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Jungheinrich EFX 413 User Manual

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

Table of Contents

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Jungheinrich EFX 413 Specifications

General IconGeneral
BrandJungheinrich
ModelEFX 413
CategoryTrucks
LanguageEnglish

Summary

EFX 410 / 413 Operating instructions

Operating instructions

General instructions for operating the EFX 410/413 truck.

Declaration of Conformity

Foreword

Notes on the operating instructions

Explains the structure and scope of the operating instructions for different truck models.

Safety notices and text mark-ups

Defines symbols used for safety instructions and explanations like DANGER, WARNING, CAUTION, NOTE.

Copyright

A Correct Use and Application

General

Specifies that the truck must be used, operated, and serviced according to the instructions.

Correct application

Details permitted operations and prohibited actions for safe truck usage.

Approved application conditions

Outlines the conditions under which the truck can be operated, including extreme conditions.

Proprietor responsibilities

Defines the duties of the operating company for safe truck usage and adherence to guidelines.

B Truck Description

Application

Describes the EFX as an electric tri-lateral stacker designed for specific lifting and transport tasks.

Travel direction definition

Defines the directions of travel for the truck: left, drive, load, and right.

Assemblies and Functional Description

Details the truck's assemblies and their functions, including safety mechanisms.

4 Technical Specifications

Performance data

Provides performance metrics like travel speed, lift speed, and traverse speed for EFX 410 and EFX 413.

Dimensions (as per data plate)

Lists detailed dimensions of the truck, categorized by D, x, y, z, h1-h7, Ast, Wa, s, e, l, m1, m2, r.

Mast versions

Describes different mast designs, including telescopic and triplex stage masts with their technical data.

Weights

Details the basis truck weight including attachments and counterweights, without battery.

Tare weight / axle loads

Provides information on tare weight and axle loads for EFX 410 and EFX 413 trucks.

Wheels, chassis

Describes wheel specifications and chassis details for EFX 410 and EFX 413.

Engine Data

Lists output power for drive, lift, and steer motors.

EN norms

Specifies noise emission levels in accordance with EN 12053.

Vibration

Details weighted vibration acceleration on the seat and seat cushioning values.

Electromagnetic compatibility (EMC)

Confirms truck adherence to electromagnetic emission and resistance limits.

Conditions of use

Outlines operating conditions, including extreme conditions and ambient temperature/humidity limits.

Electrical requirements

Certifies manufacturer compliance with EN 1175 for electrical equipment design.

5 Identification points and data plates

Indication Points

Shows and lists various indication points and labels on the truck for identification and warnings.

Data plate

Explains the information contained on the truck's data plate, including type, serial number, capacity, and manufacturer.

Truck capacity plate

Details how the capacity plate indicates the truck's capacity Q (kg) for an upright mast.

Attachment capacity plate

Explains how the attachment capacity plate indicates the truck's capacity in conjunction with the fitted attachment.

Jack contact points

Indicates where the truck may be lifted and jacked up using the "Jack contact point" decal.

6 Stability

C Transport and Commissioning

Transport

Details the two methods for transporting the truck, depending on mast height and local conditions.

Lifting by crane

Provides essential safety instructions and requirements for lifting the truck using a crane.

Securing the truck during transport

Outlines procedures and warnings for securely fastening the truck and mast during transport.

Using the Truck for the First Time

Covers initial setup and operations, including moving without a battery and mast installation/removal.

Commissioning

Describes the steps for preparing the truck for operation after delivery or transport.

Tilt safety device

Explains the function of the tilt safety device and its importance for truck stability.

D Battery - Servicing, Recharging, Replacement

Safety Regulations Governing the Handling of Lead-Acid Batteries

Details critical safety regulations for handling lead-acid batteries, including maintenance personnel and fire protection.

General notes on handling batteries

Covers hazards associated with batteries and guidelines for using approved Jungheinrich batteries.

Battery types

Lists available battery types for EFX trucks, including voltage and capacity, and relevant standards.

Dimensions of the battery compartment

Addresses the impact of battery dimensions on truck stability and operational safety.

