Jungheinrich ETV Q20 Operating Instructions Manual
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Jungheinrich ETV Q20 Operating Instructions Manual

Jungheinrich ETV Q20 Operating Instructions Manual

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ETV Q20/Q25
Operating instructions
51858233
11.23
05.22
en-GB
ETV Q20
ETV Q25

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Summary of Contents for Jungheinrich ETV Q20

  • Page 1 ETV Q20/Q25 05.22 Operating instructions en-GB 51858233 11.23 ETV Q20 ETV Q25...

  • 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 Q20 ETV Q25 On behalf of Date EU DECLARATION OF CONFORMITY The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006/42/EG (Machinery Directive) and 2014/30/EU (Electromagnetic Compatibility - EMC).
  • Page 4 Declaration of Conformity (o) Product: ETV Q20/Q25 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 Residual risk Proprietor responsibilities Adding attachments and/or optional equipment Removal of components Truck Description Application Truck models and rated capacity Travel Direction Definition Travel direction definition Assembly description Functional Description Technical Specifications Performance data Dimensions...
  • Page 8 Removing or installing the battery Removing and Installing the Battery with Crane Lifting Gear 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 operation Entering or exiting Setting up the operator position Starting up the truck...
  • Page 9 Truck maintenance Spare Parts Operational Safety and Environmental Protection Maintenance Safety Regulations Cleaning Working on the electrical system Consumables and used parts Tyre type Lift Chains Hydraulic system Energy saving components Lubricants and Lubrication Schedule Handling consumables safely Lubrication Schedule Consumables Maintenance and repairs Preparing the truck for maintenance and repair work...

  • 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: 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 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 ETV Q20/Q25 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 Travel direction definition The following conventions have been agreed 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 Control unit Brake pedal t soloPILOT Mast o multiPILOT Deadman switch t Emergency disconnect Overhead guard switch t Key switch Free lift cylinder o Keypad Protective screen panel o EasyAccess Fork positioner t Battery trolley unlatch pedal Drive wheel t Control and display unit Support arms...

  • Page 21: Functional Description

    Functional Description Safety mechanisms An enclosed truck perimeter with rounded edges ensures safe handling of the ETV Q20/Q25. The driver is protected by the overhead guard (15). The drive wheel (19) and load wheels (21) are protected by a solid skirt. A slight danger remains for third parties, even when a drive wheel cover is used.
  • Page 22 The Easy Access option with PIN code (o) allows the truck to be switched on via the control and display unit. Displays Control and display unit (10) with integrated residual time display, battery discharge indicator, lift and travel profile setting and steer angle display. The battery discharge indicator and hour meter (10) are combined on the control and display unit.
  • Page 23 mast (DZ) a free lift cylinder (16) initially lifts the load carriage (free lift) without changing the overall height of the truck. Hydraulic system The hydraulic system is driven by a pump unit with a threephase motor and a quiet running precision high pressure pump.

  • Page 24: Technical Specifications

    Technical Specifications The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines. Technical modifications and additions reserved. Load centre distance The load centre distance D of the load handler is specified as the horizontal distance from the front face and the vertical distance from the upper edge of the load handler. The capacity plate for standard load handlers specifies valid load centre distances of 500 mm, 600 mm and 700 mm.

  • Page 25: Performance Data

    Performance data Description ETV Q20 ETV Q25 Capacity (where c = 600 mm) 2000 2500 Travel speed with/without load 14.0/14.0 14.0/14.0 km/h 0.38/0.64 0.35/0.64 Lift speed with/without load (±10%) 0.55/0.55 0.55/0.55 Lowering speed with/without load (-15%) 0.2/0.2 0.2/0.2 Traverse speed with/without load...

  • Page 26: Dimensions

    Dimensions...
  • Page 27 Description ETV Q20 ETV Q25 s/e/l Fork dimensions 50/140/1150 50/140/1150 Load centre distance Load distance, mast retracted Load distance, mast extended Wheelbase 1528 1683 Overhead guard height 2150 2150 Seat height/standing height Support arm height 2433 2518 Overall length 1283 1368 Length incl.

