Page 1 EFG 535k - S50 11.15 Operating instructions en-GB 51477773 06.20 EFG 535k EFG 535ks EFG 540 EFG 540s EFG 540k EFG 540ks EFG 545 EFG 545s EFG 545k EFG 545ks EFG 550 EFG 550s EFG S40 EFG S40s EFG S50...
Page 3: Declaration Of Conformity
Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture EFG 535k EFG 535ks EFG 540 EFG 540s EFG 540k EFG 540ks EFG 545 EFG 545s EFG 545k EFG 545ks EFG 550...
Page 5 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.
Page 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...
Page 7: Table Of Contents
Contents Correct Use and Application General Correct application Approved application conditions Internal Operation in Cold Stores with Cold Store Equipment (o) Proprietor responsibilities Adding attachments and/or optional equipment Removal of components Truck Description Application Truck models and rated capacity Assemblies and Functional Description Travel direction definition Assembly Overview Functional Description...
Page 8 Potential hazards Touch voltage hazard Safety Regulations for Handling Lead-Acid Batteries Safety regulations for handling lithium-ion batteries Fire Hazard Particular hazard from combustion products Special fire fighting protective equipment Additional fire fighting instructions Instructions for cooling an overheated, non physically damaged battery Battery types Battery dimensions...
Page 9 Activating the lithium-ion battery (o) Preparing the truck for operation Setting the time Parking the truck securely Emergency Disconnect Travel Steering Brakes 4.10 Adjusting the forks 4.11 Replacing the forks 4.12 Lifting, transporting and depositing loads 4.13 Operating the Lift Mechanism and Integrated Attachments 4.14 Safety instructions for operating additional attachments 4.15 Operating additional attachments for the SOLO-PILOT 4.16 Operating additional attachments for the Multi Pilot...
Page 10: Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement
6.35 Operating the Auxiliary Hydraulics without Pressing the Acknowledgement Key 6.36 Special control layout 6.37 Floor-Spot 6.38 StVZO road traffic regulations equipment 6.39 Horn Button on Overhead Guard Troubleshooting Troubleshooting Operating the truck without its own drive system Emergency lowering Industrial Truck Maintenance Spare Parts Operational Safety and Environmental Protection...
Page 11: A Correct Use And Application
A Correct Use and Application 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. Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must...
Page 12 The following operations are in accordance with regulations and are permitted: – Lifting and lowering of loads. – Stacking and retrieving loads – Transporting lowered loads over short distances. – The mast must be tilted back when transporting loads that are not secured against slipping and falling.
Page 13: Approved Application Conditions
Approved application conditions WARNING! Do not exceed the permissible surface and point loading limits on the travel paths. A second person is required as a lookout at blind spots. The operator must ensure that the loading ramp/dock cannot move or come loose during loading/unloading.
Page 14: Proprietor Responsibilities
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.
Page 15: B Truck Description
B Truck Description Application The EFG 535k - S50 is a four-wheel electric sit-down forklift truck. It is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attached in front. Closed bottom pallets can also be lifted.
Page 16: Assemblies And Functional Description
Assemblies and Functional Description Travel direction definition The following determinations have been made for travel direction specification: The following conventions have been agreed for travel direction specification: Item Travel direction Left Reverse Forward Right...
Page 17: Assembly Overview
Assembly Overview Item Designation Item Designation t Driver's seat Fork arms t Overhead guard Steer axle t Lift Mast Counterweight t Steering wheel Trailer coupling t Lift mechanism control Fork carriage t Control and display unit Drive system t Emergency disconnect Battery door switch...
Page 18: Functional Description
Functional Description Chassis The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components. Operator position and overhead guard The overhead guard comes in a range of models and protects the operator from falling objects and other external influences.
Page 19 Wheels There is a choice of super elastic or fully rubber tyres as well as optional pneumatic tyres. Drive and brake system The front drive provides maximum traction to the drive wheels at all times. The Bowden cable operated oil bath multi-plate brakes form the operating brake and are practically maintenance-free.
Page 20: Technical Specifications
Technical Specifications All technical details refer to standard trucks. Values indicated with *) may vary, depending on the types of equipment used (e.g. mast, cabin, tyres etc.). The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Load centre distance The load centre distance D of the load handler is specified as the horizontal distance from the front face and the vertical distance from the upper edge of the load handler.
Page 21 Designation 535k/ 540k/ 540/ S40/ 535ks 540ks 540s S40s Rated capacity 3500 4000 4000 4000 (for C) C Load centre of gravity Max. gradeability ) with/ 17/27.8 15.4/26.1 15.4/26.1 13.7/23.4 without load (drive&liftPLUS) Drawbar pull with/without 5300/ 5100/ 5100/ 4900/ load (drive&liftPLUS) 5800 5600...
Page 22 Designation 545k/ 545/ 550/ S50/ 545ks 545s 550s S50s Rated capacity 4500 4500 4990 5000 (for C) C Load centre of gravity Travel speed with/without 15.0/17.0 15.0/17.0 15.0/17.0 15.0/17.0 km/h load (drive&liftPLUS) Lift speed with/without 0.33/0.45 0.33/0.45 0.33/0.45 0.31/0.45 load (drive&liftPLUS) Lowering speed with/ without load 0.55/0.50 0.55/0.50 0.55/0.50 0.55/0.50...
Page 23: Dimensions
Dimensions EFG 535k-S40s Designation 535k/ 540k/ 540/ S40/ 535ks 540ks 540s S40s Height, mast lowered* 2300 2290 2290 2290 Free lift* Lift* 3100 3000 3000 3000 Mast height extended* 3889 3715 3715 3858 Overhead guard height* 2365 2365 2365 2350...
Page 25 EFG 545-S50s Designation 545k/ 545/ 550/ S50/ 545ks 545s 550s S50s Height, mast lowered* 2290 2290 2290 2440 Free lift* Lift* 3000 3000 3000 3030 Mast height extended* 3715 3715 3858 4003 Overhead guard height* 2350 2350 2350 2350 Seat height* 1303 1303 1303...
Page 26: Weights
Weights All dimensions in kg. EFG 535k-S50s Model 535k/ 540k/ 540/5 S40/ 545k/ 545/5 550/5 S50/ 535ks 540ks S40s 545ks S50s Truck weight 5830 6726 6701 7176 7186 7161 7549 8036 (including battery) Drive axle laden 8310 9730 9726 10025 10608 10549 11282 11677...
Page 27: Mast Versions
Mast versions All dimensions in mm. EFG 535k/EFG 535ks Designation Lift h Free lift Height mast Height mast without without retracted h extended h ZH with without front front window window (a/b°) (a/b°) EFG 535k/ EFG 535k/ 535k/ 535k/ 535k/...
Page 28 EFG 540k / EFG 540 / EFG 545k / EFG 545 including 3A fork carriage with 4 rollers (standard) Designation Lift h Free lift Overall Overall Without Without height height Mast Mast Without With retracted h extended h front front windscre windscr en (a/b°)
Page 29 Designation Lift h Free lift Overall Overall Without Without height height Mast Mast Without With retracted h extended h front front windscre windscr en (a/b°) een (a/b °) 4150 1382 2140 4908 4400 1465 2223 5158 4700 1565 2323 5458 4850 1615 2373...
Page 30 Designation Lift h Free lift Overall Overall Without Without height height ZH, with Mast Mast without front retracted h extended h front windscr windscre een (a/b en (a/b°) °) 2775 1332 2140 3683 3142 1415 2323 4050 3342 1515 2423 4250 3542 1615...
Page 31 EFG S40 / EFG 550 including 3A fork carriage with 6 rollers (standard) / integrated 3A side shift with 6 rollers (option) Designation Lift h Free lift Overall Overall Without Without height height ZH, with Lift mast Lift mast without front retracted h extended h...
Page 32 EFG S50 for integrated 4A side shift with 6 rollers (standard) Designation Lift h Free lift Height, Height, Without Without mast mast ZH, with retracted h extended h without front front windscr windscre een (a/b en (a/b°) °) 2480 2165 3453 2846 2348...
Page 33 EFG S50 including 3A fork carriage with 6 rollers (standard) / integrated 4A side shift with 6 rollers (option) Designation Lift h Free lift Height, Height, Without Without mast mast ZH, with retracted h extended h without front front windscr windscre een (a/b en (a/b°)
Page 34: Tyre Type
When replacing rims and tyres fitted at the factory, only use the manufacturer’s original spare parts. Otherwise the manufacturer’s specifications cannot be ensured. If you have any queries contact the manufacturer's customer service department. EFG 535k - S50 Model 535k/540/540k 545/545k/550...
Page 35: Engine Data
Engine Data Designation EFG 535k-S50 Drive motor 18 kW Lift motor 24 kW Designation Unit 535k/ 540k/ S40/ 545k/ S50/ 535k 540ks/ S40s 545ks S50s Energy 10.6 10.8 11.1 11.4 11.6 kWh/h consumption according to EN cycle CO2 equivalent 5.08 5.73...
Page 36: En Norms
EN norms Noise emission level – EFG 535k-S50: 69 dB(A) *+/- 3 dB(A) depending on the truck's equipment in accordance with 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle. The noise level is measured at the level of the driver's ear.
Page 37: Conditions Of Use
Conditions of use Ambient temperature – operating at -20°C to +40°C – for parking and charging +5°C to+40°C – Cold store version in permanent use: -5°C to -20°C – Tropical version in permanent use: +30°C to +50°C Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature or condensing air humidity fluctuations.
Page 38: Specifications According To Red Guideline (Radio Equipment Directive) For Radio Units
3.10 Specifications according to RED guideline (Radio Equipment Directive) for radio units The table contains any components installed according to the European Directive 2014/53/EU. The table shows the affected frequency range and the emitted transmission power for each component. Component Frequency range Transmission power WMT 110...
Page 39: Identification Points And Data Plates
Identification Points and Data Plates Indication Points Warnings and notices such as capacity charts, strap points and data plates must be legible at all times. Replace if necessary.
