Page 1 EFG 535k - S50 09.22 Operating instructions en-GB 51962068 07.24 EFG 535k EFG 540 EFG 540k EFG 545 EFG 545k EFG 550 EFG S40 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 540 EFG 540k EFG 545 EFG 545k EFG 550 EFG S40 EFG S50 On behalf of Date EU DECLARATION OF CONFORMITY...
Page 4 Declaration of Conformity (o) Product: EFG 535k - S50 Serial number/type number Manufacturer: Jungheinrich Aktiengesellschaft 22039 Hamburg, Germany UK representative: Jungheinrich UK Ltd Sherbourne House Sherbourne Drive Tilbrook Milton Keynes MK7 8HX Authorised to compile documentation: The manufacturer is authorised to compile the technical documentation and its...
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 Instructions for Trucks with Lithium-Ion Batteries Internal Operation Combined with Brief External or Cold Store Operation (t) Indoor Application Predominantly inside the Cold Store (o) Hot country or tropical use (o) Ambient Conditions for Charging Residual risk Proprietor responsibilities...
Page 8 Using the Truck for the First Time Battery - Servicing, Recharging, Replacement General notes on handling batteries Potential hazards Touch voltage hazard Battery handling safety regulations 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...
Page 9 Entering or exiting Trucks with reduced headroom (o) Setting up the operator position Restraint systems Seat Belt Working with the truck Safety regulations for travel mode Preparing the truck for operation Activating the lithium-ion battery (o) Parking the truck securely Emergency Disconnect Travel Steering...
Page 10 6.29 Camera system 6.30 Control layout “N” 6.31 Operating the auxiliary hydraulics without pressing the acknowledgement key 6.32 Special control layout 6.33 Floor-Spot 6.34 Floor-Bow 6.35 Optional Equipment for Road Traffic as per StVZO 6.36 Horn Button on Overhead Guard 6.37 Antistatic strap Troubleshooting Troubleshooting...
Page 11 Maintenance, inspection and changing of maintenance parts requiring replacement Maintenance Contents EFG 535k-S50 Owner Customer Service...
Page 13: A Correct Use And Application
A Correct Use and Application General WARNING! Risk of accident, risk of injury and risk of material damage due to improper use of trucks, misconduct or failure to observe the operating instructions Improper use of trucks, misconduct or failure to observe the operating instructions can lead to accidents, injuries and material damage.
Page 14 When towing trailers, the load must be secured on the trailer. The permissible trailer load must not be exceeded. The following operations are prohibited: – Travelling with a raised load (> 30 cm). – Transporting persons. • No persons may be transported in addition to the operator, neither on the load handler nor in the operating area.
Page 15: Approved Application Conditions
Approved application conditions DANGER! Do not exceed the permissible surface and point loading on the travel lanes. At blind spots get a second person to assist. The driver must ensure that the loading dock /dock leveller cannot be removed or come loose during loading/unloading.
Page 16: Instructions For Trucks With Lithium-Ion Batteries
Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature fluctuations or condensing air humidity. Instructions for Trucks with Lithium-Ion Batteries WARNING! Danger of accidents due to regenerative braking fault Regenerative braking faults can result in extended stopping distances and accidents, particularly when travelling on inclines.
Page 17: Internal Operation Combined With Brief External Or Cold Store Operation (T)
Internal Operation Combined with Brief External or Cold Store Operation (t) In addition to the permissible operating conditions in industrial and commercial environments, the truck can also be used in outdoor environments, cold stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.
Page 18: Indoor Application Predominantly Inside The Cold Store (O)
Indoor Application Predominantly inside the Cold Store (o) The truck is manufactured as a cold store version o) and is equipped with hydraulic oil suitable for cold stores. In addition to the permissible operating conditions in industrial and commercial environments, the truck remains predominantly in the cold store and may only leave the cold store briefly for load transfer.
Page 19: Hot Country Or Tropical Use (O)
Hot country or tropical use (o) The truck is manufactured as a tropical version (o) and is equipped with hydraulic oil specially designed for use at high temperatures. NOTICE Damage to the lead battery due to low state of charge and extreme temperatures Elevated temperatures accelerate chemical reactions and self-discharge of the battery.
Page 20: Ambient Conditions For Charging
Ambient Conditions for Charging The industrial truck may be charged in closed rooms and also in covered outdoor areas protected from moisture. Observe the permissible operating and ambient conditions of the battery and the battery charger. CAUTION! Risk of electrical-system damage If the electronic system assemblies (controllers, sensors, motors etc.) come in contact with water, this can damage the electrical system.
Page 21: Residual Risk
Residual risk WARNING! Risk of accident and injury due to incorrect behaviour in the case of unavoidable residual risks Incorrect behaviour or failure to observe the operating instructions can lead to accidents and injuries. uThe operator must be instructed in the operation of the truck, optional equipment and attachments, specifically with regard to appropriate behaviour in hazardous areas as well as in situations where unavoidable residual risks exist or implemented safety measures cannot be fully effective.
Page 22: 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 23: 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 24: 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 25: 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 26: 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 27 Wheels There is a choice of super elastic or fully rubber tyres as well as optional pneumatic tyres. Hydraulic system for operating functions A multi-function control valve allows for sensitive operation of the functions via the controls. A speed-controlled hydraulic pump ensures a proportionate and efficient supply to the hydraulic functions.
Page 28: Technical Specifications
Technical Specifications All technical specifications refer to a standard truck. All values marked with *) may vary depending on the type of equipment used (mast, cabin, tyres etc.). The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved.
Page 29: Performance Data
Performance data Description 535k 540k Rated capacity 3500 4000 4000 4000 (for C) C Load centre Travel speed with/ 14.0/17.0 13.0/16.0 13.0/16.0 13.0/16.0 without load (Efficiency/ km/h 16.0/16.0 16.0/16.0 16.0/16.0 16.0/16.0 drivePLUS) Lift speed with/without 0.36/0.50 0.28/0.37 0.28/0.37 0.28/0.37 load (Efficiency) Lift speed with/without 0.42/0.55 0.33/0.44 0.33/0.44 0.33/0.44 load (drivePLUS)
Page 30 The values shown represent the maximum gradeability to overcome short differences in height and surface unevenness (surface edges). The truck must not operate on inclines of more than 15%.
Page 31 Description 545k Rated capacity 4500 4500 4990 5000 (for C) C Load centre Travel speed with/without 13/16 13/16 12/15 12/15 km/h load (Efficiency/liftPLUS) 15/16 16/16 15/16 15/16 Lift speed with/without 0.28/0.37 0.28/0.37 0.28/0.37 0.28/0.37 load (Efficiency) Lift speed with/without 0.33/0.44 0.33/0.44 0.33/0.44 0.33/0.44 load (liftPLUS) Lowering speed with/ without load (Efficiency/...
Page 32: Dimensions
Dimensions EFG 535k-S40 Description 535k 540k 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 Seat height* 1313 1313 1313 1303...
Page 34 EFG 545-S50 Description 545k 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 1303 Coupling height 396/566 396/566 396/566...
Page 35: Weights
Weights All dimensions in kg. EFG 535k-S50 Description 535k 540k 545k Net weight 5968 6711 6701 7143 7153 7143 7592 8036 (including battery) Axle load with load 8521 / 9752 / 9726 / 9992 / 10575 10468 11434 11677 front/rear...
Page 36: Mast Versions
Mast versions All dimensions in mm. EFG 535k Description Lift h Free lift Height Height without without Mast Mast ZH with retracted h extended h without front front window window (a/b°) (a/b°) 2900 2200 3689 3100 2300 3889 3300 2400...
Page 37 EFG 540k / EFG 540 / EFG 545k / EFG 545 including 3A fork carriage with 4 rollers (standard) Description Lift h Free lift Height Height Without Without Mast Mast retracted h extended h Without With front front windscre windscr en (a/b°) (a/b°) 2750...
Page 38 Description Lift h Free lift Height Height Without Without Mast Mast retracted h extended h Without With front front windscre windscr en (a/b°) (a/b°) 4150 1382 2140 4908 4400 1465 2223 5158 4700 1565 2323 5458 4850 1615 2373 5608 5000 1665 2423...
Page 39 EFG 540k / EFG 540 / EFG 545k / EFG 545 for integrated 3A side shift with 6 rollers (option) Description Lift h Free lift Height Height Without Without Mast Mast ZH, with retracted h extended h without front front windscr windscre en (a/b°)
Page 40 Description Lift h Free lift Height Height Without Without Mast Mast ZH, with retracted h extended h without front front windscr windscre en (a/b°) (a/b°) 4150 1232 2140 5058 4400 1315 2223 5308 4700 1415 2323 5608 4850 1465 2373 5758 5000 1515...