  • Page 28: Weights

    6.2.1 Standard mast version dimensions Description Triplex mast Duplex mast (DZ) (DZ) reinforced Mast height retracted 2400 2400 Free lift 1670 1670 Lift 5300 5300 Mast height extended 6046 6046 Weights Model Triplex mast Duplex mast (DZ) (DZ) reinforced 4060 4150 Net weight incl.

  • Page 29: Tyre Type

    Tyre type Description ETV Q20 ETV Q25 Tyre type Vulkollan Tyre size, front (drive wheel) 343 x 140 Tyre size, rear (load wheels) 343 x 140 Wheels, number front / rear (x = 1x/2 driven) Battery Approved battery types see page 53.

  • Page 30: Mast Weights

    6.7.1 Example of determining the weight of a mast – Truck name (23): ETV Q20 – Mast (24): GN E DZ – Mast weight = 1.2 x lift height + 435 kg / 959 lb –...
  • Page 31 Truck series Mast Lift height Weight calculation Design without fork arms ETV Q20/Q25 GE DZ 1.0 x lift height + 400 kg ETV Q20/Q25 GNE DZ h3 < 1000 1.2 x lift height + 400 kg ETV Q20/Q25 GNE DZ 1000 ≤...

  • Page 32: Norms

    The sound pressure level is measured at the operator's ear. Vibration – ETV Q20/Q25 MSG 65: 0,31 m/s² The internal accuracy of the measuring chain for at 21°C at ± 0,02 m/s². Further deviations may occur in particular through the positioning of the sensor and different driver weights.

  • Page 33: Conditions Of Use

    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 34: Electrical Requirements

    For trucks with a lithium-ion battery (o), the permissible ambient temperature during operation changes to 0°C to +30°C. An ambient temperature of up to +35°C is permissible for a short period but no longer than 1 month per year. Longer periods of use reduce the expected service life of the lithium-ion battery.

  • Page 35: Identification Points And Data Plates

    Identification points and data plates Overview of marking points 1,5 V...
  • Page 36 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 (31) and universal joints (32). Item Description Attachment points for loading by crane Lift height limits Capacity plate, capacity/load centre of gravity/forks "Final inspection completed"...

  • Page 37: 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 38: Truck Load Chart

    Truck load chart 7.3.1 Capacity plate The capacity plate (27) 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 (62) on the inner and outer masts show the driver when the specified lift limits have been reached.
  • Page 39 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 40: 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 41: 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 42: Lifting By Crane

    Lifting by crane WARNING! Improper loading by crane can result in accidents Improper use or use of unsuitable lifting gear can cause the truck to crash when being loaded by crane. Prevent the truck from hitting other objects during lifting, and avoid uncontrolled movements.

  • Page 43: 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 44 Loading the truck by crane Requirements – Truck parked securely, see page 127. Tools and Material Required – Crane lifting gear – Lifting slings – Wedges...
  • Page 45 Procedure • Route rope slings around the two strap points (64) of the overhead guard strut. • Attach crane lifting gear to the two attachment points (65) on the support arms. • Load the truck. • Park the truck securely – see page 127. •...
  • Page 46 Lifting the truck and cabin by crane Requirements – Truck parked securely, see page 127. Tools and Material Required – Sufficiently wide cross member – Crane lifting gear with hook – Wedges Procedure • Secure the crane lifting gear to the attachment points (66). Loading by crane with a weather-proof cab (o) is subject to restrictions.