Page 40 Item Description Lift limits Do not travel with a raised load or operate the mast forward tilt with a raised load Capacity (or reduced capacity) Cold-store equipment (o) Attachment points for loading by crane Wear seat belt Add hydraulic oil Max.
Page 41: Data Plate
Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Model Item Model Rated capacity (kg) Load centre distance (mm) Battery voltage (V) Drive output Net weight w.o. battery (kg) Min./max.
Page 42: Truck Capacity Plate
Truck capacity plate CAUTION! Accident risk from fork replacement If you replace the forks with ones that differ from the originals, the capacity will change. uWhen replacing the forks you must attach an additional capacity plate to the truck. uTrucks supplied without forks are given a capacity plate for standard forks (length: 1150 mm).
Page 44: Attachment Capacity Plate
Attachment capacity plate The attachment capacity plate is next to the truck capacity plate and gives the truck capacity Q (in kg) in conjunction with the attachment and the specified fork arms (t) (56) and where applicable fork extensions (o) (57). The model name and/or serial number for the attachment indicated on the attachment capacity plate must match the data plate of the attachment.
Page 45 4.4.1 Attachment with More Than 100 mm Side Shift The capacity plate of the attachment with more than 100 mm possible side shift for a current working position in the centre position (58) or pushed out offset to max. 100 mm side shift is affixed next to the truck capacity plate.
Page 46 WARNING! Risk of accident from offset load centre of gravity The capacity of the truck is reduced when using side shifts that are more than 100 mm outside the truck centre. uNote the capacity plate with the reduced capacity. The capacity plate of the attachment with more than 100 mm possible side shift for a current clear offset working position with 100 mm side shift pushed out (59) is affixed separately to the other capacity plates.
Page 47: Stability
Stability The truck's stability has been tested according to latest technological standards. These take into account the dynamic and static tipover forces that can occur if used correctly. The operational stability of the truck can also be affected by factors such as: –...
Page 49: C Transport And Commissioning
C Transport and Commissioning Transport Transport can be carried out in two different ways, depending on the height of the mast and the local conditions. – Vertically, with the mast assembled (for low heights) – Vertically, with the mast dismantled (for large heights), all mechanical connections and hydraulic lines between the basic truck and the mast separated.
Page 50: Lifting The Truck By Crane
Lifting the truck by crane WARNING! All persons involved in loading by crane must be trained Incorrect crane loading procedures due to untrained personnel can cause the truck to fall. There is a risk of injury to personnel and a risk of material damage to the truck.
Page 51 Lifting the truck by crane Requirements – Park the truck securely, see page 133. Procedure • Secure the crane slings to the attachment points (60) and (61. • Raise and load the truck. • Lower and deposit the truck carefully (see page 133).
Page 52: Loading With Another Industrial Truck
Loading with another industrial truck WARNING! The truck can be damaged The truck to be loaded can be damaged when loading with another industrial truck. uOnly trained specialist personnel should load the truck. uUse only trucks with sufficient capacity for loading. uOnly for loading and unloading.
Page 53: Securing The Truck During Transport
Securing the truck during transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
Page 54 Securing with a mast Securing without a mast Securing the industrial truck for transport Requirements – Position the industrial truck securely on a lorry or trailer, see page 133. Tools and Material Required – 2 fastening belts with a tensioner –...
Page 55: Using The Truck For The First Time
Using the Truck for the First Time Safety instructions for assembly and commissioning WARNING! Incorrect assembly can result in accidents The assembly of the truck at the application site, commissioning and operator training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.
Page 57: D Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement General notes on handling batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. Park the truck securely before carrying out any work on the batteries (see page 133).
Page 58: Touch Voltage Hazard
Touch voltage hazard WARNING! Hazardous contact voltages only arise in the event of a technical or physical defect. The batteries are normally charged. There is still some residual voltage in a discharged battery. This must be considered as a hazardous contact voltage. With this kind of defect the battery must not be touched and must not come into contact with metal objects see page 57.
Page 59: Safety Regulations For Handling Lead-Acid Batteries
Safety Regulations for Handling Lead-Acid Batteries WARNING! Batteries can be hazardous Batteries contain an acid solution which is poisonous and corrosive. Avoid contact with battery acid at all times. uDispose of used battery acid in accordance with regulations. uAlways wear protective clothing and goggles when working with batteries. uDo not let battery acid come into contact with skin, clothing or eyes.
Page 60: Safety Regulations For Handling Lithium-Ion Batteries
Safety regulations for handling lithium-ion batteries The following hazards can arise in the event of improper use: – Physical damage: This can occur if a battery falls or is deformed through pressure (e.g. truck forks penetrate the battery housing). Mechanical damage includes cracks, breakage, splinters or holes in the battery housing.
Page 61: Particular Hazard From Combustion Products
Particular hazard from combustion products WARNING! Contact with combustion products can be hazardous Fires produce combustion products. Combustion is a chemical process by which a flammable material combines with oxygen under heat and light (fire). The resulting combustion products can occur in the form of smoke, through leaking fluids, escaping gases, debris as well decomposition products of certain chemicals.
Page 62: Battery Types
The truck will be equipped with different battery models, depending on the application. The following table shows which combinations are included as standard: Truck type Model Capacity EFG 535k/EFG 540k/EFG 545k 80V - 5PzS 700-775 Ah EFG 540/EFG 545/EFG 80V - 6PzS...
Page 63: Battery Dimensions
Battery dimensions Traction battery 80 V similar DIN 43535 Dimension (mm) Rated weight Truck (-5/+8%) in L max. B max. H1+/- H2 +/- 2 mm 2 mm 535k/EFG 1028 1863 700-775 Ah 540k/EFG 545k EFG 540/ 545/EFG 550/ 1028 2178 840-930 Ah S40/EFG The dimensions of the lithium-ion batteries are identical to the dimensions of the...
Page 64: Exposing The Battery
Exposing the battery Requirements – Park the truck securely, see page 133. – Load handler lowered. – Key switch set to OFF. – Key removed. – Set the Emergency Disconnect OFF. Procedure • Open the battery door (64) as far as the stop.
Page 65: Battery Removal And Installation
Battery removal and installation WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. uNote the "Safety regulations for handling acid batteries" section in this chapter. uWear safety shoes when removing and installing the battery.
Page 66: Removal And Installation Using A Pallet Truck And Snapfit Battery Holder O
Removal and installation using a pallet truck and Snapfit battery holder o CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Removing the battery Requirements –...
Page 67 Raise the fork arms until the battery can be pulled clear of the battery compartment. NOTICE Risk of material damage Risk of material damage to the truck chassis while the battery is being pulled out. uRaise the fork tines. While pulling out the battery, do not allow it to strike the truck chassis on the top or bottom.
Page 68 Battery installation Procedure • Drive the pallet truck and battery to the truck. • Deposit the battery trolley with the rollers (78) on the base of the truck. • Lower the fork arms of the pallet truck until the battery is horizontal. Align the height and push the forks of the pallet truck underneath the truck base.
Page 69 7.1.1 Battery holder assembly CAUTION! The battery holder can only be fitted to pallet trucks or hand pallet trucks with notice signs. Requirements – Pallet truck or hand pallet truck available with holes in accordance with assembly instructions, see page 70. Procedure •...
Page 70 7.1.2 Assembly instructions Ø Ø 16 16 x4 x4...
Page 71 Procedure • Drill 4 holes with a 16 mm diameter into the pallet truck or hand pallet truck according to the drill patterns. • Make sure there is sufficient distance between the connecting rod and the bottom of the forks. Attach safety notices to the pallet truck.
Page 73: Removal And Installation Using A Fork Shoe (O)
Removal and installation using a fork shoe (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Battery removal and installation Requirements – Truck parked securely, see page 133. –...
Page 74 • Pull out the battery as far as the stop (76) on the truck chassis. • Raise the fork carriage. • Tilt the mast back fully and bring the battery to the charging station to be charged. • Place battery carefully onto the charging...
Page 75: Removal And Installation Using A Roller Conveyor (O)
Removal and installation using a roller conveyor (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Battery removal and installation Requirements – Park the truck securely, see page 133. –...
Page 76: Removal And Installation For Service Using A Hand Pallet Truck With Snapfit (O)
Removal and installation for service using a hand pallet truck with Snapfit (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Battery removal and installation Requirements –...
Page 77 • Engage the safety catches (70) on the battery trolley. • To do this, press the pedals (69). Do not raise the forks. • Undo the catch (77). • Undo the battery latch (66). • Using the hand pallet truck, slowly remove the battery as far as the stop (81).
Page 78: Removal And Installation For Service Using A (Hand) Pallet Truck Without Snapfit
Removal and installation for service using a (hand) pallet truck without Snapfit CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Bring the battery to the service position Requirements –...
Page 79: Hydraulic Battery Extractor (O)
Hydraulic Battery Extractor (o) CAUTION! Trapping hazard Trapping hazard when extracting and inserting the battery. uWhen removing and installing the battery door, do not put your hands between the battery door and the chassis. uWear safety shoes. uWhile sliding out the battery, stand behind the open battery door. uMake sure that no one is in the hazardous area.
Page 80 Procedure • Open the battery door as far as the stop. • Disconnect the battery connector from the truck. • Connect the battery connector to the hydraulic battery extractor. • Open the battery latch. • Stand behind the open battery door and actuate the actuation button on the hydraulic battery extractor until the battery is fully extracted.
Page 81 Inserting the battery Requirements – Truck parked securely, see page 133. – Battery door opened as far as the stop. – Battery connector connected to the hydraulic battery extractor. – Battery cable is at least 1650 mm long. Procedure • Stand behind the open battery door and actuate the actuation button on the hydraulic battery extractor until the battery is fully inserted.
Page 82: Charging The Battery
Charging the battery Charging the Lead Battery WARNING! The gases produced during charging can cause explosions The battery produces a mixture of oxygen and hydrogen (electrolytic gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited.
