Jungheinrich EFX 413 User manual

EFX 410 / 413 03.13
Operating instructions
51296679
04.19
en-GB
EFX 410
EFX 413

2

Declaration of Conformity
Manufacturer
Jungheinrich AG, 22039 Hamburg, Germany
Description
Industrial truck
Type Option Serial no. Year of
manufacture
EFX 410
EFX 413
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 12
4 Proprietor responsibilities 14
5 Adding attachments and/or optional equipment 14
.
B Truck Description 15
.
1 Application 15
2 Travel direction definition 17
3 Assemblies and Functional Description 18
3.1 Functional Description 18
3.2 Assembly Overview 24
4 Technical Specifications 26
4.1 Performance data 28
4.2 Dimensions (as per data plate) 29
4.3 Mast versions 33
4.4 Weights 35
4.5 Wheels, chassis 38
4.6 Engine Data 39
4.7 EN norms 39
4.8 Conditions of use 41
4.9 Electrical requirements 42
5 Identification points and data plates 43
5.1 Indication Points 43
5.2 Data plate 45
5.3 Truck capacity plate 46
5.4 Attachment capacity plate 47
5.5 Jack contact points 47
6 Stability 48
.
C Transport and Commissioning 49
.
1 Transport 49
2 Lifting by crane 51
2.1 Lifting by crane with mast assembled 52
2.2 Lifting the basic truck by crane 54
2.3 Lifting the mast by crane 56
2.4 Lifting the battery by crane 58
3 Securing the truck during transport 60
3.1 Mast transport retainer 60
3.2 Basic truck transport retainer 62
3.3 Transport retainer for basic truck with the mast assembled 64
4 Using the Truck for the First Time 66
4.1 Moving the industrial truck without a battery 66
4.2 Installing and removing the mast 66
4.3 Commissioning 68
4.4 Tilt safety device 69
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.
D Battery - Servicing, Recharging, Replacement 71
.
1 Safety Regulations Governing the Handling of Lead-Acid Batteries 71
1.1 General notes on handling batteries 72
2 Battery types 73
2.1 Dimensions of the battery compartment 74
3 Exposing the battery 76
4 Charging the battery 78
5 Battery removal and installation 82
6"Battery lock" sensors (o) 86
.
E Operation 89
.
1 Safety Regulations for the Operation of the
Forklift Truck 89
2 Displays and Controls 92
2.1 Controls and displays on the control panel 92
2.2 Driver's display 97
2.3 Hourmeter 103
2.4 "Bar display" battery discharge indicator 104
2.5 "Percentage display" battery discharge indicator (o) 106
2.6 Driver's display function symbols 108
3 Preparing the Truck for Operation 117
3.1 Checks and operations to be performed before starting daily operation 117
3.2 Entry and exit 121
3.3 Setting up the operator position 122
3.4 Checking, putting on and taking off the seat belt 127
4 Industrial Truck Operation 131
4.1 Safety regulations for truck operation 131
4.2 Preparing the truck for operation 138
4.3 Preparing the truck for operation with an additional access code (o) 139
4.4 Date and time setting 143
4.5 Checks and operations to be carried out when the truck is operational 145
4.6 Main Lift referencing 147
4.7 Emergency Disconnect 151
4.8 Travel 153
4.9 Steering 157
4.10 Brakes 157
4.11 Negotiating narrow aisles 159
4.12 Diagonal travel 170
4.13 Lifting / lowering – outside and inside narrow aisles 171