  • Page 47: Securing The Truck During Transport

    Securing the truck during transport WARNING! Accidental movement during transport Improper fastening of the truck and mast during transport can result in serious accidents. uLoading must only be performed by specialist personnel trained for this purpose. The specialist personnel must be instructed in securing loads on road vehicles and handling load securing devices.
  • Page 48 Securing the truck for transport Requirements – 2 tensioning belts Procedure • Secure the fastening belts (68) through the guide on the overhead guard strut. • Secure the fastening belts (68) to the fastening rings. • Tighten the fastening belts (68) with the tensioner (67). The truck is now secured for transport.

  • Page 49: 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 50 With the optional panoramic window, the protective film (69) must be removed before initial commissioning of the truck.

  • Page 51: 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 52: 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 53: 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: C circuit Battery base space ETV Q20/Q25 For special configurations, the battery sizes deviate from the standard. Battery type Battery base...

  • Page 54: 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 55 • Release the battery unlatch pedal (72). • Turn off the emergency disconnect switch and key switch. The battery unlatch safety switch only allows for travel at crawl speed if the battery trolley is unlatched and the indicator lamp (70) is still on. Before starting up the truck again, the battery trolley must be restored to its initial position in order to uncouple the battery trolley and the mast support.

  • Page 56: 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 57 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 58 EP 48460 CWT-R3-E / EP 48310 CWT-R2-E (o)
  • Page 59 48 V LiB 360 MH / 48 V LiB 480 MH (o)

  • Page 60: Removing Or Installing The Battery

    Removing or installing the battery After each replacement, check that the battery is properly secured by the battery lock. 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.

  • Page 61: Removing And Installing The Battery With Crane Lifting Gear

    Removing and Installing the Battery with Crane Lifting Gear Removing the battery Requirements – Battery exposed, see page 54. Tools and Material Required – Crane lifting gear Procedure • Loosen the jam nut (77) on the battery lock (78). • Undo the retaining screw (76). •...
  • Page 62 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 (74). uThe cable duct (74) must match the battery used.

  • Page 63: 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 64 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 65 WARNING! Loss of operational stability can cause accidents Extended mast sections when the truck is travelling with or without load will reduce the truck's operational stability. uAlways travel with the mast holder retracted, the mast tilted back, the load centre in the middle of the truck's longitudinal axis and the load handler lowered.

  • Page 66: 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 67 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 70 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 71 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 72: Display Unit

    Display unit 2.1.1 Display 2.1.1.1 Display 2 inch ----kg 10:10 ----mm...
  • Page 73 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 74 2.1.1.2 4-inch display (o) - - - - kg R 7 : 30 A - - - - - - - - mm 08:37...
  • Page 75 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 76 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 77: 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 78 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 79 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 80: 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 81 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 82 2.1.5 Battery discharge indicator The battery charge status is shown on the truck display via a battery symbol (102). When a battery is discharged to the permissible discharge level, the battery symbol (102) is displayed empty. (see page 72) The standard setting for the battery discharge indicator (102) is based on a truck delivered with a standard battery.

  • Page 83: Pilots

    Pilots Item Control/display Function t Lever for operating the basic lift/mast Basic hydraulic 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 or neutral position Travel direction button (not available with twin- pedal control)

  • Page 84: 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) The pictogram shows the direction of movement that is...

  • Page 85: Preparing The Truck For Operation

    Preparing the Truck for Operation Checks and operations to be performed before starting daily operation 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 87: Entering Or Exiting

    Entering or exiting Entry and exit Requirements – Truck braked to a halt. Procedure • To enter, take hold of the grab handle (80), see page 66. • Enter or leave the truck.