Page 83 8.1.1 Charging the Lead Battery with a Stationary Battery Charger WARNING! Risk of electric shock and fire due to lacking or inappropriate residual current devices A lack of residual current devices or the use of inappropriate residual current devices can result in fatal injury due to electric shocks or electrical fires in the event of a fault. uThe owner must conduct an operational risk assessment of the usage location.
Page 84 Spark formation and uncontrolled movement of electronically controlled components may cause personal injury. uThe battery may only be charged with the Jungheinrich battery charger designed for this battery. uUse only battery chargers approved by the manufacturer.
Page 85 • Depending on the battery you may need to attach the water connection (86) to the battery charger station. • Switch on the battery charging station and charge the battery in accordance with the battery and charging station manufacturers’ instructions. After charging, test the fans and remove the connector.
Page 86: Charging Lithium-Ion Batteries (O)
Charging lithium-ion batteries (o) WARNING! Risk of electric shock and fire due to lacking or inappropriate residual current devices A lack of residual current devices or the use of inappropriate residual current devices can result in fatal injury due to electric shocks or electrical fires in the event of a fault. uThe owner must conduct an operational risk assessment of the usage location.
Page 87 8.2.1 Charging the Lithium-Ion Battery with a Comfort Charger Socket (o) on the Truck Charging Requirements – Truck parked securely, page 133. Procedure • Connect the charger cable of the battery charger station charger socket (87). • Switch on the battery charging station and charge the battery in accordance with the battery and charging...
Page 89: Operation
E Operation Safety Regulations for the Operation of Forklift Trucks Driver authorisation The truck may only be used by suitably trained personnel, who have demonstrated to the proprietor or his representative that they can drive and handle loads and have been authorised to operate the truck by the proprietor or his representative.
Page 90 Hazardous area WARNING! Risk of accidents/injury in the hazardous area of the truck A hazardous area is defined as the area in which people are at risk due to travel or lifting operations of the truck, its load handler or the load. This also includes the area within reach of falling loads or lowering/falling operating equipment.
Page 91: Displays And Controls
Displays and Controls Controls Item Control/display Function Steering wheel Steering the industrial truck. Flashing lever Flashes in the required travel direction. “Reverse” accelerator The truck reverses when the accelerator twin pedal control pedal is applied. Provides infinitely variable travel speed. Brake pedal Provides infinitely variable braking control.
Page 92 Armrest control panel Used to switch optional electrical equipment on and off. Side-compartment Used to switch optional electrical control panel equipment on and off. *If equipped with a Jungheinrich fleet management component, see the “Jungheinrich fleet management system” operating instructions.
Page 94: Pilots
Pilots Item Control / Function Display t Lever for operating the basic lift/tilt Basic hydraulic functions lever hydraulic functions. Sideshifter/auxiliary t Sideshifter or auxiliary hydraulics 1 button hydraulics 1 optional button / lever t Selects travel direction / neutral position. Travel direction switch (not available with dual pedal control)
Page 95: Function Symbols For The Pilots
Function symbols for the Pilots The pictogram shows the direction of movement that is executed when the operator pulls the lever in direction (R). The counter-movement of the work function is achieved by the operator pushing the lever accordingly. For controls that operate at right angles to the travel direction, the function is shown with the actuation to the left (S) from the operator's perspective.
Page 96 Symbol Meaning Side shift left Fork positioner Outside fork positioner Inside fork positioner Left fork positioner Right fork positioner Clamp Reach fork Telescopic fork Rotate Double lift Lock Crane...
Page 97 Symbol Meaning Bucket Load holder Folding fork Empty container Pusher Adapters ZH1 to ZH4 (example symbol: ZH1) Changing attachments 1 to 4 (example: attachment 2)
Page 98: Control Panel With Display Unit
Control panel with display unit 2.4.1 2-Inch Display Item Control/display Function 107 Information line Displays event messages and speed 108 Symbol field Displays the icons see page 102. 109 Battery Type Empty = standard battery; 1 = Dry battery 110 Battery capacity display Battery discharge status.
Page 99 2.4.2 4 Inch Display (o) Item Control/display Function 107 Information line Displays speed, event messages, residual runtime and optional information such as lift height, load weight. 108 Symbol field Displays the icons see page 102. 109 Battery Type Empty = standard battery; 1 = Dry battery 110 Battery capacity display Battery discharge status.
Page 100: Button Allocation Of The Display
Button allocation of the display Symbol Meaning Information field toggle: Allows the information displayed in the information field to be changed. Slow travel: Switches slow travel on and off. Operating program down: To switch the operating program down. Operating program up: To switch the operating program up.
Page 101 Button allocation in menu for managing codes or transponders (o) Symbol Meaning Back: Cancels the current procedure and returns to the previous menu. Log-in history: Displays the chronological log-in history Change set-up code: To change the set-up code and to activate the keypad or the transponder reader.
Page 102: Symbols In The Display
Symbols in the display Any number of pictograms can be displayed in the pictogram field (108). Which pictograms are shown in the pictogram field depends on the operating and truck status. Symbol Meaning Colour Function Indicator (warning Green Indicator and warning indicator active indicator) Slow travel Green...
Page 103 Symbol Meaning Colour Function Automatic parking Green Automatic parking brake active brake Comfort feature, displayed when the automatic parking brake indicator lights up. Truck prevented from rolling away but not parked securely. The automatic parking brake is automatically activated a set time (0–60 sec) after the truck stops.
Page 104 Symbol Meaning Colour Function Lift limit switch Green Lift cut-off overridden Yellow Lift cut-off initiated Battery latch / Yellow Battery latch/door open battery door Battery acid level Battery acid level low Special symbols on the display unit when equipped with lithium-ion battery Symbol Meaning Colour Function...
Page 105: Battery Discharge Indicator
Battery discharge indicator NOTICE Full discharge can damage the battery The standard setting for the battery discharge indicator is based on standard batteries. When using maintenance-free batteries (gel batteries), the display must be reset. uThis adjustment should only be made by the manufacturer’s customer service department.
Page 106: Residual Time Display
Residual time display Setting the residual time display The residual time display (119) is switched on and off via the display toggle button (111/112).
Page 107: Operating Programs
2.10 Operating Programs Five operating programs with different performance levels are available to adapt the travel and operating functions to the application at hand. Starting from operating program 1 (limited acceleration and speed together with sensitive application of the operating functions), the performance levels increase to program 5 (maximum performance for high throughput performance).
Page 108 Symbol Function Rear windscreen wiper – Press once > button flashes green - intermittent – Press twice > button lit green - permanent operation – Press three times > off – Hold down on the button > Switch on the window washer system Rear window heating Parking brake button Secure truck parking...
Page 109 NOTICE Not all buttons are assigned. Button assignment depends on the truck's equipment.
Page 110: Side Compartment Control Panel Switch (O)
2.13 Side compartment control panel switch (o) These switches are located in the side control panel (99). Function Parking light Warning indicator...
Page 111: Preparing The Truck For Operation
Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work WARNING! Damage and other truck or attachment (optional equipment) defects can result in accidents. If damage or other truck or attachment (optional equipment) defects are discovered during the following checks, the truck must be taken out of service until it has been repaired.
Page 112 • Check the function of the restraint system monitor. • Test the function of the display unit. Belt lock control symbol (see page 102) lights up when the belt is not locked. • Test the function of the display unit. Cabin door monitoring symbol (see page 102) lights up when the summer door, the folding gate or the cabin door is not closed properly (o).
Page 113 • 0 k m h • Visually inspect the battery attachment and cable connections. • Check the battery latch is present and working.
Page 114 • On trucks with lateral battery removal, check the left and right stops (81) in the battery compartment for damage. • Check the fluid level of the windscreen washing system, see page 130. • Check the load damper hydraulic accumulator for damage (o).
Page 115: Entry And Exit
Entry and exit Requirements – Truck stationary. Procedure • Cab door open (if applicable). • To enter and exit the cab, hold onto the handle (122). Always face the truck when entering and exiting. Always use the entry aid (122) provided to climb onto the truck. An additional step is provided for the driver position extension (o).
Page 116: Setting Up The Operator Position
Setting up the operator position WARNING! Accidents can occur if the driver's seat, steering column and armrest are not engaged The driver's seat, steering column and armrest can accidentally adjust during travel and therefore cannot be operated safely. uDo not adjust the driver’s seat, steering column or armrest while travelling. Procedure •...
Page 117 Setting the driver's weight NOTICE Incorrectly adjusted seat cushioning can damage your health To achieve optimal seat cushioning, the driver’s seat must be adjusted according to the driver’s weight. Set the driver's weight when the seat is occupied. uHold the weight adjustment lever only by the recess;...
Page 118 Adjusting the seat position CAUTION! An unsecured driver's seat can cause injury An unsecured driver's seat can slide out of its guide during travel, resulting in accidents. uThe driver's seat must be locked in position. uDo not adjust the driver’s seat while travelling.
Page 119 Adjusting the backrest extension CAUTION! Accident risk when adjusting the backrest during travel adjust backrest extension while travelling. Procedure • The backrest extension height can adjusted changing detent. • Pull the backrest up and lock it in place to extend the backrest. •...
Page 120 Adjusting the lumbar support ( Procedure • Turn the hand wheel (129) to the required position. Position 0 = no warping in lumbar vertebrae area. Position 1 = increasing warping in upper lumbar vertebrae area. Position 2 = increasing warping in lower lumbar vertebrae area. The lumbar support is now adjusted.
Page 121 3.4.2 Adjusting the steering column Adjusting the steering column Procedure • Release the steering column stop (130). • Set the steering column to the required position (height and angle). • Fix the steering column stop (130) in position. The steering column is now positioned. 3.4.3 Adjusting the arm rest Adjusting the Armrest...