Page 41 EFG S40/EFG 550 including 3A fork carriage with 6 rollers (standard) / integrated 3A side shift with 6 rollers (option) Description Lift h Free lift Height Height Without Without Mast Mast ZH, with retracted h extended h without front front windscr windscre en (a/b°)
Page 42 Description Lift h Free lift Height Height Without Without Mast Mast ZH, with retracted h extended h without front front windscr windscre en (a/b°) (a/b°) 4150 1232 2140 5058 4400 1315 2223 5308 4850 1465 2373 5758 5000 1515 2423 5908 5300 1615...
Page 43 EFG S50 for integrated 4A side shift with 6 rollers (standard) Description Lift h Free lift Height, Height, Without Without mast mast ZH, with retracted h extended h without front front windscr windscre en (a/b°) (a/b°) 2480 2165 3453 2846 2348 3819 3030...
Page 44 Description Lift h Free lift Height, Height, Without Without mast mast ZH, with retracted h extended h without front front windscr windscre en (a/b°) (a/b°) 3875 1117 2140 4898 4120 1200 2223 5143 4420 1300 2323 5443 4720 1400 2423 5743 5020 1500...
Page 45 EFG S50 including 3A fork carriage with 6 rollers (standard) / integrated 4A side shift with 6 rollers (option) Description Lift h Free lift Height, Height, Without Without mast mast ZH, with retracted h extended h without front front windscr windscre en (a/b°) (a/b°)
Page 46 Description Lift h Free lift Height, Height, Without Without mast mast ZH, with retracted h extended h without front front windscr windscre en (a/b°) (a/b°) 4050 1232 2140 4958 4300 1315 2223 5208 4600 1415 2323 5508 4900 1515 2423 5808 5200 1615...
Page 47: Tyre Type
Otherwise the manufacturer’s specifications cannot be ensured. If you have any queries, contact the manufacturer's customer service department. During the wear test, the wear limit of the respective wheel must be observed. EFG 535k - S50 Description 535k/540/540...
Page 48: Engine Data
Engine Data Motor output Description EFG 535k-545k EFG 545 EFG 550-S50 Drive motor (Efficiency / 14.5 / 18 kW drivePLUS) 14.5 / 20 kW 14.5 / 18 kW Lift motor (Efficiency / 20 / 24 kW drivePLUS) 18 / 24 kW...
Page 49: 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 EN 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.
Page 50: Electrical Requirements
Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used for its intended purpose.
Page 51: Specifications According To Red Guideline (Radio Equipment Directive) For Radio Units
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 210 2.4 GHz...
Page 52: Identification Points And Data Plates
Identification Points and Data Plates Indication Points Warnings and notices such as capacity plates, attachment points and data plates must be legible at all times. Replace if necessary. (mm) Q (kg) D (mm) Item Description Lift limits Do not travel with a raised load or operate the mast forward tilt with a raised load Add hydraulic oil Capacity (or reduced capacity)
Page 53: Item Description
Item Description Max. body size (o) Inspection plaque (o) Warning: optical radiation (Floor-Spot) Procedure when truck at risk of tipover Observe the operating instructions No passengers Ground clearance (o) 24 V seat heating (o) Do not stand on load handler / Do not stand under load handler / Risk of trapping when mast extended Operating instructions for China (o) Tyre air pressure (o)
Page 55: Data Plate
Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Description Item Description Year of manufacture Net weight without battery [kg] Type Min./max. battery weight [kg] Serial number Manufacturer Option Importer - imported by (o) Rated capacity [kg]...
Page 56 4.2.1 Option The option contains information on the version of the truck and is shown on the type plate. e.g. DL G+E 115+310 ZZ Option code G+E Load handler Fork length (cm) Lift height (cm) Mast version Option code Efficiency drive&liftPLUS Load handler Fork carriage...
Page 57: Truck Capacity Plate
Truck capacity plate WARNING! Replacing the fork arms can cause accidents If you replace the fork arms with ones that differ from the originals, the capacity will change. uAn additional capacity plate must be attached to the truck when replacing the fork arms.
Page 58 Lift height limits The arrow shaped markings (58 and 59) on the inner and outer masts show the operator when the prescribed lift limits have been reached.
Page 59: 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) (60) and where applicable fork extensions (o) (61). 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 60 4.4.2 Attachment with up to 100 mm side shift h3 [mm] Q [kg] 3100 2000 1790 1620 D [mm] 4.4.3 Attachment with More Than 100 mm Side Shift 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.
Page 61: Stability
Stability WARNING! Loss of operational stability can cause accidents Changing the components can affect operational stability. uDo not exceed permissible loads and load centre distances. uOnly manufacturer-approved components may be used on the truck. Do not use components that have not been approved by the manufacturer. uThe components listed must be replaced only with the agreement of the manufacturer.
Page 63: C Transport And Commissioning
C Transport and Commissioning Transport The truck can be transported 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 removed (for large heights), all mechanical connections and all hydraulic lines between the basic unit and the mast separated.
Page 64: Lifting The Truck By Crane
Lifting the truck by crane DANGER! Crane lifting gear can tear, resulting in accidents A tear in the crane lifting gear may result in severe, irreparable accidents or even death if there are persons within the hazardous area. uOnly use crane lifting gear with sufficient capacity. uLoading weight = unladen weight of the truck (+ battery weight for electric trucks).
Page 65 Loading the truck by crane Requirements – Mast properly fitted. – Load handler lowered. – Mast tilted back fully. – Parking brake applied. – Key removed from the key switch. – Press EMERGENCY DISCONNECT switch down. – Truck switched off and parked. Tools and Material Required –...
Page 66: Loading The Truck With A Second Truck
Loading the truck with a second 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 67: Securing The Truck During Transport
Securing the truck during transport WARNING! Danger due to uncontrolled movement of the truck or the mast during transport If the truck and mast are not properly secured during transport, serious accidents can occur. Slipping lashing straps can lead to uncontrolled movements of the truck or mast and even a fall during transport.
Page 68 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 150. Tools and Material Required – 2 fastening belts with a tensioner –...
Page 69: 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 71: 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. The truck must be parked securely before all work on the batteries, see page 150.
Page 72: Touch Voltage Hazard
Touch voltage hazard WARNING! Touch voltage hazard Hazardous touch voltages may occur in the event of a technical or mechanical defect on the battery. Touch voltages also occur on seemingly discharged batteries. Touching the battery terminals or live attachments (battery cable, battery connector etc.) can result in dangerous current flows through the body.
Page 73: Safety Regulations For Handling Lead-Acid Batteries
Safety Regulations for Handling Lead-Acid Batteries WARNING! Risk of accidents and injuries when handling acid batteries Batteries contain dissolved acid, which is toxic and caustic. Above all, avoid any contact with battery acid. uDispose of used battery acid in accordance with regulations. uWear protective clothing and eye protection when working with acid batteries.
Page 74: Safety Regulations For Handling Lithium-Ion Batteries
Safety regulations for handling lithium-ion batteries Fire Hazard WARNING! Burning lithium-ion battery cells can be hazardous Physical damage, thermal effects or incorrect storage in the event of a defect can result in fire. If the inside of lithium-ion battery cells burns, the fire cannot be put out by extinguishing methods.
Page 75: Special Fire Fighting Protective Equipment
– Hydrogen fluoride (HF) Hydrofluoric acid = extremely corrosive – Risk of toxic substances produced by pyrolysis – Risk of highly flammable gas mixtures. – Other combustion products: Carbon monoxide & - dioxide. Special fire fighting protective equipment – Use self-contained breathing apparatus. –...
Page 76: 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 77: Battery Dimensions
Battery dimensions Dimension (mm) Nominal weight L max. B max. H1+/- H2 +/- Truck (-5/+8%) in 2 mm 2 mm 535k/EFG 1028 1863 540k/EFG 545k EFG 540 / EFG 545 / EFG 550 / 1028 2178 EFG S40 / EFG S50 DANGER! If the centre of gravity of the battery deviates from the geometrical centre of gravity of the battery, contact the manufacturer.
Page 78: Exposing The Battery
Exposing the battery WARNING! Danger of electric shock and risk of fire due to arcing Disconnecting the battery connector under load may cause electric shock or arcing. Electric shocks or arcs can damage adjacent parts and result in fire. uDo not disconnect the battery connector under load. Switch off the emergency disconnect switch before disconnecting the battery connector.
