Jungheinrich EFG 425 Operating Instructions Manual
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Jungheinrich EFG 425 Operating Instructions Manual

Jungheinrich EFG 425 Operating Instructions Manual

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EFG 425k - 435
Operating instructions
52427824
04.24
09.23
en-GB
EFG 425
EFG 425k
EFG 430
EFG 430k
EFG S30
EFG 435

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Summary of Contents for Jungheinrich EFG 425

  • Page 1 EFG 425k - 435 09.23 Operating instructions en-GB 52427824 04.24 EFG 425 EFG 425k EFG 430 EFG 430k EFG S30 EFG 435...

  • Page 3: Declaration Of Conformity

    Declaration of Conformity Manufacturer Jungheinrich AG, 22039 Hamburg, Germany Description Industrial truck Type Option Serial no. Year of manufacture EFG 425 EFG 425k EFG 430 EFG 430k EFG S30 EFG 435 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 Product: EFG 425k - 435 Serial number/type number Manufacturer: Jungheinrich Aktiengesellschaft 22039 Hamburg, Germany UK representative: Jungheinrich UK Ltd Sherbourne House Sherbourne Drive Tilbrook Milton Keynes MK7 8HX Authorised to compile documentation: The manufacturer is authorised to compile the technical documentation and its...
  • Page 5 Foreword Notes on the operating instructions The present ORIGINAL OPERATING INSTRUCTIONS are designed to provide sufficient instruction for the safe operation of the industrial truck. The information is provided clearly and concisely. The chapters are arranged by letter and the pages are numbered continuously.
  • Page 6 Copyright Copyright of these operating instructions remains with JUNGHEINRICH AG. Jungheinrich Aktiengesellschaft Friedrich-Ebert-Damm 129 22047 Hamburg - Germany Tel: +49 (0) 40/6948-0 www.jungheinrich.com...

  • Page 7: Table Of Contents

    Contents Correct Use and Application General Correct application Approved application conditions Instructions for Trucks with Lithium-Ion Batteries Internal Operation Combined with Brief External or Cold Store Operation (t) Indoor Application Predominantly inside the Cold Store (o) Hot country or tropical use (o) Ambient Conditions for Charging Residual risk Proprietor responsibilities...
  • Page 8 Using the Truck for the First Time Battery - Servicing, Recharging, Replacement General notes on handling batteries Potential hazards Touch voltage hazard Battery handling safety regulations Safety Regulations for Handling Lead-Acid Batteries Safety regulations for handling lithium-ion batteries Fire Hazard Particular hazard from combustion products Special fire fighting protective equipment Additional fire fighting instructions...
  • Page 9 Entering or exiting Trucks with reduced headroom (o) Setting up the operator position Restraint systems Seat Belt Working with the truck Safety regulations for travel mode Preparing the truck for operation Activating the lithium-ion battery (o) Parking the truck securely Emergency Disconnect Travel Steering...
  • Page 10 6.28 Fork Tilt Horizontal 6.29 Fire extinguisher 6.30 Simple Manoeuvring Coupling with Pin 6.31 Trailer Coupling with Hand Lever or Remote Control 6.32 Control layout “N” 6.33 Operating the auxiliary hydraulics without pressing the acknowledgement key 6.34 Special control layout 6.35 Warning Zone Light 6.36 Optional Equipment for Road Traffic According to StVZO 6.37 Horn Button on Overhead Guard...
  • Page 11 Decommissioning the Industrial Truck Prior to decommissioning During decommissioning Restoring the truck to service after decommissioning Safety tests to be performed at intervals and after unusual incidents Final de-commissioning, disposal Human vibration measurement Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement Maintenance Contents EFG 425k-435 / S30 Owner Customer Service...

  • Page 13: A Correct Use And Application

    A Correct Use and Application General WARNING! Risk of accident, risk of injury and risk of material damage due to improper use of trucks, misconduct or failure to observe the operating instructions Improper use of trucks, misconduct or failure to observe the operating instructions can lead to accidents, injuries and material damage.

  • Page 14: Correct Application

    Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must not be exceeded. The load must rest on the load handler or be lifted by an attachment approved by the manufacturer. The load must be fully raised, see page 174. The following operations are in accordance with regulations and are permitted: –...
  • Page 15 Australia: AS 2359.1 Powered Industrial Trucks, General Requirements; AS 2359.2 Powered Industrial Trucks, Operations...

  • Page 16: 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 17 Special equipment and authorisation are required if the truck is to be used continually in conditions of extreme temperature fluctuations or condensing air humidity.

  • Page 18: Instructions For Trucks With Lithium-Ion Batteries

    Instructions for Trucks with Lithium-Ion Batteries WARNING! Danger of accidents due to regenerative braking fault Regenerative braking faults can result in extended stopping distances and accidents, particularly when travelling on inclines. Other persons can be injured in the truck's hazardous area. uKeep all persons out of the hazardous area during travel operations.

  • Page 19: Internal Operation Combined With Brief External Or Cold Store Operation (T)

    Internal Operation Combined with Brief External or Cold Store Operation (t) In addition to the permissible operating conditions in industrial and commercial environments, the truck can also be used in outdoor environments, cold stores and fresh food areas. Secure parking is only permissible indoors or in a cold store environment.

  • Page 20: Indoor Application Predominantly Inside The Cold Store (O)

    Indoor Application Predominantly inside the Cold Store (o) The truck is manufactured as a cold store version o) and is equipped with hydraulic oil suitable for cold stores. In addition to the permissible operating conditions in industrial and commercial environments, the truck remains predominantly in the cold store and may only leave the cold store briefly for load transfer.
  • Page 21 Operating and ambient conditions for trucks as cold store versions Permissible temperature range in operation -20 °C to +30 °C, short-term -28 °C to +40 °C Typical temperature range in continuous use -20 °C to +20 °C Temperature range for secure parking -10 °C to +40 °C Maximum air humidity 95% non-condensing...

  • Page 22: Hot Country Or Tropical Use (O)

    Hot country or tropical use (o) The truck is manufactured as a tropical version (o) and is equipped with hydraulic oil specially designed for use at high temperatures. NOTICE Damage to the lead battery due to low state of charge and extreme temperatures Elevated temperatures accelerate chemical reactions and self-discharge of the battery.

  • Page 23: Ambient Conditions For Charging

    Ambient Conditions for Charging The industrial truck may be charged in closed rooms and also in covered outdoor areas protected from moisture. Observe the permissible operating and ambient conditions of the battery and the battery charger. CAUTION! Risk of electrical-system damage If the electronic system assemblies (controllers, sensors, motors etc.) come in contact with water, this can damage the electrical system.

  • Page 24: 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 25: 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 27: B Truck Description

    B Truck Description Application The EFG 425k - 435 is a four-wheel electric sit-down forklift truck. It is a cantilever counterbalanced truck which can lift, transport and deposit loads using the load handler attached in front. Closed bottom pallets can also be lifted. Truck models and rated capacity The rated capacity depends on the model.

  • Page 28: Assemblies And Functional Description

    Assemblies and Functional Description Travel direction definition The following conventions have been agreed for travel direction specification: Item Travel direction Left Reverse Forward Right...

  • Page 29: Assembly Overview

    Assembly Overview Item Designation Item Designation Mast Fork arms Steering wheel Fork carriage Overhead guard Drive system Driver's seat Trailer coupling Lift mechanism control Battery door Control and display unit Counterweight Emergency disconnect switch Steer axle...

  • Page 30: Functional Description

    Functional Description Chassis The chassis, in conjunction with the counterweight, forms the supporting base structure of the truck. It is used to support the main components. Operator position and overhead guard The overhead guard comes in a range of models and protects the operator from falling objects and other external influences.
  • Page 31 Hydraulic system for operating functions A multi-function control valve allows for sensitive operation of the functions via the controls. A speed-controlled hydraulic pump ensures a proportionate and efficient supply to the hydraulic functions. Mast Two or three-stage masts, optionally with free lift function; narrow mast sections ensure excellent visibility of the forks and attachments.

  • Page 32: Technical Specifications

    Technical Specifications All technical specifications refer to a standard truck with Continental tyres. All values marked with *) may vary depending on the type of equipment used (mast, cabin, tyres etc.). The technical specifications comply with the German "Industrial Truck Data Sheet" Guidelines.

  • Page 33: Performance Data

    Performance data EFG 425 EFG 425k EFG 430 Designation Li-ion Li-ion Li-ion 2500 2500 3000 Capacity (Q) Load centre (D) drive&liftPLU 20 / 20 20 / 20 20 / 20 km/h Travel speed with/ without load Efficiency 17 / 17...
  • Page 34 EFG 425 EFG 425k EFG 430 Designation Li-ion Li-ion Li-ion CO2 equivalent drive&liftPLU kg/h according to EN 16796 Efficiency Max. operating pressure Oil flow for attachments l/min With vertical mast The values specified indicate the maximum gradeability to overcome minor differences in height and unevenness in the travel lane (travel-lane edges).
  • Page 35 EFG 430k EFG S30 EFG 435 Designation Li-ion Li-ion Li-ion 3000 3000 3500 Capacity (Q) Load centre (D) drive&liftPLU 20 / 20 20 / 20 20 / 20 km/h Travel speed with/ without load Efficiency 17 / 17 17 / 17 17 / 17 km/h drive&liftPLU...
  • Page 36 EFG 430k EFG S30 EFG 435 Designation Li-ion Li-ion Li-ion CO2 equivalent drive&liftPLU kg/h according to EN 16796 Efficiency Max. operating pressure Oil flow for attachments l/min With vertical mast The values specified indicate the maximum gradeability to overcome minor differences in height and unevenness in the travel lane (travel-lane edges).

  • Page 37: Dimensions

    Dimensions EFG 425 EFG 425k EFG 430 Designation Li-ion Li-ion Li-ion a/2 Safety clearance 2325 2325 2322 Mast height retracted Free lift 3300 3300 3300 Lift 3900 3900 4057 Mast height extended 2240 2240 2240 Overhead guard height 1226 1226...
  • Page 38 EFG 430k EFG S30 EFG 435 Designation Li-ion Li-ion Li-ion a/2 Safety clearance 2322 2322 2352 Mast height retracted Free lift 3300 3300 3300 Lift Mast height extended 4057 4057 4086 2240 2240 2240 Overhead guard height 1226 1226 1226 Seat height / standing height Seating room Coupling height...

