14e03k10 Jungheinrich Efg 216 - Instructions - 1,03

INSTALLATION INSTRUCTIONS
JUNGHEINRICH
EFG 216
.
JUNGHEINRICH
EFG 216
SAFETY INSTRUCTIONS
Warning: Failure to heed all safety and operating instructions
and warnings regarding use of this product can result in serious
bodily injury.
READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS

BEFORE STARTING OF ASSEMBLY
Install all parts indicated in assembly instructions. Failure to

fully assemble product before use could result in personal
injury.
Assembly of product requires use of hand or power tools. If you

are not experienced in using these types of tools, have product
dealer do the install for you.
Some parts contain sharp edges, wear protective gloves if

necessary. Always keep your assembly area clean, uncluttered 2
and well lit.
Keep visitors and children a safe distance away from the

assembly area. Visitors should wear the same safety
equipment described under.
Never operate your UTV with the cab doors open. Failure to
properly latch the doors before moving the vehicle could result
in serious injury.
Dress for safety. DO NOT wear loose clothing, gloves, neckties

or jewelry if using power tools to assemble this product. Insert
all nut covers after you finish installation.
Never drive your UTV with the cab front window in open
position.
Failure of unproperly latched/locked front window before

driving the vehicle could result in serious injury.
DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz
Za Olšávkou 391, Uherské Hradiště 686 01 Fax: +420 572 520 071
Czech republic E-mail: dfk@dfk.cz
JUNGHEINRICH
EFG 216
MAINTANCE AND CLEANING
To clean polycarbonate surface use soapy water solution or

other subtle means.
Dirt and dust wash by gently water stream and swipe only with
wet or damp means in the direction from top to bottom.
The recommended frequency of cleaning of polycarbonate part

is about 1 time per month or according to the actual degree of
pollution.
Do not use detergents that could scratch the surface plates.

(abrasives, harsh fabrics, etc.)
Do not use solvents or alkaline detergents or cleaners with

ammonia (ammonium hydroxide).
Do not remove the impurities from the surface of the razor 3

blades or other sharp items.
Do not clean cabine, when the polycarbonate plates are heated

by the sun.
Do not use the squeegee, it could be scratched surface plates.
Do not clean the water current strength greater than 50 bar

(WAP)
The manufacturer is not responsible for scratching the surface

in case of failure to comply with the above instructions.
All bolted connections of cab must be by user at regular

intervals checked and tightened.

JUNGHEINRICH
EFG 216
ELECTROINSTALLATION
Loosen the dashboard fixing screws and remove the dashboard.

JUNGHEINRICH
EFG 216
Remove the rubber cover from the he holes for wiper motor rods.
Install the wiper motor to prepared position. 5

JUNGHEINRICH
EFG 216
Attach the wiper motor with included washers, nuts and covers.
6
Connect the wiper motor harness with the original connector.

JUNGHEINRICH
EFG 216
Unlock the rear forklift cover and remove the cover.

JUNGHEINRICH
EFG 216
Route the rear wiper harness and the washer harness through the forklift
frame hole to the behind the seat space.

JUNGHEINRICH
EFG 216
Connect the rear wiper motor harness with the rear wiper motor
connector.
9
Hide the wiper motor connector under the wiper motor cover.

JUNGHEINRICH
EFG 216
Detailed view of the the rear wiper harness and the washer harness
imput to the forklift frame.
10
Connect the rear wiper harness with the original connector XS 156 and
the washer harness with original connector XS 154.

JUNGHEINRICH
EFG 216
WASHER
Place the washer tank holder onto the forklift frame in accordance with
the original hole behind the seat on the left side.
11
Fix the washer tank holder with included fixing assembly.

JUNGHEINRICH
EFG 216
Connect the washer harness and the washer tubes with the washer tank
motors.
12

JUNGHEINRICH
EFG 216
Route the rear washer tube through the grommet on the rear glass.
Connect the rear washer tube with the rear washer jet on wiper
pantograph. Attach the washer tube on wiper pantograph with included
13
plastic cable tie.

JUNGHEINRICH
EFG 216
Route the front washer tube on the right side of the forklift and under the
floor to the original hole nex to the wiper motor.
14
Install the front washer nozzle on wiper pantograph. Connect the washer
nozzle with the washer tube.

JUNGHEINRICH
EFG 216
Attach the washer tube on wiper pantograph with included plastic cable
ties.
15

JUNGHEINRICH
EFG 216
HEATER
Remove the plastic cover from the forklift right side.
16

JUNGHEINRICH
EFG 216
Disconnect the accelerator pedal connector and remove the floor from
the forklift.
17
Remove the fixing screws and then remove the small floor cover on the
forklift right side.