Page 79 There is an alternative battery lock for lithium-ion batteries: The lithium-ion battery may only removed from industrial truck by qualified personnel during maintenance. Check the lithium-ion battery for firm seating at regular intervals and retighten, if necessary. The tightening torque of the screw is 250 Nm and must be observed.
Page 80: Removing Or Installing The Battery
Removing or installing the battery 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 governing the handling of lead-acid batteries, see page 73.
Page 81: 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 82 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 83 Installing the battery Procedure • Drive the pallet truck and battery to the truck. • Deposit the battery trolley with the rollers (73) on the base of the truck. • Lower the fork arms of the pallet truck until the battery is horizontal.
Page 84 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 85. Procedure •...
Page 85 7.1.2 Assembly instructions Ø...
Page 86 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 87: Removing Or Installing The Battery Using A Fork Shoe
Removing or installing the battery using a fork shoe 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 150. –...
Page 88 • Pull out the battery as far as the stop (82) 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 89: Removing Or Installing The Battery Using A Roller Conveyor
Removing or installing the battery using a roller conveyor WARNING! After inserting the battery close the battery lock. 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.
Page 90: Removal And Installation Using A Hand Pallet Truck With Snapfit (O)
Removal and installation using a hand pallet truck with SnapFit WARNING! After inserting the battery close the battery lock and then lower the pallet truck. 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.
Page 91 • Engage the safety catches (72) on the battery trolley. • To do this, press the pedals (71). Do not raise the forks. • Undo the catch (76). • Undo the battery latch (67). • Using the hand pallet truck, slowly remove the battery as far as the stop (84).
Page 92: Removing Or Installing The Battery Using A Pallet Truck Or Hand Pallet Truck And No "Snapfit" Battery Holder
Removing or installing the battery using a pallet truck or hand pallet truck and no "SnapFit" battery holder WARNING! After inserting the battery close the battery lock and then lower the pallet truck. CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis.
Page 93: Removal Or Installation With Battery Holder (Snapfit) And Crane Cross Member (O)
Removal or Installation with Battery Holder (SnapFit) and Crane Cross Member (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 94: Transporting The Batteries By Crane
Transporting the batteries by crane DANGER! Crane lifting gear can tear, resulting in accidents uOnly use crane lifting gear with a cross member and sufficient capacity. uObserve the crane lifting gear operating instructions. uLifting accessories of the crane lifting gear must be fastened in such a way that they do not come into contact with any attachments when lifting.
Page 95 Requirements – To prevent short circuits, batteries with exposed terminals must be covered with a rubber mat. – Battery connector disconnected from the truck connector. – Battery removed – see page 80. Procedure • Pick up the battery at the four crane eyes with suitable crane lifting gear. Crane lifting gear may only exert vertical pull on the battery trough to prevent the battery trough from being compressed.
Page 96: Charging The Battery
Spark formation and uncontrolled movement of electronically controlled components may cause 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 97: Charging The Lead Battery
Charging the Lead Battery WARNING! Risk of explosion due to gases produced while charging The battery gives off a mixture of oxygen and hydrogen (oxyhydrogen gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited.
Page 98 9.1.1 Charging the Lead Battery with a Stationary Battery Charger When charging, the battery door must be exposed by at least 200 mm to provide sufficient ventilation. Requirements – Truck parked securely, see page 150. – Battery exposed, see page 78. –...
Page 99 9.1.2 Charging the lead battery with a comfort charger socket (o) Charging WARNING! Risk of explosion due to gases produced while charging uAlways check the fans each time you charge. Requirements – Truck parked securely, see page 150. Procedure • Connect the charger cable of the battery charging station to the charging socket (92).
Page 100: Charging Lithium-Ion Batteries (O)
Charging lithium-ion batteries (o) Intermediate charging of the lithium-ion battery A lithium-ion battery that is not fully discharged can be partially or fully recharged at any time. Note the following information to ensure reliable function of the lithium-ion battery: u In the event of frequent intermediate charging, charge the lithium-ion battery fully every 4 weeks.
Page 101 9.2.2 Charging the lithium-ion battery with a comfort charger socket (o) on the truck Charging Requirements – Truck parked securely, see page 150. Procedure • Connect the charger cable of the battery charger station to the charger socket (92). • Switch on the battery charging station and charge the battery in accordance with the battery and charging station manufacturer's instructions.
Page 103: E 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 104 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 105 WARNING! Health hazard due to non-adapted workplace or failure to meet the minimum headroom Failure to adapt the workplace or to meet the minimum headroom can cause stress and endanger the operator and may lead to lasting ill health due to an unhealthy posture and excessive strain on the operator.
Page 106: Displays And Controls
Displays and Controls Controls...
Page 107 – Fwd/rev. travel direction multiPILOT – Load handler lift/lower duoPILOT – Mast forward/reverse tilt – "Horn" button – Side shift left/right (o) – Auxiliary hydraulics (o) *If equipped with a Jungheinrich fleet management component, see the “Jungheinrich fleet management system” operating instructions.
Page 108: Pilots
Pilots Item Control / display Function t Lever for operating the basic lift / tilt Basic hydraulic functions lever hydraulic functions. t Button for side shift or auxiliary hydraulics Side shift / auxiliary hydraulics 1 optional button / lever t Selects travel direction / neutral position. Travel direction switch (not available with twin-pedal control)
Page 109 107 / 110...
Page 110: 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 111 Symbol Meaning Side shift right 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 Locking mechanism...
Page 112 Symbol Meaning Crane Scoop Load holder Folding fork Empty container Pusher Adapters ZH1 to ZH4 (example symbol: ZH1) Changing attachments 1 to 4 (example: attachment 2)
Page 113: Control Panel With Display Unit
Control panel with display unit 2.4.1 2-inch display 2,5km/h Item Control or display element Function 117 Information line Displays event messages and information such as speed 118 Battery capacity display Battery discharge status. 119 Battery type Empty = Standard battery 1 = Dry battery 120 Icon field Displays the symbols, see page 118.
Page 114 2.4.2 4-inch display Item Control/display Function 117 Information line Displays speed, event messages, residual runtime and optional information such as lift height, load weight. 120 Symbol field Displays the icons see page 118. 119 Battery Type Empty = standard battery; 1 = Dry battery 118 Battery capacity display Battery discharge status.
Page 115 Symbol Meaning – Travel direction engaged: forwards – Current direction of travel: forwards – Travelling straight ahead – Travel direction engaged: reverse – Current direction of travel: reverse – Travelling straight ahead – Travel direction engaged: forwards – Current direction of travel: forwards –...
Page 116: 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 programme down: Switches the operating programme down. Operating programme up: Switches the operating programme up. Settings: Switches to setting mode.
Page 117 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 118: Symbols In The Display
Symbols in the display Any number of pictograms can be displayed in the pictogram field (120). 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 119 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 at a preset interval (0 to 60 sec) after the truck stops.
Page 120 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 Steering Failure of the hydraulic steering malfunction assistance Handbrake not Manual parking brake engaged applied Special symbols on the display unit when equipped with lithium-ion battery...
Page 121: Symbol Meaning
Symbol Meaning Colour Function Battery low Yellow Temperature of the lithium-ion battery temperature is below 5°C. Discharge currents and energy recovery are reduced. Temperature of the lithium-ion battery is below 0°C. Lithium-ion battery below permissible temperature range. Regenerative Yellow Effect of regenerative braking is reduced. brake fault Maximum travel speed is reduced.
Page 122: 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 123: 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 124: Residual Time Display
2.10 Residual time display Setting the residual time display The residual time display (129) is switched on and off via the display toggle button (122/123).
Page 125: Operating Programs
2.11 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 126 Symbol Function Rear windscreen wiper – 1 press > button flashes green - intermittent – 2 press > button lights up green - continuous operation – 3 press > off – Press and hold > switch on the windscreen washing system Rear windscreen heater Parking brake button Parking the truck securely...
Page 127: Side Compartment Control Panel Switch (O)
2.14 Side compartment control panel switch (o) These switches are on the side control panel (132). Function Parking light Warning indicator Work lights Beacon / strobe light...
Page 128: 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 129 Checks before daily operation Procedure • Visually inspect the entire truck (particularly the wheels, wheel bolts and load handler) for damage, rattling noises, mechanical wear, rust or heavy soiling. • For pneumatic tyres (o): check the air pressure. • Visually inspect the visible area of the hydraulic system for damage and leaks.