  • Page 88: 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 89 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. Set the driver's weight when the seat is occupied. uHold the weight adjustment lever only by the recess; do not reach through underneath the weight adjustment lever.
  • Page 90 Switching the seat heating on and off Procedure • Press the seat heating switch (123). Switch setting 1 = Seat heating on. Switch setting 0 = Seat heating off. Adjusting the lumbar support ( Procedure • Turn the hand wheel (122) to the required position.
  • Page 91 3.3.2 Adjusting the driver’s seat 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 92 The seat position is now correctly set. The optional seat heating (124) is operated via the switch on the driver's seat. Adjust the seat heating ( NOTICE Avoid prolonged contact of uncovered / unprotected skin with the heated seat. Procedure •...
  • Page 93 3.3.3 Adjusting the steering column Adjusting the steering column Procedure • Release the steering column stop (84). • Position the steering head (126). • Fix the steering column stop (84) in position. The steering column is now positioned.
  • Page 94 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 95 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 96: 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 97 WARNING! Electromagnetic influence can result in accidents Strong magnets can cause electronic components such as Hall sensors to become damaged, resulting in accidents. uDo not use magnets in the operating area of the truck. Exceptions to this rule are commercial, weak clamping magnets for attaching notices. Negotiating slopes and inclines Negotiating slopes and inclines up to 15 % is only permitted when they are recognised lanes.

  • Page 98: Preparing The Truck For Operation

    Preparing the truck for operation The truck carries out a self-test when it is switched on. Do not activate any controls, such as the deadman button, during the self-test. Switching on the truck Requirements – Checks operations performed before starting daily work, see page 85.

  • Page 99: Emergency Disconnect

    Emergency Disconnect CAUTION! Applying maximum braking can result in accidents Applying the Emergency Disconnect switch during travel will cause the truck to decelerate to a halt at maximum force. This may cause the load to slide off the load handler. There is a higher risk of accidents and injury. uDo not use the Emergency Disconnect switch as a service brake.

  • Page 100: 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 (10), see page 66.

  • Page 101: 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 102 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. • Select the travel direction; to do this •...

  • Page 103: 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 104 4.6.1 Braking with the reversing brake Braking with the reversing brake Procedure • Set the travel direction switch (91) to the opposite direction while travelling. The truck decelerates until it starts to travel in the opposite direction. This method reduces energy consumption. Energy is recovered, which is controlled by the traction current controller.
  • Page 105 4.6.2 Braking with the coasting brake Braking with the coasting brake Procedure • Take your foot off the accelerator pedal (11). The truck decelerates. 4.6.3 Braking with the service brake Braking with the service brake Procedure • Depress the brake pedal (12) until you feel the brake pressure.

  • Page 106: Steering

    Steering 4.7.1 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. 4.7.2 Steering modes The directions "left"...
  • Page 107 Normal travel (130) – Home position: 0° to the truck's longitudinal direction. – Steering: only with the drive wheel. – Steer angle: +/- 90° – 360° endless steering Modified normal travel (132) – Home position: 0° to the truck's longitudinal direction. –...
  • Page 108 Parallel travel (133) – Home position: 0° to the truck's longitudinal direction. – Steering: all-wheel steering. – Steer angle: When steering, all three wheels turn at the same angle. – The "parallel travel" steering mode allows the truck to move diagonally or transversely without turning the truck's longitudinal axis.
  • Page 109 4.7.3 Changing steering mode The luminous bar above the button shows the current steering mode selected. Backlit (shown in white) travel modes can be selected from the current travel situation. Non-backlit (shown in grey) travel modes cannot be selected from the current travel situation.
  • Page 110 4.7.4 Adjusting the steer angle Press the steer angle button (86) to change between 180° and 360° steering. The range selected is shown in the control and display unit (10). Adjusting the steer angle Procedure • Press the steer angle button (86). The steer angle is now set.

  • Page 111: 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 112 4.8.1 Assembling/disassembling the fork arms Disassembling the fork arms Requirements – Truck parked securely, see page 127. Procedure • Detach the fork arms from the cylinders of the fork positioner. • Push the left fork into the centre of the front chassis by hand. •...

