .........F 11 6.7Changing the suction filter of the motor fan ............ ...........F 12 6.8 Restraint belt maintenance .. .......F 12 6.9Checking electrical fuses ... .........F 13 6.10Recommissioning ............... .........F 14 7Decommissioning the forklift truck ......................................................F 14 7.1 Prior to decommissioning: .. .........F 14 7.2 During decommissioning: ..... .......F 14 7.3 Recommissioning ............... .........F 15 8 ......F 15 9Final de-commissioning, disposal ........... ...........F 15
ACorrect Use and Application of the Truck
ZThe “Guidelines for the Correct Use and Application of Industrial Trucks” (VDMA) are supplied with the truck. The guidelines form part of these operating instructions and must be observed. National regulations apply in full.
The truck described in the present operator manual is an industrial truck designed for lifting and transporting load units. It must be used, operated and serviced in accordance with the present instructions. Any other type of use is beyond the scope of application and can result in damage to personnel, the truck or property. In particular, avoid overloading the truck with loads which are too heavy or placed on one side. The data plate attached to the truck or the load diagram are binding for the maximum load capacity. The industrial truck must not be used in fire or explosion endangered areas or in places which can result in corrosion or produce dust.
Proprietor responsibilities: The “proprietor” within the meaning of this operator manual 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.
The proprietor must ensure that the truck is only used for the purpose it is designed for and that any dangers to life and limb of the user and third parties is avoided. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The proprietor must ensure that all truck users have read and understood this operator manual.
MFailure to comply with the operator manual shall invalidate the warranty. The same applies if improper work is carried out on the truck by the customer or third parties without the permission of the manufacturer’s customer service department.
Mounting attachments: The mounting or installation of additional equipment which affects or supplements the performance of the industrial truck requires the written permission of the manufacturer. In some cases, local authority approval shall be required.
Approval of the local authorities however does not constitute the manufacturer’s approval.
A 1
BTruck Description
1Application
The EFG is a 4-wheel electric sit-down truck with front wheel drive which collects, transports and lifts its load outside the wheelbase. It is a cantilever counterbalanced truck which uses the front-positioned load handler to unload lorries and place the load on ramps or in racks. It can be used to stack and transport standardised DIN 15142 pallets, DIN 15144 lattice box pallets and other palletised loads.
Truck models and maximum capacity:
*)The load charts on the truck are binding for the capacity.
B 1
Type Max. capacity *) Load centre of gravity EFG 535 3.500 kg 500 mm EFG 540 4.000 kg 500 mm EFG 545 4.500 kg 500 mm EFG 550 4.990 kg 500 mm
2Assemblies and Operational Description
B 2
ItemDescription
1 t Overhead guard
2 t Driver’s seat
3 t Counterweight
4 t Steering axle
5 t Drive axle
6 t Fork carriage
1 2 3 4 5 6 7 8
7 t Mast 8 t Steering
Steering (8): When the driver’s seat is occupied the steering is set to stand-by. The steering unit operates at a preset speed. Depending on the steering requirements the speed of the steering pump increases, and the travel speed reduces as a function of the steering angle (Curve Control). The steering angle is shown in the display.
Driver’s seat (2): The driver’s seat is a comfortable seat, the steering column is adjustable. There are storage facilities for paper or the driver’s personal items. The MULTI PILOT combines all the hydraulic functions and the travel direction switch in one lever.
Electrics/Electronics: State-of-the-art electronics provide data transmission (CAN Bus) with just a few wire leads. This ensures less downtime through broken wires and faster troubleshooting. The complex Total Control system follows a simple, safe and flexible design. The driver can choose one of five operating programs depending on the load and the environment: from high performance to energy saving. Simple to operate and above all rapid error analysis and programming can be carried out using a PC.
Drive system and brakes: The front wheel drive system provides optimum traction to the drive wheels at all times.
The hydraulically actuated oil batch multi-plate brake which operates as a service brake is practically maintenance-free. The transmission encapsulation allows the truck to be used even in hostile environments. The truck can also be generatively braked via the traction motor until it comes to a halt. This minimises energy consumption.
The spring-loaded accumulator brake is applied approx. 5 seconds after the truck comes to a halt or 5 to 120secs (this time is adjustable) after the driver’s seat has been vacated.