Page 122: Restraint Systems
3.4.4 Adjusting the armrest Adjusting the armrest Procedure • Fold up the armrest (131). • Set the height adjuster (133) to the desired position (high/low). • Fold the armrest (131) down. Restraint systems Restraint systems Approved restraint systems: – Seat belt (see page 123) –...
Page 123: Seat Belt
Seat Belt WARNING! Travelling without a seat belt increases the risk of injury. Accidents or personal injury can result if the seat belt is not worn or is modified. uAlways put the seat belt on before starting the industrial truck. uDo not modify the seat belt.
Page 124 DANGER! A faulty seat belt can cause injury Using a faulty seat belt can result in injury. uOnly operate the truck with the seat belt intact. A faulty seat belt should be replaced immediately. uThe truck must remain decommissioned until a functional seat belt has been fitted. CAUTION! Accident risk when opening the seat belt during travel If the seat belt is opened while driving, the truck automatically brakes to a maximum...
Page 125: Industrial Truck Operation
Industrial Truck Operation Safety regulations for truck operation WARNING! Magnetic fields can cause accidents Electronic components can be affected or damaged by external magnetic fields. This can lead to malfunctions or accidents. uDo not use or keep magnets or clamping magnets in the immediate vicinity of the controls.
Page 126 travel against the load direction. If this is not possible, a second person must walk alongside the truck as a lookout to observe the travel route while maintaining eye contact with the operator. Proceed only at walking pace and with particular care. Stop the truck as soon as you lose eye contact.
Page 127 Negotiating slopes and inclines Negotiating slopes and inclines up to 15% is only permitted if they are specifically designed as travel routes, are clean and have a non-slip surface and providing they can be safely travelled along in accordance with the truck's technical specifications. The truck must always be driven with the load facing uphill.
Page 128 Activating the lithium-ion battery (o) The lithium-ion battery can be deactivated to guard against deep discharge or faults. In the event that no fault is present, the lithium-ion battery can be activated by charging. Requirements – For troubleshooting, see the operating instructions for the lithium-ion battery. Procedure •...
Page 129 Wake-up button on the control panel For easy activation lithium-ion battery, trucks are equipped with an additional wake-up button in the right control panel of the truck. battery activation button/ wake-up button activates lithium-ion battery and switches it back to normal operation from energy-saving operation.
Page 130 Preparing the truck for operation Switching on the truck Requirements – For checks and operations to be performed before starting daily operation, see page 111.
Page 131 Procedure • Unlock the emergency disconnect switch (96); to do this, • press the rocker in (s) and pull it up until you feel the emergency disconnect switch engaging. • Insert the key in the key switch (93) and turn it clockwise as far as it will go to the “I”...
Page 132: Setting The Time
Setting the time 0 k m h Setting the time Symbol Procedure Press the button under the settings symbol. Press the button under the clock symbol. Use the arrow up key to change the time digit selected. Use the arrow down key to change the time digit selected. Press the confirm key to move to the next digit or to confirm the time.
Page 133: Parking The Truck Securely
Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load / load handler is dangerous and is strictly prohibited. uAlways park the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 134: Emergency Disconnect
Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. uDo not use the Emergency Disconnect switch as a service brake.
Page 135 Travel WARNING! Improper travel can result in accidents uDo not get up from the driver’s seat during travel. uDo not drive the truck unless your are wearing a seat belt and the panels and doors are properly locked. uDo not lean out of the truck while travelling. uMake sure that the travel area is clear.
Page 136 Dual pedal (optional equipment) Requirements – Truck prepared for operation, see page 130. Procedure For trucks with a dual pedal the travel direction is selected via the accelerator pedals (91;89). When the driver leaves the truck, the truck is automatically set to “Neutral”. •...
Page 137 Steering Requirements – Truck prepared for operation, see page 130. Procedure • To negotiate a right-hand bend: • Turn the steering wheel clockwise to match the desired steering radius. • To negotiate a left-hand bend: • Turn the steering wheel anti-clockwise to match the desired steering radius. The truck travels in the required travel direction.
Page 138 Brakes WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions. uThe operator must take into account the travel route conditions when braking. uBrake with care to prevent the load from slipping. uAllow for increased braking distance when travelling with an attached load. uUse the service brake in emergencies.
Page 139 4.9.1 Coasting Brake WARNING! Immediately after the battery has been charged the brake power of the coasting brake may reduce of their own accord after long periods of application, e.g. ramp operation. uThe operator must instruct people to leave the hazardous area. uThe operator must perform test braking.
Page 140 4.9.3 Manual Parking Brake with Parking Brake Lever DANGER! Accident risk uThe parking brake will hold the truck with maximum load on a clean ground surface, on inclines of up to 15%. uDo not park and abandon the truck on an incline. uApplying the parking brake during travel will cause the truck to brake to a halt at maximum force.
Page 141 Engaging the manual parking brake with the parking brake lever Procedure • Pull the parking brake lever (92) back fully as far as the stop. The manual parking brake is now applied. The parking brake lever warning indicator (142) is displayed.
Page 142 4.9.4 Manual Parking Brake with Parking Brake Button DANGER! Accident risk uThe parking brake will hold the truck with maximum load on a clean ground surface, on inclines of up to 15%. uDo not park and abandon the truck on an incline. uApplying the parking brake during travel will cause the truck to brake to a halt at maximum force.
Page 143 Deactivating the manual parking brake with the parking brake button ( Procedure • Actuate the parking brake button (139). The red LED above the parking brake button (139) goes out. The red manual parking brake icon (140) on the display goes out and the automatic parking brake icon (143) is lit green.
Page 144 4.9.5 Automatic parking brake (o) The automatic parking brake is a comfort feature and is not designed to park the truck securely. The automatic parking brake is automatically activated a set time (0 - 60 sec) after the truck stops. The factory setting is 30 sec. The time setting can only be adjusted by the manufacturer’s customer service department.
Page 145: Adjusting The Forks
4.10 Adjusting the forks WARNING! Unsecured and incorrectly adjusted forks can cause accidents Make sure that the fork retaining mechanisms (121) are fitted before adjusting the forks. Depending on the fork carriage, the fork-retaining mechanism (121) will be either via retaining bolts (85 Nm) or fixed stops. uAdjust both forks so that they are equidistant from the outside edges of the fork carriage.
Page 146 Adjusting the forks Requirements – Park the truck securely, see page 133. Procedure • Lift up the locking lever (144). • Push the forks (145) into the correct position on the fork carriage (146). To lift the load securely, the forks (145) must be spread as far apart as possible and positioned centrally with respect to the fork carriage.
Page 147: Replacing The Forks
4.11 Replacing the forks WARNING! Unsecured forks can cause injury This is a risk of injury and trapping when replacing the forks. uWear work gloves and safety shoes. uNever pull the forks towards your body. uAlways push the forks away from your body. uSecure heavy forks with lifting accessories and a crane before pushing them down.
Page 148: Lifting, Transporting And Depositing Loads
4.12 Lifting, transporting and depositing loads WARNING! Risk of accident when the load centre is outside the load centre distance If the centre of gravity G of a raised load lies outside the load centre distance D specified for the load handler in the horizontal or vertical planes, under unfavourable conditions the raised load and also the truck can tip over while working.
Page 149 Lifting loads Requirements – Load correctly palletised. – Fork spread for the pallet checked and adjusted if necessary. – Load weight matches the truck's capacity. – Forks evenly loaded for heavy loads. Procedure • Drive the truck carefully up to the pallet. •...
Page 150 NOTICE Loads must not be deposited on travel or escape routes, in front of safety mechanisms or operating equipment that must be accessible at all times. Transporting loads Requirements – Load raised correctly. – Load handler lowered transport (approx. 150 - 200 mm above the ground).
Page 151: Operating The Lift Mechanism And Integrated Attachments
4.13 Operating the Lift Mechanism and Integrated Attachments WARNING! Operating the lifting device and integrated attachments can be hazardous Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc.
Page 152 4.13.1 Operating the lifting device with the Solo-Pilot Lifting and lowering Requirements – Truck prepared for operation, see page 130. Procedure • Pull the lever (100) in direction H to raise the load. • Push the lever (100) in direction S to lower the load.
Page 153 Positioning integrated sideshifter (option) Requirements – Truck prepared for operation, see page 130. Procedure • Pull the lever (101) in direction R to move the load handler to the right (from the driver’s viewpoint). • Push the lever (101) in direction V to move the load handler to the left (from the driver’s viewpoint).
Page 154 Positioning the forks with an integrated fork positioner (option) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation, see page 130. Procedure • Press the acknowledgement key (106) and then within 2 seconds pull the lever (104) in direction H to bring the forks together.
Page 155 4.13.2 Operating the Lift Mechanism with the MULTI-PILOT Lifting and lowering Requirements – Truck prepared for operation, see page 130. Procedure • Pull the Multi-Pilot (100) in direction R to raise the load. • Push the Multi Pilot (100) in direction V to lower the load.
Page 156 Positioning the integrated sideshift (option) Requirements – Truck prepared for operation, see page 130. Procedure • Press the button (101) to the left to move the load handler to the left (from the driver's viewpoint). • Press the button (101) to the right to move the load handler to the right (from the driver's viewpoint).
Page 157 Positioning the fork arms with an integrated fork positioner (optional equipment) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation, see page 130. Procedure • Press the acknowledgement key (147) and then within 2 seconds push the fork positioner lever (104) in direction V to move the fork arms apart.
Page 158 4.13.3 Operating the Lift Mechanism with the Duo-Pilot Lifting and lowering Requirements – Truck prepared for operation, see page 130. Procedure • Pull the lever (100) in direction R to raise the load. • Push the lever (100) in direction V to lower the load.
Page 159 Positioning the integrated sideshifter (option) Requirements – Truck prepared for operation, see page 130. Procedure • Pull the lever (101) in direction S to move the load handler to the left (from the driver’s viewpoint). • Push the lever(101) in direction H to move the load handler to the right (from the driver’s viewpoint).