  • Page 113: 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 114 Lifting and lowering with the SOLO- PILOT Procedure • Pull the SOLO-PILOT lever (141) in direction H to raise the load unit. • Push the SOLO-PILOT lever (141) in direction S to lower the load unit. • Apply the SOLO-PILOT lever (141) until you reach the required lift height.
  • Page 115 Mast lift speed reduction (o) The mast lift speed reduction safety feature prevents the truck from accelerating accidentally if the load is beyond the free lift range. After the safety switch has applied, the truck can only operate at crawl speed. Deactivating the speed reduction Procedure •...
  • Page 116 Moving the mast holder with the MULTI-PILOT Procedure • Push MULTI-PILOT (79) direction (T) to extend the mast holder forward. • Pull the MULTI-PILOT (79) in direction (U) to retract it. The mast holder is now extended. Tilting the mast / fork carriage with the SOLO-PILOT Procedure •...
  • Page 117 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 118 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 119: Operating Attachments

    4.10 Operating attachments 4.10.1 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 120 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 121 Safety instructions for rotary attachments WARNING! A non-centred load centre of gravity can result in accidents When using rotary devices and non-centred loads, the centre of gravity can be displaced from the centre with a high risk of accidents. uAdapt the travel speed to the load. uLift the load from the centre.
  • Page 122 Safety instructions for using loading buckets as attachments WARNING! Increased mast loading can cause accidents. uWhen carrying out the daily checks and operations before starting, see page 85, check in particular check the fork carriage, mast rails and mast rollers for damage. Safety instructions for fork extensions WARNING! Unsecured and oversized fork extensions can cause accidents.
  • Page 123 4.10.2 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 90 may have a different assignment. Moving the side shift Procedure •...
  • Page 124 4.10.3 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 (94) in direction (X1). The side shift moves to the left. •...

  • Page 125: Fitting Additional Attachments

    4.11 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 126: Emergency Lowering

    4.12 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 127: Parking The Truck Securely

    4.13 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 128: Troubleshooting

    Troubleshooting Recovering the truck If the truck has to be moved without its own power supply (in the event of a breakdown), the emergency stop device for the drive system must be deactivated as they are applied without power. CAUTION! This operation must only be performed by suitably trained maintenance personnel.
  • Page 129 Aligning the position of the load wheels Tools and Material Required – AF 8 deep socket – AF 10 deep socket – AF 10 Allen key Procedure • Remove the cover from the load wheels. • Remove the screw (147). •...
  • Page 130 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 131 Towing the truck WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load or 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 132 Tools and Material Required – Tow rope, drawbar pull >5 to. Procedure • Guide the tow rope around the entry grab handles on the overhead guard as shown in the diagram to tow the truck in the drive direction. • Guide the tow rope around the mast as shown in the diagram to tow the truck in the forks direction.
  • Page 133 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 134: 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 135: Optional Equipment

    Optional Equipment Keyless Access System The keyless access system allows an individual code to be allocated to each operator or group of operators. I D E N T ? mode Item Description Display unit (EasyAccess Softkey): – Description see page 139 –...
  • Page 136 When a valid code is entered or a valid transponder used, a green tick appears in the display unit. When an invalid code has been entered or a invalid transponder used, a red cross is displayed, and the entry must be repeated. If the truck is not used for a certain length of time, the display unit switches to standby mode.

  • Page 137: Commissioning The Keypad And The Transponder Reader

    Commissioning the keypad and the transponder reader If the truck is equipped with a keypad or a transponder reader, it can only be operated using the keys in the display unit. The keypad and the transponder reader have to be activated by the operating company. 6.3.1 Activating the keypad Procedure...
  • Page 138 6.3.2 Activating the transponder reader Procedure • Release the emergency disconnect switch, see page 99. • Enter the default code 1-2-3-4 using the keys below the display unit (150). The truck is switched on. • Press the key below the "Settings" symbol (154).

  • Page 139: 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 99. • Enter the access code with the buttons below the display (150). The truck is switched on. 6.4.2 Switching off the truck Procedure •...
  • Page 140 6.4.3 Changing the set-up code Requirements – The truck is switched on, see page 139. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Change set- up code" symbol (155). • Enter the set-up code using the keys below the display unit (150).
  • Page 141 6.4.4 Adding a new access code Requirements – The truck is switched on, see page 139. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Edit access code" symbol (160). The set-up code is requested. •...
  • Page 142 6.4.5 Deleting an access code Requirements – The truck is switched on, see page 139. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Edit access code" symbol (160). The set-up code is requested. •...