Exposing the battery

Explains how to open the battery panel and the safety precautions during this procedure.

Charging the battery

Provides detailed safety procedures and warnings for charging the battery, emphasizing explosion hazards.

Battery removal and installation

Outlines safety warnings and procedures for removing and installing batteries, including risks of trapping and short circuits.

"Battery lock" sensors (o)

Explains the function of "battery lock" sensors and how to operate the truck without battery locks.

E Operation

Safety Regulations for the Operation of the Forklift Truck

Details driver authorization, operator rights/responsibilities, unauthorized use, damage reporting, and repair restrictions.

Safety devices, warning signs and warning instructions

Emphasizes the importance of observing safety devices, signs, and instructions to prevent accidents.

Displays and Controls

Provides an overview of the truck's control panel and displays, identifying key components.

Driver's display

Explains the symbols and displays shown to the operator, including warning lamps and time/service hour indicators.

Hourmeter

Explains how service hours are counted while the truck is operational.

"Bar display" battery discharge indicator

Describes the bar display for battery discharge and potential damage from full discharge.

"Percentage display" battery discharge indicator (o)

Explains the percentage display for battery charge status and its implications for operation.

Driver's display function symbols

Lists and explains various symbols used in the driver's display for attachment and fork operations.

Preparing the Truck for Operation

Covers crucial checks and operations before starting daily truck use, emphasizing safety.

Entry and exit

Provides instructions on how to safely enter and exit the truck.

Setting up the operator position

Guides the operator on adjusting the seat and control panel for optimal ergonomics and safety.

Control panel height adjustment

Explains how to adjust the height of the control panel for better operator visibility and reach.

Control panel longitudinal adjustment

Details the procedure for adjusting the control panel horizontally.

Checking, putting on and taking off the seat belt

Details the importance of seat belts and procedures for checking, wearing, and removing them.

Industrial Truck Operation

Covers general safety regulations and considerations for operating the industrial truck.

Travel surface

Discusses the importance of a suitable travel surface for truck traction and stability.

Ground and ground conditions

Specifies requirements for ground conditions, including levelness, smoothness, and cleanliness.

Travel conduct

Provides guidelines for safe travel speed, maneuvers, and communication while operating the truck.

Visibility when travelling outside the narrow aisle

Advises on maintaining clear visibility and using mirrors or lookouts.

Negotiating slopes and inclines

Warns against negotiating slopes and inclines.

Travelling on docks, dock plates and loading platforms

Warns against travelling on docks, dock plates, and loading platforms.

Towing trailers and other vehicles

Prohibits towing trailers or other vehicles.

Negotiating lifts

Provides guidelines for negotiating lifts with the truck.

Work platforms

Discusses national laws and restrictions regarding the use of work platforms.

Type of loads to be carried

Covers safe practices for carrying various types of loads, including liquid, suspended, and swaying loads.

Preparing the truck for operation

Details the steps required to prepare the truck for operation, including visual checks and battery connection.

Preparing the truck for operation with an additional access code

Explains how to set up and use additional access codes for truck operation.

Log off user

Describes how to log off the user and what happens when the truck is abandoned.

Date and time setting

Explains how to select the "Set Date/Time" menu and set the truck's date and time.

Checks and operations to be carried out when the truck is operational

Lists essential checks and tests to perform while the truck is operational to ensure safety.

Main Lift referencing

Explains the procedure for performing a reference run for the main lift to adjust height display and release truck operations.

Load handler post-referencing (sideshift / fork carriage)

Details the process for post-referencing the load handler after changes in its position or rotation.

Emergency Disconnect

Explains the function and safe usage of the emergency disconnect switch, warning against misuse.

Travel

Covers safe travel practices, modes of operation (FR, RG, WG), and collision hazards.

Steering

Describes steering operations inside and outside narrow aisles.

Brakes

Details the three braking methods: coasting brake, brake pedal, and deadman button, and associated risks.

Negotiating narrow aisles

Provides critical safety instructions for entering and operating in narrow aisles, including hazards from objects and racking systems.

Diagonal travel

Explains how to perform diagonal travel, which involves simultaneous travel and lifting/lowering.