Page 130 • Test the seat switch: When the driver's seat is vacated, it should not be possible to operate the working hydraulics. • Test the controls and displays. • Test the indicators (o). • Test the lighting present and optional equipment with lights (o). •...
Page 131: Entering Or Exiting
Entering or exiting CAUTION! Risk of accident due to slippery surfaces There is a risk of accident due to slipping when walking on slippery surfaces with unsuitable footwear. uWear safety shoes or sturdy footwear with non-slip soles. uUse the non-slip step and the floor mat for entry and exit. uLook out for snow and ice when boarding and alighting the truck in cold temperatures.
Page 132: Trucks With Reduced Headroom (O)
Trucks with reduced headroom (o) The following sign is present on the industrial truck from construction period 07.24: WARNING! Health hazard due to non-adapted workplace or failure to meet the minimum headroom Failure to adapt the workplace or to meet the minimum headroom can cause stress and endanger the operator and may lead to lasting ill health due to an unhealthy posture and...
Page 133: 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 134 Setting the driver's weight WARNING! Incorrectly adjusted seat cushioning can damage your health To achieve optimal seat damping, the driver’s seat must be adjusted according to the driver’s weight. uSet the driver's weight when the seat is occupied. uHold the weight setting lever only by the recess;...
Page 135 Adjusting the backrest Procedure • Sit on the driver’s seat. • Pull the lever (145) to adjust the backrest. • Adjust the backrest tilt. • Release the lever (145) again. The backrest is locked. The backrest is now set. Adjusting the lumbar support ( Procedure •...
Page 136 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. • Pull the backrest up and lock it in place to extend the backrest.
Page 137 3.4.2 Adjusting the steering column Adjusting the steering column Procedure • Release the steering column stop (151). • Set the steering column to the required position (height and angle). • Fix the steering column stop (151) in position. The steering column is now positioned. 3.4.3 Adjusting the arm rest Adjusting the Armrest...
Page 138: Restraint Systems
3.4.4 Adjusting the armrest Adjusting the armrest Procedure • Fold up the armrest (152). • Set the height adjuster (153) to the desired position (high/low). • Fold the armrest (152) down. Restraint systems Restraint systems Approved restraint systems: – Seat belt (see page 139) –...
Page 139: Seat Belt
Seat Belt 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. WARNING! Travelling without a seat belt increases the risk of injury.
Page 140 Check the automatic locking system Procedure • Park the truck on a level surface. • Jerk the seat belt out suddenly. The locking system should prevent the belt from coming out. The seat belt has now been checked. What to do in hazardous situations If the truck is about to tip over, do not loosen the seat belt.
Page 142: Working With The Truck
Working with the truck Safety regulations for travel mode 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 143 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 144 WARNING! Risk of accident due to the truck tipping over and the load slipping down Risk of accident due to the truck tipping over and the load slipping down when driving on a slope crosswise or diagonally or with the load not guided on the uphill side.
Page 145 WARNING! Risk of injury from falling loads Incorrectly or inappropriately secured and applied loads can slip and fall during heavy braking or as a result of wind forces. uTilt the mast back when transporting loads. uOnly transport loads that have been correctly secured and positioned. Take suitable additional precautions to prevent parts of the load from tipping or falling down.
Page 146: Preparing The Truck For Operation
Preparing the truck for operation Switching on the truck Requirements – Checks and operations before starting daily work completed, see page 128.
Page 147 Procedure • Unlock the emergency disconnect switch (94); 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 148: Activating The Lithium-Ion Battery (O)
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 149 Wake-up button on the control panel For easy activation of the lithium-ion battery, trucks are equipped with an additional wake-up button in the right control panel of the truck. The battery activation button/wake-up button activates the lithium-ion battery and switches it back to normal operation from energy-saving operation. The button must be pressed for approx.
Page 150: 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 151 Park the truck securely (with the parking brake button) Procedure • Lower the load handler. • Tilt the mast forward. • Press the parking brake button (130). • Turn the key in the key switch (93) to the "0" position. Keyless access systems (o) –...
Page 152: Emergency Disconnect
Emergency Disconnect CAUTION! Faulty or non-accessible Emergency Disconnect switches can cause accidents A faulty or non-accessible Emergency Disconnect switch can cause accidents. In dangerous situations the operator cannot bring the truck to a halt in time by applying the Emergency Disconnect switch. uThe operation of the Emergency Disconnect switch must not be affected by any objects placed in its way.
Page 153 Operating the emergency disconnect switch Procedure • Press the emergency disconnect switch (94). All electrical travel, steering and hydraulic functions are cut out. Trucks with an automatic parking brake decelerate to a halt at maximum o ). force ( Releasing the Emergency Disconnect Procedure •...
Page 154: Travel
Travel WARNING! Risk of accident and personal injury due to incorrect travel and loss of operational stability Incorrect travel can lead to the truck tipping over and accidents, as well as personal injury. A laden or unladen industrial truck can tip over if the operator does not decelerate to a safe speed before a bend.
Page 155 4.6.1 Single pedal Travel Requirements – Truck prepared for operation – see page 146. Procedure • Release the parking brake (154) or press the parking brake button (130). • Select the travel direction with the travel direction switch (108). • If necessary, select the travel speed by pressing the slow travel button (155) (o) or change the operating program see page 125 •...
Page 156 10 h 30 min 0 k m h...
Page 157 4.6.2 Twin pedal (o) Twin pedal (optional equipment) Requirements – Truck prepared for operation – see page 146. Procedure For twin-pedal trucks, the travel direction is selected via the accelerator pedals (104;103). When the operator leaves the truck, the truck is automatically set to "Neutral".
Page 158 10 h 30 min 0 k m h...
Page 160 4.6.3 Changing the direction of travel CAUTION! Danger when changing direction during travel Changing direction during travel can result in the truck travelling too quickly in the opposite direction if the operator does not take his foot of the accelerator pedal in time.
Page 161: Steering
Steering WARNING! Risk of accident and personal injury due to incorrect travel and loss of operational stability Incorrect travel can lead to the truck tipping over and accidents, as well as personal injury. A laden or unladen industrial truck can tip over if the operator does not decelerate to a safe speed before a bend.
Page 162: Brakes
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 163 4.8.1 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 164 4.8.2 Service brake Braking with the service brake Procedure • Depress the brake pedal (100) until you feel the brake pressure. The truck decelerates depending on the brake pedal position.
Page 165 4.8.3 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 166 Engaging the manual parking brake with the parking brake lever Procedure • Pull the parking brake lever (154) firmly backwards until the lever engages and there is noticeable resistance; the manual parking brake is applied. The parking brake lever warning indicator (155) is displayed. The truck is now secure.
Page 167 4.8.4 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 168 Deactivating the manual parking brake with the parking brake button ( Procedure • Press the parking brake button (130). Red LED above the parking brake button (130) goes out. The red manual parking brake icon (135) on the display goes out and the automatic parking brake icon (135) is lit green.
Page 169 4.8.5 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 170: Adjusting The Forks
Adjusting the forks WARNING! Trapping hazard There is a trapping hazard when you perform this operation. uWear work gloves and safety shoes. WARNING! Unsecured and incorrectly adjusted forks can cause accidents Make sure that the fork retaining mechanisms (134) are fitted before adjusting the forks. Depending on the fork carriage, the fork- retaining mechanism (134) will be either via retaining bolts (85 Nm) or fixed stops.
Page 171 Procedure • Lift up the locking lever (162). • Push the forks (163) into the correct position on the fork carriage (164). To lift the load securely, the forks (163) must be spread as far apart as possible and positioned centrally with respect to the fork carriage. The load centre must lie centrally between the forks (163).
Page 172: Replacing The Forks
4.10 Replacing the forks WARNING! Risk of injury due to unsecured fork arms There is a risk of injury and trapping when replacing the fork arms. uWear work gloves and safety shoes. uEnsure that the fork arms have sufficient capacity. uNever pull the fork arms towards your body.
Page 173: Lifting, Transporting And Depositing Loads
4.11 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 174 WARNING! Danger of accidents when storing and retrieving loads on slopes and inclines The storage and retrieval of loads on slopes and inclines is prohibited. uAlways store or retrieve loads on a horizontal surface. uA slope of +/- 2% (e.g.: for surface drainage) is permissible in an outdoor area. WARNING! Risk of collision and damage to the mast due to lifting sequence errors In the case of masts with free lift, lifting sequence errors can occur at low ambient...
Page 175 • Slowly insert the forks into the pallet until the fork shank touches the pallet. • Raise the load handler. • Reverse carefully and slowly until the load is outside the storage area. Make sure you have enough clear space to reverse into.
