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Operating instructions 51417157 04.16 04.16 EFG 213 EFG 215 EFG 216k EFG 216 EFG 218k EFG 218 EFG 220 EFG 316k EFG 316 EFG 318k EFG 318 EFG 320 1JUNGHEINRICH Machines. Ideas. Solutions.

EFG 213-320

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Foreword

Notes on the operating instructions

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 and the pages are numbered continuously.

The operator manual details different industrial truck models . When operating and servicing the industrial truck, make sure that the particular section applies to your truck model.

Our trucks are subject to ongoing development. We reserve the right to alter the design, equipment and technical features of the system. No guarantee of particular features of the truck should therefore be assumed from the present operating instructions

Safety notices and text mark-ups

Safety instructions and important explanations are indicated by the following graphics :

,& DANGER!

Indicates an extremely hazardous situation Failure to comply with this instruction will result in severe irreparable injury and even death.

WARNING!

Indicates an extremely hazardous situation. Failure to comply with this instruction may result in severe irreparable injury and even death.

,& CAUTION!

Indicates a hazardous situation. Failure to comply with this instruction may result in slight to medium injury .

Indicates a material hazard. Failure to comply with this instruction may result in material damage.

Used before notices and explanations.

Indicates standard equipment

Indicates optional equipment

Z t o z w <O ....

NOTE

Contents A Correct Use and Application .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. ... .. .. ... .. .. .. .. 11 1 General.................................................................................................... 11 2 Correct application................................................................................... 11 3 Approved application conditions.............................................................. 12 4 Proprietor responsibilities 13 5 Adding attachments and/or optional equipment...................................... 13 B Truck Description.................................................................... 15 1 Application 15 1.1 Truck models and rated capacity............................................................. 15 2 Assemblies and Functional Description................................................... 16 2.1 Travel direction definition......................................................................... 16 2.2 Assembly Overview................................................................................. 17 2.3 Functional Description 18 3 Technical Specifications.......................................................................... 19 3.1 Performance data .. .. .. .. ... ....... .. .. ........... .. .. ....... ... .. .. ....... .. .. .. .. ........ ... .. .. ... 20 3.2 Dimensions.............................................................................................. 22 3.3 Weights.................................................................................................... 28 3.4 Mast versions ........ .. . ....... .... .. . ........ ... .. .. ....... .... .. . ....... .. .. .. . ........ .. .. .. .. ...... 29 3.5 Tyre type.................................................................................................. 30 3.6 Engine Data............................................................................................. 31 3.7 EN norms................................................................................................. 32 3.8 Conditions of use..................................................................................... 33 3.9 Electrical Requirements........................................................................... 33 4 Identification Points and Data Plates....................................................... 34 4.1 Indication Points...................................................................................... 34 4.2 Data plate .. .. .. ......... .. .. .. . ....... .. . ... . ........ .. .. ......... .. .. . ........... .. .. ....... .... .. .. .... 35 4.3 Truck capacity plate................................................................................. 36 4.4 Attachment capacity plate .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 38 5 Stability.................................................................................................... 38 5.1 Wind loads............................................................................................... 38 C Transport and Commissioning .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . .. .. . 39 1 Transport 39 2 Truck laden.............................................................................................. 39 2.1 Centre of gravity of the truck................................................................... 39 2.2 Lifting the truck by crane 40 2.3 Loading with another industrial truck....................................................... 42 3 Securing the truck during transport .. ...... .. .. .. .. .. ...... .. .. .. ...... .... .. .. ............. 43 4 Using the Truck for the First Time 45 D Battery - Servicing, Recharging, Replacement....................... 47 1 Safety Regulations Governing the Handling of Lead-Acid Batteries....... 47 1.1 General notes on handling batteries........................................................ 48 z 2 UJ Battery types............................................................................................ 49 tO 2.1 .... Battery dimensions.................................................................................. 50 ..;. 0 7

o o o o o o o o o 3 Exposing the battery 51 4 Charging the battery 52 4.1 Charging the battery with a stationary charger ....................................... . 52 4.2 Charging the Battery with a Comfort Charger Socket ( ) 53 5 Battery removal and installation 54 5.1 Removal and Installation Using a Pallet Truck and Snapfit Battery Holder ( ) 55 5.2 Battery holder assembly 58 5.3 Removal and Installation Using a Hand Pallet Truck with Snapfit Battery Holder ( ) 60 5.4 Removal and installation for service using a (hand) pallet truck without Snapfit .................................................................................................... . 63 5.5 Removal and installation using a fork shoe ( ) 64 5.6 Removal and installation using a roller conveyor ( ) ............................. . 66 5.7 Hook-on battery door removal and installation ( ) 67 5.8 Hydraulic Battery Extractor ( ) 68 E Operation ............................................................................... . 71 1 Safety Regulations for the Operation of Forklift Trucks 71 2 Displays and Controls 73 2.1 Controls 73 2.2 Pilots 76 2.3 Function symbols for the Pilots ............................................................... . 77 2.4 Control panel with display unit 79 2.5 Button allocation of the display 80 2.6 Symbols in the display ............................................................................ . 81 2.7 Battery discharge indicator 83 2.8 Battery discharge monitor 83 2.9 Residual time display .............................................................................. . 84 2.10 Operating Programs 85 2.11 Hourmeter ............................................................................................... . 86 2.12 Armrest Control Panel Switch 86 2.13 Side compartment control panel switch ( ) ........................................... . 88 3 Preparing the Truck for Operation .......................................................... . 89 3.1 Checks and Operations to Be Performed Before Starting Daily Work 89 3.2 Entry and exit. 91 3.3 Trucks with reduced headroom ( ) 91 3.4 Setting up the operator position 92 3.5 Seat Belt ................................................................................................. . 100 4 Industrial Truck Operation 102 4.1 Safety regulations for truck operation 102 4.2 Preparing the truck for operation ............................................................ . 105 4.3 Setting the time 106 4.4 Parking the truck securely 107 4.5 Emergency Disconnect. .......................................................................... . 108 4.6 Travel 110 4.7 Steering 112 4.8 Brakes .................................................................................................... . 113 4.9 Adjusting the forks 119 4.10 Replacing the forks ................................................................................. . 120 4.11 4.12 Lifting, transporting and depositing loads ............................................... . Operating the Lift Mechanism and Integrated Attachments 121 z 123 w <O 4.13 Safety instructions for operating additional attachments ........................ . 133 ..... -,i 0 8