Page 160 Positioning the forks with an integrated fork positioner (option) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation, see page 130. Procedure • Press the acknowledgement key (106) and then within 2 seconds pull the lever (104) in direction R to bring the forks together.
Page 161: Safety Instructions For Operating Additional Attachments
4.14 Safety instructions for operating additional attachments DANGER! Attaching exchangeable equipment can result in accidents. Other people can be injured when attaching exchangeable equipment. Use only exchangeable equipment that has been deemed safe after a risk analysis carried out by the owner. uOnly use attachments that have been designed by the attachment manufacturer for use with the respective industrial truck.
Page 162 Safety instructions for sideshifter and fork positioner attachments WARNING! Restricted visibility and reduced tilt resistance can cause accidents When using sideshifters and fork positioners, the change in centre of gravity can result in reduced lateral tilt resistance and accidents. Note that this affects visibility as well.
Page 163 Safety instructions for clamping attachments (e.g. baling clamps, barrel clamps, grabs, etc.) WARNING! Risk of accidents due to falling loads Operating errors can occur and the load can fall accidentally. uClamping attachments must only be used on trucks that feature a button for enabling additional hydraulic functions.
Page 164 Safety instructions for telescopic attachments WARNING! Accident risk from increased tipover hazard and reduced residual capacity There is a greater risk of tipover with extended telescopic attachments. uDo not exceed the maximum loads specified on the capacity plate. uOnly use the telescopic function for stacking and retrieving. uRetract the telescopic attachment fully during transport.
Page 165 Safety instructions for fork extensions WARNING! Unsecured and oversized fork extensions can cause accidents. uOnly use fork extensions that are suitable and have been approved for the base forks of the truck. Observe the data on the data plates of the fork extensions and truck.
Page 166: Operating Additional Attachments For The Solo-Pilot
4.15 Operating additional attachments for the SOLO-PILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. uMark the controls with symbols that indicate their function. uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
Page 167 4.15.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (101, 104, 106) is assigned function attachment. Unused levers have no function. connections page 174. Procedure • Operating hydraulic port ZH1: Move the lever (101) in direction V or R.
Page 168 4.15.3 Solo Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports Depending on the attachments used the levers / buttons (101, 104, 106, 105) assigned respective functions. Unused levers have no function. For connections see page 174. Procedure • Operating hydraulic port ZH1: Move the lever (101) in direction V or R.
Page 169: Operating Additional Attachments For The Multi Pilot
4.16 Operating additional attachments for the Multi Pilot WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. uMark the controls with symbols that indicate their function. uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
Page 170 4.16.2 Multi Pilot with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (104,100,101) is assigned the function of the attachment. Unused levers have no function. For connections see page 174. Procedure • Operating hydraulic port ZH1: Press the (101) button to the left or right.
Page 171 4.17 Operating additional Attachments for Duo-Pilot WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. uMark the controls with symbols that indicate their function. uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
Page 172 4.17.2 Duo-Pilot with Control of ZH1 and ZH2 Hydraulic Ports Depending on the attachments used the lever / button (101,104,106) is assigned 101 / 104 the function of the attachment. Unused levers have no function. For connections see page 174. Procedure •...
Page 173 4.17.3 Duo-Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports 101 / 104 Depending on the attachments used the levers / buttons (101,104,105,106) are assigned the respective functions. Unused levers have no function. For connections see page 174. Procedure •...
Page 174 4.18 Fitting additional attachments WARNING! Incorrectly connected attachments can cause accidents. Attachments with incorrectly connected hydraulic attachments can result in accidents. uAttachments must only be assembled and commissioned by trained, specialist personnel. uObserve the manufacturer’s operating instructions. uBefore starting, check the fasteners are positioned correctly and securely and make sure they are complete.
Page 175 Depressurise the hydraulic plug-in coupling Requirements – The operator is in the operating position. – Parking brake activated. – Travel direction switch in neutral. – All controls in neutral. Procedure • Press the (148) button for more than 5 seconds. •...
Page 176 WARNING! Incorrectly labelled hydraulic functions can cause accidents Labels on the pilot that do not match the directions of movement and hydraulic functions on the attachment can result in accidents. uBefore starting, make sure the pilot is correctly labelled and adjust if necessary. Connecting an attachment hydraulically Requirements –...
Page 177 The manufacturer's customer service department can correctly connect the attachment, adjust the controls and actuation directions on the pilot to the connections and directions of movement of the attachment, and label the pilot accordingly.
Page 178: Towing Trailers
Towing trailers DANGER! Inappropriate speeds and excessive trailer loads can be dangerous If you do not adapt your speed and / or use an excessive trailer load, the truck can pull apart when cornering and braking. uThe truck should only be used occasionally to tow trailers. uThe overall weight of the trailer should not exceed the capacity indicated on the capacity plate, see page 39.
Page 179 Attaching the trailer CAUTION! Trapping hazard There is a trapping risk when you attach a trailer. uFollow the instructions of the coupling manufacturer if using special trailer couplings. uSecure the trailer to prevent it from rolling away before coupling it. uDo not get caught between the truck and the tiller when coupling the trailer.
Page 180: Optional Equipment
Optional equipment Keyless Access System The keyless access system allows an individual code to be allocated to each operator or group of operators. Item Description Display unit (EasyAccess Softkey): – Description, see page 98 – Entry of 4-digit set-up and access codes –...
Page 181: General Information About The Use Of Keyless Access Systems
General Information about the Use of Keyless Access Systems The default code is to be found on a sticker. When using for the first time, change the set-up code and remove the sticker! – Default code: 1-2-3-4 – Factory set-up code: 2-4-1-2 When a valid code is entered or a valid transponder used, a green tick appears in the display unit.
Page 182 6.3.1 Activating the keypad Procedure • Release the emergency disconnect switch, see page 134. • Enter the default code 1-2-3-4 using the keys below the display unit (6). The truck is switched on. • Press the key below the "Settings" symbol (153).
Page 183 6.3.2 Activating the transponder reader Procedure • Release the emergency disconnect switch, see page 134. • Enter the default code 1-2-3-4 using the keys below the display unit (6). The truck is switched on. • Press the key below the "Settings" symbol (153).
Page 184: Using The Display
Using the Display: 6.4.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 134. • Enter the access code with the buttons below the display (6). The truck is switched on. 6.4.2 Switching off the truck Procedure •...
Page 185 6.4.3 Changing the Set-up Code Requirements – The truck is switched on, see page 184. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Change set- up code" symbol (154). • Enter the set-up code using the keys below the display unit (6).
Page 186 6.4.4 Adding a new access code Requirements – The truck is switched on, see page 184. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Edit access code" symbol (159). The set-up code is requested. •...
Page 187 6.4.5 Deleting an access code Requirements – The truck is switched on, see page 184. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Edit access code" symbol (159). The set-up code is requested. •...
Page 188 6.4.6 Displaying the Log-in Process The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 189: Using The Keypad
Using the Keypad 6.5.1 Switch on the truck with the access code. Procedure • Release the emergency disconnect switch, see page 134. • Enter the access code with the keypad (150). The truck is switched on. 6.5.2 Switching off the truck Procedure •...
Page 190 6.5.3 Changing the Set-up Code Requirements – The truck is switched on, see page 189. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Change set- up code" symbol (154). • Enter the set-up code using the keypad (150).
Page 191 6.5.4 Adding a new access code Requirements – The truck is switched on, see page 189. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Edit access code" symbol (159). The set-up code is requested. •...
Page 192 6.5.5 Deleting an access code Requirements – The truck is switched on, see page 189. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Edit access code" symbol (159). The set-up code is requested. •...
Page 193 6.5.6 Displaying the Log-in Process The use of the last different access codes is displayed during the log-in process. The last log-in is displayed first. If multiple access codes are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 194 Using the Transponder Reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 6.6.1 Switching on the truck with the transponder Procedure • Release the Emergency Disconnect switch, see page 134. •...
Page 195 6.6.3 Changing the Set-up Transponder Requirements – The truck is switched on, see page 194. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Change set-up code" symbol (154). • Place the set-up transponder on the transponder reader (151).
Page 196 6.6.4 Adding a new transponder Requirements – The truck is switched on, see page 194. Procedure • Press the key below the "Settings" symbol (153). • Press below "Edit transponder" symbol (159). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (151).
Page 197 6.6.5 Deleting transponders Requirements – The truck is switched on, see page 194. Procedure • Press the key below the "Settings" symbol (153). • Press the key below the "Edit transponder" symbol (159). set-up transponder requested. • Place the set-up transponder on the transponder reader (151).
Page 198 6.6.6 Displaying the Log-in Process The use of the last different transponders is displayed during the log-in process. The last log-in is displayed first. If multiple transponders are logged as being displayable simultaneously, the display area can be moved by scrolling forward or back. Requirements –...
Page 199: Assistance Systems
Assistance systems The Access, Drive and Lift Control systems help the driver operate the truck with regard to safety regulations, see page 125 of the present operating instructions. Travel conduct The operator must adapt the travel speed to local conditions. The truck must be driven at slow speed when negotiating bends or narrow passageways, when passing through swing doors and at blind spots.
Page 200 6.7.2 Drive Control This option restricts the travel speed of the truck as a function of the lift height. From a factory-set lift height the maximum travel speed is reduced to walking pace (approx.3 km/h) and the slow travel indicator (yellow symbol colour) is activated. When the forks fall below this height with the accelerator pedal applied, the truck accelerates at reduced levels to the speed prescribed by the accelerator pedal to prevent sudden acceleration when changing from slow travel to normal travel.
Page 201 Steel cab For trucks fitted with a steel cabin, both doors can be closed. Trucks with cabin door monitoring may experience the following situations if the cabin door is not locked: – The cabin door open symbol (see page 102) lights up in the display unit. –...
Page 202 Opening and closing the door Procedure • To unlock the cab door, turn the key anti- clockwise. • To lock the cab door, turn the key clockwise. • To open the cab door, unlock the door and pull out the handle (164). •...
