Page 1 ETM/V 210-325 11.21 Operating instructions en-GB 51857951 11.23 ETV 210 ETV 212 ETM 214 ETM 216 ETV 214 ETV 216 ETV 318 ETV 320 ETV 325 ETM 325...
Page 3: Declaration Of Conformity
Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture ETV 210 ETV 212 ETM 214 ETM 216 ETV 214 ETV 216 ETV 318 ETV 320 ETV 325 ETM 325 On behalf of...
Page 4 Product: ETM/V 210-325 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 Internal Operation in Cold Stores with Cold Store Equipment (o) Proprietor responsibilities Adding attachments and/or optional equipment Truck Description Application Truck models and rated capacity Travel direction definition Assembly description Functional Description Technical Specifications Performance data...
Page 8 Battery installation Operation Safety Regulations for the Operation of Forklift Trucks Displays and Controls Display unit Pilots Function symbols for the Pilots Preparing the Truck for Operation Checks and Operations to Be Performed Before Starting Daily Work Entering or exiting Setting up the operator position Starting up the truck Safety regulations for travel mode...
Page 9 Cleaning Working on the electrical system Consumables and used parts Tyre type Lift Chains Hydraulic system Lubricants and Lubrication Schedule Handling consumables safely Lubrication Schedule Consumables Maintenance and repairs Preparing the truck for maintenance and repair work Lifting and jacking up the truck safely Removing or installing the seat cover Removing the floor plate Checking the hydraulic oil level...
Page 11: Correct Use And Application
A Correct Use and Application General The truck must be used, operated and serviced in accordance with these operating instructions. All other types of use are beyond its scope of application and may result in damage to persons, material assets and/or the truck. Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must...
Page 12: 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 13: Internal Operation In Cold Stores With Cold Store Equipment (O)
Internal Operation in Cold Stores with Cold Store Equipment (o) In addition to the permissible operating conditions in industrial and commercial environments, the truck remains primarily in cold stores. The truck should only leave the cold store briefly to hand over a load. –...
Page 14: Proprietor Responsibilities
Proprietor responsibilities For the purposes of the present operating instructions the “operating company” is defined as any natural or legal person who either uses the industrial truck himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor is considered the person who, in accordance with existing contractual agreements between the owner and user of the industrial truck, is charged with operational duties.
Page 15: B Truck Description
B Truck Description Application The ETM/V 210-325 is a three-wheel electric side seat, clear view reach truck. It is designed to lift and transport goods on level surfaces. Open bottom pallets or pallets with transverse boards can be lifted inside or outside the area of the load wheels or roll cage.
Page 16: Travel Direction Definition
Travel direction definition The following determinations have been made for travel direction specification: Item Travel Direction Left Drive direction Load direction Right...
Page 17: Assembly Description
Assembly description...
Page 19 Item Description Item Description t Overhead guard Mast t Key switch soloPILOT o ISM access module multiPILOT Transponder duoPILOT Keypad EasyAccess o Mast protective screen Emergency disconnect panel switch o Panoramic mirror Protective screen panel o Camera system Driver's seat t Free lift cylinder Fire extinguisher t Battery compartment...
Page 20: Functional Description
Functional Description Safety mechanisms An enclosed truck perimeter with rounded edges ensures safe handling of the ETM/V 210-325. The driver is protected by the overhead guard (5). The drive wheel (34) and load wheels (28) are protected by a solid skirt. A slight danger remains for third parties, even when a drive wheel cover is used.
Page 21 Operator position The operator position is ergonomically designed with ample legroom. To achieve the correct seated position, the driver’s seat and steering head can be adjusted by the driver. The accelerator pedal and brake pedal (31, 32) are of “automotive” design. Mast reach damping (o)/active mast vibration damping (o) Damping of the vibrations of the extended mast and reduction of the travel speed to slow travel when lifting the load beyond the free lift.
Page 22 Brake system The electric braking system consists of up to two independent braking systems. Applying the brake pedal (32) results in inversion braking (plugging) in the traction motor. The parking brake is electrically released and actuated through spring pressure. The parking brake acts on the drive system. It is also used for emergency braking. A warning indicator appears when the brake is applied.
Page 23 Mast The trucks are equipped with tilting telescopic clear view masts positioned in the mast holder. Adjustable side rollers and slide pieces take up the lateral pressure exerted on the fork carriage if the load is positioned on one side. The forks are fitted to the fork carriage and are adjustable.
Page 24: Technical Specifications
Technical Specifications The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Performance data Description ETV 210 ETV 212 Capacity (with c = 600 mm) 1000 1200 Travel speed with/without 11.0/11.0 11.0/11.0 km/h load 0.48/0.70...
Page 25 Description ETM 214 ETV 214 Capacity (where c = 600 mm) 1400 1400 11.0/11.0 11.0/11.0 km/h Travel speed with/without load 14.0/14.0 14.0/14.0 0.38/0.70 0.51/0.70 Lift speed with/without load (±10%) Lowering speed with / without 0.55/0.55 0.55/0.55 load (-15%) Traverse speed with/without load 0.18/0.18 (Efficiency/liftPLUS) Gradeability with/without load...
Page 26 Description ETM 216 ETV 216 Capacity (where c = 600 mm) 1600 1600 11.0/11.0 11.0/11.0 km/h Travel speed with/without load 14.0/14.0 14.0/14.0 0.48/0.70 0.48/0.70 Lift speed with/without load (±10%) 0.55/0.55 0.55/0.55 Lowering speed with/without load (-15%) Traverse speed with/without load 0.22/0.22 (Efficiency/liftPLUS) Gradeability with/without load...
Page 27 Description ETV 318 ETV 320 Capacity (where c = 600 mm) 1800 2000 11.0 / 11.0 11.0 / 11.0 km/h Travel speed with / without load 14.0 / 14.0 14.0 / 14.0 0.32 / 0.64 0.38 / 0.64 Lift speed with/without load 0.38 / 0.64 (±10%) Lowering speed with / without...
Page 28 Description ETM 325 ETV 325 Capacity (where c = 600 mm) 2500 2500 Travel speed with / without load 14.0 / 14.0 14.0 / 14.0 km/h Lift speed with/without load 0.35 / 0.64 0.35 / 0.64 (±10%) Lowering speed with / without 0.55 / 0.55 0.55 / 0.55 load...
Page 29: Dimensions
Dimensions β β α α...
Page 30 Description ETV 210 ETV 212 s/e/l Fork arm dimensions 40/80/1150 40/80/1150 Load centre distance Load distance Load distance, mast extended Wheelbase 1300 1385 Overhead guard height (cabin) 2190 Seat height / standing height 1057 Support arm height Overall length, with fork length...
Page 31 Description ETM 214 ETV 214 s/e/l Fork arm dimensions 40/120/1150 40/120/1150 Load centre distance Load distance, mast retracted Load distance, mast extended Wheelbase 1410 1410 Overhead guard height (cabin) 2190 2190 Seat height / standing height 1057 1057 Support arm height 2418 2346 Overall length...
Page 32 Description ETM 216 ETV 216 Wheelbase 1460 1460 Height of overhead guard 2190 2190 Seat height / standing height 1057 1057 Wheel arm height 2418 2408 Overall length 1268 1258 Length to fork face Reach Length across support arms 1830 1830 Overall width 1120/1120...