  • Page 143: Using The Keypad

    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 144 6.5.2 Switching off the truck Procedure • Press the key under the "Switch off" symbol (159) in the display unit. • Press the Emergency Disconnect switch, see page 99. The truck is switched off.
  • Page 145 6.5.3 Changing the set-up code Requirements – The truck is switched on, see page 143. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Change set- up code" symbol (155). • Enter the set-up code using the keypad (151).
  • Page 146 6.5.4 Adding a new access code Requirements – The truck is switched on, see page 143. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Edit access code" symbol (160). The set-up code is requested. •...
  • Page 147 6.5.5 Deleting an access code Requirements – The truck is switched on, see page 143. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Edit access code" symbol (160). The set-up code is requested. •...
  • Page 148 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 149: 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 99. •...
  • Page 150 6.6.3 Changing the set-up transponder Requirements – The truck is switched on, see page 149. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Change set-up code" symbol (155). • Place the set-up transponder on the transponder reader (152).
  • Page 151 6.6.4 Adding a new transponder Requirements – The truck is switched on, see page 149. Procedure • Press the key below the "Settings" symbol (154). • Press below "Edit transponder" symbol (160). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (152).
  • Page 152 6.6.5 Deleting a transponder Requirements – The truck is switched on, see page 149. Procedure • Press the key below the "Settings" symbol (154). • Press the key below the "Edit transponder" symbol (160). set-up transponder requested. • Place the set-up transponder on the transponder reader (152).
  • Page 153 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 154: 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 155 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 156 6.7.6 reachCONTROL WARNING! Accident risk due to increased tipover hazard and reduced residual capacity In the case of incorrect use of the reachCONTROL option, an increased risk of tipover exists since attachments can reduce the operational stability of the truck –...
  • Page 157 6.7.8 operationCONTROL Operation Control is an assistance system. It maps the truck's capacity plates and informs the operator when the truck's capacity limit has been reached. CAUTION! Operation Control is an assistance system that only works within tolerance levels. The capacity plate data is always binding for the operator. Operation During lifting, when the load comes within less than 1000 mm of the maximum lift height indicated on the capacity plate, the "tip limit reached"...
  • Page 160 Setting the load centre DANGER! An incorrectly set load centre poses a risk of tipover If the load centre is set too low, the warning will not sound in time. This may endanger the operational stability of the truck, causing it to tip over. uSet the correct load centre.

  • Page 161: Work Lights

    Work lights Item Description Load direction work lights Drive direction work lights Work lights ON/OFF button for item 170 Work lights ON/OFF button for item 169 The work lights are fitted with a pivot that can swivel in all directions. As an option, the work lights can be controlled as a function of the travel direction.

  • Page 162: 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 fork camera is attached to the inside of the right fork.
  • Page 163 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 164 6.9.1 Service Menu Opening the service menu Procedure • Press the (173), (178), (179) keys simultaneously. 6.9.2 Camera settings Opens the camera settings Requirements – The service panel is open. Procedure • Open the camera settings with the (173) key. •...
  • Page 165 6.9.4 Keypad block Deactivates the keypad Requirements – System settings are open. Procedure • Select the keypad with the (178) and (179) keys and confirm with (180). • Select the keypad block with the (178) and (179) keys and confirm with (180). •...

  • Page 166: Beacon

    6.10 Beacon Item Description Warning beacon Warning-beacon switch ON/OFF Switching the beacon on and off Procedure • Press the beacon button (182). The beacon (181) is switched on or off.

  • Page 167: Led Work Lights On Load Handler

    6.11 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 5 mph (8 km/h).

  • Page 168: Height Cut Out

    6.12 Height cut out 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 169: Electric Lift Limit

    6.13 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 170 6.13.1 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 171 6.13.2 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 172 6.13.3 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 173: Sideshifter Centre Position

    6.14 Sideshifter Centre Position Item Description "Side shift centre position" button "Side shift centre position" display Pressing the "sideshift centre position" button (185) allows the side shifter to be centrally positioned during storage and retrieval operations. Positioning the sideshifter centrally Procedure •...

  • Page 174: Forks Horizontal Button

    6.15 Forks horizontal button Item Description "Forks horizontal" button "Forks horizontal" display The forks horizontal button (88) allows the load handler to be aligned horizontally Aligning the load handler horizontally Procedure • Press the forks horizontal button (88) until the load handler is aligned horizontally. During this procedure all other hydraulic functions are disabled and the display shows "forks horizontal"...

  • Page 175: Weigher

    6.16 Weigher Item Description "Weigher" button While the weigher button (83) 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 176: Clamp Function Release" Button

    6.17 “Clamp function release” button Item Description "Clamp function release" button 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.
  • Page 177 Requirements – Truck prepared for operation see page 98. Procedure • Pull the lever (93) in direction H, the forks move together. • Push the lever (93) in direction S, the forks move apart. The forks are now positioned.

  • Page 178: Removable Load Backrest

    6.19 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 (188). •...

  • Page 179: Floor-Spot

    6.20 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 180 4,5 m / 177 in 4 m / 157 in...
  • Page 181 6.20.1 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 accident due to dazzling Looking directly into the light beam of the Floor-Spot can dazzle and temporarily impair eyesight.

  • Page 182: Parabolic Mirror

    6.21 Parabolic mirror Item Designation Parabolic mirror (adjustable) The panoramic mirror (190) is equipped with a pivoting joint. This allows the driver to adjust the panoramic mirror (190) to his individual needs.

  • Page 183: 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 37.

  • Page 184: 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 209. The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...

  • Page 185: 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 186: 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 and in the support arm must be completely discharged. The capacitors are fully discharged approx.

  • Page 187: Lift Chains

    3.4.2 Replacing the load wheels Load wheels must only be replaced by the manufacturer’s authorised customer service department. Lift Chains WARNING! Non-lubricated and incorrectly cleaned lift chains can cause accidents Lift chains are safety-critical parts. They must not contain any serious contamination. Lift chains and pivot pins must always be clean and well lubricated.

  • Page 188: Energy Saving Components

    NOTICE Checking and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regular intervals. The application conditions of the industrial truck have a considerable impact on the ageing of the hydraulic hoses. uCheck the hydraulic hoses at least once per year and replace if necessary. uIn the case of heavy-duty operation, the inspection intervals must be reduced accordingly.

  • Page 189: 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 190 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 191: Lubrication Schedule

    Lubrication Schedule g Contact surfaces Hydraulic oil drain plug b Transmission oil filler neck Grease nipple a Transmission oil drain plug Hydraulic oil filler neck...
  • Page 192 Fork positioner lubrication chart Grease nipple...
  • Page 194 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 199.

  • Page 195: 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 196: 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 repair work. The following preparations must be made: Procedure • Park the truck on a level surface. •...

  • Page 197: 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 198: 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 (120) up and pull the seat towards the steering wheel and take it off.

  • Page 199: 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 200 Mast height 400 - 499 Approx. separating joint 500 - 599 Approx. mark I 600 - 699 Approx. mark I 700 - 799 Between marks I and II 800 - 899 Between marks I and II 900 - 999 Approx. mark II 1000 - 1099 Approx.

