Jungheinrich Electric Lift Truck EFG-Series: 213 215 216 218 220 ac Operating and Maintenance Instructions
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🏷️ Basic Information Identification Make: Jungheinrich Model: EFG-Series Electric Lift Truck Model Variants Covered: 213 ac, 215 ac, 216K ac, 218 ac, 218K ac, 220 ac Codes Series Code: EFG Drive Type: Electric (AC) 👋 Introduction Market Position Segment: Electric Counterbalance Forklift Trucks Target User: Forklift operators, maintenance technicians, service personnel, fleet managers Competitive Analysis Comparable Competitors: Other major electric forklift manufacturers such as Toyota, Hyster-Yale, Crown, Caterpillar, Komatsu (within the same production era and capacity class) Key Features Of Vehicle Power Source: Electric AC motor drive for efficiency and performance Technology: AC drive technology, advanced control systems, potential for optional support systems Key Features Of Manual Value Proposition: Provides essential information for safe and efficient operation, proper maintenance, and basic troubleshooting, ensuring maximum uptime and longevity of the equipment. Completeness Indicator: Original factory documentation ensures accuracy and completeness of information. 📋 Manual Details Coverage Areas Primary Coverage: Operation and Maintenance Instructions Specific Models Covered: Jungheinrich EFG 213 ac, 215 ac, 216K ac, 216 ac, 218 ac, 218K ac, 220 ac Production Period Covered: January 2004 - August 2004 Page Count Estimated Page Count: Varies (typical for factory manuals of this era; actual count not specified but expected to be extensive) Manual Type Type: Original Factory Operating and Maintenance Instructions Language Language: English Format Format: PDF Features: Printable, Searchable Text 📖 Manual Coverage Systems Covered Powertrain: Electric drive system (AC motor), regenerative braking Hydraulics: Lifting device, tilt, side-shift (if equipped), power steering Electrical: Battery system, charging, control systems, indicators, fuses, wiring diagrams (implied) Chassis And Body: Frame, masts, tires, operator's station, identification labels, capacity plates Procedures Included Operation: Correct use, application descriptions, driving, steering, load handling, parking, trailer towing Maintenance: Servicing and inspection, lubrication plan, fluid checks, filter changes, electrical fuse checks, safety checks (UVV) Troubleshooting: Fault location, temperature monitoring Battery Handling: Servicing, recharging, replacing, safety regulations, discharge indicators Transport And Commissioning: Crane transport, securing, first commissioning, moving without drive Operator Adjustments: Seat adjustment, steering column adjustment, safety belt Technical Depth Depth: Comprehensive factory-level detail for operation, routine maintenance, and basic troubleshooting. Includes technical data, lubrication charts, and descriptions of assemblies and functions. Likely includes circuit diagrams for electrical systems, indicated by 'circuit diagrams' in the product description. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable Text Print Quality Printability: Printable Image Quality: High Quality Illustrated Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Type: Electric Motor (AC) Manufacturer: Jungheinrich (likely internal or partnered supplier) Performance Power Output: Specific kW ratings would be found in 'Technical Data' section, varying by model (e.g., 213, 215, 216, 218, 220 implying power progression). Torque: Not explicitly stated, but AC motors provide excellent torque characteristics for material handling. Fuel System Fuel Type: Electricity Battery System: Lead-acid (specified in manual content), with potential for lithium-ion in later models or as an option not detailed here. 🔧 Transmission Standard Type: Electric Drive (AC), likely with single-speed reduction gearing for each drive wheel. Optional Optional Features: Not explicitly detailed in manual outline, but drive programs or performance settings might be adjustable. Features Regenerative Braking: Standard on AC electric forklifts, captured in operating procedures. 📐 Dimensions Exterior General Size: Compact counterbalance design suitable for indoor warehouse and distribution environments. Weights Unladen Weight: Specific weight data in kg will be present in the 'Technical Data' section, varying by model configuration and mast type. Load Capacity: The model numbers (213, 215, 216, 218, 220) likely indicate approximate load capacities in hundreds of kilograms (e.g., 1.3-2.0 tonnes). Exact capacities are detailed on capacity labels and in technical data. Tyre Equipment Tyre Type: Standard tyre equipment specified in Technical Data. Typically cushion tires for indoor use, but options may exist. 🛡️ Safety Features Ratings Compliance Standards: EN standards mentioned, indicating compliance with European safety directives for industrial trucks. UVV (Unfallverhütungsvorschrift) compliance (BGV D27) for safety checks is explicitly stated. Active Features Operator Controls: Ergonomic controls, dashboard switches, operating console switches, Multi Pilot control (optional), safety belt. Warning Systems: LED warning indicators, plain text alarm messages, battery discharge indicator/monitor. Passive Features Operator Protection: Overhead guard (standard on most forklifts), safety belt, operator's station design. Load Handling Safety: Capacity labels for truck, fork tines, and attachments to prevent overloading. 💡 Technology Features Infotainment Display Systems: Dashboard with switches, operating console, and display indicators for truck status, alarms, and driving programs. Plain text alarm messages are a key feature. Driver Assistance Operator Settings: Adjustable driver's seat, adjustable steering column, selectable driving programs (e.g., for efficiency or power). Optional Systems: Automatic/Mechanical Support System (optional) mentioned, indicating advanced operator aids or stabilization features available on certain configurations. Connectivity Data Logging: Operating hour meter mentioned, suggesting basic data logging for maintenance tracking. Advanced telematics might be available but not detailed in this manual excerpt. 🔧...