  • Page 40: Weights

    Weights All dimensions in kg. EFG 425 EFG 425k EFG 430 Description Li-ion Li-ion Li-ion Net weight (including battery) 4642 4691 5143 Front axle load (with load) 6466 6414 7395 Rear axle load (with load) Front axle load (without load)

  • Page 41: Mast Versions

    Mast versions EFG 425 / EFG 425k ZT / ZZ / DZ masts Lift h (mm) Free lift h Retracted Extended Mast weight height h height h (kg) (mm) (mm) (mm) 2900 2125 3500 3100 2225 3700 3300 2325 3900...
  • Page 42 EFG 430 / EFG 430k / EFG S30 ZT / ZZ / DZ masts Lift h (mm) Free lift h Retracted Extended Mast weight height h height h (kg) (mm) (mm) (mm) 2900 2122 3657 3100 2222 3857 3300 2322 4057 3500 2422...
  • Page 43 EFG 435 ZT / ZZ / DZ masts Lift h (mm) Free lift h Retracted Extended Mast weight height h height h (kg) (mm) (mm) (mm) 2900 2152 3686 3100 2252 3886 3300 2352 4086 3500 2452 4286 3700 2552 4486 4000 2702...

  • Page 44: Tyre Type

    Otherwise the manufacturer’s specifications cannot be ensured. If you have any queries, contact the manufacturer's customer service department. During the wear test, the wear limit of the respective wheel must be observed. Designation EFG 425 / EFG EFG 430 / EFG 430k / 425k / Li-ion...

  • Page 45: Motor Output

    Description EFG S30 / Li- EFG 435 / Li- SE (t) 315 / 45 - 12 315 / 45 - 12 22 x 10 x 16 22 x 10 x 16 Solid (o) Front tyres Pneumatic (o) Tyre pressure Torque 320 Nm 200 / 50 - 10 200 / 50 - 10...

  • Page 46: En Norms

    EN norms Noise emission level – Efficiency: 69 dB(A) – drive&liftPLUS: 70 dB(A) *+/- 3 dB(A) depending on the truck's equipment in accordance with EN 12053 as harmonised with ISO 4871. The noise emission level is calculated in accordance with standard procedures and takes into account the noise level when travelling, lifting and when idle.

  • Page 47: Electrical Requirements

    Electrical requirements The manufacturer certifies compliance with the requirements for the design and manufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety - Electrical Requirements", provided the truck is used for its intended purpose. Specifications according to RED guideline (Radio Equipment Directive) for radio units The table contains any components installed according to the European Directive 2014/53/EU.

  • Page 48: Identification Points And Data Plates

    Identification Points and Data Plates Indication Points Warnings and notices such as capacity plates, attachment points and data plates must be legible at all times. Replace if necessary. Item Description Observe the operating instructions Tyre pressure (o) Observe the operating instructions Serial number, engraved in the chassis next to the counterweight Load damping (o) –...
  • Page 49 Item Description Tyre pressure (o) No standing on the load handler, No standing under the load handler, Risk of crushing when the mast moves Attachment point for loading by crane Potentially dangerous optical radiation (o) Truck capacity plate Attachment capacity plate (o) Additional capacity plate (o) Model description Assistance interface (o)

  • Page 50: Item Designation

    XXXX Item Designation Tyre pressure (o) No standing on the load handler, No standing under the load handler, Risk of crushing when the mast moves Attachment point for loading by crane Type designation Speed (o) Attachment point for jack Risk of shearing / risk of crushing Inspection plaque (o) Lift height limits Procedure when truck at risk of tip-over, no passengers...
  • Page 51 Item Description Attachment point for loading by crane Speed (o) Jacking point Coolant for air-conditioning system (o) Transport seal for the comfort charging socket (o) Observe the operating instructions: Charge the battery only at designated charging points – see page 94. Observe the operating instructions: Use only battery chargers with a maximum 300 A charge current at the comfort charging socket (o) –...
  • Page 52 Designation Type plate (alternative position, e.g. for TÜV inspection) (o) Actuator for the swivel seat (o) Marking for hydraulic oil for the hydraulic system, e.g. Jungheinrich hydraulic oil (t) or BIO hydraulic oil (o) Attachment type plate (o) Industrial truck with special corrosion protection (o)

  • Page 53: Data Plate

    Data plate The illustration shows the standard version for EU member states. The data plate may differ in other countries. Item Description Item Description Year of manufacture Net weight without battery [kg] Type Min./max. battery weight [kg] Serial number Manufacturer Option Importer - imported by (o) Rated capacity [kg]...
  • Page 54 4.2.1 Option The option contains information on the design of the truck and is shown on the type plate. e.g. DL G+E 115+310 ZZ Option code G+E Load handler Fork length (cm) Lift height (cm) Mast version Option code Efficiency drive&liftPLUS Load handler Fork Carriage...

  • Page 55: Truck Capacity Plate

    Truck capacity plate WARNING! Replacing the fork arms can cause accidents If you replace the fork arms with ones that differ from the originals, the capacity will change. uAn additional capacity plate must be attached to the truck when replacing the fork arms.
  • Page 56 Lift height limits The arrow shaped markings (73 and 74) on the inner and outer masts show the operator when the prescribed lift limits have been reached.

  • Page 57: Attachment Capacity Plate

    Attachment capacity plate The attachment capacity plate is next to the truck capacity plate and gives the truck capacity Q (in kg) in conjunction with the attachment and the specified fork arms (t) (75) and where applicable fork extensions (o) (76). The model name and/or serial number for the attachment indicated on the attachment capacity plate must match the data plate of the attachment.
  • Page 58 4.4.2 Attachment with up to 100 mm side shift h3 [mm] Q [kg] 3100 2000 1790 1620 D [mm] 4.4.3 Attachment with More Than 100 mm Side Shift WARNING! Risk of accident from offset load centre of gravity The capacity of the truck is reduced when using side shifts that are more than 100 mm outside the truck centre.

  • Page 59: Stability

    Stability WARNING! Loss of operational stability can cause accidents Changing the components can affect operational stability. uDo not exceed permissible loads and load centre distances. uOnly manufacturer-approved components may be used on the truck. Do not use components that have not been approved by the manufacturer. uThe components listed must be replaced only with the agreement of the manufacturer.

  • Page 61: C Transport And Commissioning

    C Transport and Commissioning Transport The truck can be transported in two different ways, depending on the height of the mast and the local conditions. – Vertically, with the mast assembled (for low heights) – Vertically, with the mast removed (for large heights), all mechanical connections and all hydraulic lines between the basic unit and the mast separated.

  • Page 62: Lifting The Truck By Crane

    Lifting the truck by crane DANGER! Crane lifting gear can tear, resulting in accidents A tear in the crane lifting gear may result in severe, irreparable accidents or even death if there are persons within the hazardous area. uOnly use crane lifting gear with sufficient capacity. uLoading weight = unladen weight of the truck (+ battery weight for electric trucks).
  • Page 63 Tools and Material Required – Crane lifting gear – Suitable cross members (crane cross members or spreader cross members (rope cross members)) with 2,5 m Span Procedure • Secure the crane lifting gear at the attachment points (77) and (78) using the cross members.

  • Page 65: Loading The Truck With A Second Truck

    Loading the truck with a second truck WARNING! The truck can be damaged The truck to be loaded can be damaged when loading with another industrial truck. uOnly trained specialist personnel should load the truck. uUse only trucks with sufficient capacity for loading. uOnly for loading and unloading.

  • Page 66: Securing The Truck During Transport

    Securing the truck during transport WARNING! Danger due to uncontrolled movement of the truck or the mast during transport If the truck and mast are not properly secured during transport, serious accidents can occur. Slipping lashing straps can lead to uncontrolled movements of the truck or mast and even a fall during transport.

  • Page 68: Using The Truck For The First Time

    Using the Truck for the First Time Safety instructions for assembly and commissioning WARNING! Incorrect assembly can result in accidents The assembly of the truck at the application site, commissioning and operator training must only be performed by the manufacturer's customer service representatives who have been specially trained for these tasks.

  • Page 69: D Battery - Servicing, Recharging, Replacement

    D Battery - Servicing, Recharging, Replacement General notes on handling batteries Maintenance personnel Batteries may only be charged, serviced or replaced by trained personnel. These operating instructions and the manufacturer’s instructions concerning batteries and charging stations must be observed when carrying out the work. The truck must be parked securely before all work on the batteries, see page 158.

  • Page 70: Touch Voltage Hazard

    Touch voltage hazard WARNING! Touch voltage hazard Hazardous touch voltages may occur in the event of a technical or mechanical defect on the battery. Touch voltages also occur on seemingly discharged batteries. Touching the battery terminals or live attachments (battery cable, battery connector etc.) can result in dangerous current flows through the body.

  • Page 71: Safety Regulations For Handling Lead-Acid Batteries

    Safety Regulations for Handling Lead-Acid Batteries WARNING! Risk of accidents and injuries when handling acid batteries Batteries contain dissolved acid, which is toxic and caustic. Above all, avoid any contact with battery acid. uDispose of used battery acid in accordance with regulations. uWear protective clothing and eye protection when working with acid batteries.

  • Page 72: Safety Regulations For Handling Lithium-Ion Batteries

    Safety regulations for handling lithium-ion batteries Fire Hazard WARNING! Burning lithium-ion battery cells can be hazardous Physical damage, thermal effects or incorrect storage in the event of a defect can result in fire. If the inside of lithium-ion battery cells burns, the fire cannot be put out by extinguishing methods.

  • Page 73: Special Fire Fighting Protective Equipment

    – Hydrogen fluoride (HF) Hydrofluoric acid = extremely corrosive – Risk of toxic substances produced by pyrolysis – Risk of highly flammable gas mixtures. – Other combustion products: Carbon monoxide & - dioxide. Special fire fighting protective equipment – Use self-contained breathing apparatus. –...

  • Page 74: Battery Types

    Battery types WARNING! Danger of electric shock and risk of fire due to short circuit or over temperature A short circuit or electric shock can occur on batteries without a cover or without insulation of live parts. Damaged or unsuitable cables (wire diameter too small) can cause a short circuit or electric shock or heat up impermissibly.
  • Page 75 The following table shows which combinations are included as standard: Lead-acid batteries Truck type Description Capacity EFG 425k 80 V - 4PzS 560 - 620 Ah EFG 430k EFG 425 EFG 430 80 V - 5PzS 700 - 775 Ah EFG S30 EFG 435 Lithium-ion batteries Truck type Description...