Page 203 Sliding windows CAUTION! An unlocked sliding window can cause accidents uThe sliding windows must be locked at all times. Opening and closing the windows Procedure • Push the lock (166) up. • Move the window forward or back. • Insert the lock in the stop (165).
Page 204 6.10 Gate CAUTION! Risk of accidents due to faulty swivelling gate uNever use the truck without a fully functional swivelling gate. Have swivelling gate checked by authorised specialist personnel after an accident. Do not modify the swivelling gate. uAlways close the swivelling gate fully and make sure it is locked in place.
Page 205 Folding gate operation Procedure • To open the gate, (167) press the handle (168). The gate automatically folds up and remains in this position. • To close the gate (167), press it down until it engages. The position of the gate is monitored. Travel is only enabled when the gate is closed.
Page 206 Moving the gate Procedure • For service work the gate can be moved out. To do this, pull the spring pin (169) up and turn the gate out manually. Trucks with swivelling gate monitoring may experience the following situations if the swivelling gate is not locked: –...
Page 207: Automatic / Mechanical Folding Gate
6.11 Automatic / mechanical folding gate CAUTION! A faulty folding gate can cause accidents uNever use the truck with a non-functional folding gate. Have the folding gate checked by authorised specialist personnel after accident. Do not modify the folding gate. uAfter closing the folding gate, fasten the seat belt, see page 123.
Page 208 Automatic folding gate operation Procedure • To open, push the left gate in and at the same time lift it up. This prevents the truck from travelling. • Travel is activated again when the system has been closed.
Page 209: Panel Door
6.12 Panel door CAUTION! Open doors can result in accidents uDo not travel with an open door. When opening the door, make sure there is nobody in the door's swing range. uAlways close the door tightly and make sure it is locked. uAfter closing the summer door, fasten the seat belt, see page 123.
Page 210: Operator Position Extension
What to do in hazardous situations If the truck is about to tip over, do not loosen the seat belt. The operator must not jump off the truck. The operator must lean his upper body over the steering wheel and hold on with both hands.
Page 211 6.14 Entering and Exiting with the Hip Restraint on the Driver's Seat Procedure • Open the cab door (o). • To enter and exit the cab, hold onto the handle (122) and (172). Always face the truck when entering and exiting. Always use the entry aids (122) and (172) provided to climb onto the truck.
Page 212 6.16 Adjusting the Backrest Extension Adjusting the backrest extension ( CAUTION! Accident risk when adjusting the backrest during travel uDo not adjust the backrest extension while travelling. Procedure • The backrest extension height can be adjusted by changing the detent. •...
Page 213 6.17 Adjusting the Lumbar Vertebrae Support Adjusting the lumbar support ( Procedure • Turn the hand wheel (129) to the required position. Position 0 = no warping in lumbar vertebrae area. Position 1 = increasing warping in upper lumbar vertebrae area. Position 2 = increasing warping in lower lumbar vertebrae area.
Page 214 6.19 Auxiliary Functions on the Armrest 6.19.1 Activating the auxiliary functions on the armrest Procedure • Press the FN (173) button. Status lamp above the FN button lights Auxiliary functions are displayed. • Press corresponding button in the armrest control panel and activate/deactivate the auxiliary option.
Page 215 6.19.2 Auxiliary functions in the display unit above the FN button Symbol Meaning Tilt Control Lift cut-off override: Allows the lift cut-off to be overridden. Side shift centre position: Activates the side shift centre function Load weighing Working hydraulics function cut-out Fork tilt horizontal: Activates the fork tilt horizontal function, see page 227.
Page 216 6.19.3 USB charger module in armrest The USB charger module is designed for charging electrical devices such as smart phones etc. and is located in the storage facility in the armrest. Connection data: 5 V, max. 1 A 6.20 Operating hydraulics cutout Change over via the FN button in the armrest to deactivate all operating hydraulics functions (lifting, tilting, auxiliary functions 1, 2, 3).
Page 217 6.21 Load Weighing The integrated load weighing system measures the weight continuously with a tolerance of 2% of the rated capacity. The weighing system is not a substitute for calibrated scales. Change over via the FN button in the armrest to activate the load weighing display. A load measurement is performed for each lifting and lowering operation that lasts longer than 1 second.
Page 218: Tilt Control
Button allocation in load weighing plus option menu (o) Symbol Meaning Save the currently recorded individual weight as tare Tare: Difference between the currently recorded gross individual weight and the net individual weight currently shown Compensate for the weight of an attachment Total function: Add the currently shown net individual weight to the total weight, increase the number of weights recorded Total function: Subtract the currently shown net individual weight from...
Page 219 6.24 Tilt angle display Centre position at 0° 0 deg 0 k m / h Slightly tilted forward -1° to -5° -3 deg 0 k m / h...
Page 220 Significantly tilted forward > -5° -7 deg 0 k m / h Slightly tilted back 1° to 5° 3 deg 0 k m / h...
Page 221 Significantly tilted back > 5° 6 deg 0 k m / h...
Page 222: Item Description
6.25 Heating Item Description Body / window nozzles Temperature controller Fan settings Foot compartment jet Heating operation Procedure • Press the switch (176) to switch on the fan. • Set the nozzles (174,177) to the required position. • Turn the temperature controller (175) to the right to increase the cab temperature.
Page 223: Removable Load Backrest
6.26 Removable load backrest CAUTION! Trapping hazard and heavy load backrest weight uWear safety gloves and safety shoes when carrying out this operation. uTwo people are required to remove and attach the load backrest. Load backrest disassembly Procedure • Loosen the screws (181). •...
Page 224 6.27 Load Damping WARNING! Pressurised components and fluids can cause injury Pressurised components and fluids can cause severe injury. uDo not touch pressurised hydraulic lines. uReport any defects immediately to your supervisor. uMark defective truck and take out of service. uDo not return the industrial truck to service until you have identified and rectified the fault.
Page 225 Commissioning and operation Before commissioning the truck, check the hydraulic accumulator, the hose and the pressure relief valve for damage. Remove the truck from service immediately if you detect any damage or faults.
Page 226: Lift Cutout Override
6.28 Lift cutout override A lift cutout device can be factory fitted when working in areas of restricted height. This interrupts lifting. To continue lifting: Requirements – Inspection and tasks before starting daily operations performed (see page 111). – "Lift cutout" tested with function key (see page 214).
Page 227 6.29 Sideshifter Centre Position Automatic sideshifter centring operation. Requirements – Inspection and tasks before starting daily operations performed (see page 111). – Check automatic sideshifter centring checked with the function key, see page 100. Procedure • Press the sideshifter centring button, see page 100. •...
Page 228 6.30 Fork Tilt Horizontal Operation of automatic fork tilt horizontal. Requirements – Inspection and tasks before starting daily operations performed (see page 111). – "Fork tilt horizontal" function tested, see page 215. Procedure • Press the fork tilt horizontal button, see page 102. •...
Page 229: Fire Extinguisher
6.31 Fire extinguisher Procedure • Open the fasteners (184). • Pull the fire extinguish out of its bracket. To operate, refer to the illustrations on the fire extinguisher.
Page 230: Rockinger Coupling With Hand Lever Or Remote Control
6.32 Rockinger coupling with hand lever or remote control Refer to the instructions for towing trailers, see page 178. CAUTION! Incorrectly coupled trailers can cause accidents uMake sure the coupling is engaged securely before starting the truck. uThe control pin (187) must be flush with the control sleeve (188).
Page 231: Camera System
6.33 Camera system CAUTION! Accident risk from hidden work areas uThe camera system acts as an aid to assist safe operation. uPractice travelling and working with the camera system. uAlign the camera so that the hidden work area can be seen. When using the camera to reverse, the monitor automatically switches on when you engage reverse gear.
Page 232 6.34 Control layout “N” WARNING! Persons standing under or on a raised load handler are at risk of accidents Do not allow anyone to stand under or on a raised load handler. uDo not stand on the load handler. uDo not lift any persons on the load handler. uInstruct other people to move out of the hazardous area of the truck.
Page 233 Tilting CAUTION! Trapping hazard from inclined mast uWhen tilting the mast back, keep all parts of your body from between the mast and the front wall. Procedure • Push the Duo-Pilot lever (100) forward (direction V) to tilt the load forward. •...
Page 234 6.35 Operating the Auxiliary Hydraulics without Pressing the Acknowledgement Key WARNING! Hydraulic ports for clamping attachments uClamping attachments may only be added to trucks which have a button to enable additional hydraulic functions. WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents.
Page 235 6.35.1 Solo Pilot with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (101,104), is assigned the function of the attachment. Unused levers have no function. For connections see page 174. Procedure • Operating hydraulic port ZH1: Move the lever (101) in direction V or •...
Page 236 6.35.3 Multi-Pilot with Control of ZH1 and ZH2 Hydraulic Ports Depending on the attachments used the lever / button 100,101), is assigned the function of the attachment. Unused levers have no function. For connections see page 174. Procedure • Operating hydraulic port ZH1: Press the (101) button to the left or right.
Page 237 6.35.5 Duo-Pilot with Control of ZH1 and ZH2 Hydraulic Ports Depending on the attachments used the lever / button (101,104), is assigned the function of the attachment. Unused levers have no function. For connections see page 174. 101 / 104 Procedure •...
Page 238 6.36 Special control layout WARNING! Hydraulic ports for clamping attachments uClamping attachments may only be added to trucks which have a button to enable additional hydraulic functions. WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents.
Page 239 Changeover level The changeover level is activated and deactivated via the button (105) on the control. The symbol for the active changeover level (194) is shown in yellow on the display.
Page 240 If the operating functions at changeover level differ from the operating functions at basic level, these are indicated by grey labels with pictograms on the controls. If the operating function is not assigned, this is indicated by a label with an empty field.