  • Page 201: Checking The Electrical Fuses

    Checking the electrical fuses 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 202 Fuse ratings Item Description Application Rating Main fuse Cabin Pump motor 48 V after main contactor Left load wheel steer motor Right load wheel steer motor Control fuse Drive wheel steering Main contactor Depend ing on cabin version...
  • Page 203 Fuse ratings Item Description Application Rating Radio data 4F15 Access control Travel/lift control DC/DC converter Seat heater 3F11 Drive wheel steering Display and control unit 3F13 Left load wheel steering controller 3F14 Left load wheel steering controller 2F17 MFC hydraulics 1F13 MFC travel/brake control fuse 1F14...

  • Page 204: Checking The Wheel Attachments

    Checking the wheel attachments. Tightening Torques Load wheels (1x centre cylinder screw) 120 Nm Drive wheel 300 -10 Nm Checking the wheel attachment Requirements – Truck prepared for maintenance and repairs, see page 196. Tools and Material Required – Torque wrench Procedure •...

  • Page 205: 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 206 • Equipped with lithium-ion battery (o) with interface converter on the battery: • Pull the battery forward. • Insert the control line into the battery connection at the top of the battery or the inside of the trough. • Slide the battery back in. •...

  • Page 207: 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 209: 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 210 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 211 Chassis/structure Check labels for legibility, completeness and plausibility Supports / tilt safety devices for presence and damage Check the overhead guard and/or the driver's cab for secure attachment and damage Hydraulic operations Test hydraulic system Check fork arms or load handler for wear and damage 1.1.2.2 Optional Equipment The following points must be checked:...

  • Page 212: Customer Service

    Lead-acid battery Power supply Check the battery cable connections for secure attachment Customer Service In accordance with the ETV Q 20-25 service interval, to be performed every 1000 service hours, but at least once a year. 1.2.1 Maintenance contents 1.2.1.1 Standard equipment Brakes Test the brake.
  • Page 213 Agreed services Carry out a test run with the rated capacity or a customer-specific load. Lubricate the truck according to the lubrication schedule. Demonstration after maintenance. Steering Lubricate steering gears or steering chain. 1.2.1.2 Optional Equipment Fork positioner Hydraulic operations Adjust the axial play of the front and rear rollers.
  • Page 214 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. liftCONTROL Hydraulic operations Test "liftCONTROL"...
  • Page 215 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 Brake linings for wear and damage Electrical system Cables and motor for secure fit and damage Warning and safety equipment in accordance with the operating instructions...
  • Page 216 Chassis/structure Check mast is securely attached Check mast bearings for wear Rails for wear and damage 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 Check the overhead guard and/or the driver's cab for secure attachment and damage Hydraulic operations Test hydraulic controls and check their labels for legibility, completeness and plausibility...
  • Page 217 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 Fork positioner Hydraulic operations Check the attachment is securely attached to the truck and check the load-bearing...
  • Page 218 Telescopic forks Hydraulic operations Test attachment and check for damage Check the attachment is securely attached to the truck and check the load-bearing components for secure fit and damage Check attachment bearings, guides and stops for wear and damage Check cylinder seals for leaks and damage Check hydraulic connections, hoses and pipes are securely attached and check for leaks and damage Check pistons and piston rods for wear and damage...
  • Page 219 Video system System components Check cables are securely attached and check for damage Check camera is securely attached, test and check for damage Check display is securely attached, test and check for damage Work lights Electrical system Test lighting and check for damage Fire extinguisher Accessories Check fire extinguisher is present and securely attached and check the inspection interval...
  • Page 220 Strobe light/warning beacon Electrical system Test strobe light/warning beacon and check for damage Mast reach damping Hydraulic operations Mast reach damping and its components for functionality and damage Overhead guard cover Chassis/structure Check overhead guard cover is present and securely attached and check for damage Audible warning devices Electrical system Check buzzer/warning alarm is securely attached, test and check for damage...
  • Page 221 Lead-acid battery Power supply Check battery, battery cables and cell connectors are securely attached and check for damage 1.2.3 Maintenance parts The manufacturer recommends the replacement of the following maintenance parts at the specified intervals. 1.2.3.1 Standard equipment maintenance part service hours months Gear oil...

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