  • Page 76: Battery Dimensions

    (-5/+8%) in kg L max. B max. 2 mm 2 mm EFG 425k/430k 1028 1558 EFG 425/430/S30/435 1028 1863 DANGER! If the centre of gravity of the battery deviates from the geometrical centre of gravity of the battery, contact the manufacturer.

  • Page 77: Exposing The Battery

    Exposing the Battery WARNING! Danger of electric shock and risk of fire due to arcing Disconnecting the battery connector under load may cause electric shock or arcing. Electric shocks or arcs can damage adjacent parts and result in fire. uDo not disconnect the battery connector under load. Switch off the emergency disconnect switch before disconnecting the battery connector.
  • Page 78 There is an alternative battery latch for lithium-ion batteries: The lithium-ion battery may only removed from industrial truck by qualified personnel during maintenance. Check the lithium-ion battery for firm seating at regular intervals and retighten, if necessary. The tightening torque of the screw is 250 Nm and must be observed.

  • Page 79: Removing Or Installing The Battery

    Removing or installing the battery WARNING! Accident risk during battery removal and installation Due to the battery weight and acid there is a risk of trapping or scalding when the battery is removed and installed. uNote the safety regulations governing the handling of lead-acid batteries, see page 71.

  • Page 80: Removal And Installation Using A Pallet Truck With Snapfit Battery Holder (O)

    Removal and Installation Using a Pallet Truck with SnapFit Battery Holder (O) CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Removing the battery Requirements –...
  • Page 81 • Undo the battery latch (83). • Remove the battery with the pallet truck at slow travel as far as it will go (98). • Raise the fork arms until the battery can be pulled clear of the battery compartment. •...
  • Page 82 Installing the battery Procedure • Drive the EJE pallet truck and battery up to the truck. • Deposit the battery trolley with the rollers (87) on the base of the truck. • Lower the forks of the EJE pallet truck until the battery is horizontal.
  • Page 83 7.1.1 Battery holder assembly CAUTION! The battery holder can only be fitted to pallet trucks or hand pallet trucks with notice signs. Requirements – Pallet truck or hand pallet truck available with holes in accordance with assembly instructions, see page 84. Procedure •...
  • Page 84 7.1.2 Assembly instructions Ø...
  • Page 85 Procedure • Drill 4 holes with a 16 mm diameter into the pallet truck or hand pallet truck according to the drill patterns. • Make sure there is sufficient distance between the connecting rod and the bottom of the forks. Attach safety notices to the pallet truck.

  • Page 86: Removing Or Installing The Battery Using A Fork Shoe

    Removing or installing the battery using a fork shoe CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Battery removal and installation Requirements – Truck parked securely, see page 158. –...

  • Page 87: Removing Or Installing The Battery Using A Roller Conveyor

    Removing or installing the battery using a roller conveyor WARNING! After inserting the battery close the battery lock. CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes.

  • Page 88: Removal And Installation Using A Hand Pallet Truck With Snapfit (O)

    Removal and installation using a hand pallet truck with SnapFit WARNING! After inserting the battery close the battery lock and then lower the pallet truck. CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes.
  • Page 89 • Engage the safety catches (85) on the battery trolley. • To do this, press the pedals (86). Do not raise the forks. • Undo the catch (90). • Undo the battery latch (83). • Using the hand pallet truck, slowly remove the battery as far as the stop (98).

  • Page 90: Removing Or Installing The Battery Using A Pallet Truck Or Hand Pallet Truck And No "Snapfit" Battery Holder

    Removing or installing the battery using a pallet truck or hand pallet truck and no "SnapFit" battery holder WARNING! After inserting the battery close the battery lock and then lower the pallet truck. CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis.

  • Page 91: Removal Or Installation With Battery Holder (Snapfit) And Crane Cross Member (O)

    Removal or Installation with Battery Holder (SnapFit) and Crane Cross Member (o) CAUTION! Trapping hazard Trapping hazard when replacing the battery. uWhen replacing the battery do not reach between the battery and the chassis. uWear safety shoes. Removing the battery Requirements –...

  • Page 92: Transporting The Batteries By Crane

    Transporting the batteries by crane DANGER! Crane lifting gear can tear, resulting in accidents uOnly use crane lifting gear with a cross member and sufficient capacity. uObserve the crane lifting gear operating instructions. uLifting accessories of the crane lifting gear must be fastened in such a way that they do not come into contact with any attachments when lifting.
  • Page 93 Requirements – To prevent short circuits, batteries with exposed terminals must be covered with a rubber mat. – Battery connector disconnected from the truck connector. – Battery removed – see page 79. Procedure • Pick up the battery at the four crane eyes with suitable crane lifting gear. Crane lifting gear may only exert vertical pull on the battery trough to prevent the battery trough from being compressed.

  • Page 94: Charging The Battery

    Spark formation and uncontrolled movement of electronically controlled components may cause injury. uThe battery may only be charged with the Jungheinrich battery charger designed for this battery. uUse only battery chargers approved by the manufacturer.

  • Page 95: Charging The Lead Battery

    Charging the Lead Battery WARNING! Risk of explosion due to gases produced while charging The battery gives off a mixture of oxygen and hydrogen (oxyhydrogen gas) during charging. Gassing is a chemical process. This gas mixture is highly explosive and must not be ignited.
  • Page 96 9.1.2 Charging the lead battery with a comfort charger socket (o) Charging WARNING! Risk of explosion due to gases produced while charging uAlways check the fans each time you charge. Requirements – Truck parked securely – see page 158. Procedure •...

  • Page 97: Charging Lithium-Ion Batteries (O)

    Charging lithium-ion batteries (o) Intermediate charging of the lithium-ion battery A lithium-ion battery that is not fully discharged can be partially or fully recharged at any time. Note the following information to ensure reliable function of the lithium-ion battery: u In the event of frequent intermediate charging, charge the lithium-ion battery fully every 4 weeks.
  • Page 98 9.2.2 Charging the lithium-ion battery with a comfort charger socket (o) on the truck Charging Requirements – Truck parked securely, see page 158. Procedure • Connect the charger cable of the battery charger station to the charger socket (105). • Switch on the battery charging station and charge the battery in accordance with the battery and charging station manufacturer's instructions.

  • Page 99: 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 100 WARNING! Falling objects can cause accidents Falling objects can injure the operator while the truck is being operated. uThe operator must remain within the protected area of the overhead guard while the truck is being operated. A roof protective grille (o) is available for more demanding applications, e.g. when working at great lift heights or with loads with special characteristics.
  • Page 101 WARNING! Health hazard due to non-adapted workplace or failure to meet the minimum headroom Failure to adapt the workplace or to meet the minimum headroom can cause stress and endanger the operator and may lead to lasting ill health due to an unhealthy posture and excessive strain on the operator.

  • Page 102: Displays And Controls

    Displays and Controls Controls...
  • Page 103 Item Controls and displays Function Key switch t Switches the truck on and off. o Switches the truck on. Keyless access system Truck is switched off via the "switch off" button on the display unit. t Buttons for the functions that can be Display unit buttons operated via the display unit.

  • Page 104: Pilots

    Pilots Item Control / display Function t Lever for operating the basic lift / tilt Basic hydraulic functions lever hydraulic functions. t Button for side shift or auxiliary hydraulics Side shift / auxiliary hydraulics 1 optional button / lever t Selects travel direction / neutral position. Travel direction switch (not available with twin-pedal control)
  • Page 105 120 / 123...

  • Page 106: Function Symbols For The Pilots

    Function symbols for the Pilots The pictogram shows the direction of movement that is executed when the operator pulls the lever in direction (R). The counter-movement of the work function is achieved by the operator pushing the lever accordingly. For controls that operate at right angles to the travel direction, the function is shown with the actuation to the left (S) from the operator's perspective.
  • Page 107 Symbol Meaning Side shift right Side shift left Fork positioner Outside fork positioner Inside fork positioner Left fork positioner Right fork positioner Clamp Reach fork Telescopic fork Rotate Double lift Locking mechanism...
  • Page 108 Symbol Meaning Crane Scoop Load holder Folding fork Empty container Pusher Adapters ZH1 to ZH4 (example symbol: ZH1) Changing attachments 1 to 4 (example: attachment 2)

  • Page 109: Armrest Control Panel Buttons

    Armrest Control Panel Buttons...

  • Page 110: Symbol Function

    Symbol Function Work light – Brief press > switch on / switch off Dimmable work lights (o) – Brief press > switch on / switch off – Press and hold > dim brightness – Two brief presses > high beam / normal operation Travel light / auxiliary spotlights –...
  • Page 111 Symbol Function Rear windscreen wiper – 1 press > button flashes green - intermittent operation – 2 press > button lights up green - continuous operation – 3 press > switch off – Press and hold > windscreen washing system Rear windscreen heater (t) Rear windscreen heater and front window heating (o) –...
  • Page 112 2.4.1 Activating the auxiliary functions on the armrest Only when equipped with display unit with 4-inch display Functions and operator menus that can be operated via buttons on the armrest control panel depend on the operating situation as well as the scope and settings of the truck, see page 123.

  • Page 113: Control Panel With Display Unit

    Control panel with display unit 2.5.1 Display unit with 2-inch display 2,5km/h Item Control or display element Function 131 Information line Displays event messages and information such as speed 132 Battery capacity display Battery discharge status. 133 Battery type Empty = Standard battery 1 = Dry battery 134 Icon field Displays the symbols, see page 116.
  • Page 114 2.5.2 Display unit with 4-inch display 0 k m / h Item Control or display element Function 131 Information line Displays event messages and information such as speed, load weight (o), tilt angle (o). 132 Battery capacity display Shows the battery discharge status. 133 Battery type Empty = Standard battery 1 = Dry battery...
  • Page 115 Depiction of travel direction and steer angle on the display unit The travel direction engaged is depicted by a white semicircle. The direction of current travel and the current wheel position are displayed by a white travel-direction and steer-angle arrow. Symbol Meaning –...