4.14 Traversing / rotating outside and inside narrow aisles 175
4.15 Simultaneous traversing/rotation outside and inside narrow aisles 181
4.16 Parking the truck securely 191
5 Order picking and stacking 193
5.1 Adjusting the forks 193
5.2 Replacing the forks 195
5.3 Lifting, transporting and depositing loads 199
6 Troubleshooting 207
6.1 Troubleshooting 207
6.2 Emergency stop device 211
6.3 Load handler emergency lowering 211
6.4 Travel cutout override (o) 215
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6.5 Lift cutout override (o) 217
6.6 Lower cutout override (o) 219
6.7 End of aisle safety device (o) 221
6.8 WG emergency operation (event messages 3670 / 3752) 223
6.9 Recovering the truck from a narrow aisle / Moving the truck without a
battery 224
7Personal safety system (o) 237
7.1 Personal Protection System (PPS) 237
7.2 Functional description 238
7.3 Environmental awareness 239
7.4 Cleaning the laser scanner front screen 240
7.5 Displays on the seven segment display and indicator light (LED) 241
7.6 Daily checks before starting the Personal Protection System 243
7.7 Personal safety system 244
8 Optional equipment 247
8.1 Sideshifter / Fork positioner (o) 247
8.2 Laser beam rack compartment display (o) 253
8.3 Telescopic forks (o) 254
8.4 Operator-specific settings (o) 257
8.5 Fire extinguisher (o) 264
8.6 Rack Height Select (o) 265
8.7 Horizontal positioning (o) 281
8.8 Weighing system (o) 296
8.9 Camera system (o) 298
8.10 Working platform (o) 300
8.11 ISM access module (o) 309
8.12 Rear view mirror (o) 310
8.13 Floor-Spot (o) 311
.
F Industrial Truck Maintenance 317
.
1 Operational Safety and Environmental Protection 317
2 Maintenance Safety Regulations 319
2.1 Working on the electrical system 320
2.2 Consumables and used parts 320
2.3 Wheels 321
2.4 Attachment Repairs and Inspection 321
2.5 Lift chain inspection 322
2.6 Hydraulic system 324
3 Lubricants and Lubrication Schedule 326
3.1 Handling consumables safely 326
3.2 Lubrication Schedule 328
3.3 Consumables 329
4 Maintenance and repairs 330
4.1 Preparing the truck for maintenance and repairs 330
4.2 Lifting and jacking up the truck safely 332
4.3 Drive compartment cover disassembly/assembly 334
4.4 Checking electrical fuses 336
4.5 Cleaning 340
4.6 Lift chain servicing 344
4.7 Lubricate the lift chains, clean and grease the contact surfaces in the
mast sections 344
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4.8 Checking the hydraulic oil level 346
4.9 Restoring the truck to service after maintenance and repairs 350
5 Decommissioning the industrial truck 351
5.1 Prior to decommissioning 352
5.2 During decommissioning 353
5.3 Restoring the truck to service after decommissioning 354
6 Safety tests to be performed at intervals and after unusual incidents 355
7 Final de-commissioning, disposal 356
8 Human vibration measurement 356
.
G Maintenance, Inspection and Changing of Maintenance
Parts Requiring Replacement 357
.
1 Maintenance Contents EFX 410-413 358
1.1 Owner 358
1.2 Customer Service 362
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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.
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.

