Jungheinrich EFG 110k User manual

EFG 110-115 10.09
Operating instructions
51151449
10.20
en-GB
EFG 110k
EFG 110
EFG 113
EFG 115

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
EFG 110k
EFG 110
EFG 113
EFG 115
On behalf of
Date
EU DECLARATION OF CONFORMITY
The undersigned hereby declare that the powered truck described in detail complies
with the current versions of European Directives 2006/42/EG (Machinery Directive)
and 2014/30/EU (Electromagnetic Compatibility - EMC). The manufacturer is
authorised to compile the technical documentation.
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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.
NOTICE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
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Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
Jungheinrich Aktiengesellschaft
Friedrich-Ebert-Damm 129
22047 Hamburg - Germany
Tel: [phone]
www.jungheinrich.com
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Contents
.
A Correct Use and Application 11
.
1 General 11
2 Correct application 11
3 Approved application conditions 13
3.1 Internal Operation in Cold Stores with Cold Store Equipment (o) 13
4 Proprietor responsibilities 14
5 Adding attachments and/or optional equipment 14
6 Removal of components 14
.
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 20
3.1 Performance data 21
3.2 Dimensions 22
3.3 Weights 24
3.4 Mast versions 24
3.5 Tyre type 25
3.6 Engine Data 26
3.7 EN norms 27
3.8 Conditions of use 28
3.9 Electrical Requirements 28
3.10 Specifications according to RED guideline (Radio Equipment
Directive) for radio units 29
4 Identification points and data plates 30
4.1 Indication Points 30
4.2 Data plate 32
4.3 Truck capacity plate 33
4.4 Attachment capacity plate 35
5 Stability 36
5.1 Wind loads 37
.
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 General notes on handling batteries 47
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1.1 Potential hazards 47
1.2 Touch voltage hazard 48
2 Safety Regulations for Handling Lead-Acid Batteries 49
3 Battery types 50
4 Battery dimensions 50
5 Exposing the battery 51
6 Battery removal and installation 53
7 Charging the battery 55
7.1 Charging the battery with a stationary charger 55
8 Closing the battery cover 57
.
E Operation 59
.
1 Safety Regulations for the Operation of Forklift Trucks 59
2 Displays and Controls 61
2.1 Control panel with display unit 66
2.2 Side compartment control panel switch (o) 68
2.3 Instrument panel switches (o) 68
2.4 Display 69
3 Preparing the Truck for Operation 71
3.1 Checks and operations to be performed before starting daily operation 71
3.2 Entry and exit 74
3.3 Trucks with reduced headroom (o) 74
3.4 Setting up the operator position 75
3.5 Restraint systems 80
3.6 Seat Belt 81
4 Industrial Truck Operation 83
4.1 Safety regulations for truck operation 83
4.2 Preparing the truck for operation 86
4.3 Setting the time 87
4.4 Parking the truck securely 88
4.5 Emergency Disconnect 89
4.6 Travel 90
4.7 Steering 92
4.8 Brakes 93
4.9 Adjusting the forks 96
4.10 Replacing the forks 97
4.11 Lifting, transporting and depositing loads 98
4.12 Operating the lift mechanism and integrated attachments 101
4.13 Safety instructions for operating additional attachments 108
4.14 Operating additional attachments for the SOLO-PILOT 113
4.15 Operating additional attachments for the Multi Pilot 115
4.16 Fitting additional attachments 116
5 Towing trailers 119
6 Optional Equipment 121
6.1 Assistance systems 121
6.2 BODYGUARD 123
6.3 Panel door 123
6.4 Removable load backrest 124
6.5 Lift cutout override 126
6.6 Fire extinguisher 126
6.7 Tilt angle display 127
6.8 Rockinger coupling with hand lever or remote control 127
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6.9 Camera system 128
6.10 Control layout “N” 129
6.11 Floor-Spot 130
7 Troubleshooting 132
7.1 Troubleshooting 132
7.2 Operating the truck without its own drive system 134
7.3 Emergency lowering 135
.
