Jungheinrich EFG 213 User manual

Operating Instructions
51099986
EFG 213-320
G
06.08-
07.11

3
09.09 EN
Declaration of Conformity
Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or his authorized representative in the Community
Additional information
Authorised signatory
Date
GEU Declaration of Conformity
The signatories hereby certify that the specified powered industrial truck conforms to
the EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Mag-
netic Compatibility, EMC) including their amendments as translated into national leg-
islation of the member countries. The signatories are individually empowered in each
case to compile the technical documentation.
Type Option Serial No. Year of construc-
tion
EFG 213
EFG 215
EFG 216k
EFG 216
EFG 218k
EFG 218
EFG 220
EFG 316k
EFG316
EFG318k
EFG 318
EFG 320

09.09 EN
4

0108.GB
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:
FUsed before safety instructions which must be observed to avoid danger to
personnel.
MUsed before notices which must be observed to avoid material damage.
ZUsed before notices and explanations.
tUsed to indicate standard equipment.
oUsed 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: [phone]
www.jungheinrich.com

0108.GB

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Table of contents
A Correct Use and Application
B Truck Description
1 Application ........................................................................................... B 1
2 Assemblies and Functional Description .............................................. B 2
2.1 Truck ................................................................................................... B 3
3 Standard Version Specifications ......................................................... B 4
3.1 EFG 213-220 performance data ......................................................... B 4
3.2 EFG 316-320 performance data ......................................................... B 5
3.3 EFG 213-220 dimensions ................................................................... B 6
3.4 EFG 316-320 dimensions ................................................................... B 8
3.5 EFG 213-220 weights ......................................................................... B 10
3.6 EFG 316-320 weights ......................................................................... B 10
3.7 EFG 213-220 tyres .............................................................................. B 11
3.8 EFG 316-320 tyres .............................................................................. B 11
3.9 EFG 213-320 mast versions ............................................................... B 12
3.10 EN norms ............................................................................................ B 13
3.11 Conditions of use ................................................................................ B 13
4 Identification points and data plates .................................................... B 14
4.1 Truck data plate .................................................................................. B 16
4.2 Truck load chart .................................................................................. B 16
4.3 Fork load diagram (basic model) ......................................................... B 17
4.4 Attachment load chart ......................................................................... B 17
C Transport and Commissioning
1 Transport ............................................................................................. C 1
2 Lifting by crane .................................................................................... C 1
3 Securing the truck during transport ..................................................... C 2
4 Using the truck for the first time .......................................................... C 3
5 Operating the truck without its own drive system ................................ C 3
6 Moving the truck when the electric/hydraulic steering has failed ........ C 4
7 Towing the Truck ................................................................................. C 4

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D Battery Maintenance, Charging & Replacement
1 Safety regulations for handling acid batteries ..................................... D 1
2 Battery types ....................................................................................... D 2
3 Battery removal and installation .......................................................... D 3
3.1 Removal and installation using a multi-adapter (o) ............................ D 3
3.2 Removal and installation using a worktable for crane loading (o) ...... D 5
3.3 Removal and installation using a fork shoe (o) .................................. D 6
3.4 Removal and assembly for maintenance ............................................ D 7
4 Charging the battery ............................................................................ D 8
4.1 Charging the battery with a stationary charger ................................... D 8
4.2 Charging the battery with an on-board charger ................................... D 9
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
2.1 SOLOPILOT / MULTIPILOT ................................................................ E 4
2.2 Armrest control panel switch (o) ........................................................ E 5
2.3 Side pocket control panel switch (o) .................................................. E 5
2.4 Dashboard control panel and driver’s display ..................................... E 6
2.5 Battery Discharge Indicator, Battery Discharge Monitor, Hourmeter .. E 11
3 Starting up the truck ............................................................................ E 12
3.1 Checks and operations to be performed before starting daily
operation ............................................................................................. E 12
3.2 Adjusting the driver’s seat ................................................................... E 12
3.3 Safety restraint belt ............................................................................. E 14
3.4 Mechanical safety restraint system (o) .............................................. E 15
3.5 Adjusting the steering column ............................................................. E 16
3.6 To prepare the truck for operation ....................................................... E 16
4 Industrial Truck Operation ................................................................... E 17
4.1 Safety regulations for truck operation ................................................. E 17
4.2 Travel, steering, braking ...................................................................... E 19
4.3 Operating the lift mechanism and attachments (SOLOPILOT t) ....... E 22
4.4 Operating the lift mechanism and attachments (MULTIPILOT o) ...... E 24
4.5 Emergency lowering ............................................................................ E 26
4.6 Adjusting the forks ............................................................................... E 26
4.7 Collecting, Lifting and Transporting Loads. ......................................... E 27
4.8 Parking the truck safely ....................................................................... E 28
4.9 Towing trailers ..................................................................................... E 29
5 Troubleshooting .................................................................................. E 30
5.1 Temperature control ............................................................................ E 30

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F Industrial Truck Maintenance
1 Operational Safety and Environmental Protection ...............................F 1
2 Maintenance Safety Regulations .........................................................F 1
3 Servicing and Inspection ......................................................................F 3
4 Maintenance checklist ..........................................................................F 4
5 Lubrication Schedule ............................................................................F 6
5.1 Consumables .......................................................................................F 7
6 Maintenance Instructions .....................................................................F 8
6.1 Preparing the truck for maintenance and repairs .................................F 8
6.2 Opening the rear panel ........................................................................F 8
6.3 Checking the wheel attachments. ........................................................F 8
6.4 Rear wheel rated condition ..................................................................F 8
6.5 Checking the hydraulic oil level ............................................................F 9
6.6 Check transmission oil level .................................................................F 10
6.7 Draining the oil .....................................................................................F 10
6.8 Adding oil .............................................................................................F 10
6.9 Replacing the hydraulic oil filter ...........................................................F 10
6.10 Seat belt maintenance .........................................................................F 11
6.11 Checking electrical fuses .....................................................................F 12
6.12 Recommissioning .................................................................................F 15
7 Decommissioning the industrial truck ...................................................F 15
7.1 Prior to decommissioning .....................................................................F 15
7.2 During decommissioning ......................................................................F 15
7.3 Returning the truck to operation after decommissioning ......................F 16
8 Safety checks to be performed at intervals and after unusual events ..F 16
9 Final de-commissioning, disposal ........................................................F 16

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1
0506.GB
Appendix
JH Traction Battery Operating Instructions
ZThese operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
MIf using a battery with closed EPzV and EPzV ironclad plates, this must first be
discussed with the manufacturer.

0506.GB
2

A 1
0504.GB
A Correct Use and Application
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 operating instructions is an industrial truck
designed for lifting and transporting loads.
It must be used, operated and serviced in accordance with the present instructions.
All other types of use lie 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 and
the load diagram are binding with regard to the maximum load capacity. The owner
must ensure that any damaged and/or illegible load diagrams are replaced.
The industrial truck must not be used in fire or explosion endangered areas, or areas
threatened by corrosion or excessive dust.
Proprietor responsibilities:
For the purposes of the present operator manual the
“proprietor” 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 danger 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 operating instructions 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.
Attaching accessories: The mounting or installation of additional equipment which
affects or enhances 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.
Trailing and towed loads: The truck may only be used for trailing or towed loads for
which the truck has been approved.

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B 1
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B Truck Description
1 Application
The EFG is a three- or four-wheel electric sit-down counterbalanced truck. It is
cantilevered and the load handler mounted on the front of the truck can unload lorries
without hindrance and deposit the load on ramps or in aisles. Closed bottom pallets
can also be lifted.
Truck models and maximum capacity:
Type Max. capacity Load centre of gravity
EFG 213 1,300 kg 500 mm
EFG 215 1500 kg 500 mm
EFG 216k 1600 kg 500 mm
EFG 216 1600 kg 500 mm
EFG 218k 1800 kg 500 mm
EFG 218 1800 kg 500 mm
EFG 220 2000 kg 500 mm
EFG 316k 1600 kg 500 mm
EFG 316 1600 kg 500 mm
EFG 318k 1800 kg 500 mm
EFG 318 1800 kg 500 mm
EFG 320 2000 kg 500 mm

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2 Assemblies and Functional Description
Item Description Item Description
1tDriver's seat 8 tLoad handler
2tOverhead guard 9 tFork carriage
3tMast 10 tDrive axle
4tSteering wheel 11 tBattery door
oMultifunction steering wheel 12 oOn-board charger
(in battery compartment)
5tSOLOPILOT 13 tSteering axle
oMULTIPILOT 14 tTrailer coupling
6tDashboard control panel 15 tCounterweight
7tEMERGENCY DISCONNECT
switch
t= Standard equipment o = Optional equipment
1
2
3
4
5
7
6
8
9
10
11
12
13
14
15

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2.1 Truck
Safety mechanisms: The overhead guard (2) protects the driver from falling objects.
Pressing the EMERGENCY DISCONNECT switch rapidly disconnects all electrical
functions in hazardous situations. Travelling and lifting can only be activated when
the driver is seated. The dashboard control panel (6) displays the truck information.
Steering: The travel speed reduces as a function of the steering angle
(“CurveControl”). The steering angle is shown in the display.
Operator position: The driver’s seat (1) is a “comfort” seat, the steering column is
adjustable. There are storage facilities for paper and the driver's personal items.
The control and warning displays on the dashboard control panel (6) enable the
system to be monitored during operation, thereby ensuring a very high level of safety.
Electrical/Electronic System: The driver can choose from five travel programs,
depending on the load and the environment: from maximum performance to energy
saving. The latest threephase system using a CAN Bus allows for rapid
troubleshooting. The advanced controller is simple, safe and flexible.
Drive System and Brakes: The 2-motor front drive provides maximum traction to the
drive wheels at all times. Each motor receives the exact power it requires in
proportion to the steering angle. The wheels do not spin and energy is converted
efficiently.
The mechanical disk brake which acts as a service brake is maintenance-free.
Encapsulated, it allows the truck to be used even in hostile environments. The truck
also brakes to a halt regeneratively via the traction motors. This minimizes energy
consumption.
The parking brake is electrically actuated. It is also used for emergency braking.
A warning indicator appears when the parking brake is applied.
Brake system faults are shown on the driver’s display.
Emergency Stop Safety Feature: The emergency stop is controlled by the steering
and traction controllers. If an error is detected the truck automatically brakes to a halt.
Control displays on the driver’s display indicate the emergency stop. Every time the
truck is switched on, the system performs a self-diagnosis which only releases the
parking brake (emergency stop) if the functionality test is positive.
Hydraulic System: All functions must be performed sensitively. To ensure greater
efficiency, a hydraulic unit and a steering motor operate independently of each other.
The micro pressure filter can be replaced from the top (without spilling hydraulic oil).
Mast: The maximum strength steel sections are narrow, allowing for good fork
visibility in particular with the three-stage mast. The lift rails and the fork carriage run
on permanently-lubricated and hence maintenance-free angled rollers.

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3 Standard Version Specifications
ZTechnical specification details in accordance with VDI 2198. Technical modifications
and additions reserved.
3.1 EFG 213-220 performance data
*) with vertical mast
Description EFG
213 215 216k 218k 220
216 218
QCapacity
(where C = 500 mm) *) 1300 1500 1600 1800 2000 kg
CLoad centre of gravity
distance 500 500 500 500 500 mm
Travel speed
with / without load 16/16 16/16 16/16 16/16 16/16 km/h
Raise lift speed
with / without load 0.48/0.60 0.46/0.60 0.49/0.60 0.44/0.55 0.40/0.55 m/s
Lower lift speed
with / without load 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 m/s
Gradeability
(30 min)
with / without load
7.6/12.5 7.3/12.3
7.3/12.3 6.2/10.7
5.7/10.4 %
7.0/11.5 5.9/10.5
Max. gradeability
(5 min)
with / without load
28.0/35.0 27.0/35.0 27.0/35.0
26.0/35.0
24.0/35.0 %
25.0/35.0
Acceleration (10m)
with / without load 3.6/3.2 3.8/3.4 3.8/3.4 3.9/3.5 4.0 / 3.5 s

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3.2 EFG 316-320 performance data
*) with vertical mast
Description EFG
316k 316 318k 318 320
Q
Capacity
(where C =
500 mm) *)
1600 1600 1800 1800 2000 kg
CLoad centre of
gravity distance 500 500 500 500 500 mm
Travel speed
with / without load 17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 17.0/17.0 km/h
Raise lift speed
with / without load 0.49/0.60 0.49/0.60 0.44/0.55 0.44/0.55 0.40/0.55 m/s
Lower lift speed
with / without load 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 0.55/0.55 m/s
Gradeability
(30 min)
with / without load
7.3/12.3 7/11.5 6.2/10.7 5.9/10.5 5.7/10.4 %
Max. gradeability
(5 min rating)
with / without load
27/35 27/35 26/35 25/35 24/35 %
Acceleration (10m)
with / without load 3.8/3.4 3.8/3.4 3.9/3.5 3.9/3.5 4/3.5 s

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3.3 EFG 213-220 dimensions
ZAll dimensions in mm
1) = + 25 mm DZ mast
Description EFG
213 215 216k 218k 220
216 218
h1Mast height retracted 2000 2000 2000 2000 2000
h2Free lift 150 150 150 150 150
h3Lift 3000 3000 3000 3000 3000
h4Mast height extended 3560 3560 3560 3587 3587
h6Overhead guard height 2040 2040 2040 2040 2040
h7Seat height 920 920 920 920 920
h10 Tow height 560 560 560 560 560
L1Length including forks 2924 2924 3037 3037 3145
3145 3145
L2Length incl. fork shank 1) 1774 1774 1887 1887 1995
1995 1995
b1 Overall width 1060 1060 1060 1120 1120
e Fork width 100 100 100 100 100
m1
Ground clearance
with load below mast 80 80 80 80 80
m2
Centre wheel base ground
clearance 100 100 100 100 100
Ast Working Aisle Width
800 x 1200 longitudinal pallets 3226 3226 3339 3339 3446
3446 3446
Ast Working Aisle Width
1000 x 1200 traverse pallets 3104 3104 3216 3216 3323
3323 3323
WaTurning radius 1440 1440 1548 1548 1655
1655 1655
x Load distance 1) 335 335 340 340 340
y Wheel base 1249 1249 1357 1357 1465
1465 1465

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h6
h7
h
y
l
x
10
m
s
2
1
m2
L2
h2
h1
h3
h4
L1
l6
b12
RWa
b
a
e
c
Q
Ast
2
a