Forklift operators, maintenance technicians, service personnel, fleet managers
Competitive Analysis
Comparable Competitors:
Other major electric forklift manufacturers such as Toyota, Hyster-Yale, Crown, Caterpillar, Komatsu (within the same production era and capacity class)
Key Features Of Vehicle
Power Source:
Electric AC motor drive for efficiency and performance
Technology:
AC drive technology, advanced control systems, potential for optional support systems
Key Features Of Manual
Value Proposition:
Provides essential information for safe and efficient operation, proper maintenance, and basic troubleshooting, ensuring maximum uptime and longevity of the equipment.
Completeness Indicator:
Original factory documentation ensures accuracy and completeness of information.
Crane transport, securing, first commissioning, moving without drive
Operator Adjustments:
Seat adjustment, steering column adjustment, safety belt
Technical Depth
Depth:
Comprehensive factory-level detail for operation, routine maintenance, and basic troubleshooting. Includes technical data, lubrication charts, and descriptions of assemblies and functions. Likely includes circuit diagrams for electrical systems, indicated by 'circuit diagrams' in the product description.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable Text
Print Quality
Printability:
Printable
Image Quality:
High Quality Illustrated
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Type:
Electric Motor (AC)
Manufacturer:
Jungheinrich (likely internal or partnered supplier)
Performance
Power Output:
Specific kW ratings would be found in 'Technical Data' section, varying by model (e.g., 213, 215, 216, 218, 220 implying power progression).
Torque:
Not explicitly stated, but AC motors provide excellent torque characteristics for material handling.
Fuel System
Fuel Type:
Electricity
Battery System:
Lead-acid (specified in manual content), with potential for lithium-ion in later models or as an option not detailed here.
🔧 Transmission
Standard
Type:
Electric Drive (AC), likely with single-speed reduction gearing for each drive wheel.
Optional
Optional Features:
Not explicitly detailed in manual outline, but drive programs or performance settings might be adjustable.
Features
Regenerative Braking:
Standard on AC electric forklifts, captured in operating procedures.
📐 Dimensions
Exterior
General Size:
Compact counterbalance design suitable for indoor warehouse and distribution environments.
Weights
Unladen Weight:
Specific weight data in kg will be present in the 'Technical Data' section, varying by model configuration and mast type.
Load Capacity:
The model numbers (213, 215, 216, 218, 220) likely indicate approximate load capacities in hundreds of kilograms (e.g., 1.3-2.0 tonnes). Exact capacities are detailed on capacity labels and in technical data.
Tyre Equipment
Tyre Type:
Standard tyre equipment specified in Technical Data. Typically cushion tires for indoor use, but options may exist.
🛡️ Safety Features
Ratings
Compliance Standards:
EN standards mentioned, indicating compliance with European safety directives for industrial trucks. UVV (Unfallverhütungsvorschrift) compliance (BGV D27) for safety checks is explicitly stated.
Active Features
Operator Controls:
Ergonomic controls, dashboard switches, operating console switches, Multi Pilot control (optional), safety belt.
Warning Systems:
LED warning indicators, plain text alarm messages, battery discharge indicator/monitor.
Passive Features
Operator Protection:
Overhead guard (standard on most forklifts), safety belt, operator's station design.
Load Handling Safety:
Capacity labels for truck, fork tines, and attachments to prevent overloading.
💡 Technology Features
Infotainment
Display Systems:
Dashboard with switches, operating console, and display indicators for truck status, alarms, and driving programs. Plain text alarm messages are a key feature.
Driver Assistance
Operator Settings:
Adjustable driver's seat, adjustable steering column, selectable driving programs (e.g., for efficiency or power).
Optional Systems:
Automatic/Mechanical Support System (optional) mentioned, indicating advanced operator aids or stabilization features available on certain configurations.
Connectivity
Data Logging:
Operating hour meter mentioned, suggesting basic data logging for maintenance tracking. Advanced telematics might be available but not detailed in this manual excerpt.
🔧 Maintenance
Service Intervals
Scheduled Maintenance:
Detailed maintenance checklist provided for EFG 213/215/216k/216/218k/218/220. Specific intervals for checks (daily, weekly, monthly, annual) would be within the 'Servicing and inspection' section.
Fluid Specifications
Hydraulic Fluid:
Specific hydraulic oil type and viscosity to be found in the 'Lubrication plan' section. ISO VG rating typical.
Transmission Fluid:
Specific transmission oil type and viscosity to be found in the 'Lubrication plan' section. Typically gear oil.
Brake Fluid:
Checking the brake fluid is listed, implying a hydraulic braking system that uses standard automotive brake fluid (e.g., DOT 3 or DOT 4), but specific type would be in manual.
Known Issues
Common Wear Items:
Tire wear, hydraulic system seal leaks, battery terminal corrosion, mast component wear are common across most forklifts.
Electrical Component Reliability:
AC drive systems are generally reliable, but electronic controllers and sensors can be subject to failure over time due to heat or vibration. Manual covers fuse checks and general troubleshooting.
Lubrication Plan
Plan Availability:
Detailed lubrication plan provided, covering all lubrication points and recommended lubricants for various components.
📚 Vehicle History
Brand Heritage
Brand Focus:
Jungheinrich is a global leader in material handling equipment, known for innovation and quality in warehouse technology and forklifts.
Model Evolution
Series Development:
The EFG-Series represents Jungheinrich's line of electric counterbalanced trucks, with AC technology being a significant advancement for improved efficiency and performance over older DC models.
Production
Production Era:
Early to mid-2000s, characterized by the adoption of AC motor technology in industrial forklifts.
🏆 Awards & Recognition
Recognitions
Industry Accreditations:
Compliance with EN standards signifies adherence to recognized European industry benchmarks for safety and performance.
Ratings
Reliability Reputation:
Jungheinrich generally has a strong reputation for reliable and durable material handling equipment.
Certifications
Safety Certifications:
UVV compliance (BGV D27) is a critical safety certification for industrial truck operation in many regions, indicating the manual supports safe operational practices.