JUNGHEINRICH
EFG 216
Find out the heater harness connection points under the floor.
Detail view on the heater harness connection points.
18

JUNGHEINRICH
EFG 216
Disconnect the original connectors and the wire eyes with the marks I, II,
III for better acces.
Connect the convereter input harness wire eye (-) to the control unit 19
connection point.

JUNGHEINRICH
EFG 216
Connect the two heater harness and the converter input harness red wire
eyes (+) to the original control unit connection point.
20
Illustration view of the converter input harness connection to the control
unit.

JUNGHEINRICH
EFG 216
Connect the original connectors and the wire eyes with the marks I, II, III
back to the control unit.
Mount the small floor cover back to the original position with original 21
screws.

JUNGHEINRICH
EFG 216
Find out the original welded screws under the rear forklift cover.
22
Mount the converter onto the welded screws under the rear forklift
cover.

JUNGHEINRICH
EFG 216
Connect the converter imput harness with the original connector XS 171.
23
Connect the converter output harness with the original connector XS 35.

JUNGHEINRICH
EFG 216
Route the converter output harness from the converter through the
original frame hole.
24
Connect the converter output harness with the heater harness.

JUNGHEINRICH
EFG 216
Route converter input harness and the heater harness under the right
side plastic cover. Attach the harnesses with included tightening ties.
25
Cut the hole ø 30 mm to the plastic cover for the heater harness.

JUNGHEINRICH
EFG 216
Install the heater holders from the inside of the cover.
26
Mount the plastic cover back to the original position. Route the heater
harness through the prepared hole.

JUNGHEINRICH
EFG 216
Detail view on the heater harness routed through the hole in the cover.
Mount the heater onto the heater holders with included fixing
assemblies.
27

JUNGHEINRICH
EFG 216
Connect the heater harness with the heater.
Connect the heater harness with the ventilator switch and the heating
spirals switches on the upper heater cover. 28

JUNGHEINRICH
EFG 216
Place the side heater covers onto the heater. Mark the covers fixing
points onto the plastic cover. Drill two holes ø 9 mm for the plastic push
pin rivets.
29
Mount the right heater cover with included plastic push pin rivet.

JUNGHEINRICH
EFG 216
Mount the left heater cover with included plastic push pin rivet. Route
one heater air hose through the hole in this cover.
30
Mount the upper heater cover onto the heater with included four screws.

JUNGHEINRICH
EFG 216
Shorten the heater air hoses to the correct length. Install the air vents
onto the heater air hoses with included Al tape.
31
Press the heater air vents into the heater cover holes.

JUNGHEINRICH
EFG 216
PREPARATION FOR INSTALLATION:

Uninstall all additional systems from the forklift frame (work lights, rear
mirrors, drink holders etc.)
CAB PREVIEW
32

JUNGHEINRICH
EFG 216
LEFT DOOR + RIGHT DOOR

Place the left door hinges onto the forklift frame in accordance with
original threaded holes.
33

JUNGHEINRICH
EFG 216
Attach the left door hinges with included fixing assemblies.
34

JUNGHEINRICH
EFG 216
Install the left door onto the prepared hinges.
35

JUNGHEINRICH
EFG 216
Adjust the left door to the best position and tighten the hinges screws
hard (red circles).
36

JUNGHEINRICH
EFG 216
RIVET NUT INSTALLATION

Use the rivet nut installation tool for rivet nut installation. A rivet nut can
be applied to an existing hole if it is a suitable size, or a new hole can be
drilled to suit your desired rivet nut and bolt.
Installation tools example preview
Installation process instructions 37
1. 2. 3. 4.
1. Drill the hole of the correct size for the rivet nut or use the original
hole.
2. Insert the rivet nut into the hole.
3. Squeeze the handles together until it reaches a stop. The rivet nut tool
is removed by unscrewing the mandrel.
4. Installed rivet nut.
JUNGHEINRICH
EFG 216
Install the rivet nuts into the original forklift frame holes.
38

JUNGHEINRICH
EFG 216
Place the left door stop assembly onto the forklift frame in accordance
with prepared rivet nuts.
39

JUNGHEINRICH
EFG 216
Attach the left door stop assembly with included fixing assembly.
40

JUNGHEINRICH
EFG 216
Place the left door gas spring holder onto the forklift frame in accordance
with the original hole.
41

JUNGHEINRICH
EFG 216
Fix the left door gas spring holder with included fixing assembly.
42