When the accelerator is pressed the spring-loaded accumulator brake is automatically released.
Hydraulic System: All functions are sensitive, proportional and simultaneous (where they do not affect safety). To improve efficiency, the hydraulic unit and the steering auxiliary motor operate independently of each other. The micro pressure filter can be replaced from the top (without spilling hydraulic oil).
Mast (7): The aim is to optimise visibility. The extremely rigid steel sections are narrow, allowing for excellent fork visibility in particular with the three-stage mast. The same level of standard has been achieved for the fork carriage. Both the mast and the fork carriage run on permanently lubricated and hence maintenance-free inclined castor wheels.
B 3
2.1Truck
3Standard Version Specifications
B 4
DescriptionEFG 535 EFG 540 EFG 545 EFG 550 h1 Mast height retracted 240524052405mm h2 Free lift 150150150150mm h3 Lift 300030003000mm h4 High mast extended 383038303830mm h6 Height above overhead guard (cabin) 2320232023202320mm h7 Seat height / standing height1165116511651165mm Seat freedom H11105110511051105mm h10 Coupling height 390/ 500 390/ 500 390/ 500 390/ 500 mm L1 Overall length, including Forks3975398039803980mm L2 Length including forks back2830283028302830mm b1Overall width1340134013401450mm b3Fork carriage width1120126012601260mm m1 Ground clearance with load below mast 120120120120mm m2 Ground clearance centre wheelbase160160160160mm AstWorking aisle width @ 800 x 1200 length 426042604260mm AstWorking aisle width @ 1000 x 1200 traverse 406040604060mm Wa Turning radius 245024502450mm xLoad distance (DZ mast + 32 mm) 510510510mm yWheelbase 1855200020002000mm DescriptionEFG 535EFG 540EFG 545EFG 550 QCapacity/Load 3.54.04.54.99t cLoad centre of gravity500500500500mm Travel speed w / w.o. load 16/1715/1715/16.515/16km/h Lift speed w / w.o. load0.38/0.500.35/0.470.33/0.450.31/0.45m/s Lowering speed w / w.o. load 0.58/0.550.55/0.500.55/0.500.55/0.50m/s Gradeability w / w.o. load S2 30 min 8.5/14.58/13.57/126.5/12% Max. gradeability w / w.o. load S2 5 min 15.5/2514/23.512.5/21.512/21 %
3.1Performance data
B 5
3.2Weights (all weights in kg)
3.3Tyres
ZPermissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries please contact your Jungheinrich customer adviser.
B 6
DescriptionEFG 535EFG 540EFG 545EFG 550 Net. weight (including battery) 5800660069507300kg Battery weight1863217821782178kg Axle load (laden) front/rear 8350/9509700/90010400/105011200/1100kg Axle load unladen front/rear 3000/28003700/29003700/32503700/3600kg Model EFG 535EFG 540EFG 545EFG 550 Tyre size, frontSE 250 -15 28 x 12,5 - 15 Rubber 28 x 10 x 22 28 x 12 x 22 Tyre size, rearSE 21 x 8 -9 Rubbe 21 x 7 -15 1/8“
3.4EN norms
Noise emission: 75 dB(A)
in accordance with prEN 12053 as harmonised with ISO 4871.
ZThe noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the driver’s ear.
Vibration:0.64 m/s2
in accordance with prEN13059.
ZThe vibration acceleration acting on the body in the operating position is, in accordance with standard procedures, the linearly integrated, weighted acceleration in the vertical direction. It is calculated during travel over bumps at constant speed.
Electromagnetic compatibility (EMC)
The manufacturer confirms that equipment complies with tolerance levels for electromagnetic emissions and resistance as well as static electricity discharge testing in accordance with prEN12895 including the normative procedures contained therein.
Z No changes to electrical or electronic components or their assembly may be made without the written agreement of the manufacturer.
3.5Conditions of use
Ambient temperature
- operating at -20 pC to 40 pC
ZSpecial equipment and authorisation is required if the truck is to operate constantly below 5 pC or in a cold store or in extreme temperatures or conditions of fluctuating air humidity.
B 7
• Thank you very much for reading the preview of the manual.
• You can download the complete manual from: www.heydownloads.com by clicking the link below
• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
CLICK HERE TO DOWNLOAD THE COMPLETE MANUAL