Page 176 Transporting loads Requirements – Load raised correctly. – Load handler lowered transport (approx. 150 - 200 mm above the ground). – Mast tilted back fully. Procedure • On slopes and inclines always carry the load facing uphill, never approach at an angle or turn.
Page 177: Operating The Lift Mechanism And Integrated Attachments
4.12 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 178 4.12.1 Operating the lift mechanism with soloPILOT Lifting and lowering Requirements – Truck prepared for operation, see page 146. Procedure • Pull the lever (106) in direction H to raise the load. • Push the lever (106) in direction S to lower the load.
Page 179 Positioning integrated sideshifter (option) Requirements – Truck prepared for operation, see page 146. Procedure • Pull the lever (107) in direction R to move the load handler to the right (from the driver’s viewpoint). • Push the lever (107) in direction V to move the load handler to the left (from the driver’s viewpoint).
Page 180 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 146. Procedure • Press the acknowledgement key (112) and then within 2 seconds pull the lever (110) in direction H to bring the forks together.
Page 181 4.12.2 Operating the lift mechanism with multiPILOT Lifting and lowering Requirements – Truck prepared for operation – see page 146. Procedure • Pull the multiPILOT (106) in direction R to raise the load. • Push the multiPILOT (106) in direction V to lower the load.
Page 182 Positioning the integrated sideshift (option) Requirements – Truck prepared for operation, see page 146. Procedure • Press the button (107) to the left to move the load handler to the left (from the driver's viewpoint). • Press the button (107) to the right to move the load handler to the right (from the driver's viewpoint).
Page 183 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 146. Procedure • Press the acknowledgement key (167) and then within 2 seconds push the fork positioner lever (166) in direction V to move the fork arms apart.
Page 184 4.12.3 Operating the lift mechanism with duoPILOT Lifting and lowering Requirements – Truck prepared for operation, see page 146. Procedure • Pull the lever (106) in direction R to raise the load. • Push the lever (106) in direction V to lower the load.
Page 185 Positioning the integrated sideshifter (option) Requirements – Truck prepared for operation, see page 146. Procedure • Pull the lever (107) in direction S to move the load handler to the left (from the driver’s viewpoint). • Push the lever(107) in direction H to move the load handler to the right (from the driver’s viewpoint).
Page 186 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 146. Procedure • Press the acknowledgement key (112) and then within 2 seconds pull the lever (110) in direction R to bring the forks together.
Page 187: Safety Instructions For Operating Additional Attachments
4.13 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 approved by the manufacturer of the truck.
Page 188 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 189 CAUTION! Danger of crushing due to clamping functions There is a risk of crushing using attachments with clamping functions. uIn the case of attachments with a clamping function, keep body parts away from the space between the attachment and the load. uWear safety shoes.
Page 190 Safety instructions for telescopic attachments WARNING! Accident risk due to increased tipover hazard and reduced residual capacity An increased risk of tipover exists with extended telescopic attachments since incorrectly carried loads can reduce the stability of the truck. When the residual capacity is reduced, a risk of serious material damage and personal injury due to falling loads exists in the vicinity of the truck.
Page 191 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 192: Operating Additional Attachments With Solopilot
4.14 Operating additional attachments with soloPILOT 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 193 4.14.2 soloPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (107, 110, 112) is assigned the function of the attachment. Unused levers have no function. For connections see page 200. Procedure •...
Page 194 4.14.3 soloPILOT with control of ZH1, ZH2 and ZH3 hydraulic ports Depending on the attachments used the levers / buttons (107, 110, 112, 111) are assigned the respective functions. Unused levers have no function. For connections see page 200. Procedure •...
Page 195: Operating Additional Attachments With Multipilot
4.15 Operating additional attachments with multiPILOT 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 196 4.15.2 multiPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used, the levers/buttons (114, 166, 167) are assigned the function of the attachment. Unused levers have no function. For ports, see page 200. Procedure • Operating hydraulic port ZH1: Press the button (114) to the left or right.
Page 197: Operating Additional Attachments With Duopilot
4.16 Operating additional attachments with duoPILOT 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 198 4.16.2 duoPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used, the lever / button (107, 110, 112) is assigned 107 / 110 the function of the attachment. Unused levers have no function. For ports, see page 200.
Page 199 4.16.3 duoPILOT with control of ZH1, ZH2 and ZH3 hydraulic ports 107 / 110 Depending on the attachments used the levers / buttons (107,110,111,112) are assigned the respective functions. Unused levers have no function. For connections see page 200. Procedure •...
Page 200: Fitting Additional Attachments
4.17 Fitting additional attachments WARNING! Hot hydraulic oil can cause injury Hot hydraulic oil can cause serious injuries such as burns or scalds. uWait until the hydraulic oil has cooled down. uDo not drain or pump hot hydraulic oil out of the system. uIn the case of injuries, seek medical assistance immediately.
Page 201 Depressurise hydraulic plug-in couplings (2-inch display) Requirements – The operator is in the operating position. – Parking brake activated. – Travel direction switch in neutral. – All controls in neutral. Procedure • Press the button (169) for more than 5 seconds. •...
Page 202 Depressurise hydraulic plug-in couplings (4-inch display) Requirements – The operator is in the operating position. – Parking brake activated. – Travel direction switch in neutral. – All controls in neutral. Procedure • Actuate the "depressurise auxiliary hydraulics" button, see page 116. Warning triangle in the display lights up flashing yellow, see page 118.
Page 203 WARNING! Unsecured hydraulic functions can cause accidents Failure to secure hydraulic functions for releasing functions on attachments that hold loads using force (e.g. paper clamps, load holder) can result in accidents. uHydraulic functions for releasing functions that hold loads using force must be secured such that they can be used only after actuation of the acknowledgement button.
Page 204 Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance with environmental regulations. If hydraulic oil comes into contact with the skin, wash it off immediately with soap and water. If it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor.
Page 205: 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 52.
Page 206 Attaching the trailer Requirements – Truck and trailer are on a level surface. – Trailer prevented from rolling away. Procedure • Push the tow pin (170) down and turn it 90°. • Pull up the tow pin (170) and insert the tiller of the trailer into the opening.
Page 207: Optional Equipment
Optional Equipment CAUTION! Risk of collision with optional equipment on the A-pillar and armrest Before setting off, ensure that there is not risk of a collision of the armrest controls with optional equipment on the A-pillar. Unintentional movements of the operating functions are thus avoided.
Page 208 Operation of transponder reader Plus (173) corresponds to the operation of the standard transponder reader (172).
Page 209: 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 210 6.3.1 Activating the keypad Procedure • Release the emergency disconnect switch, see page 152. • 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 (174).
Page 211 6.3.2 Activating the transponder reader Procedure • Release the emergency disconnect switch, see page 152. • Enter the default code 1-2-3-4 using the keys below the display unit (6). The truck is switched on. • Press below "Settings" symbol (174). •...
Page 212: Keyless Access System - Display Unit
Keyless access system - display unit 6.4.1 Switching on the truck with an access code unit (display unit) Procedure • Release the emergency disconnect switch, see page 152. • Enter the access code with the buttons below the display (6). The truck is switched on.
Page 213 6.4.3 Changing the set-up code Requirements – The truck is switched on, see page 212. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Change set- up code" symbol (175). • Enter the set-up code using the keys below the display unit (6).
Page 214 6.4.4 Adding a new access code Requirements – The truck is switched on, see page 212. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Edit access code" symbol (180). The set-up code is requested. •...
Page 215 6.4.5 Deleting an access code Requirements – The truck is switched on, see page 212. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Edit access code" symbol (180). The set-up code is requested. •...
Page 216 6.4.6 Displaying the log-in history 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 217: Keyless Access System - Keypad
Keyless access system - keypad 6.5.1 Switching on the truck with the access code (keypad) Procedure • Release the emergency disconnect switch, see page 152. • Enter the access code with the keypad (171). The truck is switched on. The truck can only be switched on when the display unit (6) is lit. If the display unit is in standby the code or transponder will not be recognised.
Page 218 6.5.3 Changing the set-up code Requirements – The truck is switched on, see page 217. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Change set- up code" symbol (175). • Enter the set-up code using the keypad (171).
Page 219 6.5.4 Adding a new access code Requirements – The truck is switched on, see page 217. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Edit access code" symbol (180). The set-up code is requested. •...
Page 220 6.5.5 Deleting an access code Requirements – The truck is switched on, see page 217. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Edit access code" symbol (180). The set-up code is requested. •...