  • Page 116: Symbols In The Display

    Symbols in the display The symbols shown depend on the truck equipment. Symbol Meaning Colour Function Indicator Green Indicator or warning indicator active Slow travel Green Slow travel activated by operator Yellow Slow travel activated by truck Emergency travel operation (speed 2 km/h) with reduced performance, activated by truck Service note...
  • Page 117 Symbol Meaning Colour Function Regenerative Yellow Effect of regenerative braking is reduced. brake fault Maximum travel speed is reduced. Effect of regenerative braking is considerably reduced. Maximum travel speed is considerably reduced. Special attention when on slopes: Do not travel faster than crawl speed. Automatic parking Green Automatic parking brake active –...
  • Page 118 Symbol Meaning Colour Function Battery low Yellow Temperature of the lithium-ion battery temperature is below 5°C. Discharge currents and energy recovery are reduced. Temperature of the lithium-ion battery is below 0°C. Lithium-ion battery below permissible temperature range. Seat switch Fixed Seat switch not actuated yellow Flashing...
  • Page 119 Symbol Meaning Colour Function Fork tilt horizontal Green Forks horizontal, mast tilt 0° Forks tilted forward Yellow Forks tilted forward slightly, slightly mast tilt +1° to +4° Forks tilted forward Yellow Forks tilted forward significantly, significantly mast tilt > +4 ° Side shift centred Green Side shift centred...
  • Page 120 Maintenance notice with advance warning and travel speed reduction o Regulations require the industrial truck to undergo maintenance after 1000 hours. 150 hours before maintenance is due, the yellow maintenance interval symbol flashes on the display for approx. 60 seconds after switching on the industrial truck.

  • Page 121: Battery Discharge Indicator

    Battery discharge indicator NOTICE Full discharge can damage the battery The standard setting for the battery discharge indicator is based on standard batteries. When using maintenance-free batteries (gel batteries), the display must be reset. uThis adjustment should only be made by the manufacturer’s customer service department.

  • Page 122: Operating Programs

    2.10 Operating Programs Five operating programs with different performance levels are available to adapt the travel and operating functions to the application at hand. Operating program Function Operating program 1 – Significantly reduced travel speed – Slow response – Significantly reduced lift speed –...

  • Page 123: Button Allocation Of The Display

    2.12 Button allocation of the display Functions and operator menus that can be operated via the icons and keys of the display unit depend on the operating situation as well as the scope and settings of the truck. 2.12.1 Display unit with 2-inch display Button assignment in the main menu Symbol Meaning...

  • Page 124: Symbol Meaning

    Symbol Meaning Front work lights (o): To switch on/off the front work lights. Rear work lights (o): To switch on/off the rear work lights. Roof windscreen wiper (o): – 1 press > button flashes green - intermittent operation – 2 press > button lights up green - continuous operation –...
  • Page 125 Button allocation in menu for managing codes or transponders (o) Symbol Meaning Back: Cancels the current procedure and returns to the previous menu. Log-in history: Displays the chronological log-in history Change set-up code: To change the set-up code and to activate the keypad or the transponder reader.
  • Page 126 2.12.2 Display unit with 4-inch display Activate the display of auxiliary functions in the display unit via the FN button on the armrest control panel – see page 112. While the status lamp above the FN button is illuminated, the first six buttons on the control panel can be used instead of the display unit buttons –...
  • Page 127 Assign a favourites button Symbol Meaning Assign a favourites button: Press and hold the button for the changing the assignment of a favourites button. If you then press a favourites button at the same time, this takes you to the selection of the available symbols, thus allowing you to assign the relevant function or operating menu (see below).
  • Page 128 Symbol Meaning Deactivation of the rear Floor-Spot (o) or Floor-Bow (o) warning device – Deactivation of the side Floor-Stripes warning device (o) Lighting on the mast (o): To switch on/off the lighting on the mast. Front work lights (o): To switch on/off the front work lights. Rear work lights (o): To switch on/off the rear work lights.
  • Page 129 Button allocation in menu for managing codes or transponders (o) Symbol Meaning Back: Cancels the current procedure and returns to the previous menu. Log-in history: Displays the chronological log-in history Change set-up code: To change the set-up code and to activate the keypad or the transponder reader.
  • Page 130 Button allocation in load weighing plus option menu (o) Symbol Meaning Save the currently recorded individual weight as tare Tare: Difference between the currently recorded gross individual weight and the net individual weight currently shown Compensate for the weight of an attachment Total function: Add the currently shown net individual weight to the total weight, increase the number of weights recorded Total function: Subtract the currently shown net individual weight from...
  • Page 131 Button assignment in media player options menu (o) Symbol Meaning Playback control of the audio source connected via Bluetooth® (where supported and available): Play the current audio file from the beginning, play the previous audio file, skip back to previous audio files "FM"...
  • Page 132 Button assignment in sound module settings menu Symbol Meaning Switch off the sound module Source selection: Switch between "FM" radio, "DAB" radio, an audio source connected via Bluetooth® ("Bluetooth", only when connected to digital end device) and an audio signal connected to the analogue input "Aux In"...
  • Page 133 Button assignment in hands-free system options menu (o) Symbol Meaning Answer incoming phone call End current phone call Mute Reduce volume When pressed, the volume is muted. Increase volume Bluetooth pairing – see page 250 Back: Returns to the previous menu. The settings menu for the hands-free system can be accessed directly with a double-press of the FN button.

  • Page 134: Setting The Time

    2.13 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 135: Side Compartment Control Panel Switch (O)

    2.14 Side compartment control panel switch (o) The switches available in the side control panel depend on the truck equipment. 2.14.1 Battery Activation Button A preset time after actuating the emergency disconnect switch and to protect against deep discharge and malfunctions, the lithium- ion battery deactivates and switches to energy-saving mode.
  • Page 136 2.14.3 Parking Light The parking light is activated by actuating the switch on the control panel. Activating the parking light Procedure • Press the parking light switch. The parking lights are activated. To deactivate the parking lights Procedure • Press the parking light switch back to home position. The parking lights are deactivated.

  • Page 137: 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 138 Checks before daily operation Procedure • Visually inspect the entire truck (in particular mud flaps, wheels, wheel bolts and load handler) for damage. • For pneumatic tyres (o): check the air pressure. • Visually inspect the visible area of the hydraulic system for damage and leaks.
  • Page 139 • Check that the driver's seat has been adjusted to the correct position. • Test the seat switch: When the driver's seat is vacated, it should not be possible to operate the working hydraulics. • Test the controls and displays. •...
  • Page 140 • Version accordance with Australian guidelines: • ZZ and DZ masts: Check that the travel speed is reduced to 3 km/h and limited as of the free lift. • ZT mast: Check that the travel speed is reduced to 3 km/h and limited from a lift height of 800 mm.

  • Page 141: Entering Or Exiting

    Entering or exiting CAUTION! Risk of accident due to slippery surfaces There is a risk of accident due to slipping when walking on slippery surfaces with unsuitable footwear. uWear safety shoes or sturdy footwear with non-slip soles. uUse the non-slip step and the floor mat for entry and exit.

  • Page 142: Trucks With Reduced Headroom (O)

    Trucks with reduced headroom (o) WARNING! Health hazard due to non-adapted workplace or failure to meet the minimum headroom Failure to adapt the workplace or to meet the minimum headroom can cause stress and endanger the operator and may lead to lasting ill health due to an unhealthy posture and excessive strain on the operator.

  • Page 143: 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 144 Setting the driver's weight WARNING! Incorrectly adjusted seat cushioning can damage your health To achieve optimal seat damping, the driver’s seat must be adjusted according to the driver’s weight. uSet the driver's weight when the seat is occupied. uHold the weight setting lever only by the recess;...
  • Page 145 Adjusting the backrest Procedure • Sit on the driver’s seat. • Pull the lever (154) to adjust the backrest. • Adjust the backrest tilt. • Release the lever (154) again. The backrest is locked. The backrest is now set. Adjusting the lumbar support ( Procedure •...
  • Page 146 Adjusting the backrest extension ( CAUTION! Accident risk when adjusting the backrest during travel uDo not adjust the backrest extension while travelling. Procedure • The backrest extension height can be adjusted by changing the detent. • Pull the backrest up and lock it in place to extend the backrest.
  • Page 147 3.4.2 Adjusting the steering column Adjusting the steering column Procedure • Release the steering column stop (160). • Set the steering column to the required position (height and angle). • Fix the steering column stop (160) in position. The steering column is now positioned. 3.4.3 Adjusting the "Basic"...
  • Page 148 3.4.4 Adjusting the Multifunction Armrest Procedure • Press the lock (165) and hold it in this position. • Move the armrest (164) vertically and horizontally. • Release the lock (165) at the desired position. • Push the armrest (164) slightly forward or back until it locks in position. The armrest is now positioned.
  • Page 149 3.4.5 Adjusting the armrest Adjusting the armrest Procedure • Fold up the armrest (164). • Set the height adjuster (166) to the desired position (high/low). • Fold the armrest (164) down.

  • Page 150: Restraint Systems

    Restraint systems Approved restraint systems: – Seat belt (see page 150) – Cabin door (see page 230) – Swivelling gate (see page 238) – Summer door (see page 240) At least one of these restraint systems is present and is monitored electrically. Further restraint systems with or without electrical monitoring may be present as options.
  • Page 151 Checking the seat belt Procedure • Check the attachment points for wear and damage. • Check the cover for damage. • Pull the belt out fully from the retractor and check for damage (loose seams, fraying and nicks). • Test the belt buckle and make sure the belt returns correctly into the retractor. Check the automatic locking system Procedure •...

  • Page 152: Working With The Truck

    Working with the truck Safety regulations for travel mode WARNING! Magnetic fields can cause accidents Electronic components can be affected or damaged by external magnetic fields. This can lead to malfunctions or accidents. uDo not use or keep magnets or clamping magnets in the immediate vicinity of the controls.
  • Page 153 travel against the load direction. If this is not possible, a second person must walk alongside the truck as a lookout to observe the travel route while maintaining eye contact with the operator. Proceed only at walking pace and with particular care. Stop the truck as soon as you lose eye contact.
  • Page 154 WARNING! Risk of accident due to the truck tipping over and the load slipping down Risk of accident due to the truck tipping over and the load slipping down when driving on a slope crosswise or diagonally or with the load not guided on the uphill side.
  • Page 155 WARNING! Risk of injury from falling loads Incorrectly or inappropriately secured and applied loads can slip and fall during heavy braking or as a result of wind forces. uTilt the mast back when transporting loads. uOnly transport loads that have been correctly secured and positioned. Take suitable additional precautions to prevent parts of the load from tipping or falling down.

  • Page 156: Preparing The Truck For Operation

    Preparing the truck for operation The truck may only be operated from the driver's seat. Switching on the truck Requirements – Checks and operations before starting daily work completed, see page 137. Procedure • Activate the lithium-ion battery – see page 157. •...