Lifting / lowering – outside and inside narrow aisles

Covers accident risks associated with lifting and lowering operations, emphasizing hazardous areas and load safety.

Traversing / rotating outside and inside narrow aisles

Details safe practices for traversing and rotating, including risks of trapping and handling faulty attachments.

Simultaneous traversing/rotation outside and inside narrow aisles

Addresses risks related to simultaneous traversing/rotation movements and handling attachments.

Parking the truck securely

Provides instructions for safely parking the truck, including warnings about unsecured conditions.

Order picking and stacking

Guides the operator on performing order picking and stacking operations.

Adjusting the forks

Explains how to adjust fork spread and position for safe load handling, including warnings about unsecured loads.

Replacing the forks

Provides safety warnings and procedures for replacing fork tines, emphasizing injury risks and proper handling.

Lifting, transporting and depositing loads

Covers crucial safety aspects for lifting, transporting, and depositing loads, warning about unsecured loads and persons.

Troubleshooting

Provides guidance on identifying and rectifying basic faults or operational errors.

Emergency stop device

Details the function of the automatic emergency stop and procedures for switching off the truck after activation.

Load handler emergency lowering

Provides warnings and procedures for emergency lowering of the load handler, emphasizing risks of accidents and damage.

Travel cutout override (o)

Explains the travel cutout override function and how to operate the truck with it deactivated.

Lift cutout override (o)

Describes the automatic lift cutout function and how to override it, with warnings about extended masts.

Lower cutout override (o)

Explains the automatic lower cutout function and how to override it, with warnings about load handler placement.

End of aisle safety device (o)

Details the function of the end of aisle safety device and procedures for continuing travel after braking.

WG emergency operation (event messages 3670 / 3752)

Covers emergency operations for wire-guided trucks when the guide wire is lost or other faults occur.

Recovering the truck from a narrow aisle / Moving the truck without a battery

Outlines procedures for recovering the truck from a narrow aisle or moving it without a battery, emphasizing risks and specialist personnel.

Release and activate the drive wheel brake

Explains how to release and activate the drive wheel brake for recovery operations.

Steering the truck without its own drive system

Details how to steer the truck without its drive system when stationary, noting potential hazards.

Recovering the truck from a narrow aisle

Provides warnings and procedures for recovering the truck from a narrow aisle, emphasizing accident risks.

Recovering the truck in the load direction with and without load

Covers procedures for recovering the truck in the load direction, with and without load.

Recovering the truck in the drive direction with and without load

Details procedures for recovering the truck in the drive direction, with and without load.

Personal safety system (o)

Details the Personal Protection System (PPS) and its components for ensuring operator safety.

Personal Protection System (PPS)

Describes the PPS as an integrated system for protecting persons using laser scanner technology.

Functional description

Explains the functional aspects of the PPS, including obstacle detection and standard functions.

Displays on the seven segment display and indicator light (LED)

Describes the meaning of various displays and LED signals from the laser scanner for the operator.

Daily checks before starting the Personal Protection System

Outlines daily checks for the PPS, including cleaning and performing a cycle test.

Personal safety system

Details how the PPS indicates obstacles or persons in warning and protection fields, affecting truck speed or stopping.

Optional equipment

Lists and describes various optional equipment available for the truck.

Sideshifter / Fork positioner (o)

Covers the functionality and operation of sideshifter and fork positioner attachments, including warnings.

Fork positioner (o)

Explains how to adjust fork spread using the fork positioner, noting that forks adjust simultaneously.

Symmetric sideshift with integrated fork positioner (o)

Discusses symmetric sideshift operation with an integrated fork positioner.

Laser beam rack compartment display (o)

Explains the laser beam system for correct truck positioning relative to rack compartments.

Telescopic forks (o)

Describes the use of telescopic forks for increased stacking depth and associated risks.

Operator-specific settings (o)

Details how user access codes affect the ability to display or change operator-specific settings.

Fire extinguisher (o)

Explains the function and operation of the fire extinguisher, including warnings about unsuitable extinguishing agents.

Rack Height Select (o)

Describes the Rack Height Select function for pre-selected storage locations and associated display symbols.