o 4.14 4.15 4.16 4.17 5 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 6.25 6.26 6.27 6.28 6.29 6.30 6.31 6.32 7 7.1 7.2 7.3 F 1 2 2.1 2.2 2.3 z 2.4 UJ 2.5 tO .... 2.6 ..;. 0 Operating additional attachments for the SOLO-PILOT.......................... 137 Operating additional attachments for the Multi Pilot................................ 139 Operating additional Attachments for Duo-Pilot...................................... 141 Fitting additional attachments.................................................................. 143 Towing trailers......................................................................................... 147 Optional equipment................................................................................. 149 Keyless Access System 149 General Information about the Use of Keyless Access Systems 150 Commissioning the Keypad and the Transponder Reader...................... 150 Using the Display:.................................................................................... 153 Operating the transponder reader........................................................... 157 Assistance systems................................................................................. 161 Steel cab.................................................................................................. 163 Sliding windows....................................................................................... 164 Automatic/ mechanical folding gate........................................................ 165 Panel door 166 Operator position extension..................................................................... 166 Entering and Exiting with the Hip Restraint on the Driver's Seat............. 167 Auxiliary Functions on the Armrest.......................................................... 168 Operating hydraulics cutout............. ..... ............... ..................... ............ ... 170 Load Weighing......................................................................................... 171 Tilt Control............................................................................................... 171 Tilt angle display...................................................................................... 172 Heating 175 Removable load backrest........................................................................ 177 Load Damping 178 Lift cutout override 180 Sideshifter Centre Position ... .. .. ........ .... .. .. ....... .. .. .. .. ....... .... .. . ........ ... .. ..... 180 Fork Tilt Horizontal 181 Fire extinguisher...................................................................................... 182 Rockinger coupling with hand lever or remote control............................. 183 Camera system 184 Control layout "N" .................................................................................... 185 Operating the Auxiliary Hydraulics without Pressing the Acknowledgement Key 187 Special control layout .. .. . ....... .. .. ........... .. .. ......... .. .. ....... ..... .. . ........ .... .. ..... 192 Floor Spot ( ) ...... 196 Horn Button on Overhead Guard............................................................. 197 StVZO road traffic regulations equipment .. .. .. .. .............. ...... .. .. .... ...... .. .. . 198 Troubleshooting....................................................................................... 199 Troubleshooting....................................................................................... 199 Operating the truck without its own drive system .. .. .. .. .... ...... .. .. .... ...... .. .. 201 Emergency lowering 205 Industrial Truck Maintenance .................................................. 207 Operational Safety and Environmental Protection................................... 207 Maintenance Safety Regulations............................................................. 208 Working on the electrical system............................................................. 209 Consumables and used parts.................................................................. 210 Wheels ..................................................................................................... 210 Attachment Repairs and Inspection......................................................... 210 Lift Chains................................................................................................ 211 Hydraulic system..................................................................................... 212 9

10 3 Lubricants and Lubrication Schedule 213 3.1 Handling consumables safely.................................................................. 213 3.2 Lubrication Schedule............................................................................... 215 3.3 Consumables........................................................................................... 216 4 Maintenance and repairs......................................................................... 218 4.1 Preparing the truck for maintenance and repairs ............ ........... ... .......... 218 4.2 Lifting and jacking up the truck safely...................................................... 219 4.3 Opening the rear panel............................................................................ 220 4.4 Checking the Wheel Mounting................................................................. 221 4.5 Replacing wheels 222 4.6 Hydraulic system .......... .. .................... ............. ........... ... ............. ... .......... 224 4.7 Replacing the hydraulic oil filter............................................................... 226 4.8 Replacing the ventilation/discharge filter................................................. 227 4.9 Checking the Electric Steering Oil Level................................................. 228 4.1 O Replacing the Electric Steering Oil Filter................................................. 229 4.11 Check the gear oil level 230 4.12 Heating .................................................................................................... 231 4.13 Adding window washer system fluid........................................................ 231 4.14 Checking electrical fuses......................................................................... 232 4.15 Cleaning ............... .............. ...... ... ........... ... ........... ... ........... ......... ............ 237 4.16 Working on the electrical system............................................................. 240 4.17 Restoring the truck to service after maintenance and repairs ................. 241 5 Decommissioning the Industrial Truck..................................................... 242 5.1 Prior to decommissioning 243 5.2 During decommissioning ....... ........... ................ ............ .............. ............. 243 5.3 Restoring the truck to service after decommissioning 244 6 Safety tests to be performed at intervals and after unusual incidents ..... 245 7 Final de-commissioning, disposal............................................................ 246 8 Human vibration measurement............................................................... 246 G Maintenance and Inspection ................................................... 247 1 Maintenance checklist EFG 213-220....................................................... 248 1.1 Owner...................................................................................................... 248 1.2 Customer Service.................................................................................... 251 2 Maintenance checklist EFG 316-320....................................................... 261 2.1 Owner...................................................................................................... 261 2.2 Customer Service .................................................................................... 264 z w <O ..... "" 0