Page 33 Description ETV 318 ETV 320 s/e/l Fork arm dimensions 40/120/1150 50/140/1150 Load centre distance Load distance, mast retracted Load distance, mast extended Wheelbase 1460 1518 Height of overhead guard 2190 2190 Seat height / standing height 1057 1057 Wheel arm height 2418 2459 Overall length...
Page 34 Description ETM 325 ETV 325 Wheelbase 1673 1673 Height of overhead guard 2190 2190 Seat height / standing height 1057 1057 Wheel arm height 2547 2547 Overall length 1494 1396 Length to fork face Reach Length across support arms 2075 2075 Overall width 1198/1120...
Page 35: Weights
2050 - 2900 Free lift 1415 - 2265 Lift 4550 - 7100 Mast height extended 5185 - 7735 Weights Description ETV 210 ETV 212 Net weight incl. battery 2910 2930 Axle load, forks retr., without 1587/973 1587/993 load, front/rear Axle load, forks extd., with load,...
Page 36: Tyre Type
Tyre type Description ETV 210/212 Tyre size, front (drive wheel) 343 x 114 Tyre size, rear (load wheels) 230 x 85 Wheels, number front / rear (x = driven) 1x/2 Component ETV 214/216 ETM 214/216 Tyre size, front (drive wheel)
Page 37: Mast Weights
Mast weights The weight of the mast can be calculated using the formulae given below. The necessary details such as truck name, model and length of the extended mast (lift height) can be taken from the data plate. The weight of the truck and the battery can be found on the data plate.
Page 38: Norms
EN norms Continuous sound pressure level – ETM/V 210-325: 64 dB(A) in accordance with EN 12053 as harmonised with ISO 4871. The continuous sound pressure level is calculated according to standard procedures and takes into account the sound pressure level when travelling, lifting and idling. The sound pressure level is measured at the operator's ear.
Page 39 Component Frequency range Transmission power Telematics box basic 2G 2.4 GHz (Bluetooth) < 20 mW 900 MHz (2G) < 2 W 1800 MHz (2G) < 1 W Telematics box basic 2.4 GHz (Bluetooth) < 20 mW 3G/2G INT 850/ 900 MHz (2G) <...
Page 40: Conditions Of Use
Conditions of use Ambient temperature – During operation -28°C to +40°C Special equipment and authorization are required if the truck is to be used continually in conditions of extreme temperature fluctuations or condensing air humidity. Special equipment and authorisation are required if the truck is to be constantly used in 0°C.
Page 41: Identification Points And Data Plates
Identification Points and Data Plates Overview of marking points...
Page 43 CAUTION! Overload through bolt-on components M device and universal joints can only withstand the weights indicated on the capacity plates. uNote the maximum weights for M device (44) and universal joints (45). Item Model Brake pedal Cold store (o) Lift height limits Warning notice: “Trapping hazard”...
Page 44 Item Model Truck data plate Model description Information notice: "Faults with hydraulic functions on trucks with cold store equipment" (o) Warning notice: "Do not disconnect Li-ion battery connector" (o)
Page 45: 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 Type Net weight without battery [kg] Option Min./max. battery weight [kg] Serial number Manufacturer Year of manufacture Importer - imported by (o) Rated capacity [kg] QR code...
Page 46 7.2.1 Position of serial number NOTICE The truck serial number (62) is indicated on the data plate (57) and is stamped on the chassis (58) (see page 41). 7.2.2 QR code QR code The QR code contains the serial number and product hierarchy of the truck.
Page 47: Truck Capacity Plate
Truck capacity plate 7.3.1 Capacity plate The capacity plate (40) gives the capacity (Q) of the truck in kg for a vertical mast. The maximum capacity is shown as a table with a standard load centre of gravity distance * C (in mm) and the required lift height H (in mm). The arrow shape markings (76) on the inner and outer masts show the driver when the specified lift limits have been reached.
Page 48 7.3.2 Attachment load chart The attachment capacity plate is next to the truck's capacity plate and gives the truck’s capacity Q (in kg) in conjunction with the respective attachment. The serial number for the attachment indicated on the capacity plate must match the data plate of the attachment.
Page 49 7.3.3 Capacity plate for side shift The capacity plate (43) gives the reduced capacity Q (in kg) when the sideshift is extended. 7.3.4 Jacking points for jacks The "Jack contact point" decal (60) indicates where the truck may be lifted and jacked up (see page 207)
Page 50: Stability
Stability The truck's stability has been tested according to latest technological standards. These take into account the dynamic and static tipover forces that can occur if used correctly. Stability can also be affected by the following factors: – Battery size and weight –...
Page 51: Transport And Commissioning
C Transport and Commissioning Transport Depending on the height of the mast and local conditions, the truck can be transported in three different ways: – Vertically, with the mast assembled (for low heights) – Vertically, with the mast partially assembled and leaning against the overhead guard (for medium heights);...
Page 52 Attachment points for the mast assembly...
Page 53: Lifting By Crane
Lifting by crane 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. uDo not let battery acid come into contact with skin, clothing or eyes.
Page 54: Lifting The Truck By Crane
Lifting the truck by crane CAUTION! The mast can get damaged uLoading by crane is only intended for the initial transport before the truck is used for the first time. uLoading must be carried out by specially trained staff in accordance with recommendations contained in Guidelines VDI 2700 and VDI 2703 DANGER! Crane lifting gear can tear, resulting in accidents...
Page 56 Lifting the truck by crane Requirements – Truck parked securely, see page 153. Tools and Material Required – Crane lifting gear – Lifting slings – Wedges Procedure • Route rope slings around the two strap points (78) of the overhead guard strut. •...
Page 57 Lifting the truck and cab by crane Requirements – Truck parked securely, see page 153. Tools and Material Required – Sufficiently wide cross member – Crane lifting gear with hook – Wedges Procedure • Secure the crane lifting gear to the strap points (80).
Page 58: 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 59 Securing the industrial truck for transport Requirements – 2 tensioning belts Procedure • Pull the tensioning belts (82) through the overhead guard over the strut. • Secure the tensioning belts (82) to the fastening rings. • Tighten the tensioning belts (82) with the tensioner (81). The truck is now secured for transport.
Page 60: Using The Truck For The First Time
Using the Truck for the First Time 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. uThe hydraulic lines may only be connected to the basic truck / mast interface when the mast has been properly assembled.
Page 61 With the optional panoramic window, the protective film (83) must be removed before initial commissioning of the truck.
Page 63: Battery - Servicing, Recharging, Replacement
D Battery - Servicing, Recharging, Replacement For use of lithium-ion batteries (o), see the manufacturer's operating instructions. Safety instructions for handling lead-acid 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.
Page 64 Battery disposal Batteries may only be disposed of in accordance with national environmental protection regulations or disposal laws. The manufacturer’s disposal instructions must be observed.
Page 65: General Notes On Handling Batteries
The use of unsuitable batteries that have not been approved for the truck by Jungheinrich, can lead to a deterioration of the braking characteristics of the truck during energy recovery, causing considerable damage to the electric controller and resulting in serious danger to the health and safety of individuals.