Page 241 Acknowledgement feature Certain hydraulic functions (e.g. opening a load clamp) must be confirmed via the acknowledgement key (106) on the control. The acknowledgement feature is activated by actuating the acknowledgement key (106) with the padlock symbol. If a hydraulic function is set to require acknowledgement, the acknowledgement key (106) must be actuated regardless of the lever assignment at operating level.
Page 242 6.37 Floor-Spot CAUTION! Risk of accident due to dazzling Looking directly into the light beam of the Floor-Spot can dazzle and temporarily impair eyesight. uDo not look directly into the light beam of the Floor-Spot. uDo not adjust the position and alignment of the Floor-Spot on the truck. The Floor-Spot serves as an auxiliary device and, with the travel direction selected, projects a coloured dot on the floor at a distance of 5 m.
Page 243 6.37.1 Additional information on Floor-Spot blue Only for Floor-Spot blue (51466740/51631731) The activated Floor-Spot gives persons advance warning of the travel path of the forklift truck by projecting a blue dot onto the ground at a set distance. CAUTION! Risk of retinal damage due to blue light The Floor-Spot on the truck is classified in risk group 2 according to the standard IEC 62471: medium risk.
Page 244 6.38 StVZO road traffic regulations equipment CAUTION! Requirement to use winter tyres when driving the truck on public highways (StVZO, German road traffic regulations) The StVZO requires the use of winter tyres on trucks used on public highways. uEither pneumatic or SE tyres with a minimum profile depth of 4 mm may meet the requirement.
Page 245 6.39 Horn Button on Overhead Guard When the horn button on the overhead guard is actuated, an acoustic signal is triggered. Use the horn button on the overhead guard only when reversing.
Page 246: Troubleshooting
Troubleshooting Troubleshooting This chapter enables the operator to localize and rectify basic faults or the results of incorrect operation himself. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error code, contact the manufacturer’s service department.
Page 247 Fault Possible cause Actions Truck does not start – Battery connector not – Check battery connector plugged in. and plug in if necessary. – Emergency disconnect – Unlock the emergency switch pressed. disconnect switch. – Key switch set to O. –...
Page 248 Troubleshooting Fault Possible cause Action Truck does not start – Battery connector not – Check battery connector plugged in. and plug in if necessary. – Control line not – Check control line and connected to lithium-ion connect if necessary. battery (o) or interface converter (o) of lithium- ion battery.
Page 249: Operating The Truck Without Its Own Drive System
Operating the truck without its own drive system 7.2.1 Towing the truck WARNING! Accident risk Other people can be injured if the truck is towed incorrectly. uOnly use vehicles to tow the truck which have sufficient tow and brake forces for the trailer load without its own braking system.
Page 250 7.2.2 Operating the truck without its own drive system WARNING! Uncontrolled truck movement The truck can roll away if the spring pressure brake is released and if there is insufficient protection. uRelease the spring pressure brake to move the truck without power. uSuitable measures must first be taken to prevent the truck from rolling away.
Page 251 Releasing the parking brake Requirements – Turn off the emergency disconnect switch and key switch. – Equipped with lithium-ion battery (o): • Disconnect the truck-side control line from the connection on the battery trough or the interface converter (o) on the battery. •...
Page 252 Applying the parking brake Procedure • Turn the auxiliary tool (200) carefully to the left to the “travel position”. The brakes are applied to the drive wheels and the truck is now parked securely.
Page 253 7.2.3 Steering the truck when the electric/hydraulic steering has failed The truck cannot be steered if the steering hydraulic system or the truck electronics are damaged. Steering the truck when the electric/hydraulic steering has failed Requirements – Turn off the emergency disconnect switch and key switch. –...
Page 254: Emergency Lowering
Emergency lowering WARNING! Load handler emergency lowering uInstruct other people to move out of the hazardous area of the truck during emergency lowering. uNever step or stand underneath a raised load handler. uOnly operate the emergency lowering valve when standing next to the truck. uWhen the load handler is in the racking, emergency lowering is not permitted.
Page 255: F Industrial Truck Maintenance
The manufacturer cannot be held liable for damage caused by the use of non-original spare parts. product-related electronic spare parts catalogue found (www.jungheinrich.de/spare-parts-search) by entering the serial number. The serial number can be found on the data plate, see page 41.
Page 256: Operational Safety And Environmental Protection
Operational Safety and Environmental Protection The inspections and maintenance tasks listed in chapter "Maintenance, inspection and changing of maintenance parts requiring replacement" must be performed according to the defined service intervals (see page 297). The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, inspection and changing of maintenance parts requiring replacement"...
Page 257: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance and repair personnel The manufacturer has a customer service department specially trained for these tasks. A maintenance contract with the manufacturer will support trouble-free operation. Truck maintenance, repair work and changing of parts requiring replacement must only be carried out by specialist personnel.
Page 258: Consumables And Used Parts
Consumables and used parts CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.
Page 259: Lift Chains
Lift Chains WARNING! Risk of accident from non-lubricated and incorrectly cleaned lift chains Lift chains are safety-critical parts. Lift chains must not show signs of serious contamination. Lift chains and pivot pins must always be clean and sufficiently lubricated. uThe lift chains are cleaned by wiping or brushing. Significant contamination can be softened by a paraffin derivative such as petroleum.
Page 260: Hydraulic System
Hydraulic system WARNING! Leaky hydraulic systems can result in accidents Hydraulic oil can escape from leaky and faulty hydraulic systems. uReport any defects immediately to your supervisor. uMark defective truck and take out of service. uDo not return the industrial truck to service until you have identified and rectified the fault.
Page 261: Lubricants And Lubrication Schedule
Lubricants and Lubrication Schedule Handling consumables safely Handling consumables Consumables must always be handled correctly. Follow the manufacturer’s instructions. WARNING! Improper handling is hazardous to health, life and the environment Consumables can be flammable. uKeep consumables away from hot components and naked flames. uAlways keep consumables in prescribed marked containers.
Page 262 WARNING! Improper handling of oils can be hazardous Oils (chain spray / hydraulic oil) are flammable and poisonous. uDispose of used oils in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations. uDo not spill oil.
Page 263: Lubrication Schedule
Lubrication Schedule g Contact surfaces Hydraulic oil drain plug Grease nipple b Transmission oil filler neck Hydraulic oil filler neck a Transmission oil drain plug...
Page 264 Consumables Quant Order no. Volume Description Used for 51132827 HVLP 32 50429647 20 l Renolin 22 HLPD 51037497 Renolin 22 HLPD 35 l Hydraulic system Plantosyn 46 HVI 51082888 (BIO hydraulic oil) 51048560 HV 68 14038650 400 g Rear wheel Lubrication grease bearings / KP 2 K...
Page 265 *The trucks are factory-equipped with a special manufacturer's hydraulic oil (the Jungheinrich hydraulic oil with a blue colouration) or the Plantosyn 46 HVI bio hydraulic oil. This special hydraulic oil can only be obtained from the manufacturer's customer service department. The use of named alternative hydraulic oils is not prohibited, but may lead to a decline in functionality.
Page 266: Preparing The Truck For Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repairs All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: Procedure • Park the truck securely, see page 133. •...
Page 267: Lifting And Jacking Up The Truck Safely
Lifting and jacking up the truck safely WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. uNote the weight of the truck on the data plate. uAlways use a jack with a minimum capacity of 5000 kg kg.
Page 268: Opening The Rear Panel
Opening the rear panel Opening the panel Requirements – Prepare the truck for maintenance and repairs (see page 266). Procedure • Undo quick release fasteners (202). • Pull the rear panel back and remove it. The rear panel is now open. The fuses and other electrical components can now be reached.
Page 269 Checking the Wheel Mounting WARNING! Using different tyres can cause accidents The quality of the tyres affects the operational stability and performance of the truck. uThe diameter of the wheels must differ by no more than 15 mm. uAlways replace tyres in pairs, i.e. left and right at the same time. After replacing the tyres check the wheel nuts are secure after 10 service hours.
Page 270: Replacing Wheels
Replacing wheels WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. uNote the weight of the truck on the data plate. uAlways use a jack with a minimum capacity of 5000 kg kg. uRaise the unladen truck on a level surface.
Page 271 Fitting the wheels Procedure • Fit the wheel using a suitable mounting lever if necessary. • Fit the wheel attachment. • Remove the hard wooden blocks. • Lower the truck. • Torque the wheel attachment (203) crosswise with a torque wrench; tightening torques see page 34.
Page 272 Hydraulic system CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. uDo not touch pressurised hydraulic lines. uDispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
Page 273 5.6.1 Checking the hydraulic oil level CAUTION! The use of unsuitable hydraulic oils can cause damage Trucks with bio hydraulic oil have a warning notice on the hydraulic reservoir: “Add hydraulic oil only”. uUse only BIO hydraulic oil. Checking the hydraulic oil level and adding hydraulic oil Requirements –...
Page 274 5.6.2 Replacing the hydraulic oil filter Replacing the oil filter Requirements – Park the truck on a level surface. – Prepare the truck for maintenance and repair work (see page 266). Procedure • Unscrew the hydraulic oil filter cap (206). The filter element is located on the cap.
Page 275 5.6.4 Checking the Electric Steering Oil Level The electric steering oil level can be checked with the dipstick. Requirements – Park the truck on a level surface. – Prepare the truck for maintenance and repairs (see page 266). – Panel open, see page 268. Procedure •...
Page 276 5.6.5 Replacing the Electric Steering Oil Filter Requirements – Park the truck on a level surface. – Prepare the truck for maintenance and repairs (see page 266). – Panel open, see page 268. Procedure • Undo the screws (208) from the cover (209) of the electric steering with a screwdriver (key width 10) and remove them.
Page 277: Check The Gear Oil Level
Check the gear oil level CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.
Page 278 Adding oil Procedure • Insert the oil drain plug (213). • When screw with integrated dipstick (211) has been removed, add new transmission oil into the filler hole (212). The oil has now been added.