  • Page 157: Activating The Lithium-Ion Battery (O)

    Activating the lithium-ion battery (o) A preset time after actuating the emergency disconnect switch and to protect against deep discharge and malfunctions, the lithium-ion battery deactivates and switches to energy-saving mode. To activate the sufficiently charged lithium-ion battery back into normal operation, actuate the battery activation button on the control panel or actuate the battery activation button on the battery tray (depending on equipment).

  • Page 158: Parking The Truck Securely

    Parking the truck securely WARNING! An unsecured truck can cause accidents Parking the truck on an incline, without the brakes applied or with a raised load / load handler is dangerous and is strictly prohibited. uAlways park the truck on a level surface. In special cases the truck may need to be secured with wedges.

  • Page 159: 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 161: Travel

    Travel WARNING! Risk of accident and personal injury due to incorrect travel and loss of operational stability Incorrect travel can lead to the truck tipping over and accidents, as well as personal injury. A laden or unladen industrial truck can tip over if the operator does not decelerate to a safe speed before a bend.
  • Page 162 4.6.1 Single pedal Requirements – Truck prepared for operation, see page 156. Procedure • Release the parking brake, to do this press the parking brake button (148). • Move the travel direction switch (121) from the neutral position into the desired travel direction.
  • Page 163 4.6.2 Twin pedal (o) Requirements – Truck prepared for operation, see page 156 Procedure For trucks with a twin pedal, the travel direction is selected via the accelerator pedals (117;116). When the driver leaves the truck, the truck is automatically set to "Neutral".
  • Page 164 4.6.3 Changing the direction of travel CAUTION! Danger when changing direction during travel Changing direction during travel can result in the truck travelling too quickly in the opposite direction if the operator does not take his foot of the accelerator pedal in time.

  • Page 165: Steering

    Steering WARNING! Risk of accident and personal injury due to incorrect travel and loss of operational stability Incorrect travel can lead to the truck tipping over and accidents, as well as personal injury. A laden or unladen industrial truck can tip over if the operator does not decelerate to a safe speed before a bend.

  • Page 166: Brakes

    Brakes WARNING! Accident risk The brake pattern of the truck depends largely on the ground conditions. uThe operator must take into account the travel route conditions when braking. uBrake with care to prevent the load from slipping. uAllow for increased braking distance when travelling with an attached load. uIn an emergency, operate the brake pedal with maximum force to initiate heavy braking.
  • Page 167 4.8.1 Braking with the coasting brake WARNING! Immediately after the battery has been charged the brake power of the coasting brake may reduce of their own accord after long periods of application, e.g. ramp operation. uThe operator must instruct people to leave the hazardous area. uThe operator must perform test braking.
  • Page 168 4.8.2 Braking with the Service Brake When the brake pedal is actuated, the mechanical multi-plate brake is activated and regenerative braking also takes place. If the truck reaches a standstill, the automatic parking brake is applied after a preset time. Braking the truck with the brake pedal Procedure •...
  • Page 169 4.8.3 Parking brake DANGER! Risk of accident On a clean floor surface, the parking brake will hold the truck with the permissible maximum load on inclines or slopes of up to 15 %. Do not park and abandon the truck on an incline or slope. Applying the parking brake during travel will cause the truck to brake to a halt in a controlled manner.
  • Page 170 4.8.4 Automatic parking brake The automatic parking brake is a comfort function. The truck is prevented from rolling away but not parked securely. The automatic parking brake is automatically activated a preset time (0 to 60 sec) after the truck stops. The factory setting is 30 sec. The setting can be changed by the manufacturer's customer service department.

  • Page 171: Adjusting The Forks

    Adjusting the forks WARNING! Trapping hazard There is a trapping hazard when you perform this operation. uWear work gloves and safety shoes. WARNING! Unsecured and incorrectly adjusted forks can cause accidents Make sure that the fork retaining mechanisms (147) are fitted before adjusting the forks. Depending on the fork carriage, the fork- retaining mechanism (147) will be either via retaining bolts (85 Nm) or fixed stops.
  • Page 172 Procedure • Lift up the locking lever (173). • Push the forks (174) into the correct position on the fork carriage (175). To lift the load securely, the forks (174) must be spread as far apart as possible and positioned centrally with respect to the fork carriage. The load centre must lie centrally between the forks (174).

  • Page 173: Replacing The Forks

    4.10 Replacing the forks WARNING! Risk of injury due to unsecured fork arms There is a risk of injury and trapping when replacing the fork arms. uWear work gloves and safety shoes. uEnsure that the fork arms have sufficient capacity. uNever pull the fork arms towards your body.

  • Page 174: Lifting, Transporting And Depositing Loads

    4.11 Lifting, transporting and depositing loads WARNING! Risk of accident when the load centre is outside the load centre distance If the centre of gravity G of a raised load lies outside the load centre distance D specified for the load handler in the horizontal or vertical planes, under unfavourable conditions the raised load and also the truck can tip over while working.
  • Page 175 WARNING! Risk of collision and damage to the mast due to lifting sequence errors In the case of masts with free lift, lifting sequence errors can occur at low ambient temperatures or with cold hydraulic oil, in combination with high lift speeds and when lifting without an attachment or without a load.
  • Page 176 Transporting loads Requirements – Load raised correctly. – Load handler lowered transport (approx. 200 mm above the ground). – Mast tilted back fully. Procedure • On slopes and inclines always carry the load facing uphill, never approach at an angle or turn. •...
  • Page 177 Depositing loads Requirements – Storage location suitable for storing the load. Procedure • Set the mast vertical. • Drive the truck carefully up to the storage location. • Carefully lower the load handler so that the forks are clear of the load. Avoid depositing the load to prevent damage to the load and the load handler.

  • Page 178: Operating The Lift Mechanism And Integrated Attachments

    4.12 Operating the lift mechanism and integrated attachments WARNING! Operating the lifting device and integrated attachments can be hazardous Other people can be injured in the truck's hazardous area. The hazardous area is defined as the area in which people are at risk from the truck movement, the load handler, attachments etc.
  • Page 179 4.12.1 Operating the lift mechanism with soloPILOT Lifting and lowering Requirements – Truck prepared for operation, see page 156. Procedure • Pull the lever (119) in direction H to raise the load. • Push the lever (119) in direction S to lower the load.
  • Page 180 Positioning integrated sideshifter (option) Requirements – Truck prepared for operation, see page 156. Procedure • Pull the lever (120) in direction R to move the load handler to the right (from the driver’s viewpoint). • Push the lever (120) in direction V to move the load handler to the left (from the driver’s viewpoint).
  • Page 181 Positioning the forks with an integrated fork positioner (option) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation, see page 156. Procedure • Press the acknowledgement key (125) and then within 2 seconds pull the lever (123) in direction H to bring the forks together.
  • Page 182 4.12.2 Operating the lift mechanism with multiPILOT Lifting and lowering Requirements – Truck prepared for operation, see page 156. Procedure • Pull the Multi-Pilot (119) in direction R to raise the load. • Push the Multi Pilot (119) in direction V to lower the load.
  • Page 183 Positioning the integrated sideshift (option) Requirements – Truck prepared for operation, see page 156. Procedure • Press the button (120) to the left to move the load handler to the left (from the driver's viewpoint). • Press the button (120) to the right to move the load handler to the right (from the driver's viewpoint).
  • Page 184 Positioning the fork arms with an integrated fork positioner (optional equipment) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation – see page 156. Procedure • Press the acknowledgement key (177) and then within 2 seconds push the fork positioner lever (176) in direction V to move the fork arms apart.
  • Page 185 4.12.3 Operating the lift mechanism with duoPILOT Lifting and lowering Requirements – Truck prepared for operation, see page 156. Procedure • Pull the lever (119) in direction R to raise the load. • Push the lever (119) in direction V to lower the load.
  • Page 186 Positioning the integrated sideshifter (option) Requirements – Truck prepared for operation, see page 156. Procedure • Pull the lever (120) in direction S to move the load handler to the left (from the driver’s viewpoint). • Push the lever(120) in direction H to move the load handler to the right (from the driver’s viewpoint).
  • Page 187 Positioning the forks with an integrated fork positioner (option) CAUTION! Do not use the fork positioner to clamp loads. Requirements – Truck prepared for operation, see page 156. Procedure • Press the acknowledgement key (125) and then within 2 seconds pull the lever (123) in direction R to bring the forks together.

  • Page 188: Safety Instructions For Operating Additional Attachments

    4.13 Safety instructions for operating additional attachments DANGER! Attaching exchangeable equipment can result in accidents Other people can be injured when attaching exchangeable equipment. Use only exchangeable equipment that has been deemed safe after a risk analysis carried out by the owner. uOnly use attachments that have been approved by the manufacturer of the truck.
  • Page 189 Safety instructions for sideshifter and fork positioner attachments WARNING! Restricted visibility and reduced tilt resistance can cause accidents When using sideshifters and fork positioners, the change in centre of gravity can result in reduced lateral tilt resistance and accidents. Note that this affects visibility as well.
  • Page 190 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 191 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 137, 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 192: Operating Additional Attachments With Solopilot

    4.14 Operating additional attachments with soloPILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. uMark the controls with symbols that indicate their function. uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
  • Page 193 4.14.2 soloPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (120, 123, 125) is assigned the function of the attachment. Unused levers have no function. For connections see page 200. Procedure •...
  • Page 194 4.14.3 soloPILOT with control of ZH1, ZH2 and ZH3 hydraulic ports Depending on the attachments used the levers / buttons (120, 123, 125, 124) are assigned the respective functions. Unused levers have no function. For connections see page 200. Procedure •...

  • Page 195: Operating Additional Attachments With Multipilot

    4.15 Operating additional attachments with multiPILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. uMark the controls with symbols that indicate their function. uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
  • Page 196 4.15.2 multiPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used, the levers/buttons (127, 176, 177) are assigned the function of the attachment. Unused levers have no function. For ports, see page 200. Procedure • Operating hydraulic port ZH1: Press the button (127) to the left or right.

  • Page 197: Operating Additional Attachments With Duopilot

    4.16 Operating additional attachments with duoPILOT WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents. uMark the controls with symbols that indicate their function. uSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so that they match the controls’...
  • Page 198 4.16.2 duoPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (120,123,125) is assigned 120 / 123 the function of the attachment. Unused levers have no function. For connections see page 200. Procedure •...
  • Page 199 4.16.3 duoPILOT with control of ZH1, ZH2 and ZH3 hydraulic ports 120 / 123 Depending on the attachments used the levers / buttons (120,123,124,125) are assigned the respective functions. Unused levers have no function. For connections see page 200. Procedure •...