Page 66: Battery Types
The following table shows which combinations are included as standard: B circuit Battery base space ETV 210 ETV 212 ETM 214 ETM 216 ETM 325 For special configurations, the battery sizes deviate from the standard. C circuit Battery base space ETV 214 ETV 216 ETV 318 ETV 320 ETV 325 For special configurations, the battery sizes deviate from the standard.
Page 67 Battery type Battery base Voltage [V] Mass [kg] space Lithium-ion 51.1-51.8 Lithium-ion 51.1-51.8 Lithium-ion 51.1-51.8 Lithium-ion 51.1-51.8 1119 Lithium-ion 51.1-51.8 1309 Values can deviate depending on battery manufacturer. Tolerance +/-5%...
Page 68: Exposing The Battery
Exposing the battery CAUTION! Moving parts can cause accidents The mast moves when the battery is exposed. This constitutes a risk of accidents and trapping in the hazardous area. uInstruct any persons to leave the hazardous area. uMake sure there is nothing between the battery and the mast holder when you move the mast holder.
Page 71 Exposing the battery Requirements – Truck prepared for operation, see page 105. Procedure • Press battery unlock button (86) button until the battery trolley reaches unlocking position. • Release battery unlock button pedal (86). • Press the battery unlock pedal (87) with your right foot and hold it in this position.
Page 72 Inserting the battery Requirements – Truck prepared for operation, see page 105. – Battery exposed. Procedure • Pull the lever (88) in the direction of the arrow (U) and retract the mast holder. The "battery unlocked" (red graphic symbol) (85) goes out on the display unit.
Page 73: Charging The Battery
Spark formation and uncontrolled movement of electronically controlled components may cause personal injury and material damage. uThe battery must only be charged with the Jungheinrich battery charger designed for this battery. uUse only battery chargers approved by the manufacturer.
Page 74 WARNING! Risk of accidents and injuries when handling lithium-ion batteries. Improper use can result in overheating, fire or a battery explosion. uDo not expose the lithium-ion battery for charging. uObserve the operating instructions for charging the lithium-ion battery. uDo not use the lithium-ion battery cable for charging. The battery cable is permanently connected to the truck.
Page 76: Removing Or Installing The Battery
Removing or installing the battery WARNING! Improper loading by crane can result in accidents Improper use or use of unsuitable lifting gear can cause the truck to fall when being loaded by crane. uPrevent the truck from hitting other objects during lifting, and avoid uncontrolled movements.
Page 77: Removing The Battery
Removing the battery...
Page 78 Removing the battery Requirements – Battery exposed, see page 68. Tools and Material Required – Crane lifting gear Procedure • Loosen the jam nut (91) on the battery lock (90). • Undo the retaining screw (92). • Pull out the battery stop (90). •...
Page 79 Removing the battery with the battery trolley ( Requirements – Battery exposed, see page 68. Tools and Material Required – Battery trolley Procedure CAUTION! An unsecured battery can result in accidents When the battery stop (90) is removed, the battery can roll out if the truck is not horizontal.
Page 80: Battery Installation
Battery installation NOTICE Trapped battery cables can cause damage When the battery is inserted the battery cable can be damaged if fitted without a cable duct. uAlways install the battery with a cable duct (84). uThe cable duct (84) must match the battery used. The battery cable length depends on the battery type.
Page 81 Battery installation Requirements – Battery removed. – Battery cover removed. Tools and Material Required – Crane lifting gear Procedure • Strap the crane lifting gear to both sides of the battery container. • Lift the battery with the crane lifting gear, lift it in from the side and lower it. •...
Page 82 Installing the battery with the battery trolley ( Requirements – Battery removed. – Battery cover removed. Tools and Material Required – Battery trolley Procedure • Bring the battery trolley with the battery up to the truck. • Push the battery off the trolley into the battery compartment. •...
Page 83: 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 84 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 85: Displays And Controls
Displays and Controls Item Control and display Function item soloPILOT Functions: – Fwd/rev. travel direction multiPILOT – Lifting/lowering load – Mast forward/reverse tilt duoPILOT – Horn button – Sideshift left / right – Auxiliary hydraulics (o) – Mast reach forward / reverse –...
Page 86 Item Control and display Function item Key switch Switches control current on and off. Removing the key prevents the truck from being switched on by unauthorised personnel. ISM access module Switches the truck on Keypad Transponder EasyAccess storage compartment Control and display unit Displays steering modes, warning indicators, incorrect operation notes and service displays...
Page 88 Item Control and Function display element o Weighs the load. Weighing button Steering column stop Limit switch system and o Prevents damage to the truck and the load. lift height display override button o Switches the steering mode between 180° Steering mode button and 360°.
Page 89 Item Control and Function display element t Button for side shift or auxiliary hydraulics 1 Side shift/auxiliary hydraulics 1 optional button/lever t Selects travel direction/neutral position. Travel direction button t Activates a signal Horn button o Button for fork positioner or auxiliary Fork positioner/auxiliary hydraulics 2 button/lever hydraulics 2...
Page 90: Display Unit
Display unit 2.1.1 Display 2.1.1.1 Display 2 inch ----kg 10:10 ----mm...
Page 91 Item Control and display item Function Steering mode 180° steering 360° steering Arrow to display the travel Shows the current travel and steering directions direction of the truck and the current wheel position in 15° segments. Time Shows the time. Power display Shows the travel/lift speed as a bar value...
Page 92 2.1.1.2 4-inch display (o) - - - - kg R 7 : 30 A - - - - - - - - mm 08:37...
Page 93 Item Control and display item Function Steering mode 180° steering 360° steering Arrow to display the travel and steering Shows the current travel direction directions of the truck and the current wheel position in 15° segments. Time Shows the time. Power display Shows the travel/lift speed as a bar value...
Page 94 Item Control and display item Function Steering mode 180° steering 360° steering Arrow to display the travel and steering Shows the current travel direction directions of the truck and the current wheel position in 15° segments. Time Shows the time. Power display Shows the travel/lift speed as a bar value...
Page 95: Symbol Description
2.1.2 Symbols in the display Symbol Description Colour Function/meaning Parking brake Parking brake is activated Slow travel Green Slow travel is activated Service note Yellow Attention: SDO request read or write parameters Execute service function line-rupture safety valve test Warning Yellow Operating error Truck malfunction Stop notice...
Page 96 Symbol Description Colour Function/meaning Lift cut-off Yellow Overriding the lift cut-off Lowering cut-off Green Lowering cut-off is overridden (limit switch Yellow Lowering cut-off is initiated system) Side shift Green Positioning of the side shift in centre centred position Battery release Battery is released Battery charge Yellow Battery charge status is between 1...
Page 97 2.1.3 Soft keys (o) Symbol Meaning Function Button assignment Switches the operating level Slow travel Switches to slow travel Travel programs Switches to the travel program menu menu Travel program up Switches the travel program up Line laser Actuation of the line laser (o) Battery release Releases the battery trolley Free-text display...