0506.GB
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0506.GB
2

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 199.
The following operations are in accordance with regulations and are permitted:
– Lifting, lowering and transporting of loads.
– When transporting a load outside the narrow aisle, always keep it as low as
possible allowing for ground clearance.
– Negotiating narrow aisles.
• The racking systems and the truck must be equipped to allow operation in
narrow aisles.
• The safety clearances required by the manufacturer (design safety clearance)
must be adhered to, see page 12 and see page 15.
The following operations are prohibited:
– Carrying and lifting passengers.
– Pushing or pulling loads.
– Driving on slopes and inclines.
– Driving on ramps and docks.
– Towing trailers.
– Transporting hanging loads.
– Transporting swaying loads.
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3 Approved application conditions
WARNING!
Operation under extreme conditions
Operating the industrial truck under extreme conditions can lead to 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.
uIt is forbidden to operate the truck in areas where there is a risk of explosion.
uIt is forbidden to operate the truck near the unprotected active components of
electrical equipment.
– Operation in industrial and commercial environments.
– Operate the truck in enclosed indoor areas with a maximum air humidity of 95%,
non-condensing.
– Permissible temperature range of 5°C to 40°C.
– Application only on level surfaces in accordance with VDMA guideline.
– Do not exceed the permissible surface and spot load limits on the travel routes.
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Safety clearance (design safety distance)
The racking systems must be set up for the EFX. The safety clearance in the narrow
aisle required by the manufacturer between the following truck components and the
racking system must be observed:
– The safety clearance on both sides between the swivel traverse frame and the
racking and between the racking and the stored goods.
– The safety clearance on both sides between the support arm and the racking and
also the stored goods.
– The safety clearance on both sides between the correctly raised load and the
racking and also the stored goods.
For the safety clearance in the narrow aisle required by the manufacture depending
on the type of guidance in the narrow aisle and the lift height (h3) refer to the
following table:
Truck guidance in the narrow
aisle Lift height (h3)Safety clearance
Wire-guided truck depending on the lift
height (h3)125 mm
Rail-guided truck
to 4000 mm 90 mm
to 6000 mm 100 mm
from 6000 mm 125 mm
ZThe safety distance may, however, increase if special attachments are fitted.
WARNING!
An insufficient safety distance between the guided truck and the rack can
result in accidents
Failure to maintain the required and prescribed safety distance can result in
collisions between the guided truck and the rack.
uThe maximum travel speeds are reduced if the safety distances required and
prescribed by the manufacturer are not maintained.
uYou must observe the minimum safety distance in accordance with EN 1726-2
item 7.3.2 90 mm. Do not operate the truck in these narrow aisles.
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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.
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B Truck Description
1 Application
The EFX is an electric tri-lateral stacker.
The EFX is designed to lift. lower and transport on level surfaces in accordance with
the VDMA guideline.
Open bottom pallets or pallets with diagonal boards can be lifted outside the range of
the load wheels. Loads can be stacked, unstacked and transported over long
distances.
If the EFX is used for assembly work with an correspoding working platform, the
working platform must be supplied or approved in writing by the manufacturer.
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Safety clearance (design safety distance)
The racking systems must be set up for the EFX. The safety clearance in the narrow
aisle required by the manufacturer between the following truck components and the
racking system must be observed:
– The safety clearance on both sides between the swivel traverse frame and the
racking and between the racking and the stored goods.
– The safety clearance on both sides between the support arm and the racking and
also the stored goods.
– The safety clearance on both sides between the correctly raised load and the
racking and also the stored goods.
For the safety clearance in the narrow aisle required by the manufacture depending
on the type of guidance in the narrow aisle and the lift height (h3) refer to the
following table:
Truck guidance in the narrow
aisle Lift height (h3)Safety clearance
Wire-guided truck depending on the lift
height (h3)125 mm
Rail-guided truck
to 4000 mm 90 mm
to 6000 mm 100 mm
from 6000 mm 125 mm
ZThe safety distance may, however, increase if special attachments are fitted.
WARNING!
An insufficient safety distance between the guided truck and the rack can
result in accidents
Failure to maintain the required and prescribed safety distance can result in
collisions between the guided truck and the rack.
uThe maximum travel speeds are reduced if the safety distances required and
prescribed by the manufacturer are not maintained.
uYou must observe the minimum safety distance in accordance with EN 1726-2
item 7.3.2 90 mm. Do not operate the truck in these narrow aisles.
ZThe ground surface must comply with the VDMA guideline.
Guide rails must be provided in the narrow aisles for the rail guidance system.
Vulkollan guide wheels attached to the truck chassis guide the truck between the
guide rails.
A guide wire must be routed in the ground for the wire guidance system. The signals
from the wire are received by sensors on the chassis and processed by the on-board
computer.
ZThe capacity is shown on the data plate.
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2 Travel direction definition
The following determinations have been made for travel direction specification:
1
4
2
3
Item Travel direction
1 Left
2 Drive direction
3 Load direction
4 Right
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3 Assemblies and Functional Description
3.1 Functional Description
Safety mechanisms
– An enclosed truck geometry with rounded edges ensures safe truck handling. The
overhead guard protects the operator from falling objects.
– The drive wheel and the load wheels are protected by a solid skirt. A slight danger
nevertheless remains for third parties.
– The emergency disconnect switch immediately disables all truck functions in
hazardous situations.
– Travelling, lifting and lowering can only be activated when the dead man's switch
is depressed.
– Transverse and swivel operations can only be activated when the dead man's
switch is not depressed.
– Line-rupture safety valves in the lift cylinders prevent the load from lowering in the
event of a hydraulic system failure.
Dead man's switch
When the truck is ready for operation, the following truck functions will be enabled or
locked when the dead man's switch in the footwell is depressed.
ZPreparing the truck for operation, see page 138 or see page 139.
– Press and hold down on the dead man's switch.
– Drive functions are enabled.
– Steering functions are enabled.
– Brake functions are enabled.
– Lifting and lowering functions are enabled.
– Traverse and swivel functions are disabled.
– Dead man's switch is not depressed:
– Traverse and swivel functions are enabled.
– Steering functions are enabled.
– Brake functions are enabled. After releasing the dead man's switch, the parking
brake is applied when the truck comes to a halt (prevents the truck from
accidentally rolling off).
– Travel functions are disabled.
– Lifting and lowering functions are disabled.
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