Page 221 6.5.6 Displaying the log-in history 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 222: Keyless Access System - Transponder Reader
Keyless access system - 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 a transponder Procedure • Release the Emergency Disconnect switch, see page 152.
Page 223 6.6.3 Changing the set-up transponder Requirements – The truck is switched on, see page 222. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Change set-up code" symbol (175). • Place the set-up transponder on the transponder reader (172).
Page 224 6.6.4 Adding a new transponder Requirements – The truck is switched on, see page 222. Procedure • Press the key below the "Settings" symbol (174). • Press below "Edit transponder" symbol (180). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (172).
Page 225 6.6.5 Deleting a transponder Requirements – The truck is switched on, see page 222. Procedure • Press the key below the "Settings" symbol (174). • Press the key below the "Edit transponder" symbol (180). set-up transponder requested. • Place the set-up transponder on the transponder reader (172).
Page 226 6.6.6 Displaying the log-in history 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 227: Voltage Transformer
Voltage Transformer Voltage transformer and interfaces Performance data 12V: 12V / 150 W Pin 1 and 2 Pin no. Pin definition 12 V Performance data 24V: 24V / 150 W Pin 1 and 2 Pin no. Pin definition 24 V Rear and storage facility Voltage tap central 24V: 96 Watt Pin no.
Page 228 Overhead guard WMT voltage supply (permanent voltage) Performance data: 24 V Pin no. Pin definition 0V (GND) + (with key switch switched) + (permanent)
Page 229 Voltage supply – radio preparation Pin no. Pin definition Telemute Battery +12V Switch output +12V Lighting ACC +12V Earth 0V Rear right (+) Rear right (-) Front right (+) Front right (-) Front left (+) Front left (-) Rear left (+) Rear left (-)
Page 230: Assistance Systems
Assistance systems The Access, Drive and Lift Control systems help the driver operate the truck with regard to safety regulations, see page 142 of the present operating instructions. The assistance systems have no safety functions and do not disrupt the truck safety functions.
Page 231 6.8.2 driveCONTROL 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 232: Steel Cab
Steel cab WARNING! Risk of accidents due to fogged, icy mirrors and windows Windows (e.g. rear windscreen, front window) and mirrors may be fogged or iced up. This can lead to accidents and injuries. uAlways clean or de-ice the windows and mirrors before operation. WARNING! Open doors can result in accidents uDo not travel with an open door.
Page 233 6.9.1 Door Monitoring CAUTION! Accident risk when opening the cabin door during travel If the cabin door is opened while driving, the truck automatically brakes to a maximum speed of 4 km/h or comes to a standstill. There is a risk of collision and injury when opening the cabin door while driving. uDo not open the cabin door while driving.
Page 234: Sliding Windows
6.10 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 (187) up. • Move the window forward or back. • Insert the lock in the stop (186).
Page 235: Gate
6.11 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 236 Folding gate operation Procedure • To open the gate, (188) press the handle (189). The gate automatically folds up and remains in this position. • To close the gate (188), press it down until it engages. The position of the gate is monitored. Travel is only enabled when the gate is closed.
Page 237 Moving the gate Procedure • For service work the gate can be moved out. To do this, pull the spring pin (190) 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 238: Panel Door
6.12 Panel door WARNING! 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 139.
Page 239: 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 240: Entering Or Exiting With The Hip Restraint On The Driver's Seat
6.14 Entering or exiting with the hip restraint on the driver's seat Requirements – Truck stationary. Procedure • Open the cab door (if applicable) (o). • To enter and exit, use the step and hold onto the handle (137) with one hand. •...
Page 241: Auxiliary Functions On The Armrest
6.15 Auxiliary Functions on the Armrest 6.15.1 Activating the auxiliary functions on the armrest Procedure • Press the FN (194) button. Status lamp above the FN button lights Auxiliary functions are displayed. • Press corresponding button armrest control panel and activate/ deactivate the auxiliary option.
Page 242 6.15.2 Auxiliary functions in the display unit above the FN button Symbol Meaning Lift cut-off override: Allows the lift cut-off to be overridden. Side shift centre position: Activates the side shift centre function Load weighing Operating hydraulics function cut-off Fork tilt horizontal: Activates the fork tilt horizontal function, see page 252.
Page 243: Switching Off The Operating Hydraulics
6.15.3 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 6.16 Switching off the operating hydraulics Change over via the FN button in the armrest to deactivate all operating hydraulics functions (lifting, tilting, auxiliary functions 1, 2, 3).
Page 244: Load Weighing
6.17 Load Weighing The integrated load weighing system measures the weight continuously with a tolerance of 5% of the rated capacity. For industrial trucks with load damping, the tolerance increases in the upper range of the capacity to 10% of the rated capacity. The weighing system is not a substitute for calibrated scales.
Page 245 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 246: Tilt Angle Display
6.19 Tilt angle display The tilt angle is shown in the information line and in the symbol field of the display unit. The mast tilt angle is determined relative to the truck (not relative to the axis of the earth). Tilt angle display on the display unit Symbol Meaning Colour...
Page 247: Heating
6.20 Heating Item Description Body / window nozzles Temperature controller Fan settings Foot compartment jet Heating operation Procedure • Press the switch (197) to switch on the fan. • Set the nozzles (195,198) to the required position. • Turn the temperature controller (196) to the right to increase the cab temperature.
Page 248: Removable Load Backrest
6.21 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 (202). •...
Page 249: Load Damping
6.23 Load damping WARNING! Risk of injury from energy-storing pressure vessels The hydraulic accumulator is a pressure vessel connected to the hydraulic line with a membrane and a compressed gas (nitrogen) under pre-charge pressure. Pressurised components and fluids can cause severe injury. If the pressure in the hydraulic line increases, the pressure on the membrane also increases and the gas is further compressed.
Page 250 Load damping reduces the shocks and impacts acting on the load to be moved by means of a hydraulic accumulator. If pressure fluctuations occur in the hydraulic system e.g. due to potholes, they will be absorbed and minimised by the hydraulic accumulator.
Page 251: Overriding The Lift Cut-Off
6.24 Overriding the lift cut-off 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 128). – "Lift cutout" tested with function key (see page 241).
Page 252: Sideshifter Centre Position
6.25 Sideshifter Centre Position Automatic sideshifter centring operation. Requirements – Inspection and tasks before starting daily operations performed (see page 128). – Check automatic sideshifter centring checked with the function key, see page 116. Procedure • Press the sideshifter centring button, see page 116. •...
Page 253: Fork Tilt Horizontal
6.26 Fork Tilt Horizontal Alignment of the fork arms parallel to the travel path. Requirements – Checks and operations before starting daily work completed, see page 128. – "Fork tilt horizontal" function tested, see page 241. Procedure • Press the fork tilt horizontal button (see page 118) if the function is not permanently triggered after switching on (o) or through previous actuation (o).
Page 254: Fire Extinguisher
6.27 Fire extinguisher Procedure • Open the fasteners (205). • Pull the fire extinguish out of its bracket. To operate, refer to the illustrations on the fire extinguisher.
Page 255: Trailer Coupling With Hand Lever Or Remote Control
6.28 Trailer coupling with hand lever or remote control DANGER! Danger of falling due to use of the trailer coupling as an attachment point Use of the trailer coupling as a lifting point for using a crane or jacking up is prohibited.
Page 256 CAUTION! Incorrectly coupled trailers can cause accidents If the trailer coupling is incorrectly locked, the trailer can come loose during travel. uMake sure that the coupling is engaged securely before commencing travel. uThe control pin (208) must be flush with the control sleeve (209).
Page 257: Camera System
6.29 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 258: Control Layout "N
6.30 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 259 Tilting CAUTION! Trapping hazard from tilted mast uWhen tilting the mast back, keep all parts of your body from between the mast and the front wall. Procedure • Push duoPILOT lever (106) forwards (direction V) to tilt the load forward. •...
Page 260: Operating The Auxiliary Hydraulics Without Pressing The Acknowledgement Key
6.31 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 261 6.31.1 soloPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (107,110), is assigned the function of the attachment. Unused levers have no function. For connections see page 200. Procedure • Operating hydraulic port ZH1: Move the lever (107) in direction V or •...
Page 262 6.31.3 multiPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used, the lever/button (106, 114) is assigned the function of the attachment. Unused levers have no function. For ports, see page 200. Procedure • Operating hydraulic port ZH1: Actuate the button (114) to the left or right.
Page 263 6.31.5 duoPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (107,110), is assigned the function of the attachment. Unused levers have no function. For connections see page 200. 107 / 110 Procedure •...