F Industrial Truck Maintenance 137
.
1 Spare Parts 137
2 Operational Safety and Environmental Protection 138
3 Maintenance Safety Regulations 139
3.1 Consumables and used parts 140
3.2 Wheels 140
3.3 Attachment Repairs and Inspection 140
3.4 Lift Chains 141
3.5 Hydraulic system 142
4 Lubricants and Lubrication Schedule 143
4.1 Handling consumables safely 143
4.2 Lubrication Schedule 145
4.3 Consumables 146
5 Maintenance and repairs 148
5.1 Preparing the truck for maintenance and repairs 148
5.2 Lifting and jacking up the truck safely 149
5.3 Opening the battery panel 150
5.4 Checking the wheel attachments. 152
5.5 Replacing wheels 153
5.6 Hydraulic system 155
5.7 Check the gear oil level 157
5.8 Adding window washer system fluid 158
5.9 Checking electrical fuses 159
5.10 Cleaning 162
5.11 Working on the electrical system 165
5.12 Restoring the truck to service after maintenance and repairs 166
6 Decommissioning the industrial truck 167
6.1 Prior to decommissioning 168
6.2 During decommissioning 168
6.3 Restoring the truck to service after decommissioning 169
7 Safety tests to be performed at intervals and after unusual incidents 170
8 Final de-commissioning, disposal 171
9 Human vibration measurement 171
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 173
.
1 Maintenance Contents EFG 110-115 174
1.1 Owner 174
1.2 Customer Service 178
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A Correct Use and Application
1 General
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.
2 Correct application
NOTICE
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,see page 98.
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The following operations are in accordance with regulations and are permitted:
– Lifting and lowering of loads.
– Stacking and retrieving loads
– Transporting lowered loads over short distances.
– The mast must be tilted back when transporting loads that are not secured
against slipping and falling.
– Picking up and using attachments and accessories approved by the manufacturer;
this may require additional approval from local authorities or an expert opinion.
– When travelling with a load, bring the mast into tilted-back position.
– The mast must be tilted back when transporting loads that are not secured against
slipping and falling.
– The operator must adjust the travel speed so that the load does not slip off the
load handler during acceleration and braking, changes in direction and when
driving on ramps.
– Occasional towing of trailer loads with the trailer coupling.
ZWhen towing trailers, the load must be secured on the trailer. The permissible trailer
load must not be exceeded.
The following operations are prohibited:
– Do not travel with a raised load (>30 cm).
– Carrying and lifting persons without approved attachments or optional equipment
a)
– Pushing or pulling loads, with the exception of occasional towing of trailers with
the trailer coupling
– Transporting suspended loads without expert certification and without authorised
optional equipment
ZIf the truck is to be operated with suspended loads, proof of sufficient operational
stability under local operating conditions must be obtained from a specialist
assessor.
a) Lifting passengers with a working platform or a work basket may be
permitted in some countries. This must be verified by the owner.
ZGermany: DGUV information 208-031 (BGI/GUV-5183) Use of Working Platforms on
Industrial Trucks with Masts
ZAustralia: AS 2359.1 Powered Industrial Trucks, General Requirements; AS 2359.2
Powered Industrial Trucks, Operations
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3 Approved application conditions
WARNING!
Do not exceed the permissible surface and point loading limits on the travel paths.
A second person is required as a lookout at blind spots.
The operator must ensure that the loading ramp/dock cannot move or come loose
during loading/unloading.
WARNING!
Use under extreme conditions
Using the truck under extreme conditions can result in malfunctions and accidents.
uSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
uThe truck cannot be used in areas at risk of explosion.
uIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
– 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 point load limits on the travel routes.
– Operation only on travel paths 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.
3.1 Internal Operation in Cold Stores with Cold Store Equipment (o)
In addition to the permissible operating conditions in industrial and commercial
environments, the truck remains primarily in cold stores. The truck should only leave
the cold store briefly to hand over a load.