Entering area recognition (zones)

Explains manual and automatic methods for entering area recognition zones.

Rack number entry (lift height)

Details how to enter rack numbers (lift height) using the numerical keypad for precise positioning.

Approaching the warehouse location with Rack Height Select

Guides on approaching warehouse locations using Rack Height Select, with arrow indicators for lift adjustments.

Stacking operation (o)

Explains the general procedure and available options for stacking operations.

Manual stacking operation

Describes how to perform manual stacking and retrieval operations based on driver display prompts.

Automatic stacking operation with the "hydraulic functions" control lever (version A)

Details automatic stacking using the hydraulic control lever in version A.

Automatic stacking operation with the "hydraulic functions" control lever (version B)

Details automatic stacking using the hydraulic control lever in version B.

Driver's display

Explains the symbols displayed for truck travel and fork adjustments in relation to destination requirements.

Horizontal positioning error description

Lists common errors encountered during horizontal positioning and their corresponding descriptions and remedies.

Storage mode symbols in the driver's display

Explains symbols displayed in the driver's display during storage mode for various attachment movements.

Warehouse target destination entry

Details methods for entering warehouse destinations, including manual, barcode, and radio input.

Manual destination entry (default setting)

Guides on manually entering area, rack row, location, rack height, and zone for destination.

Destination input with barcode scanner

Explains how to use a barcode scanner for destination input and potential manual fallback.

Stacking / retrieval after target entry

Covers automatic horizontal and manual vertical destination approach for stacking/retrieval.

Weighing system (o)

Describes the optional weighing system and how it displays load weight.

Tare function (o)

Explains the tare function of the weighing system, which sets the display to zero.

Camera system (o)

Details the camera system's function as an aid for safe operation and how to use its monitor.

Working platform (o)

Discusses risks and regulations associated with using work platforms on industrial trucks.

Work platform components

Lists and describes the components of a work platform.

Lifting the work platform with the standard attachment

Provides procedures for safely lifting the work platform with the standard attachment.

Operation in the work platform

Covers safety mechanisms and procedures for operating the truck while the person is in the work platform.

Lowering the work platform with the standard attachment

Details the procedure for safely lowering the work platform after use.

Floor-Spot (o)

Describes the Floor-Spot as a visual aid for safety, projecting a light spot on the ground.

List of assemblies for Floor-Spot

Lists the components related to the Floor-Spot assembly.

Activating the Floor-Spot outside of narrow aisles (free ranging truck)

Explains when the Floor-Spot is activated or deactivated based on truck travel function.

Activating the Floor-Spot in narrow aisles (truck with rail or wire guidance)

Details Floor-Spot activation/deactivation during narrow aisle operations with rail or wire guidance.

F Industrial Truck Maintenance

Operational Safety and Environmental Protection

Emphasizes performing inspections and maintenance tasks according to defined intervals and safety standards.

Maintenance Safety Regulations

Outlines regulations for maintenance and repair personnel, including owner responsibilities and customer services.

Wheels

Warns about using non-compliant wheels and describes wheel flattening due to long-term parking.

Attachment Repairs and Inspection

Stresses the hazard of faulty attachments and the need for daily checks and reporting defects.

Lift chain inspection

Details procedures for inspecting lift chains for wear and damage, warning about risks from damaged chains.

Hydraulic system

Covers warnings related to leaky hydraulic systems and faulty hydraulic hoses, including injury risks.

Lubricants and Lubrication Schedule

Provides information on handling consumables safely and outlines the lubrication schedule.

Consumables

Lists required consumables like hydraulic oil, grease, and cleaning agents with their order numbers and applications.

Maintenance and repairs

Covers preparations for maintenance and repairs, including switching off the truck and disconnecting the battery.

Lifting and jacking up the truck safely

Provides critical safety instructions for lifting and jacking up the truck, warning against tipover risks.

Drive compartment cover disassembly/assembly

Details the procedure for removing and reattaching the drive compartment cover.

Checking electrical fuses

Explains how to check electrical fuses, warning about risks of electrical current and incorrect fuse usage.