Page 98: Symbol Meaning
Symbol Meaning Function Load chart A Load centre for the current stacking operation (o) Load chart B Load chart C Light menu Switches to the light menu (o) Fork work lights Actuates the work lights on the fork (o) Drive direction work Actuates the work lights in the drive lights direction on the overhead guard (o)
Page 99 2.1.4 Setting the time 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 100 2.1.5 Battery discharge indicator The battery charge status is shown on the truck display via a battery symbol (116). When a battery is discharged to the permissible discharge level, the battery symbol (116) is displayed empty. (see page 90) The standard setting for the battery discharge indicator (116) is based on a truck delivered with a standard battery.
Page 101: Pilots
Pilots Item Control/ Function display element t Lever for operating the basic lift/mast Basic hydraulic functions lever reach hydraulic functions t Forwards and backwards tilt of the mast Tilt button/lever o Auxiliary hydraulics (ZH 1/ZH 2) t Selects travel direction / neutral position Travel direction button (not available with twin- pedal control)
Page 103: Function Symbols For The Pilots
Function symbols for the Pilots The symbols shown are examples. The actual direction of movement of the hydraulic functions must be determined from the labels on the levers of the Pilots. Symbol Meaning Lift Tilt Side shift Fork positioner Reach fork Telescopic fork Adapters ZH1 to ZH4 (example symbol ZH1)
Page 104 pictogram shows direction 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 in the travel direction, the function is shown with the actuation to the left (S) from the operator's perspective.
Page 105: 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 106: Entering Or Exiting
Entering or exiting Entry and exit Requirements – Truck braked to a halt. Procedure • To enter, take hold of the grab handle (26), see page 85. • Enter or leave the truck.
Page 107: Setting Up The Operator Position
Setting up the operator position 3.3.1 Adjusting the Driver's Seat The procedure for adjusting the driver’s seat applies to standard models. For other models, follow the manufacturer’s setting instructions. When adjusting, ensure that all controls are within easy reach. WARNING! Risk of accidents and damage to health An unsecured or incorrectly adjusted driver’s seat can result in accidents or damage to health.
Page 108 The driver’s weight is now set. Switching the seat heating on and off Procedure • Press the seat heating switch (137). Switch setting 1 = Seat heating on. Switch setting 0 = Seat heating off. Adjusting lumbar vertebrae support Procedure •...
Page 109 3.3.2 Adjusting the driver’s seat Cold store version (o) CAUTION! Moving the driver's seat is a trapping hazard uDo not reach between the seat and the side wall or overhead guard when adjusting the seat. Adjusting the driver's weight NOTICE To achieve optimal seat cushioning the driver’s seat must be set to the driver’s weight.
Page 110 Adjusting the backrest Procedure • Sit on the driver’s seat. • Pull the lever (135) to adjust the backrest. • Adjust the backrest tilt. • Release the lever (135) again. The backrest is locked. The backrest is now set. Adjusting the seat position CAUTION! An unsecured driver's seat can cause injury An unsecured driver's seat can slide out of its guide during travel, resulting in...
Page 111 Adjust the seat heating ( NOTICE Avoid prolonged contact of uncovered / unprotected skin with the heated seat. Procedure • Press the seat heating button (138) a single time. The heating changes to heat mode level 3 (highest level), all LEDs (139) are permanently lit.
Page 112 3.3.3 Adjusting the steering column Adjusting the steering column Procedure • Release the steering column stop (98). • Position the steering head (140). • Fix the steering column stop (98) in position. The steering column is now positioned.
Page 113 3.3.4 Seat belt (o) NOTICE Seat belt optional equipment On request from the customer, the truck can be fitted with a seat belt for special applications. uAlways put on the seat belt before starting the industrial truck. uDo not modify the seat belt. uDamaged or non-operational seat belts must be replaced by trained personnel.
Page 114 Putting on the seat belt Procedure • Sit on the driver's seat so that your back is resting against the backrest. • Pull the seat belt smoothly out of the retractor. • Place the seat belt tight against your body. Take care not to twist it. •...
Page 115: Starting Up The Truck
Starting up the truck Safety regulations for travel mode Travel routes and work areas Only use lanes and routes specifically designated for truck traffic. Unauthorised third parties must stay away from work areas. Loads must only be stored in places specially designated for this purpose.
Page 116 Negotiating slopes and inclines Negotiating slopes and inclines up to 15 % is only permitted when they are recognised lanes. The slopes and inclines must be clean, have a non-slip surface, and negotiating them safely must be within the technical specifications of the truck. The truck must always be driven with the load facing uphill.
Page 117: Emergency Disconnect
Emergency Disconnect Applying the emergency disconnect switch Procedure CAUTION! Risk of accident The operation of the emergency disconnect switch must not be affected by any objects placed in its way. Do not use the emergency disconnect switch (10) as a service brake. Press the emergency disconnect switch (10).
Page 118: Emergency Stop
Emergency stop The truck is fitted with an emergency stop device. If a system fault is detected, the truck automatically brakes until it comes to a halt. If a fault is detected in the steering or brake systems, an information message will appear on the display and control unit (20), see page 85.
Page 119: Travel
Travel WARNING! Improper travel can result in accidents uDo not get up from the driver’s seat during travel. uMake sure that the travel area is clear. uAdapt the travel speed to the conditions of the route, the work area and the load. uTilt the mast back and raise the fork carriage approx.
Page 120 Travel Requirements – Truck prepared for operation, see page 115. Procedure • The parking brake is released automatically when starting up. • The parking brake is automatically applied when the truck comes to a standstill and the deadman button is released at the same time. •...
Page 121: Brakes
Brakes The truck’s brake pattern depends largely on the ground conditions. The driver must take this into consideration when handling the truck. The truck can brake in three different ways: – With the service brake – With the coasting brake –...
Page 122 4.5.1 Braking with the reversing brake Braking the truck with the inversion brake Procedure • Set the travel direction switch (105) to the opposite travel direction while travelling. The truck brakes until it starts to travel in the opposite travel direction. This method reduces energy consumption.
Page 123 4.5.2 Braking with the coasting brake Braking with the coasting brake Procedure • Take your foot off the accelerator pedal (31). The truck brakes. 4.5.3 Braking with the service brake Braking with the service brake Procedure • Press down on the brake pedal (32) until you reach the required deceleration.
Page 124: Steering
Steering 4.6.1 Steering type Reverse steering When travelling forward (travel in direction of entry = drive direction) steer left to turn into a left hand bend and right into a right hand bend. The drive wheel position is indicated on the driver’s display. Forward steering (o) When travelling forward (travel in direction of entry = drive direction) steer left to turn into a right hand bend and right into a left hand bend.
Page 125 4.6.2 Setting the Steering Mode Press the steer mode button (100) to change between 180° and 360° steering. The range selected is shown in the control and display unit (20). Setting the steering mode Procedure • Press the steering mode button (100). The steering mode is now set.
Page 126: Forks
Forks WARNING! Risk of injury due to unsecured fork arms You can injure your legs when replacing the forks. uNever pull the forks towards your body. uAlways push the fork arms away from your body. uSecure heavy fork arms with lifting accessories and a crane before pushing them down from the fork carriage.
Page 127 Securing the fork arms with an integrated fork positioner Procedure • Tighten the mounting screws (4x) (148). Tightening torque 20 Nm. • Secure the mounting screws (4x) with Loctite 243.