Page 264: Special Control Layout
6.32 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 265 Changeover level The changeover level is activated and deactivated via the button (168) on the control. The symbol for the active changeover level (216) is shown in yellow on the display. 0 k m / h...
Page 266 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 267 Acknowledgement feature Certain hydraulic functions (e.g. opening a load clamp) must be confirmed via the acknowledgement key (112) on the control. The acknowledgement feature is activated by actuating the acknowledgement key (112) with the padlock symbol. If a hydraulic function is set to require acknowledgement, the acknowledgement key (112) must be actuated regardless of the lever assignment at operating level.
Page 268: Floor-Spot
6.33 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 alter the position and alignment of the Floor-Spot on the truck. uDeactivate the Floor-Spot when travelling on public roads.
Page 269 6.33.1 Additional information on Floor-Spot blue 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 270: Floor-Bow
6.34 Floor-Bow CAUTION! Risk of accident due to dazzling Looking directly into the light beam of the Floor-Bow can dazzle and temporarily impair eyesight. uDo not look directly into the light beam of the Floor-Bow. uDo not alter the position and alignment of the Floor-Bow on the truck. uDeactivate the Floor-Bow when travelling on public roads.
Page 271 6.34.1 Additional information for the blue Floor-Bow The activated Floor-Bow forewarns people of the truck's travel path by projecting a blue dot onto the floor at the set distance. CAUTION! Risk of retinal damage due to blue light The Floor-Bow on the truck is classified in risk group 2 according to the standard IEC 62471: medium risk.
Page 272: Optional Equipment For Road Traffic As Per Stvzo
6.35 Optional Equipment for Road Traffic as per StVZO WARNING! Risk of accidents in public traffic areas The use of public traffic areas and travel on public roads in particular requires utmost caution at all times as well as consideration and awareness for other traffic participants in order to avoid dangerous situations and accidents.
Page 273: Horn Button On Overhead Guard
6.36 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 274: Antistatic Strap
6.37 Antistatic strap The antistatic strap (222) depends on the tyres and ensures that the truck does not become statically charged. Before setting off, make sure that the antistatic strap (222) is undamaged and clean. When the truck is stationary, the contact surface of the antistatic strap (222) should be approx.
Page 275: Troubleshooting
Troubleshooting Troubleshooting This chapter allows operators to identify and rectify simple faults or the results of incorrect operation themselves. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the industrial truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error message, contact the manufacturer’s customer service department.
Page 276 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 277 Troubleshooting Fault Possible cause Actions 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- connect if necessary. ion battery (o) or interface converter (o) of lithium-ion battery.
Page 278 Fault Possible cause Actions Load cannot be lifted – Truck not operational. – Carry out all actions listed under "Truck does not start". – Hydraulic oil level too – Check the hydraulic oil low. level and top up, if necessary. –...
Page 279: Moving A Truck Without Its Own Drive System
Moving a truck without its own drive system 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. uAlways use a pull rod to tow.
Page 280 7.2.1 Towing the truck Requirements – Park the truck securely. – Disconnect the battery connector. Procedure • Connect pull trailer coupling (63) of the towing truck and attach it to the truck to be towed. • Release the parking brake, see page 165. •...
Page 281 7.2.2 Release and activate the parking brake Release 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 tray or the interface converter (o) on the battery.
Page 282 Applying the parking brake Procedure • Turn the auxiliary tool (223) carefully to the left to the “travel position”. The brakes are applied to the drive wheels and the truck is now parked securely.
Page 283: Emergency Lowering
Emergency lowering The load handler can be lowered manually if a fault occurs in the hydraulic controller. 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.
Page 284: Exiting The Driver's Cab Via The Right-Hand Side Window Or The Rear Windscreen (Emergency Exit)
Exiting the Driver's Cab via the Right-Hand Side Window or the Rear Windscreen (Emergency Exit) CAUTION! Risk of injury when striking the side window or the rear windscreen Striking the side window or the rear windscreen can result in facial injuries due to splinters of glass.
Page 287: F 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 55.
Page 288: 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 337. The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...
Page 289: Maintenance Safety Regulations
Maintenance Safety Regulations WARNING! Danger from hot fluids and hot components Operating materials (hydraulic oil) as well as components of the hydraulic system and the drive train become very hot during operation. Hot components are freely accessible when the panels are open or the covers are removed. Direct contact with hot operating materials can cause scalds.
Page 290: Working On The Electrical System
Working on the electrical system WARNING! Risk of accidents due to electrical current Make sure the electrical system is voltage-free before starting work on it. The capacitors in the control unit must be completely discharged. The capacitors are fully discharged approx. 10 minutes after disconnecting the electrical system from the battery.
Page 291 WARNING! Risk of burns due to hot controller parts After switching off the truck, the temperature on the controller surface can be up to 85 °C. There is risk of burns when touching the controller. uWait for the controller to cool down before commencing work. uWear protective gloves if necessary.
Page 292: 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 293: 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 294: 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 295: Air Conditioning System
Air conditioning system WARNING! Environmental and health hazards due to insufficient maintenance The air conditioning coolant contains fluorinated greenhouse gases. Leaking coolant pollutes the environment; if there is a high concentration of air or oxygen, there is a risk of suffocation. Contact with liquid coolant can cause cold burns or frostbite.
Page 296: 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 297 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 298: Lubrication Schedule
Lubrication Schedule E (O) E (O)
Page 299: Consumables
g Contact surfaces Hydraulic oil drain plug b Transmission oil filler neck Grease nipple a Transmission oil drain plug Hydraulic oil filler neck Consumables Suppli Order no. Volume Description Used for quanti 51132827 HVLP 32 50429647 20 l Renolin 22 HLPD 51037497 Renolin 22...
Page 300 Applicable for temperature range +30/+50°C WARNING! Danger of contamination of the area of use The trucks are factory-equipped with the "HLP D22" hydraulic oil or the "Plantohyd 22 S" bio hydraulic oil. You cannot change from "Plantohyd 22 S" bio hydraulic oil to the manufacturer's hydraulic oil.
Page 301: Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repair work WARNING! Risk of accidents when working under the load handler, driver's cab and lift truck uWhen working under a raised load handler, driver's cab or a raised truck, secure them to prevent the truck from from lowering, tipping or sliding away.
Page 302: 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.
Page 303: Opening Or Closing The Rear Panel
Opening or closing the rear panel Opening the panel Requirements – Truck prepared for maintenance and repair work – see page 301. Procedure • Undo two quick release fasteners (228). • 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 304: Replacing The Wheels
Replacing the 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. uRaise the unladen truck on a level surface.
Page 305 Removing the wheels Requirements – Truck prepared for maintenance and repair work – see page 301. Tools and Material Required – Jack – Hard wooden blocks – Mounting lever – Torque wrench Procedure • Place the jack against an indicated contact point.
Page 306: Checking The Attachment Of The Wheels
Checking the attachment of the wheels 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. uAfter changing the tyres, check that the wheel nuts/wheel bolts are secure after 10 operating hours.
Page 307: Hydraulic System
Hydraulic system WARNING! Danger from hot fluids and hot components Operating materials (hydraulic oil) as well as components of the hydraulic system and the drive train become very hot during operation. Hot components are freely accessible when the panels are open or the covers are removed. Direct contact with hot operating materials can cause scalds.
Page 308 CAUTION! Consumables and used parts represent an environmental hazard uDispose of used operating materials and used parts in accordance with the applicable environmental protection regulations. uOil changes may only be performed by the manufacturer's customer service department. uNote the safety regulations when handling these substances. When carrying out maintenance and repair work in the engine compartment, the pedal plate/floor plate must be removed.
Page 309 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 310 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 301). Procedure • Unscrew the hydraulic oil filter cap (232). The filter element is located on the cap.
Page 311: Checking The Gear Oil Level
Checking the gear oil level CAUTION! Consumables and used parts represent an environmental hazard uDispose of used operating materials and used parts in accordance with the applicable environmental protection regulations. uOil changes may only be performed by the manufacturer's customer service department.
Page 312 The oil is now drained. Adding oil Procedure • Insert the oil drain plug (235). • When screw with integrated dipstick (233) has been removed, add new transmission oil into the filler hole (234). The oil has now been added.
Page 313: Heating
Heating WARNING! Danger from hot fluids and hot components Operating materials (hydraulic oil) as well as components of the hydraulic system and the drive train become very hot during operation. Hot components are freely accessible when the panels are open or the covers are removed. Direct contact with hot operating materials can cause scalds.