Fuse ratings

Lists fuse items, electric circuits, and their corresponding values (Amps).

Controller display

Describes display statuses when the truck is switched off and on, indicating fuse status.

Cleaning

Provides instructions and warnings for cleaning the truck, emphasizing fire hazards and risks of component damage.

Cleaning the electrical system assemblies

Guides on cleaning electrical system assemblies safely using air or suction, avoiding water.

Cleaning the front screens of the optical sensors for optional features

Explains how to clean front screens of optical sensors, warning about potential damage from improper cleaning.

Cleaning the front screen of the laser scanners of the personal protection system (PPS)

Refers to another section for cleaning the PPS laser scanner front screen.

Lift chain servicing

Details lift chain servicing, including warnings about non-lubricated chains and hazardous solvents.

Lubricate the lift chains, clean and grease the contact surfaces in the mast sections

Explains how to lubricate lift chains and clean mast sections, highlighting risks of working at heights.

Checking the hydraulic oil level

Provides crucial safety information and procedures for checking and adding hydraulic oil, warning about pressurised systems and overfilling.

Restoring the truck to service after maintenance and repairs

Outlines the procedures required to return the truck to service after maintenance, including testing safety mechanisms and brakes.

Decommissioning the industrial truck

Covers procedures for taking the truck out of service for extended periods, including storage and jacking requirements.

Prior to decommissioning

Details preparatory steps before decommissioning, such as cleaning, lubrication, and battery disconnection.

During decommissioning

Provides a notice regarding battery discharge during decommissioning.

Restoring the truck to service after decommissioning

Lists steps for restoring the truck to service after decommissioning, including cleaning, lubrication, and brake testing.

Safety tests to be performed at intervals and after unusual incidents

Emphasizes the need for regular safety inspections and tests, and the operating company's responsibility for fault rectification.

Final de-commissioning, disposal

Covers final decommissioning procedures and disposal regulations for the truck.

Human vibration measurement

Explains human vibrations and the manufacturer's service for assessing application situations.

G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement

Maintenance Contents EFX 410-413

Lists standard maintenance tasks for EFX 410-413, including brakes and hydraulic operations.

Owner

Specifies the frequency for owner maintenance tasks, every 50 service hours or weekly.

Inspection contents

Details points to check for standard equipment, including electrical, power supply, travel, chassis, hydraulic, and steering systems.

Customer Service

Outlines maintenance tasks to be performed by customer service at specified intervals, including brakes, electrical systems, and travel.

Horizontal positioning

Describes testing of Horizontal Positioning (HozPos) functions like Emergency Stop and positioning accuracy.

Optional equipment

Lists inspection points for optional equipment such as JH personal protection system, aisle recognition, and load sensing.

Access module

Checks the secure seating and function of the access module and for damage.

A Traction battery

Correct Use and Application

Specifies correct usage and warns against unauthorized repairs or parts that invalidate the warranty.

Data plate

Explains the components of the battery data plate, including model, serial number, voltage, capacity, and manufacturer.

Safety Instructions, Warning Indications and other Notes

Details safety precautions for handling batteries, including hazardous waste disposal and fire/explosion hazards.

Lead acid batteries with armour plated cells and liquid electrolyte

Describes Jungheinrich traction batteries (PzS, PzB, PzS Lib, PzM) and electrolyte properties.

Operation

Covers battery commissioning, discharging, and charging procedures.

Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells

Provides daily, weekly, monthly, and annual servicing instructions for sealed lead-acid batteries.

Aquamatik water replenishment system

Describes the design of the Aquamatik system for automatic electrolyte level adjustment.

Electrolyte circulation

Explains the function of electrolyte circulation during charging to mix electrolyte and prevent gas formation.

Cleaning batteries

Details procedures for cleaning batteries and trays to maintain cell insulation and prevent damage.

Storing the battery

Provides guidelines for storing batteries to maintain functionality, including charging recommendations.

Troubleshooting

Guides users on how to identify and resolve faults with batteries or chargers.

Disposal

Covers proper disposal methods for batteries, emphasizing recycling and avoiding household waste.

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