JUNGHEINRICH
EFG 216
Install the door gas spring onto the gas spring pins.
43

JUNGHEINRICH
EFG 216
Repeat the previous steps with the right door assembly.
44

JUNGHEINRICH
EFG 216
FRONT PANEL
Remove the front glass upper holders completely. Loosen the bottom and
middle holders screws (red circles) before installation.
45

JUNGHEINRICH
EFG 216
Place front glass onto the forklift frame. Adjust the front glass to the best
position.
46

JUNGHEINRICH
EFG 216
Turn the bottom and middle holders to the correct position on both sides.
47

JUNGHEINRICH
EFG 216
Place the front glass upper holders onto the forklift frame in accordance
with the holes.
48

JUNGHEINRICH
EFG 216
Attach the front glass upper holders with included fixing assemblies.
Tighten all six holders screws.
49

JUNGHEINRICH
EFG 216
Install the front wiper pantograph onto the front wiper rods.
50

JUNGHEINRICH
EFG 216
Attach the front wiper pantograph with included washers and nuts.
51

JUNGHEINRICH
EFG 216
REAR PANEL
Place the rear panel onto the forklift frame. Adjust the rear panel to the
best position.
52

JUNGHEINRICH
EFG 216
Attach the rear panel with included fixing assemblies on both sides.
53

JUNGHEINRICH
EFG 216
ROOF
Remove the roof panel holders from the roof glass.
54

JUNGHEINRICH
EFG 216
Place the roof glass onto the forklift frame. Adjust the roof glass to the
best position.
55

JUNGHEINRICH
EFG 216
Place the roof panel holders onto the forklift frame and the roof glass in
accordance with the holes.
56

JUNGHEINRICH
EFG 216
Attach the roof panel holders with included fixing assemblies.
57

JUNGHEINRICH
EFG 216
HEATER
Place the heater with heater holder onto the forklift plastic cover and
mark position of the heater holder holes.
58

JUNGHEINRICH
EFG 216
Drill four holes Ø 9 mm on marked positions. Place the opposite heater

holder parts into the forklift plastic cover from inside.
59

JUNGHEINRICH
EFG 216
Place the heater with the heater holder onto the opposite heater holder
parts.
60

JUNGHEINRICH
EFG 216
Attach the heater with included washers and nuts on both sides.
61

JUNGHEINRICH
EFG 216
Place the right heater cover assembly onto the forklift body.
62

JUNGHEINRICH
EFG 216
Mark the position of the right heater cover fixing points. Drill two holes Ø
9 mm for the plastic push pin rivets.
63

JUNGHEINRICH
EFG 216
Place the left heater cover assembly onto the forklift body.
64

JUNGHEINRICH
EFG 216
Mark the position of the right heater cover fixing points. Drill two holes Ø
9 mm for the plastic push pin rivets.
65

JUNGHEINRICH
EFG 216
Place the heater upper cover onto the left and right heater covers.
66

JUNGHEINRICH
EFG 216
Attach the heater upper cover with included screws.
67

JUNGHEINRICH
EFG 216
68

Declaration of Conformity
DFK Cab, s.r.o.

Za Olšávkou 391
686 01 Uherské Hradiště
Česká republika / Czech Republic
Date of Issue: 31-3-2017

.

14e03k10 Jungheinrich Efg 216 - Instructions - 1,03

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

14e03k10 Jungheinrich Efg 216 - Instructions - 1,03

Uploaded by

Copyright:

Available Formats

INSTALLATION INSTRUCTIONS

READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS

Install all parts indicated in assembly instructions. Failure to

Assembly of product requires use of hand or power tools. If you

Some parts contain sharp edges, wear protective gloves if

Keep visitors and children a safe distance away from the

Dress for safety. DO NOT wear loose clothing, gloves, neckties

Failure of unproperly latched/locked front window before

MAINTANCE AND CLEANING

To clean polycarbonate surface use soapy water solution or

The recommended frequency of cleaning of polycarbonate part

Do not use detergents that could scratch the surface plates.

Do not use solvents or alkaline detergents or cleaners with

Do not remove the impurities from the surface of the razor 3

Do not clean cabine, when the polycarbonate plates are heated

Do not use the squeegee, it could be scratched surface plates.

Do not clean the water current strength greater than 50 bar

The manufacturer is not responsible for scratching the surface

All bolted connections of cab must be by user at regular

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Install the wiper motor to prepared position. 5

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Unlock the rear forklift cover and remove the cover.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Remove the plastic cover from the forklift right side.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Detail view on the heater harness connection points.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Install the heater holders from the inside of the cover.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Connect the heater harness with the heater.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

PREPARATION FOR INSTALLATION:

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

LEFT DOOR + RIGHT DOOR

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Attach the left door hinges with included fixing assemblies.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Install the left door onto the prepared hinges.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz