EFG 535k - S50
Operating instructions
51313258
06.14
06.14 -
EFG 535k
EFG 535ks
EFG 540k
EFG 540ks
EFG 540
EFG 540s
EFG 545
EFG 545s
EFG 545k
EFG 545ks
EFG 550
EFG 550s
EFG S40
EFG S40s
EFG S50
EFG S50s
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2
Declaration of Conformity
Jungheinrich
TypeOptionSerial no.Year of manufacture
EFG 535k
EFG 535ks
EFG 540
EFG 540s
EFG 540k
EFG 540ks
EFG 545
EFG 545s
EFG 545k
EFG 545ks
EFG 550
EFG 550s
EFG S40
EFG S40s
EFG S50
EFG S50s
Additional information
On behalf of Date
G EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in detail complies with the European Directives 2006/42/EC (Machinery Directive) and 2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well as the legislative decree to incorporate the directives in national law. The signatories are in each case individually authorized to compile the technical documents.
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AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union
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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.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in material damage.
Used before notices and explanations.
t Indicates standard equipment
o Indicates optional equipment
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Z
Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
6 Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
7 Contents ACorrect Use and Application...................................................11 1General................. ...........11 2Correct application.............. ...........11 3Approved application conditions..............................................................12 4Proprietor responsibilities..... ...........13 5Adding attachments and/or optional equipment........... ...........13 BTruck Description....................................................................15 1Application...............................................................................................15 1.1Truck models and rated capacity............... .............15 2Assemblies and Functional Description...................................................16 2.1Travel direction definition.... ...........16 2.2Assembly Overview.............. ...........17 2.3Functional Description.............................................................................18 3Technical Specifications....... ...........20 3.1Performance data....................................................................................20 3.2Dimensions..............................................................................................24 3.3Weights............ ...........27 3.4Mast versions..........................................................................................28 3.5Tyre type............... ...........32 3.6Engine Data............ ...........32 3.7EN norms.................................................................................................33 3.8Conditions of use.................... ........35 3.9Electrical Requirements...........................................................................35 4Identification Points and Data Plates.......................................................36 4.1Indication Points..... 36 4.2Data plate................................................................................................38 4.3Truck capacity plate............ ...........39 4.4Attachment capacity plate..... ...........41 5Stability....................................................................................................41 5.1Wind loads.............. ...........41 CTransport and Commissioning................................................43 1Transport.................................................................................................43 2Truck laden............... .............43 2.1Centre of gravity of the truck.............. ...........43 2.2Lifting the truck by crane.........................................................................44 2.3Loading with another industrial truck....... ........46 3Securing the truck during transport.........................................................47 4Using the Truck for the First Time...........................................................49
8 DBattery - Servicing, Recharging, Replacement.......................51 1Safety Regulations Governing the Handling of Lead-Acid Batteries.......51 1.1General notes on handling batteries........................................................52 2Battery types............................................................................................53 3Exposing the battery............. ...........55 4Charging the battery................................................................................56 4.1Charging the battery with a stationary charger........................................57 4.2Charging the Battery with a Comfort Charger Socket (o).......................58 5Battery removal and installation..............................................................59 5.1Removal and installation using an EJE pallet truck with Snapfit battery holder (o)................................................................................................60 5.2Removal and installation using a fork shoe (o)......................................65 5.3Removal and installation using a roller conveyor (o)..............................67 5.4Removal and installation for service using a hand pallet truck with Snapfit (o)...........................................................................................................68 5.5Removal and installation for service using a (hand) pallet truck without Snapfit.....................................................................................................70 EOperation................................................................................71 1Safety Regulations for the Operation of the Forklift Tr uck.......................71 2Displays and Controls..............................................................................73 2.1Pilots........................................................................................................76 2.2Control panel with display unit............................................. ........77 2.3Button allocation of the display................................................................79 2.4Symbols in the display........ ...........80 2.5Hourmeter............... ...........82 2.6Armrest Control Panel Switch ..................................................................82 2.7Side compartment control panel switch (o)............................................84 3Preparing the Truck for Operation............. .............85 3.1Checks and Operations to Be Performed Before Starting Daily Work....85 3.2Entry and exit................. ...........88 3.3Trucks with reduced headroom (o).........................................................88 3.4Setting up the operator position............... ........89 3.5Seat Belt............... ...........94 4Industrial Truck Operation.......................................................................96 4.1Safety regulations for truck operation.......... ...........96 4.2Preparing the truck for operation............. ........99 4.3Setting the Time...................................................................................... 100 4.4Parking the truck securely.... ...........101 4.5Emergency Disconnect............................................................................102 4.6Travel.......................................................................................................103 4.7Steering................ ...........105 4.8Brakes.....................................................................................................106 4.9Adjusting the forks........... ...........111 4.10Replacing the forks.......... ...........112 4.11Lifting, transporting and depositing loads................................................113 4.12Operating the Lift Mechanism and Integrated Attachments....................115 4.13Safety instructions for operating additional attachments.........................125 4.14Operating additional attachments for the SOLO-PILOT..........................129
9 4.15Operating additional attachments for the Multi Pilot................................131 4.16Operating additional Attachments for Duo-Pilot.... ........133 4.17Fitting additional attachments..................................................................135 5Towing trailers.........................................................................................139 6Optional equipment.............. ...........141 6.1Keyless Access System..........................................................................141 6.2General Information about the Use of Keyless Access Systems............142 6.3Commissioning the Keypad and the Transponder Reader......................142 6.4Using the Display:....................................................................................145 6.5Using the Transponder Reader.. .............149 6.6Assistance systems.................................................................................153 6.7Steel cab............... ...........155 6.8Sliding windows........ .............156 6.9Automatic / mechanical folding gate........................................................157 6.10Panel door.............. ...........158 6.11Operator position extension. ........158 6.12Entering and Exiting with the Hip Restraint on the Driver's Seat .............159 6.13Adjusting the Swivel Seat................... ...........159 6.14Adjusting the Backrest Extension............................................................160 6.15Adjusting the Lumbar Vertebrae Support ........161 6.16Switching the Seat Heating On and Off.......... ...........161 6.17Auxiliary Functions on the Armrest..........................................................162 6.18Operating hydraulics cutout.. ...........164 6.19Load Weighing.........................................................................................165 6.20Tilt Control...............................................................................................165 6.21Heating.......... ...........166 6.22Removable load backrest........................................................................167 6.23Load Damping.......... .............168 6.24Lift cutout override......... ...........170 6.25Sideshifter Centre Position ......................................................................170 6.26Fire extinguisher.............. ...........171 6.27Rockinger coupling with hand lever or remote control. .............172 6.28Camera system.......................................................................................173 6.29Control layout “N”............ ...........174 6.30Operating the Auxiliary Hydraulics without Pressing the Acknowledgement Key................ ...........176 6.31Floor Spot............. ...........180 6.32Horn Button on Overhead Guard .............................................................181 7Troubleshooting............. ...........182 7.1Troubleshooting........... ...........182 7.2Operating the truck without its own drive system....................................184 7.3Emergency lowering............. ...........189 FIndustrial Truck Maintenance..................................................191 1Operational Safety and Environmental Protection........ ...........191 2Maintenance Safety Regulations.............................................................192 2.1Consumables and used parts.... .............193 2.2Wheels.....................................................................................................193 2.3Lift Chains................................................................................................194 2.4Hydraulic system...... .............195 3Lubricants and Lubrication Schedule................. ........196
10 3.1Handling consumables safely ..................................................................196 3.2Lubrication Schedule............ ...........198 3.3Consumables...........................................................................................199 4Maintenance and repairs.........................................................................201 4.1Preparing the truck for maintenance and repairs...... .............201 4.2Lifting and jacking up the truck safely......................................................202 4.3Opening the rear panel......... ...........203 4.4Checking the Wheel Mounting.................................................................204 4.5Replacing wheels....................................................................................205 4.6Hydraulic system...... .............207 4.7Check the gear oil level...........................................................................212 4.8Heating....................................................................................................214 4.9Adding window washer system fluid.......... .............214 4.10Checking electrical fuses.........................................................................215 4.11Cleaning................. ...........222 4.12Working on the electrical system................. ...........225 4.13Restoring the truck to service after maintenance and repairs.................226 5Decommissioning the Industrial Truck.............. ...........227 5.1Prior to decommissioning........................................................................ 228 5.2During decommissioning...... ...........228 5.3Restoring the truck to service after decommissioning........... ......229 6Safety tests to be performed at intervals and after unusual incidents.....230 7Final de-commissioning, disposal.............. .............231 8Human vibration measurement...............................................................231 9Servicing and Inspection.........................................................................232 10Maintenance checklist.......... ...........233 10.1Operating Company................................................................................233 10.2Customer Service............... ...........235
ACorrect Use and Application
1General
The truck must be used, operated and serviced in accordance with the present instructions. All other types of use are beyond its scope of application and may result in damage to personnel, the industrial truck or property.