  • Page 200: Fitting Additional Attachments

    4.17 Fitting additional attachments WARNING! Hot hydraulic oil can cause injury Hot hydraulic oil can cause serious injuries such as burns or scalds. uWait until the hydraulic oil has cooled down. uDo not drain or pump hot hydraulic oil out of the system. uIn the case of injuries, seek medical assistance immediately.
  • Page 201 Depressurising hydraulic plug-in couplings (2-inch display) Requirements – The operator is in the operating position. – Parking brake activated. – Travel direction switch in neutral. – All controls in neutral. Procedure • Press the button (180) for more than 5 seconds. •...
  • Page 202 Depressurise hydraulic plug-in couplings (4-inch display) Requirements – The operator is in the operating position. – Parking brake activated. – Travel direction switch in neutral. – All controls in neutral. Procedure • Actuate the "depressurise auxiliary hydraulics" button (181) – see page 126. Warning triangle on the display lights up flashing yellow –...
  • Page 203 WARNING! Unsecured hydraulic functions can cause accidents Failure to secure hydraulic functions for releasing functions on attachments that hold loads using force (e.g. paper clamps, load holder) can result in accidents. uHydraulic functions for releasing functions that hold loads using force must be secured such that they can be used only after actuation of the acknowledgement button.
  • Page 204 Spilled hydraulic oil must be set using a suitable agent and disposed of in accordance with environmental regulations. If hydraulic oil comes into contact with the skin, wash it off immediately with soap and water. If it comes into contact with the eyes rinse them immediately with flowing water and call for a doctor.

  • Page 205: Assistance Systems

    4.18 Assistance systems The Access, Drive and Lift Control systems help the driver operate the truck with regard to safety regulations, see page 152 of the present operating instructions. The assistance systems have no safety functions and do not disrupt the truck safety functions.
  • Page 206 Symbol Meaning Colour Function Seat switch Fixed Seat switch not actuated yellow Flashing – Seat switch not actuated, actuated yellow function requires seated operator – Seated operator / activated seat switch implausible. Vacate the driver's seat. – Seat switch operated continuously for more than 6 hours.

  • Page 207: Towing Trailers

    Towing trailers DANGER! Inappropriate speeds and excessive trailer loads can be dangerous If you do not adapt your speed and / or use an excessive trailer load, the truck can pull apart when cornering and braking. uThe truck should only be used occasionally to tow trailers. uThe overall weight of the trailer should not exceed the capacity indicated on the capacity plate, see page 55.
  • Page 208 Attaching the trailer Requirements – Truck and trailer are on a level surface. – Trailer prevented from rolling away. Procedure • Push the tow pin (182) down and turn it 90°. • Pull up the tow pin (182) and insert the tiller of the trailer into the opening. Reverse the truck for coupling until the tow pin of the coupling and the hole in the tiller are flush.
  • Page 209 Detaching the trailer Requirements – Truck and trailer are on a level surface. – Trailer prevented from rolling away. Procedure • Push the tow pin (182) down and turn it 90°. • Pull up the tow pin (182) until the tiller of the trailer hangs freely. To uncouple, drive the industrial truck forwards until the tiller of the trailer is free.

  • Page 210: Optional Equipment

    Optional Equipment Keyless Access System The keyless access system allows an individual code to be allocated to each operator or group of operators. Item Description Display unit (EasyAccess Softkey): – Description see page 113 – Entry of 4-digit set-up and access codes –...

  • Page 211: 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 212 6.3.1 Activating the keypad Procedure • Release emergency disconnect switch, see page 159. • Enter the default code 1-2-3-4 using the keys below the display unit (6). The truck is switched on. • Press the key below the "Settings" symbol (186). •...
  • Page 213 6.3.2 Activating the transponder reader Procedure • Release emergency disconnect switch, see page 159. • Enter the default code 1-2-3-4 using the keys below the display unit (6). The truck is switched on. • Press the key below the "Settings" symbol (186).

  • Page 214: Keyless Access System - Display Unit

    Keyless access system - display unit 6.4.1 Switching on the Truck with an Access Code Procedure • Release the emergency disconnect switch, see page 159. • Enter the access code with the buttons below the display (6). The truck is switched on. The truck can only be switched on when the display unit (6) is lit.
  • Page 215 6.4.3 Changing the set-up code Requirements – The truck is switched on, see page 214. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Change set- up code" symbol (187). • Enter the set-up code using the keys below the display unit (6).
  • Page 216 6.4.4 Adding a new access code Requirements – The truck is switched on, see page 214. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Edit access code" symbol (192). The set-up code is requested. •...
  • Page 217 6.4.5 Deleting an access code Requirements – The truck is switched on, see page 214. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Edit access code" symbol (192). The set-up code is requested. •...
  • Page 218 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 219: Keyless Access System - Keypad

    Keyless access system - keypad 6.5.1 Switching on the Truck with an Access Code Procedure • Release the emergency disconnect switch, see page 159. • Enter the access code with the keypad (183). The truck is switched on. The truck can only be switched on when the display unit (6) is lit. If the display unit is in standby the code or transponder will not be recognised.
  • Page 220 6.5.3 Changing the set-up code Requirements – The truck is switched on, see page 219. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Change set- up code" symbol (187). • Enter the set-up code using the keypad (183).
  • Page 221 6.5.4 Adding a new access code Requirements – The truck is switched on, see page 219. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Edit access code" symbol (192). The set-up code is requested. •...
  • Page 222 6.5.5 Deleting an access code Requirements – The truck is switched on, see page 219. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Edit access code" symbol (192). The set-up code is requested. •...
  • Page 223 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 224: Keyless Access System - Transponder Reader

    Keyless access system - transponder reader NOTICE Take care not to damage the transponder. If the transponder is damaged, the truck cannot be switched on. 6.6.1 Switching on the truck with a transponder Procedure • Release the Emergency Disconnect switch, see page 159.
  • Page 225 6.6.3 Changing the set-up transponder Requirements – The truck is switched on, see page 224. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Change set-up code" symbol (187). • Place the set-up transponder on the transponder reader (184).
  • Page 226 6.6.4 Adding a new transponder Requirements – The truck is switched on, see page 224. Procedure • Press the key below the "Settings" symbol (186). • Press below "Edit transponder" symbol (192). The set-up transponder is requested. • Place the set-up transponder on the transponder reader (184).
  • Page 227 6.6.5 Deleting a transponder Requirements – The truck is switched on, see page 224. Procedure • Press the key below the "Settings" symbol (186). • Press the key below the "Edit transponder" symbol (192). set-up transponder requested. • Place the set-up transponder on the transponder reader (184).
  • Page 228 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 229: Tilt Angle Display

    Tilt angle display The tilt angle is shown in the information line and in the symbol field of the display unit. The mast tilt angle is determined relative to the truck (not relative to the axis of the earth). Tilt angle display on the display unit Symbol Meaning Colour Function...

  • Page 230: Steel Cab

    Steel cab WARNING! Risk of accidents due to fogged, icy mirrors and windows Windows (e.g. rear windscreen, front window) and mirrors may be fogged or iced up. This can lead to accidents and injuries. uAlways clean or de-ice the windows and mirrors before operation. WARNING! Open doors can result in accidents uDo not travel with an open door.
  • Page 231 6.8.1 Door Monitoring CAUTION! Accident risk when opening the cabin door during travel If the cabin door is opened while driving, the truck automatically brakes to a maximum speed of 4 km/h or comes to a standstill. There is a risk of collision and injury when opening the cabin door while driving. uDo not open the cabin door while driving.
  • Page 232 The front section of the door can be opened to approx. 180° and locked in the open position. The rear section of the door is fixed with screws and can be opened for maintenance work. Opening the cabin door from the outside Procedure •...
  • Page 233 Closing the cabin door from the inside Procedure • Before boarding, actuate the turning mechanism (199) and release the front section of the cabin door from the stop (201). • To close the cabin door, pull the door shut carefully until the lock audibly engages. When boarding the industrial truck, guide or hold the cabin door as it moves freely and is not cushioned by a gas strut.
  • Page 234 Attaching the plastic side panel – right-hand side Procedure • Hang the plastic side panel (205) in the top left-hand corner. • Fasten the zips (204) where necessary. The plastic side panel is installed. Opening and rolling up the plastic side panel – left-hand side Procedure •...

  • Page 235: Optional Cabin Interior Equipment

    Optional Cabin Interior Equipment CAUTION! Risk of injury if the sun blind is pulled together too quickly There is a risk of trapping your fingers when rolling up the sun blind. uCarefully and slowly retract the sun blind when rolling it up. Possible cabin interior equipment: –...
  • Page 236 Unrolling the sun blind Procedure • To unroll the sun blind (208), use the tab (207) on the eyelets (206). Note: The tab is part of the eyelet and not a separate element. • Carefully pull out the sun blind (208) and hook the eyelets (206) at the rear position on the hooks (211).

  • Page 237: Sliding Windows

    6.10 Sliding windows CAUTION! An unlocked sliding window can cause accidents uThe sliding windows must be locked at all times. Opening and closing windows Procedure • Press the lock (215) down. • Move the window forward or back. • Engage the lock in the stop (216).

  • Page 238: Gate

    6.11 Gate CAUTION! Risk of accidents due to faulty swivelling gate uNever use the truck without a fully functional swivelling gate. Have the swivelling gate checked by authorised specialist personnel after an accident. Do not modify the swivelling gate. uAlways close the swivelling gate fully and make sure it is locked in place. uAfter closing the swivelling gate, fasten the seat belt, see page 150.
  • Page 239 Trucks with swivelling gate monitoring may experience the following situations if the swivelling gate is not locked: – The "cabin door open" symbol lights up in the display unit. – The truck speed is limited to a maximum of 4 km/h or the travel cut-off is activated.

  • Page 240: Panel Door

    6.12 Panel door WARNING! Open doors can result in accidents uDo not travel with an open door. When opening the door, make sure there is nobody in the door's swing range. uAlways close the door tightly and make sure it is locked. uAfter closing the summer door, fasten the seat belt, see page 150.
  • Page 241 Trucks with summer door monitoring may experience the following situations if the summer door is not locked: – The cabin door open symbol lights up in the display unit (see page 116). – The truck speed is limited to a maximum of 4 km/h or the travel cut-off is activated.