Page 128: Lifting, Transporting And Depositing Loads
Lifting, transporting and depositing loads WARNING! Unsecured and incorrectly positioned loads can cause accidents Before lifting a load unit the driver must ensure that it has been correctly palletised and does not exceed the truck’s capacity. uInstruct other people to move out of the hazardous area of the industrial truck. Stop working with the truck if people do not leave the hazardous area.
Page 129 Lifting and lowering with the SOLO- PILOT Procedure • Pull the SOLO-PILOT lever (149) in direction H to raise the load unit. • Push the SOLO-PILOT lever (149) in direction S to lower the load unit. • Apply the SOLO-PILOT lever (149) until you reach the required lift height.
Page 130 On trucks equipped with the loweringPRO option with automatic balancing, the acknowledgement button (109) cannot be used for balancing purposes following a cancelled lowering operation. Mast balancing is performed automatically. loweringPRO can cause excess temperatures on the system. Excess temperatures are indicated by the symbol (150).
Page 131 Procedure Operating the work cage with persons is prohibited and not permitted. Do not use the loweringPRO option during multi-hour lift operation. Trucks equipped with the loweringPRO option reach an increased lowering speed of up to 1.2 m/s. • Push the multiPILOT (94) at least 2/3 towards the stop in direction S to rapidly lower the load unit.
Page 132 Lifting and lowering Requirements – Truck prepared for operation, see page 105. Procedure • Pull the lever (103) in direction H to raise the load. • Push the lever (103) in direction S to lower the load. The load is now raised or lowered.
Page 133 Deactivating the speed reduction Procedure • Lower the load handler. • Set the accelerator pedal to the zero (home) position. This deactivates the speed reduction and releases normal travel. CAUTION! Risk of trapping from moving parts! When the mast holder moves you can get trapped between the mast and battery tray.
Page 134 Moving the mast holder with the duoPILOT Procedure • Push the duoPILOT lever (103) in direction (T) to extend the mast holder forward. • Pull the duoPILOT lever (103) in direction (U) to retract it. The mast holder is now extended.
Page 135 Tilting the mast / fork carriage with the SOLO-PILOT Procedure • Push the SOLO-PILOT lever (151) in direction (V) to tilt the mast holder forward. • Pull the SOLO-PILOT lever (151) in direction (R) to retract it. The mast / fork carriage is tilted. Tilting the mast / fork carriage with the MULTI-PILOT Procedure...
Page 136 Tilting the mast/fork carriage with the duoPILOT Procedure • Push the duoPILOT lever (104) in direction (V) to tilt the mast holder forward. • Pull the duoPILOT lever (104) in direction (R) to retract it. The mast/fork carriage is tilted.
Page 137 Lifting load units Requirements – Load unit correctly palletised. – Fork spread for the pallet checked and adjusted if necessary. – Load unit weight matches the truck's capacity. – Forks evenly loaded for heavy loads. Procedure • Drive the truck carefully up to the pallet. •...
Page 138 Transporting loads Requirements – Load raised correctly. – Position the fork arms under the load with the maximum possible spacing. – Mast and load section tilted back fully. Procedure • Lower the load into transport position. • Accelerate and decelerate the truck carefully. •...
Page 139: Operating Attachments
Operating attachments 4.9.1 Safety instructions for operating additional attachments Optionally, trucks can be fitted with one or more auxiliary hydraulic functions to operate attachments. The auxiliary hydraulics are indicated with HF4 and HF5. Auxiliary hydraulic functions for exchangeable equipment are fitted with replacement couplings on the fork carriage.
Page 140 If visibility in the travel direction is impaired, the operating company must determine and apply suitable measures to ensure the safe operation of the truck. A lookout may have to be used or certain hazardous areas may have to be cordoned off. The truck can also be equipped with optional visual aids such as a camera system or mirrors.
Page 141 Safety instructions for side shifter and fork adjuster attachments WARNING! When using multi fork adjusters (multi pallet clamps), restricted visibility and reduced lateral tilt resistance can result in accidents. uAdapt the travel speeds to the visibility and load. uMake sure you have sufficient visibility when travelling in the load direction. Safety instructions for clamping attachments (bale clamps, barrel clamps, grabs, etc.) WARNING!
Page 142 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 143 Safety instructions for attachments when transporting suspended loads WARNING! Swinging loads and a reduced residual capacity can result in accidents. Transporting hanging loads can reduce the stability of the truck. uAdapt the travel speed to the load, less than walking pace. uSecure swinging loads for example with lifting slings.
Page 144 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 145 4.9.2 Integral sideshifter (SOLO-PILOT) The directions "left" and "right" refer to the load handler when viewed from the operator position. On trucks without integrated side shift and HF4 connection, the lever 104 may have a different assignment. Moving the side shift Procedure •...
Page 146 4.9.3 Integral sideshifter (MULTI-PILOT) The directions "left" and "right" refer to the load handler when viewed from the operator position. Moving the side shift Procedure • Press the lever (108) in direction (X1). The side shift moves to the left. •...
Page 147 4.9.3.1 Operating additional attachments with multiPILOT The control lever (107) has functions (X2) and (Y2) to operate hydraulic attachments connected to the terminal HF5 (see manufacturer's operating instructions). Controlling auxiliary hydraulic function using the acknowledgement button ( Procedure • Press the acknowledgement button (109) •...
Page 148 4.9.4 Integrated side shift (duoPILOT) The directions "left" and "right" refer to the load handler when viewed from the operator position. On trucks without integrated side shift and HF4 connection, the lever 104 may have a different assignment.
Page 149 4.9.4.1 Operating additional attachments with duoPILOT Moving the side shift Procedure • Press the button (104) in direction (X1). The side shift moves to the left. • Press the button (104) in direction (Y1). The side shift moves to the right. Note the capacity reduces when traversing.
Page 150 4.9.4.3 duoPILOT with control of ZH1, ZH2 and ZH3 hydraulic ports Depending on the attachments used, the lever/button (104,109) is assigned the function of the attachment. Unused levers have no function. For connections see page 139. Operating hydraulic port ZH1 Procedure •...
Page 151: Fitting Additional Attachments
4.10 Fitting additional attachments WARNING! Incorrectly connected attachments can cause accidents. Attachments that are incorrectly hydraulically or mechanically connected can result in accidents. There is a risk of fingers or hands being crushed. uAttachments must only be assembled and commissioned by trained, specialist personnel.
Page 152: Emergency Lowering
4.11 Emergency lowering The load handler can be lowered manually if a fault occurs in the hydraulic controller. WARNING! Lowering the mast can result in injuries uInstruct other people to move out of the hazardous area of the truck during emergency lowering.
Page 153: Parking The Truck Securely
4.12 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 154: Troubleshooting
Troubleshooting Recovering the truck CAUTION! This operation must only be performed by suitably trained maintenance personnel. When the brakes are de-activated the truck must be parked on a level surface, since the brakes are no longer effective.
Page 155 Preparing to move the truck without its own drive system Procedure • Turn the Emergency Disconnect switch and key switch off. • Disconnect the battery. • Prevent the truck from rolling away. • Remove the seat panel, see page 222. Truck prepared.
Page 156 Aligning the drive wheel Procedure • Remove the protective cap over the centre screw. CAUTION! Tensioned tyres can cause accidents When steering in the standing position the driving wheel band is under tension. Releasing the Allen key or steering crank can create a correcting moment.
Page 157 Towing the truck WARNING! An unsecured truck can cause accidents Parking the truck on an incline or with a raised load handler is dangerous and is strictly prohibited. uPark the truck on a level surface. In special cases the truck may need to be secured with wedges.
Page 159 Procedure •...
Page 160 Guide the tow rope around the struts of the overhead guard as shown in the figure to tow the truck in drive direction. • Guide the tow rope around the mast as shown in the figure to tow the truck in fork direction.
Page 161 Activating the magnetic brake Tools and Material Required – Screws 2 x M6 – Allen key Procedure • Remove the screws (2 x M6) from their holes in the magnetic brake and insert them in the drive plate. • Connect the two-pin connector to the magnetic brake. Magnetic brake is activated.
Page 162: Warning Messages
Warning messages Display Cause Action 1901 During system start-up, the Do not press the accelerator pedal accelerator pedal zero position during system start-up. could not be determined. 1904 Accelerator pedal pressed, but no Take your foot off the accelerator travel direction selected. pedal, select a travel direction and set off.
Page 163: Optional Equipment
Optional Equipment Changes to the factory configuration of the truck are not permitted and can lead to material damage and personal injury. This applies to the following, for example: – Change to fork arms – Telescopic forks – Fork positioners –...
Page 164: 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 165: Commissioning The Keypad And The Transponder Reader
Button allocation in the submenus Symbol Meaning Selection up: To select access codes or transponders, to scroll back during the log-in process Selection down: To select access codes or transponders, to scroll forward during the log-in process Delete: To delete access codes selected Add: To add a new access code Confirm:...
Page 166 6.3.1 Activating the keypad Procedure • Release the emergency disconnect switch, see page 117. • Enter the default code 1-2-3-4 using the keys below the display unit (157). The truck is switched on. • Press the key below the "Settings" symbol (161).
Page 167 6.3.2 Activating the transponder reader Procedure • Release the emergency disconnect switch, see page 117. • Enter the default code 1-2-3-4 using the keys below the display unit (157). The truck is switched on. • Press the key below the "Settings" symbol (161).
Page 168: Using The Display
Using the Display: 6.4.1 Switching on the truck with an access code Procedure • Release the emergency disconnect switch, see page 117. • Enter the access code with the buttons below the display (157). The truck is switched on. 6.4.2 Switching off the truck Procedure •...
Page 169 6.4.3 Changing the set-up code Requirements – The truck is switched on, see page 168. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Change set- up code" symbol (162). • Enter the set-up code using the keys below the display unit (157).
Page 170 6.4.4 Adding a new access code Requirements – The truck is switched on, see page 168. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Edit access code" symbol (167). The set-up code is requested. •...
Page 171: Item Description
6.4.5 Deleting an access code Requirements – The truck is switched on, see page 168. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Edit access code" symbol (167). The set-up code is requested. •...
Page 172 6.4.6 Displaying the Log-in History (Display Unit) 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 174: Using The Keypad
Using the Keypad 6.5.1 Switching on the truck with an access code Procedure • Release the emergency disconnect switch, see page 117. • Enter the access code with the keypad (158). The truck is switched on. 6.5.2 Switching off the truck Procedure •...
Page 175 6.5.3 Changing the set-up code Requirements – The truck is switched on, see page 174. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Change set- up code" symbol (162). • Enter the set-up code using the keypad (158).
Page 176 6.5.4 Adding a new access code Requirements – The truck is switched on, see page 174. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Edit access code" symbol (167). The set-up code is requested. •...
Page 177 6.5.5 Deleting an access code Requirements – The truck is switched on, see page 174. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Edit access code" symbol (167). The set-up code is requested. •...
Page 178 Requirements – The truck is switched on, see page 174. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Log-in process" symbol (170). • Enter the set-up code using the keypad (158). The set-up code entered is shown in the display unit (157) as filled-in circles.
Page 179: Operating The Transponder Reader
Operating the transponder reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 6.6.1 Switching on the truck with a transponder Procedure • Release the Emergency Disconnect switch, see page 117. •...
Page 180 6.6.3 Changing the set-up transponder Requirements – The truck is switched on, see page 179. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Change set-up code" symbol (162). • Place the set-up transponder on the transponder reader (159).
Page 181 6.6.4 Adding a new transponder Requirements – The truck is switched on, see page 179. Procedure • Press the key below the "Settings" symbol (161). • Press below "Edit transponder" symbol (167). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (159).
Page 182 6.6.5 Deleting a transponder Requirements – The truck is switched on, see page 179. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Edit transponder" symbol (167). set-up transponder requested. • Place the set-up transponder on the transponder reader (159).
Page 183 Requirements – The truck is switched on, see page 168. Procedure • Press the key below the "Settings" symbol (161). • Press the key below the "Log-in process" symbol (170). • Place the set-up transponder on the transponder reader (159). •...
Page 184: Assistance Systems
The Jungheinrich assistance system supports the operator, but does not release him from his responsibility: When using the assistance system, responsibility for the safe operation of the truck lies with the operator.
Page 185 WARNING! Risk of accidents due to malfunctions or overfamiliarity when operating the forklift truck Faults or malfunctions of the truck or the assistance system can result in the assistance system or other functions no longer being performed correctly. Operating the forklift truck with a poor view of the operating and working area or a lack of attention due to overfamiliarity can lead to dangerous situations, collisions with persons and objects or injuries.
Page 186 6.7.4 curveCONTROL (o) The curveCONTROL assistance system helps the operator to operate the truck safely. When cornering, the maximum travel speed is reduced according to the steer angle. The default setting can be changed by the manufacturer's customer service department 6.7.5 warehouseCONTROL Warehouse...
Page 187: Work Lights
Work lights 175 174 The work lights are fitted with a pivot that can swivel in all directions. The button (175) switches the work lights (173) in the drive direction on or off. The button (174) switches the work lights (172) in the fork direction on or off. As an option, the work lights can be controlled as a function of the travel direction.
Page 188: Camera System
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. The camera is secured to the inside of the right fork.
Page 189 Item Component Function Camera selection Selects a camera manually. The LED next to the key indicates that camera selection is activated. Press the key again to switch the camera display. Day/night setting Press the key to change between ABC mode, day and night setting.
Page 190 6.9.1 Service Menu Opening the service menu Procedure • Press the (176), (181), (182) keys simultaneously. 6.9.2 Camera settings Opens the camera settings Requirements – The service panel is open. Procedure • Open the camera settings with the (176) key. •...
Page 191 6.9.4 Keypad block Deactivates the keypad Requirements – System settings are open. Procedure • Select the keypad with the (181) and (182) keys and confirm with (183). • Select the keypad block with the (181) and (182) keys and confirm with (183). •...
Page 192: Beacon
6.10 Beacon Switching the beacon on and off Procedure • Press the beacon button (185). The beacon (184) is switched on or off.