2Correct application
NOTE
The maximum load and load distance are indicated on the capacity plate and must not be exceeded.
The load must rest on the load handler or be lifted by an attachment approved by the manufacturer.
The load must be fully raised, siehe "Lifting, transporting and depositing loads" auf Seite113.
–Lifting and lowering loads.
–Transporting lowered loads over short distances.
–Do not travel with a raised load (>30 cm).
–Do not carry or lift passengers.
–Do push or pull load units.
–Occasional towing of trailer loads.
–When towing trailer loads the load must be secured on the trailer.
–The permissible trailer load must not be exceeded.
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3Approved application conditions
–Operation in industrial and commercial environments.
–Permissible temperature range -20°C to +40°C.
–Operation only on secure, level surfaces with sufficient capacity.
–Do not exceed the permissible surface and spot load limits on the travel routes.
–Operation only on routes that are visible and approved by the operating company.
–Negotiating inclines up to a maximum of 15 %.
–Do not travel across or at an angle on inclines. Travel with the load facing uphill.
–Operation in partially public traffic.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents. Special equipment and authorisation are required if the truck is to be constantly used in extreme conditions, especially in dusty or corrosive atmospheres. The truck cannot be used in areas at risk of explosion. In adverse weather conditions (thunder, lightning) the industrial truck must not be operated outside or in endangered areas.
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4Proprietor responsibilities
For the purposes of the present operating instructions the “operating company” 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 industrial truck is used only for the purpose it is intended for and that danger to life and limb of the user and third parties are excluded. Furthermore, accident prevention regulations, safety regulations and operating, servicing and repair guidelines must be followed. The operating company must ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions invalidates 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.
5Adding attachments and/or optional equipment
The mounting or installation of additional equipment which affects or enhances the performance of the industrial truck requires the written permission of the manufacturer. Local authority approval may also need to be obtained. Local authority approval however does not constitute the manufacturer’s approval.
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BTruck Description
1Application
The EFG 535k - S50 is a four-wheel electric sit-down forklift truck. It is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attach ed in front. Closed bottom pallets can also be lifted.
1.1Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from the model name.
EFG535ks
EFGModel name
5Series
35Rated capacity x 100 kg
kShort
sHigh performance (Drive&Lift Plus)
EFG S50
EFGModel name
SLoad centre = 600 mm
50Rated capacity x 100 kg
The rated capacity is not generally the same as the permissible capacity. The capacity can be found on the capacity plate attached to the truck.
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2Assemblies and Functional Description
2.1Travel direction definition
The following determinations have been made for travel direction specification:
The following conventions have been agreed for travel direction specification:
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ItemTravel direction 1Left 2Reverse 3Forward 4Right 1 2 3 4
2.2Assembly Overview
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Item ComponentItem Component 1 t Driver's seat 8 t Fork tines 2 t Overhead guard 9 t Fork carriage 3 t Mast 10 t Drive system 4 t Steering wheel 11 t Battery door 5 t Lifting mechanism control12 t Steer axle 6 t Control and display unit13 t Trailer coupling 7 t Emergency Disconnect switch 14 t Counterweight t Standard equipment 12 4 3 6 5 7 8 9 10 11 14 12 13
2.3Functional Description
Chassis
The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components.
Operator position and overhead guard
The overhead guard comes in a range of models and protects the operator from falling objects and other external influences. All the controls are ergonomically arranged. The steering column and driver's seat can be adjusted individually.
The controls and warnings on the control and display unit enable the system to be monitored during operation, thereby ensuring a very high level of safety.
Steering axle
The steer axle is fully floating in the chassis to ensure excellent grip even on non-level surfaces.
Hydraulic steering
The height and tilt angle of the steering column are adjustable and can be set to suit all operators. The steer cylinder of the hydrostatic steering is integrated in the steer axle and is controlled by the power steering.
Electric steering (o)
The electric steering offers a high level of efficiency and ergonomics. The height and tilt angle of the steering column are adjustable and can be set to suit all operators. The low cross-section means the operator has the largest possible legroom at all times. The steering is particularly smooth, offering a high level of efficiency. This significantly reduces the overall energy consumption. Depending on the display version the steer angle is shown in the display unit (optional).
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• 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
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