  • Page 242: Operator Position Extension

    6.13 Operator position extension DANGER! Altering the tilt resistance can be dangerous The lateral tilt resistance reduces with a higher truck centre of gravity. The height above the overhead guard (h ) increases by 150 mm / 300 mm, see page 37. uAdapt the travel speed of the truck, in particular when cornering.

  • Page 243: Heater, Fan, Air Conditioning System

    6.15 Heater, fan, air conditioning system 6.15.1 Heating The heater and ventilation are operated via the control panel. The controls are illuminated. Regular maintenance is required to ensure that the air-conditioning system functions correctly – see page 363. At the latest, when only a reduced air flow with increased temperature comes out of the air flow jets, the air filter is used up and must be replaced immediately.
  • Page 244 Item Description Item Description Windscreen jets Control panel Body jet Off position Footwell jet Fan controller Temperature controller...
  • Page 245 6.15.2 Air Conditioning and Heater CAUTION! Too great a temperature difference affects health uWhen operating the air-conditioning system, do not exceed a temperature difference of 6 °C in relation to the air outside. uKeep doors and windows closed when operating the air-conditioning system. uDo not direct air flow jets towards persons.
  • Page 246 Using the air conditioning for temporary dehumidification in high air humidity and high temperatures Procedure • Turn the fan controller (228) clockwise as far as the stop. • Switch on the cooling button (230). • Adjust the temperature controller (225) according to the outside temperature. •...

  • Page 247: Switching Off The Operating Hydraulics

    6.16 Switching off the operating hydraulics All functions of the working hydraulics (lifting, tilting, ZH1, ZH2, ZH3) can be cut off via the display unit keypad or using the buttons on the armrest control panel. Button assignment Symbol Meaning Cut-off of all working hydraulics functions Appearance on the display unit Symbol Meaning...

  • Page 248: Usb Charger Module In Armrest

    6.17 USB Charger Module in Armrest The USB charger module is designed for charging electrical devices such as smart phones etc. and is located in the storage facility in the armrest. Connection data: 5 V, max. 1 A 6.18 USB Charger Module in Storage Facility The USB charger module is designed for charging electrical devices such as smart phones and is located in the front-right storage...

  • Page 249: Voltage Transformer

    6.19 Voltage Transformer Power supply in the rear under the service 12VDC access max. 12A – Optional power supply – 12 V / 150 W or 24 V / 150 W version Connection assignment 12 V / 150 W version 24 V / 150 W version 12 V 24 V...

  • Page 250: Sound Module

    The "media player" button function can be displayed on the display unit via the buttons of the armrest control panel, see page 112. When pressed, the "Sound module Premium" is switched on. Upon activation, the sound module is visible for 60 seconds as the "Jungheinrich sound module" Bluetooth device. Symbol...
  • Page 251 • Initiate the search for visible Bluetooth devices on the digital end device and select the "Jungheinrich sound module" entry to establish the connection. • In order to play audio files, verify that the "Jungheinrich sound module" entry on the digital end device has the necessary authorisation. Adjust the authorisation if necessary.
  • Page 252 Symbol Meaning Reduce volume Press and hold the button to mute. Increase volume Sound module settings menu Back: Returns to the previous menu. Button assignment in sound module settings menu Symbol Meaning Switch off the sound module Source selection: Switch between "FM" radio, "DAB" radio, an audio source connected via Bluetooth®...
  • Page 253 Button assignment in hands-free system options menu (o) Symbol Meaning Answer incoming phone call End current phone call Mute Reduce volume When pressed, the volume is muted. Increase volume Bluetooth pairing – see page 250 Back: Returns to the previous menu. The settings menu for the hands-free system can be accessed directly with a double-press of the FN button.

  • Page 254: Load Weighing

    6.21 Load Weighing Only when equipped with display unit with 4-inch display The integrated load weighing system measures the weight continuously with a tolerance of 5 % of the rated capacity. For industrial trucks with load damping, the tolerance increases in the upper range of the capacity to 10 % of the rated capacity. The weighing system is not a substitute for calibrated scales.

  • Page 255: Load Weighing Plus

    6.22 Load Weighing Plus Load weighing plus expands the load weighing function with a controllable tare and total function in order to, for example, compensate for the weight of an attachment and to track the total weight when loading a lorry. The display unit shows the current net individual weight and, after an "S", also shows the number and total weight of the individual weights saved.
  • Page 256 Button allocation in individual weights submenu (o) Symbol Meaning Reset the addition of the last net individual weight Last weights Back: Returns to the previous menu.

  • Page 257: Removable Load Backrest

    6.23 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 (237). •...

  • Page 258: Load Damping

    6.25 Load damping WARNING! Risk of injury from energy-storing pressure vessels The hydraulic accumulator is a pressure vessel connected to the hydraulic line with a membrane and a compressed gas (nitrogen) under pre-charge pressure. Pressurised components and fluids can cause severe injury. If the pressure in the hydraulic line increases, the pressure on the membrane also increases and the gas is further compressed.
  • Page 259 Load damping reduces the shocks and impacts acting on the load to be moved by means of a hydraulic accumulator. If pressure fluctuations occur in the hydraulic system e.g. due to potholes, they will be absorbed and minimised by the hydraulic accumulator.

  • Page 260: Lift Cut-Off

    6.26 Lift cut-off A lift cutout device can be factory fitted when working in areas of restricted height. This interrupts lifting. To continue lifting: Requirements – Inspection and tasks before starting daily operations performed (see page 137). – "Lift cutout" tested with function key (see page 126). Procedure •...

  • Page 261: Sideshifter Centre Position

    6.27 Sideshifter Centre Position Automatic side shift centre position operation. Requirements – Checks and operations before starting daily work completed, see page 137. – "Automatic side shift centre position" function checked with the function key, see page 123. Procedure • Press the side shift centre position button (see page 123) if the function is not permanently triggered after switching on (o) or through previous actuation (o).

  • Page 262: Fork Tilt Horizontal

    6.28 Fork Tilt Horizontal Only when equipped with display unit with 4-inch display Alignment of the fork arms parallel to the travel path. Requirements – Checks and operations before starting daily work completed, see page 137. – "Fork tilt horizontal" function tested, see page 123. Procedure •...

  • Page 263: Fire Extinguisher

    6.29 Fire extinguisher Procedure • Open the fasteners (240). • Pull the fire extinguish out of its bracket. To operate, refer to the illustrations on the fire extinguisher.

  • Page 264: Simple Manoeuvring Coupling With Pin

    6.30 Simple Manoeuvring Coupling with Pin DANGER! Danger of falling due to use of the trailer coupling as an attachment point Use of the trailer coupling as a lifting point for using a crane or jacking up is prohibited. There is a danger of falling.
  • Page 265 Operating manoeuvring coupling – uncoupling the trailer Procedure • Prevent the trailer from rolling away. • Release and pull out the tow pin (242). • Drive the truck forwards. The trailer has been uncoupled.

  • Page 266: Trailer Coupling With Hand Lever Or Remote Control

    6.31 Trailer Coupling with Hand Lever or Remote Control Refer to the instructions for towing trailers, see page 207. DANGER! Danger of falling due to use of the trailer coupling as an attachment point Use of the trailer coupling as a lifting point for using a crane or jacking up is prohibited.

  • Page 268: Control Layout "N

    6.32 Control layout “N” WARNING! Persons standing under or on a raised load handler are at risk of accidents Do not allow anyone to stand under or on a raised load handler. uDo not stand on the load handler. uDo not lift any persons on the load handler. uInstruct other people to move out of the hazardous area of the truck.
  • Page 269 Tilting CAUTION! Trapping hazard from inclined mast uWhen tilting the mast back, keep all parts of your body from between the mast and the front wall. Procedure • Push the Duo-Pilot lever (119) forward (direction V) to tilt the load forward. •...

  • Page 270: Operating The Auxiliary Hydraulics Without Pressing The Acknowledgement Key

    6.33 Operating the auxiliary hydraulics without pressing the acknowledgement key WARNING! Hydraulic ports for clamping attachments uClamping attachments may only be added to trucks which have a button to enable additional hydraulic functions. WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents.
  • Page 271 6.33.1 soloPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (120,123), is assigned the function of the attachment. Unused levers have no function. For connections see page 200. Procedure • Operating hydraulic port ZH1: Move the lever (120) in direction V or •...
  • Page 272 6.33.3 multiPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used, the lever/button (119, 127) is assigned the function of the attachment. Unused levers have no function. For ports, see page 200. Procedure • Operating hydraulic port ZH1: Actuate the button (127) to the left or right.
  • Page 273 6.33.5 duoPILOT with control of ZH1 and ZH2 hydraulic ports Depending on the attachments used the lever / button (120,123), is assigned the function of the attachment. Unused levers have no function. For connections see page 200. 120 / 123 Procedure •...

  • Page 274: Special Control Layout

    6.34 Special control layout WARNING! Hydraulic ports for clamping attachments uClamping attachments may only be added to trucks which have a button to enable additional hydraulic functions. WARNING! Incorrect symbols can cause accidents Symbols on controls that do not depict the function of the attachments can cause accidents.
  • Page 275 Changeover level The changeover level is activated and deactivated via the button (178) on the control. The symbol for the active changeover level (248) is shown in yellow on the display.
  • Page 276 If the operating functions at changeover level differ from the operating functions at basic level, these are indicated by grey labels with pictograms on the controls. If the operating function is not assigned, this is indicated by a label with an empty field.
  • Page 277 Acknowledgement feature Certain hydraulic functions (e.g. opening a load clamp) must be confirmed via the acknowledgement key (125) on the control. The acknowledgement feature is activated by actuating the acknowledgement key (125) with the padlock symbol. If a hydraulic function is set to require acknowledgement, the acknowledgement key (125) must be actuated regardless of the lever assignment at operating level.