Page 314: Adding Window Washer System Fluid
Adding window washer system fluid Procedure • Make sure there is sufficient window fluid in the container (236). • If necessary top up with anti-freeze.
Page 315: Checking The Electrical Fuses
5.10 Checking the 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 150). 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 316 5.10.1 Fuse ratings Electrical system fuses Item Description Electrical circuit Rating / type Main fuse (emergency 80 V / 452 A disconnect) FK1 MINI 32V / 2A / 24V standby FK1 MINI 32V / 2A / 9F33 Windscreen washer pump FK1 MINI 32V / 2A / Internal control...
Page 317 Item Description Electrical circuit Rating / type FK1 MINI 32V / 2A / 9F14 Rear windscreen wiper Beacon, reading lamp, additional FK1 MINI 32V / 4A / fan, signals (reversing, brake light) FK1 MINI 32V / 4A / 5F11 Front left-hand work light FK1 MINI 32V / 4A / 5F11.3 Rear right-hand work light...
Page 318 Item Description Electrical circuit Rating / type Charge circuit internal, battery FKS 80V / 3 A / UL discharge monitoring Electronics controller - T/L (controller control unit and FKS 80V / 3 A / UL element) FK3 MAXI 80V / Heater (PTC) 30A /UL DC/DC converter, controller-...
Page 320 Electrical system fuses Item Description Electrical circuit Rating / type FK1 MINI 32V / 15A / Output fuse DVC 150 FK1 MINI 32V / 7.5A / F3.1 Output fuse DVC 150 FK1 MINI 32V / 4A / 9F17.9 Option fuse 24V FK1 MINI 32V / 4A / 9F17.6 Option fuse 24V...
Page 322 Electrical system fuses Item Description Electrical circuit Rating / type FK1 MINI 32V / Output fuse DVC 150 15A / UL FK1 MINI 32V / F3.1 Output fuse DVC 150 7.5A / UL FK1 MINI 32V / 4F6.1 LH brake light control fuse 3A / UL FK1 MINI 32V / 4F6.2...
Page 324 Overhead guard connector positions Item Description Electrical circuit LH tail lights control fuse 2U13 soloPILOT Control unit display Keypad Key switch 3U10 Steering set point Indicator switch 1B19 Brake pedal sensor Display locking interface Front windscreen wiper motor X159 interface X127 Front work lights interface Mechanical parking brake interface...
Page 325 Item Description Electrical circuit XS171 DC/DC converter POC interface Interface for warning beacon/strobe XS138 light XS156 Rear windscreen interface XS154 Wash pump interface...
Page 327 Item Description Electrical circuit E17/5E21 Overhead guard rear left work light 4H3.1 Strobe light 5E18/5E22 Overhead guard rear right work light 3 E2 Right-hand combi tail light 3 E1 Left-hand combi tail light 9M2.2 Rear windscreen wiper motor Rear windscreen heater DC/DC converter 80V/24V Cust R1-4 Cust relays...
Page 328: Cleaning
5.11 Cleaning Cleaning tasks may only take place in the designated locations, which adhere to the stipulations of the country of use. The cleaning interval must be adapted to the operating conditions of the truck. Before setting off, ensure that the field of view is clear! CAUTION! Risk of injury due to falling from the truck Do not climb on the truck, there is a risk of becoming stuck, slipping and falling.
Page 329 Cleaning the truck Requirements – Truck prepared for maintenance and repair work (see page 301). Tools and Material Required – Water-based cleaning agents – Clean sponges, rags, cotton cloths or paper towels Procedure • Clean the surface of the truck with water-based solvents and water. Use a clean sponge, rags, cotton cloths or paper towels for cleaning purposes.
Page 330 5.11.1 Cleaning the roof window 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 331 Tools and Material Required – Compressor with water separator – Non-conductive, antistatic brush Procedure • Expose the electrical system – see page 303. • Clean the electrical system assemblies with weak suction or compressed air (use a compressor with a water separator) and a non-conductive, anti-static brush. •...
Page 332: Restoring The Truck To Service After Maintenance And Repairs
5.12 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see page 328. • Lubricate the truck according to the lubrication diagram, see page 298. • Clean the battery, grease the terminals and connect the battery. •...
Page 333: 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 334: Prior To Decommissioning
Prior to decommissioning Procedure • Thoroughly clean the truck – see page 328. • Prevent the truck from rolling away accidentally. • Check the hydraulic oil level and replenish if necessary, see page 309. • Apply a thin layer of oil or grease to any non-painted mechanical components. •...
Page 335: 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 337 G Maintenance, inspection and changing of maintenance parts requiring replacement WARNING! Risk of accidents during repair and maintenance work Maintenance, service and repair work may only be carried out when the truck is de-energised. uPark the truck securely (see page 150). uPress the emergency disconnect switch.
Page 338 Maintenance Contents EFG 535k-S50 Issued on: 2024-07-15 14:00 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 brake. Hydraulic operations Lubricate the load chains. Correct the hydraulic-oil level.
Page 339 1.1.2 Inspection contents 1.1.2.1 Standard equipment The following points must be checked: Electrical system Warning and safety equipment in accordance with the operating instructions Functionality of display and controls Test emergency disconnect switch and check for damage Power supply Check battery and battery components for damage Battery connector for secure fit, functionality and damage Travel Check wheels for wear and damage...
Page 340: Customer Service
Check battery and battery components for damage Lead-acid battery Power supply Check the battery cable connections for secure attachment Customer Service In accordance with the EFG 535k-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...
Page 341 Travel Correct the transmission oil level or grease filling of the transmission. Hydraulic operations Adjust the slide pieces. Adjust the load chains. Lubricate the load chains. Lubricate the contact surfaces of the mast. Test emergency lowering. Correct the hydraulic-oil level. Test and adjust the pressure relief valve.
Page 342 Telescopic forks Hydraulic operations Adjust the attachment. Clean and grease attachment bearings, guides and stops. Adjust the pistons and piston rods. Windscreen washing system Chassis/structure Correct the fill level of the windscreen washer reservoir. Radio data System components Clean the scanner and terminal. Video system System components Clean the camera.
Page 343 Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage. Correct the battery-acid level using demineralised water. Lead-acid battery Electrical system Perform insulation inspection. Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage.
Page 344 Chassis/structure Check chassis connections and screw connections are securely attached and check for damage Check labels for legibility, completeness and plausibility Check driver's seat for damage Check driver's seat is securely attached and test adjustment mechanism Check doors or covers for damage Check the counterweight is securely attached Check mast is securely attached Check mast bearings for wear...
Page 345 1.2.2.2 Optional Equipment Electrolyte recirculation Power supply Hose connections and pump for correct function Aquamatic Power supply Aquamatic plug, hose connections and float for functionality and sealing Flow indicator for functionality and sealing Battery refill system Power supply Refill system for functionality and leaks Boom Hydraulic operations Check the attachment is securely attached to the truck and check the load-bearing...
Page 346 Hydraulic operations Check attachment bearings, guides and stops for wear and damage Check hydraulic connections are securely attached and check for leaks Check cylinder seals for leaks and damage Check cylinder rods and their bushings for wear and damage Side shift Hydraulic operations Test attachment and check for damage Check the attachment is securely attached to the truck and check the load-bearing...
Page 347 Windscreen washing system Chassis/structure Check windscreen washer reservoir for leaks and damage Test windscreen wipers and check for damage Trailer coupling Chassis/structure Test trailer coupling stop or tow mechanism stop and check for damage Seat heating Electrical system Check connections and cables are securely attached and check for insulation damage and other signs of damage Shock sensor/data recorder Electrical system...
Page 348 Weigher sensors/switches Electrical system Weigher for damage Access module Electrical system Check access module is securely attached, test and check for damage Electrical heating Chassis/structure Test the heater Weather protection Chassis/structure Test window heating and check for damage Test doors and check for damage Optional electrical equipment Electrical system Fuses for correct ratings...
Page 349 Belt lock monitoring Chassis/structure Test seat belt monitoring and check for damage Discharge strap Electrical system Check presence of electrostatic discharge strap or chain and check for damage Restraint system / HRS-E-DUO Electrical system Check connections and cables are securely attached and check for insulation damage and other signs of damage Chassis / structure The secure seating of the electrical connections and for damage.
Page 350 Lead-acid battery, international Power supply Check battery, battery cables and cell connectors are securely attached and check for damage Ensure safety labels are present and check for damage Lead-acid battery Power supply Check battery, battery cables and cell connectors are securely attached and check for damage 1.2.3 Maintenance parts...

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Jungheinrich EFG 535k Operating Instructions Manual

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