Page 193: Lift Height Cut-Off (O)
6.11 Lift Height Cut-off (o) The lift height cut-off is an electrical lift limit for restricting the maximum lift height in the mast lift range. The pump motor is deactivated when the set lift height is reached. The lift function is blocked. The magnetic switch on the mast is not present with the rack height select option (o) or the operationCONTROL option (o).
Page 194 Overriding the lift limit cut-off with the override button Procedure • Press the lift limit override button (99) while simultaneously pulling the lever (103) in direction H. The lift limit cut-off is now overridden. Lifting can now be performed at reduced lift speed.
Page 195: Electric Lift Limit
6.12 Electric lift limit The lift limit system comes in versions 1, 2 and 3. The aim of the lift limit system is to prevent damage to the truck and the load near the wheel arms due to incorrect operation. Item Description Side shift display Lift limit override button...
Page 196 6.12.1 Lift limit 1 Lift limit 1 is only available for trucks with an integrated side shift. Operation Lift limit 1 determines the position of the mast and fork carriage via sensors in the mast. If the mast is fully extended or if the fork carriage is outside the safety range (500 - 600 mm above the wheel arms), Lift Limit 1 releases all hydraulic functions.
Page 197 6.12.2 Lift limit 2 Lift limit 2 is available for trucks with an integrated side shift and various attachments, such as fork positioner and ball clamps. Operation Lift limit 2 determines the position of the mast and forks via sensors in the mast. If the mast is fully extended or if the forks are outside the safety range (500 - 600 mm above the wheel arms), Lift Limit 2 releases all hydraulic functions.
Page 198 6.12.3 Lift limit 3 Lift limit 3 is only available for trucks with tilting forks in conjunction with a fork positioner. Operation Lift limit 3 determines the position of the mast and forks via sensors in the mast. If the mast is fully extended or if the forks are outside the safety range (500 - 600 mm above the wheel arms), Lift Limit 3 releases all hydraulic functions.
Page 199: Clamp Function Release" Button
6.13 “Clamp function release” button Item Description "Clamp-function release" button...
Page 200: Positioning The Forks With An Integrated Fork Positioner (Option)
When the "Clamp function release" button is pressed and the corresponding hydraulic function applied simultaneously, the clamp function is activated. The auxiliary hydraulic function must be actuated within 1.5 seconds of the acknowledgement button being pressed. (see page 139) 6.14 Positioning the forks with an integrated fork positioner (option) WARNING! Clamping loads with the fork positioner can result in accidents...
Page 201: Weigher
6.15 Weigher Item Description "Weigher" button While the weigher button (97) is pressed, the load is raised approx. 10 cm and then lowered again. This process determines the load weight which is then shown on the driver’s display. The weigher function is not a substitute for a calibrated weigher. The weigher function must not be used to lift the load freely.
Page 202: Led Work Lights On Load Handler
6.16 LED work lights on load handler Item Component Load handler work lights LED Load handler work lights LEDs are available for trucks that work with a sideshifter. The LED work lights on the load handler are – switched on automatically when a hydraulic function is activated and the travel speed is less than 8 km/h.
Page 203: Removable Load Backrest
6.17 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 (189). •...
Page 204: Floor-Spot
6.18 Floor-Spot The floor spot serves as an auxiliary device and, with the travel direction switch engaged, projects a coloured dot on the floor at a distance of 4,5 m / 4 m. When the truck travels forward, the coloured dot is in front of the truck. When reversing, it is behind the truck.
Page 205 4,5 m / 177 in 4 m / 157 in 6.18.1 Additional information on Floor-Spot blue Only for Floor-Spot blue (51466740/51631731) The activated Floor-Spot gives persons advance warning of the travel path of the forklift truck by projecting a blue dot onto the ground at a set distance. CAUTION! Risk of accident due to dazzling Looking directly into the light beam of the Floor-Spot can dazzle and temporarily...
Page 206 The warning notice "Caution! Potentially dangerous optical radiation" is attached to the side of the chassis or to the overhead guard. Small warning notices are attached to the side of the Floor-Spot.
Page 207: F Truck Maintenance
(www.jungheinrich.de/spare-parts-search) by entering the serial number. The serial number can be found on the data plate, see page 45. 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 –...
Page 208 – Carry out and have authorised the respective changes to the capacity data plates, decals and stickers as well as the operating instructions and workshop manuals – Attach a permanent and clearly visible marking to the truck indicating the types of changes made, the date of the changes and the name and address of the organisation responsible for the work.
Page 209: Maintenance Safety Regulations
Maintenance Safety Regulations Maintenance personnel The truck should only be serviced and repaired by the manufacturer's specialist customer service personnel who have been trained to do this. We therefore recommend that you enter into a maintenance contract with the manufacturer’s local sales office.
Page 210: 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 211: Tyre Type
Tyre type WARNING! The use of tyres that do not match the manufacturer's specifications can result in accidents. The quality of the tyres affects the operational stability and performance of the truck. Uneven wear reduces the operational stability of the truck and increases the stopping distance.
Page 212: 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 213 NOTICE Possible faults with hydraulic functions on trucks with cold store equipment Commissioning the truck after an extended period of out of use or in ambient temperatures outside of the deep-freeze area in which the truck is intended to be used can give rise to noticeable noise development, jerky cylinder movements and damage to the hydraulic system.
Page 214: 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 215 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 216: Lubrication Schedule
Lubrication Schedule Min. = 16l Max.= 29l ETM/V 214-216 Max.= 34l ETM/V 318-325 2,75l g Contact surfaces Hydraulic oil drain plug b Transmission oil filler neck Grease nipple a Transmission oil drain plug Hydraulic oil filler neck Compound ratio for cold store usage 1:1 Capacity, see page 223.
Page 218 g Contact surfaces Hydraulic oil drain plug b Transmission oil filler neck Grease nipple a Transmission oil drain plug Hydraulic oil filler neck Compound ratio for cold store usage 1:1 Capacity, see page 223.
Page 219: Consumables
The Jungheinrich hydraulic oil is available only from the Jungheinrich service department. The use of named alternative hydraulic oils is not prohibited, but may lead to a decline in functionality. The Jungheinrich hydraulic oil may be mixed with one of the named alternative hydraulic oils.
Page 220: Maintenance And Repairs
Maintenance and repairs Preparing the truck for maintenance and repair work All necessary safety measures must be taken to avoid accidents when carrying out maintenance and repairs. The following preparations must be made: Procedure • Park the truck on a level surface. •...
Page 221: 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 sufficient capacity.
Page 222: Removing Or Installing The Seat Cover
Removing or installing the seat cover The drive unit and hydraulic aggregate can be made accessible for service by removing the seat panel. Removing the seat panel Procedure • Pull seat locking lever (134) up and pull the seat towards the steering wheel and take it off.
Page 223: Checking The Hydraulic Oil Level
Checking the hydraulic oil level CAUTION! The hydraulic oil is pressurised during operation and is a hazard to health and to the environment. uDo not touch pressurised hydraulic lines. uDispose of used oil in accordance with regulations. Store used oil safely until it can be disposed of in accordance with regulations.
