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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