Page 279 Heating Replacing the air conditioning filter Requirements – Filter contaminated Procedure • Loosen the screws (178). • Remove the panel (179). • Replace the filter (180). • Attach the panel (179). • Tighten the screws (178). The filter cassette is now replaced. Regular maintenance is required to ensure that the heater functions correctly, see page 297 Adding window washer system fluid...
Page 280: Checking Electrical Fuses
5.10 Checking electrical fuses WARNING! Electrical current can cause accidents Ensure the electrical system is de-energised before starting work. Before starting maintenance on the electrical system: uPark the truck securely (see page 133). uPress the emergency disconnect switch. u Equipped with lithium-ion battery (o): disconnect the truck-side control line from the connection on the battery trough or the interface converter (o) on the battery.
Page 281 5.10.1 Fuse ratings...
Page 282 Electrical system fuses Item Description Electric circuit Rating / type Main fuse (emergency disconnect) 425 A 24V standby FK1 MINI 32V / 2A / UL 9F33 Windscreen washer pump FK1 MINI 32V / 2A / UL Internal controller FK1 MINI 32V / 2A / UL 9F14 Rear windscreen wiper FK1 MINI 32V / 2A / UL...
Page 284 Electrical system fuses Item Model Electric circuit Rating / type Output fuse DVC 150 15 A F3.1 Output fuse DVC 150 7.5 A 9F17.9 Fuse option 24 V 9F17.6 Fuse option 24 V 9F17.3 Fuse option 24 V 9F17.8 Fuse option 24 V 9F17.5 Fuse option 24 V 9F17.2...
Page 286 Electrical system fuses Item Model Electric circuit Rating / type Output fuse DVC 150 15 A F3.1 Output fuse DVC 150 7.5 A 4F6.1 Control fuse, LH brake light 4F6.2 Control fuse, RH brake light Illumination control fuse 5F5.3 Control fuse, RH tail lights 4F5.1 Left indicator control fuse 5F4.1...
Page 287 5.11 Cleaning The truck may only be cleaned in the designated locations, which adhere to the stipulations of the country of use. 5.11.1 Cleaning the truck CAUTION! Fire hazard Do not use flammable liquids to clean the industrial truck. uDisconnect the battery before starting cleaning work. uCarry out all necessary safety measures to prevent sparking before cleaning (e.g.
Page 288 NOTICE Risk of damage to the roof window Dry cleaning, cleaning with paper towels or cleaning with dirty or large-fibre cleaning cloths can scratch the polycarbonate roof window. The static charge caused by dry cleaning can attract more dust to the roof window. The use of unsuitable cleaning agents can also damage the roof window.
Page 289 5.11.2 Cleaning the electrical system assemblies CAUTION! Risk of electrical system damage Cleaning the assemblies (controllers, sensors, motors etc.) of the electronic system with water can damage the electrical system. uDo not clean the electrical system with water. uClean the electrical system with weak suction or compressed air (use a compressor with a water trap) and not a conductive, anti-static brush.
Page 290: Working On The Electrical System
5.12 Working on the electrical system WARNING! Electrical current can cause accidents Ensure the electrical system is de-energised before starting work. The capacitors in the control must be completely discharged. The capacitors are fully discharged approx. 10 minutes after disconnecting the electrical system from the battery. Before starting maintenance on the electrical system: uOnly suitably trained electricians may work on the truck's electrical system.
Page 291 5.13 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see page 287. • Lubricate the truck according to the lubrication diagram, see page 263. • Clean the battery, grease the terminals and connect the battery. •...
Page 292: Decommissioning The Industrial Truck
Decommissioning the Industrial Truck If the truck is to be out of service for more than a month, it must be stored in a frost- free and dry room. All necessary measures must be taken before, during and after decommissioning as described hereafter. When the truck is out of service it must be jacked up so that all the wheels are clear of the ground.
Page 293: Prior To Decommissioning
Prior to decommissioning Procedure • Thoroughly clean the truck, see page 287. • Prevent the truck from rolling away accidentally. • Check the hydraulic oil level and top up if necessary, see page 273. • Apply a thin layer of oil or grease to any non-painted mechanical components. •...
Page 294 • Equipped with lead-acid battery (t): Clean the battery, grease the battery terminal screws with terminal grease and connect the battery. • Equipped with lithium-ion battery (o) without interface converter on the battery: Insert the truck-side control line into the connection on the battery trough. •...
Page 295: Safety Tests To Be Performed At Intervals And After Unusual Incidents
Safety tests to be performed at intervals and after unusual incidents The truck must be inspected at least annually (refer to national regulations) or after any unusual event by a qualified inspector. The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose.
Page 297 G Maintenance, inspection and changing of maintenance parts requiring replacement WARNING! Lack of maintenance can result in accidents Failure to perform regular maintenance and inspections can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert maintenance and inspections are among the most important requirements for the safe operation of the industrial truck.
Page 298 Maintenance Contents EFG 535-S50 Issued on: 2020-02-12 16:50 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains. Correct the hydraulic oil level.
Page 299 1.1.1.2 Optional equipment Wiper/washer system Chassis/structure Correct the fill level of the windscreen washer reservoir. Electrical heating Chassis/structure Clean the heater breather filter. Automatic battery extraction Chassis/structure Clean and lubricate the contact surfaces Pneumatic tyres Travel Correct the tyre pressure. Lead-acid battery, international Power supply Correct the battery acid level using demineralised water.
Page 300 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage Power supply Battery and battery components for damage The function and secure seating of the battery connector and for damage Travel...
Page 301 1.1.2.2 Optional equipment The following points must be checked: Wiper/washer system Chassis/structure The windscreen washer reservoir for leaks and damage Road traffic approval Electrical system The function of the lighting and for damage Work lights Electrical system The function of the lighting and for damage Electrical heating Chassis/structure The function of the heater...
Page 302: Customer Service
Customer Service In accordance with the EFG 535-S50 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1 Maintenance contents 1.2.1.1 Standard equipment Brakes Test the function of the brakes Adjust and lubricate the brake mechanism. Test the function of the emergency release mechanism of the spring brake cylinder.
Page 303 1.2.1.2 Optional equipment Fork adjuster Hydraulic operations Adjust the attachment. Clean and grease attachment bearings, guides and stops. The axial play of the front and rear rollers. Clamping device Hydraulic operations Adjust the attachment. Clean and grease attachment bearings, guides and stops. The axial play of the front and rear rollers.
Page 304 Weigher sensors / switches Electrical system Test the weighing system. Automatic battery extraction Chassis/structure Clean and lubricate the contact surfaces Pneumatic tyres Travel Correct the tyre pressure. Lead-acid battery, international Power supply Clean and grease the battery terminals. Clean the battery. Measure the acid density and battery voltage.
Page 305 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Brakes Brake mechanism for function and damage Electrical system Warning and safety devices are in accordance with the operating instructions Function of display and controls The function of the emergency disconnect and for damage The function of the fan and for damage Connections and cables are secure and for insulation damage and other damage Power supply...
Page 306 Hydraulic operations The function of the "hydraulic system" controls and for legibility, completeness and plausibility The hydraulic control elements for correct assignment. The secure seating of the cylinders and piston rods and for leaks and damage The function of the hose guide and for damage Lateral play of the mast sections and fork carriage Slides and stops for wear and damage Load chain mounting elements and chain pins for wear and damage...
Page 307 1.2.2.2 Optional equipment Electrolyte circulation Power supply The function of the hose connections and pump Aquamatik Power supply The function of the Aquamatik plug, hose connections and float and for leaks The function of the flow indicator and for leaks Battery refill system Power supply The function of the battery refill system and for leaks...
Page 308 Hydraulic operations The function of the attachment and for damage The secure seating of the hydraulic connections and for leaks Cylinder rods and their bushings for wear and damage Cylinder seals for leaks and damage Sideshifter Hydraulic operations Attachment bearings, guides and stops for wear and damage Proper securing of the attachment to the truck and the load-bearing components for secure fit and damage Sliding blocks are complete and for wear and damage...
Page 309 Wiper/washer system Chassis/structure The windscreen washer reservoir for leaks and damage The function of the windscreen wipers and for damage Seat heating Electrical system Connections and cables are secure and for insulation damage and other damage Shock sensor / data recorder Electrical system The shock sensor/data recorder is secure and for damage Data radio...
Page 310 Access module Electrical system Access module is secure and functions correctly and for damage Electrical heating Chassis/structure The function of the heater Weather proofing Chassis/structure The function of the windscreen heating and for damage The function of the doors and for damage Electrical optional equipment Electrical system Fuse ratings...
Page 311 Discharge strap Electrical system Electrostatic discharge strap or chain is present and for damage Restraint system / SUN protector Electrical system The secure seating of the electrical connections and for damage. Restraint system is complete and functions correctly and for damage The function of the restraint system sensor system and for damage Connections and cables are secure and for insulation damage and other damage Chassis/structure...
Page 312 Hydraulic operations The presence of safety labels are present and for damage The secure seating of the cylinders and piston rods and for leaks and damage The function of the hydraulic system The secure seating of the hydraulic connections, hoses and pipes and for leaks and damage The secure seating and function of the microswitches and sensors and for damage The electric wiring for damage (insulation damage, connections) and the fuse ratings...
Page 313 1.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 1.2.3.1 Standard equipment maintenance part service hours months Hydraulic oil 2000 Hydraulic system - breather filter 2000 Hydraulic oil filter 2000 Oil filter of the electric/hydraulic steering 2000 Oil from the electric/hydraulic steering 2000...

This manual is also suitable for:

Efg 535ks Efg 540 Efg 540s Efg 540k Efg 540ks Efg 545 ... Show all

Jungheinrich EFG 535k Operating Instructions Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Jungheinrich EFG 535k

Summary of Contents for Jungheinrich EFG 535k

This manual is also suitable for:

Table of Contents