Page 224 Check the hydraulic oil level Requirements – Truck prepared for maintenance and repairs, see page 220. Procedure • Push the driver’s seat forward. • Check oil level in hydraulic reservoir (195). • If necessary add hydraulic oil of the correct grade in the filler neck. •...
Page 225: Checking The Electrical Fuses
Checking the electrical fuses 5.6.1 ETM/V 210-216 Removing the safety cover Procedure CAUTION! Trapping hazard uCarefully pull off the cover. Forcibly pull off the safety cover (196) from the (197) points at the top left and bottom right and place them to one side.
Page 226 Fuse ratings Item Component Application Rating Main fuse Travel/lift 48 V behind main contactor Overall control circuit fuse Drive wheel steering Main contactor...
Page 227 Fuse ratings Item Component Application Rating Data radio 4F15 Access control Traction / lift controller DC/DC converter Seat heating 3F11 Drive wheel steering Display and Control Unit Not used Not used 2F17 MFC hydraulics 1F13 Travel / brake MFC control fuse 1F14 Travel / brake MFC control fuse 2F18...
Page 228 5.6.2 ETM/V 318-325 Removing the safety cover Procedure CAUTION! Trapping hazard uCarefully pull off the cover. Forcibly pull off the safety cover (196) from the (197) points at the top left and bottom right and place them to one side. •...
Page 229 221 204 202 Fuse ratings Item Description Application Voltage Rating Main fuse DC/DC converter control fuse Overall control circuit fuse Travel/lifting 48 V after main contactor Drive wheel steering...
Page 230 Fuse ratings Item Description Application Voltage Rating 1F13 MFC travel/brake control fuse Electronic system control fuse Display and control unit control fuse Display and control unit 2F17 MFC hydraulics 4F15 Access control Radio data Seat heating DC/DC converter Travel/lift control XB20 Service PC interface...
Page 231 Item Description Application Voltage Rating 3F11 Drive wheel steering 3F12 Load wheel steering control fuse Control fuse 48V fuse...
Page 232: Checking The Attachment Of The Wheels
Checking the attachment of the wheels Tightening Torques Load wheels (1x centre cylinder screw) 90 Nm Drive wheel 300 -10 Nm Checking the wheel attachment Requirements – Truck prepared for maintenance and repairs, see page 220. Tools and Material Required –...
Page 233: 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 234: Prior To Decommissioning
Prior to decommissioning Procedure • Thoroughly clean the truck – see page 209. • Prevent the truck from rolling away accidentally. • Check the hydraulic oil level and replenish if necessary, see page 214. • Apply a thin layer of oil or grease to any non-painted mechanical components. •...
Page 235: Restoring The Truck To Service After Decommissioning
Restoring the truck to service after decommissioning Procedure • Thoroughly clean the truck – see page 209. • Lubricate the forklift truck according to the lubrication schedule – see page 216. • Equipment with lead-acid battery (t): Clean the battery, grease the battery terminal screws with terminal grease and connect the battery.
Page 236: 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 237: Final De-Commissioning, Disposal
Final de-commissioning, disposal Final de-commissioning or disposal of the truck in must be performed in accordance with the regulations of the country of use. In particular, regulations governing the disposal of batteries, consumables and electronic and electrical systems must be observed.
Page 239: Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement
G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement WARNING! Lack of maintenance can result in accidents Failure to perform regular maintenance and inspections can lead to truck failure and poses a potential hazard to personnel and equipment. uThorough and expert maintenance and inspections are among the most important requirements for the safe operation of the industrial truck.
Page 240 1.1.1.2 Optional Equipment Fork positioner Hydraulic operations Clean and grease attachment bearings, guides and stops. Telescopic forks Hydraulic operations Clean and lubricate the attachment. Windscreen washing system Chassis/structure Correct the fill level of the windscreen washer reservoir. Lead-acid battery, international Power supply Correct the battery-acid level using demineralised water.
Page 241 Chassis/structure Check labels for legibility, completeness and plausibility Mechanism to protect against trapping and shearing is present, secure, functions correctly and is free of dirt and damage Supports / tilt safety devices for presence and damage Hydraulic operations Test hydraulic system Check fork arms or load handler for wear and damage 1.1.2.2 Optional Equipment...
Page 242: Customer Service
Lead-acid battery, international Power supply Check the battery cable connections for secure attachment Check battery and battery components for damage Lead-acid battery Power supply Check the battery cable connections for secure attachment Check battery and battery components for damage Customer Service In accordance with the ETM/V 210-325 service interval, to be performed every 1000 service hours, but at least once a year.
Page 243 Hydraulic operations Test and adjust the pressure relief valve. Mounting and safeguard against side shift frame detachment for wear and correct function Test the side shift adjustment. Where two tilt cylinders with the same stroke are used, measure their relative adjustment. Agreed services Carry out a test run with the rated capacity or a customer-specific load.
Page 244 Lift cut-off Hydraulic operations Test the lift-limit cut-off/lift cut-off. Radio data System components Clean the scanner and terminal. Video system System components Clean the camera. Clean the display. Weigher sensors/switches Electrical system Test the weigher. Seat switch Chassis/structure Test the seat switch. Automatic crawl speed Travel Clean sensors/switches.
Page 245 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. Correct the battery-acid level using demineralised water. 1.2.2 Inspection contents The following points must be checked: 1.2.2.1 Standard equipment Brakes...
Page 246 Chassis/structure Check chassis connections and screw connections are securely attached and check for damage Battery trolley lock for functionality and 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 mast is securely attached Check mast bearings for wear Rails for wear and damage...
Page 247 1.2.2.2 Optional Equipment Cold store cabin Chassis/structure Roof hatch for functionality and damage Cold store cabin for secure fit and damage Windscreens for damage Test window heating and check for damage Test doors and check for damage Electrolyte recirculation Power supply Hose connections and pump for correct function Aquamatic Power supply...
Page 248 Fork positioner Hydraulic operations Check the attachment is securely attached to the truck and check the load-bearing components for secure fit and damage Check sliding blocks for completeness, wear and damage Check attachment bearings, guides and stops for wear and damage Check hydraulic connections are securely attached and check for leaks Fork positioner for functionality and damage Check cylinder seals for leaks and damage...
Page 249 Windscreen washing system Chassis/structure Check windscreen washer reservoir for leaks and damage Test windscreen wipers and check for damage Lift cut-off Hydraulic operations Lift-limit cut-off/lift cut-off for secure fit and 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 250 Access module Electrical system Check access module is securely attached, test and check for damage Weather protection Electrical system Fuses for correct ratings Chassis/structure Test window heating and check for damage Test doors and check for damage Optional electrical equipment Electrical system Test optional electrical equipment and check for damage Restraint system...
Page 251 Lift height display System components Lift height display and its components for functionality and damage Belt lock monitoring Chassis/structure Test seat belt monitoring and check for damage Automatic crawl speed Travel Sensors/switches for secure fit, functionality and damage Discharge strap Electrical system Check presence of electrostatic discharge strap or chain and check for damage Lead-acid battery, international...
Page 252 1.2.3.2 Optional Equipment Cold store application maintenance part service hours months Transmission oil in cold store application 1000 Transmission oil additive 1000 Hydraulic oil 1000...

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Jungheinrich ETV 210 Operating Instructions Manual

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