– Permissible temperature range -30°C to +40°C.
– Maximum air humidity 95% non-condensing.
– Thawing is permissible only if the truck can be subsequently dried thoroughly.
– In cold store areas below -20°C the truck must be operated permanently and
should not be parked securely for more than 15 minutes.
– Do not charge the battery below +5°C.
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4 Proprietor 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.
NOTICE
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.
5 Adding 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.
6 Removal of components
It is forbidden to modify or remove truck components, particularly protective and
safety equipment.
ZIf in doubt, contact the manufacturer's customer service department.
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B Truck Description
1 Application
The EFG 110 - 115 is a three-wheel electric sit-down forklift truck. It is a cantilever
counterbalanced truck which can lift, transport and deposit loads using the load
handler attached in front.
Closed bottom pallets can also be lifted.
1.1 Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model name.
EFG110
EFG Model name
1 Series
10 Rated 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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2 Assemblies and Functional Description
2.1 Travel direction definition
The following determinations have been made for travel direction specification:
1
2 3
4
The following conventions have been agreed for travel direction specification:
Item Travel direction
1 Left
4 Reverse
2 Forward
3 Right
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2.2 Assembly Overview
1
2
3
4
5
6
7
8
9
10
11
12
13
Item Component
1tDriver's seat
2tOverhead guard
3tMast
4tSteering wheel
5tControl and display unit
6tLifting mechanism control
7tEmergency Disconnect switch
8tForks
9tFork carriage
10 tBattery cover
11 tDrive
12 tTrailer coupling
13 tCounterweight
tStandard equipment
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2.3 Functional 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
A low steer effort of 15 N as well as a favourable transmission ratio of 5 steering
wheel revolutions for an 180° steer angle. A hydraulic steer motor actuates the drive
wheel via a gear wheel pair. Efficient energy deployment through the load sensing
system. The steering column is adjustable.
Wheels
There is a choice of super elastic or fully rubber tyres as well as optional pneumatic
tyres.
Brake System
The hydraulically activated drum servo brake acting on both front wheels provides
effective deceleration with minimal pedal force. The truck also brakes to a halt
regeneratively via the traction motor. This makes the foot brake virtually redundant,
minimising energy consumption and brake wear.
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Drive system
The entire drive unit is enclosed in the counterweight. The steered rear wheel is also
the drive wheel. A fixed, low-noise three-phase motor is driven via a transmission.
The electronic traction controller ensures the smooth rotation of the drive motor and
as a result consistently smooth travel, powerful acceleration and electrically
controlled braking with energy recovery. With steer angle detection (o) the system
automatically reduces the travel speed as a function of the steer angle.
Hydraulic system
A multi-pilot valve allows for sensitive operation of the functions via the controls. A
speed-controlled hydraulic pump ensures a proportionate and efficient supply to the
hydraulic functions.
Mast
Two or three-stage masts, optionally with free lift function; narrow mast sections
ensure excellent visibility of the forks and attachments. Fork carriage and mast run
on permanently lubricated and hence maintenance-free support rollers.
Attachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.
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3 Technical Specifications
All technical details refer to standard trucks.
Values indicated with *) may vary, depending on the
types of equipment used (e.g. mast, cabin, tyres etc.).
ZThe technical specifications comply with the German "Industrial Truck Data Sheet"
Guidelines.
Technical modifications and additions reserved.
Load centre distance
G
D
DD
G
d
dd
1
22
The load centre distance D of the load handler is specified as the horizontal distance
from the front face and the vertical distance from the upper edge of the load handler.
ZThe capacity plate for standard load handlers specifies valid load centre distances of
500 mm, 600 mm and 700 mm.
The distances d1 and d2 depicted in the illustration between the load handler and the
actual centre of gravity G of the load must be smaller or equal to the load centre
distance D (d1 ≤ D and d2 ≤ D) to avoid the risk of overturning, see page 98.
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