  • Page 278: Warning Zone Light

    6.35 Warning Zone Light CAUTION! Risk of accident due to dazzling Looking directly into the light beam of a warning zone light can dazzle and temporarily impair eyesight. uDo not look directly into the light beam of a warning zone light. uDo not alter the position and alignment of the warning zone light on the truck.
  • Page 279 6.35.1.1 Additional information on Floor-Spot blue The activated Floor-Spot gives persons advance warning of the travel path of the forklift truck by projecting a blue dot onto the ground at a set distance. CAUTION! Risk of retinal damage due to blue light The Floor-Spot on the truck is classified in risk group 2 according to the standard IEC 62471: medium risk.
  • Page 280 6.35.2 Floor-Bow The Floor-Bow serves as an auxiliary device and projects a coloured arc on the ground behind the truck when reverse travel (t) is selected or after pressing a button (o – see page 123).
  • Page 281 6.35.2.1 Additional information for the blue Floor-Bow The activated Floor-Bow forewarns people of the truck's travel path by projecting a blue dot onto the floor at the set distance. CAUTION! Risk of retinal damage due to blue light The Floor-Bow on the truck is classified in risk group 2 according to the standard IEC 62471: medium risk.
  • Page 282 6.35.3 Floor-Stripes The Floor-Stripes serve as auxiliary devices and project a coloured stripe on the ground on the left and right at a distance of 1 m from the truck when reverse travel (t) is selected or after pressing a button (o – see page 123).

  • Page 283: Optional Equipment For Road Traffic According To Stvzo

    6.36 Optional Equipment for Road Traffic According to StVZO WARNING! Risk of accidents in public traffic areas The use of public traffic areas and travel on public roads in particular requires utmost caution at all times as well as consideration and awareness for other traffic participants in order to avoid dangerous situations and accidents.
  • Page 284 The following assemblies are available as optional equipment for road traffic: – Warning indicator (251) – Warning triangle (250) – Fork cover (253) – Wheel chock (252)

  • Page 285: Horn Button On Overhead Guard

    6.37 Horn Button on Overhead Guard When the horn button on the overhead guard is actuated, an acoustic signal is triggered. Use the horn button on the overhead guard only when reversing.

  • Page 286: Options Bracket

    6.38 Options bracket WARNING! Risk of collision when using optional equipment on the options bracket Use of optional equipment installed on the options bracket during travel or hydraulic operations can lead to collisions with persons and objects. uDo not use the optional equipment on the options bracket during travel or hydraulic operations.
  • Page 287 The options bracket for attaching suitable optional equipment is mounted on the right A-pillar and can support a weight of up to 5,3 kg with a maximum spacing of 180 mm. Optional equipment mounted on the options bracket must not extend beyond the truck contour.

  • Page 288: Antistatic Strap

    6.39 Antistatic strap The antistatic strap (254) depends on the tyres and ensures that the truck does not become statically charged. Before setting off, make sure that the antistatic strap (254) is undamaged and clean. When the truck is stationary, the contact surface of the antistatic strap (254) on the ground should be approx.

  • Page 289: Troubleshooting

    Troubleshooting Troubleshooting This chapter allows operators to identify and rectify simple faults or the results of incorrect operation themselves. When trying to locate a fault, proceed in the order shown in the remedy table. If, after carrying out the following remedial action, the industrial truck cannot be restored to operation or if a fault in the electronics system is displayed with a corresponding error message, contact the manufacturer’s customer service department.
  • Page 290 Display Meaning Limitation of hydraulic-pump speed to reduce heat input into the 2412.1 hydraulic oil. Seat switch or seat belt lock or cabin door not closed. 2908 Industrial truck ready for operation, hydraulic function actuated, operating position not properly assumed. 2951 Hydraulic function applied during power-up.
  • Page 291 Fault Possible cause Actions Truck does not start – Battery connector not – Check battery connector plugged in. and plug in if necessary. – Emergency disconnect – Unlock the emergency switch pressed. disconnect switch. – Key switch set to O. –...
  • Page 292 Troubleshooting Fault Possible cause Actions Truck does not start – Battery connector not – Check battery connector plugged in. and plug in if necessary. – Control line not – Check control line and connected to lithium- connect if necessary. ion battery (o) or interface converter (o) of lithium-ion battery.
  • Page 293 Fault Possible cause Actions Load cannot be lifted – Truck not operational. – Carry out all actions listed under "Truck does not start". – Hydraulic oil level too – Check the hydraulic oil low. level and top up, if necessary. –...

  • Page 294: Moving A Truck Without Its Own Drive System

    Moving a truck without its own drive system WARNING! Accident risk Other people can be injured if the truck is towed incorrectly. uOnly use vehicles to tow the truck which have sufficient tow and brake forces for the trailer load without its own braking system. uAlways use a pull rod to tow.
  • Page 295 Towing the truck Requirements – Truck parked securely. – Actuate the emergency disconnect switch and switch off the key switch. – Disconnect the battery connector. Tools and Material Required – Size 8 hexagon socket torque wrench – Size 17 hex torque wrench –...

  • Page 297: Emergency Lowering

    Emergency lowering The load handler can be lowered manually if a fault occurs in the hydraulic controller. WARNING! Load handler emergency lowering uInstruct other people to move out of the hazardous area of the truck during emergency lowering. uNever step or stand underneath a raised load handler. uOnly operate the emergency lowering valve when standing next to the truck.

  • Page 298: Exiting The Driver's Cab Via The Right-Hand Side Window Or The Rear Windscreen (Emergency Exit)

    Exiting the Driver's Cab via the Right-Hand Side Window or the Rear Windscreen (Emergency Exit) CAUTION! Risk of injury when striking the side window or the rear windscreen Striking the side window or the rear windscreen can result in facial injuries due to splinters of glass.

  • Page 301: 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 53.

  • Page 302: 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 363. The manufacturer recommends the replacement of the maintenance parts also listed in chapter "Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement"...

  • Page 303: Maintenance Safety Regulations

    Maintenance Safety Regulations WARNING! Danger from hot fluids and hot components Operating materials (hydraulic oil) as well as components of the hydraulic system and the drive train become very hot during operation. Hot components are freely accessible when the panels are open or the covers are removed. Direct contact with hot operating materials can cause scalds.

  • Page 304: 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 305: Consumables And Used Parts

    Consumables and used parts CAUTION! Consumables and used parts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental-protection regulations. Oil changes should be carried out by the manufacturer's customer service department, whose staff are specially trained for this task.

  • Page 306: Lift Chains

    Lift Chains WARNING! Risk of accident from non-lubricated and incorrectly cleaned lift chains Lift chains are safety-critical parts. Lift chains must not show signs of serious contamination. Lift chains must always be clean and sufficiently lubricated. uThe lift chains are cleaned by wiping or brushing. Significant contamination can be softened by a paraffin derivative such as petroleum.

  • Page 307: Air Conditioning System

    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 308: 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 309 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 310: Lubrication Schedule

    Lubrication Schedule Wheel hub transmission oil filler g Contact surfaces plug Wheel hub transmission oil drain Grease nipple plug Check hole / oil filler hole in the Hydraulic oil filler plug drive axle brake c Hydraulic oil drain plug Drive axle brake oil drain plug Windscreen washer fluid filler plug Brake system brake oil filler (inside the cabin)
  • Page 311 Wheel hub transmission oil filler g Contact surfaces plug Wheel hub transmission oil drain Grease nipple plug Check hole / oil filler hole in the Hydraulic oil filler plug drive axle brake c Hydraulic oil drain plug Drive axle brake oil drain plug Windscreen washer fluid filler plug Brake system brake oil filler (inside the cabin)

  • Page 312: Consumables

    Consumables Code Order no. Delivere Filling- Description Used for quantity quantity 51132826 29 l Jungheinrich Hydraulic system hydraulic oil 51132827 HVLP 32 51188578 20 l 51037497 Renolin 22 HLPD 50429647 20 l 51887189 20 l Plantosyn 46 HVI (BIO hydraulic oil)
  • Page 313 WARNING! Danger of contamination of the area of use by hydraulic oil from the hydraulic system Conversion of the hydraulic system from BIO hydraulic oil to another permissible hydraulic oil or vice versa or mixed operation is prohibited! The use of hydraulic oil of another specification or viscosity as well as the mixing of additives is prohibited! uDo not switch to from using BIO hydraulic oil to another hydraulic oil and vice versa.

  • Page 314: Maintenance And Repairs

    Maintenance and repairs Preparing the truck for maintenance and repair work WARNING! Risk of accidents when working under the load handler, driver's cab and lift truck uWhen working under a raised load handler, driver's cab or a raised truck, secure them to prevent the truck from from lowering, tipping or sliding away.

  • Page 316: Checking The Bonding Adhesive On The Roof Window

    Checking the bonding adhesive on the roof window WARNING! Risk of injury from falling loads The glued-in roof window protects the operator from falling loads. The intact sealing joint on the top protects the adhesive bonding of the roof window from external influences.

  • Page 317: Lifting And Jacking Up The Truck Safely

    Lifting and jacking up the truck safely WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. uNote the weight of the truck on the data plate. uAlways use a jack with a minimum capacity of 5000 kg.

  • Page 319: Opening Or Closing The Rear Panel

    Opening or closing the rear panel Opening the panel Requirements – Prepare the truck for maintenance and repairs (see page 314). Procedure • Undo the two screws (262). • Pull the rear panel back and remove it. The rear panel is now open. The fuses and other electrical components can now be reached.

  • Page 320: Disassembling Or Assembling The Floor Plate

    Disassembling or assembling the floor plate WARNING! Danger from hot fluids and hot components Operating materials (hydraulic oil) as well as components of the hydraulic system and the drive train become very hot during operation. Hot components are freely accessible when the panels are open or the covers are removed. Direct contact with hot operating materials can cause scalds.

  • Page 321: Replacing The Wheels

    Replacing the wheels WARNING! A truck tipover can cause accidents In order to raise the truck, use only suitable lifting gear at the points specially provided for this purpose. uNote the weight of the truck on the data plate. uAlways use a jack with a minimum capacity of 5000 kg. uRaise the unladen truck on a level surface.
  • Page 322 Removing the wheels Requirements – Truck prepared for maintenance and repair work – see page 314. Tools and Material Required – Jack with a minimum capacity of 5000 kg – Wooden blocks with a minimum capacity of 5000 kg – Mounting lever –...

  • Page 323: Checking The Attachment Of The Wheels

    Checking the attachment of the wheels WARNING! Using different tyres can cause accidents The quality of the tyres affects the operational stability and performance of the truck. uThe diameter of the wheels must differ by no more than 15 mm. uAlways replace tyres in pairs, i.e.

  • Page 324: Hydraulic System

    Hydraulic system WARNING! Danger from hot fluids and hot components Operating materials (hydraulic oil) as well as components of the hydraulic system and the drive train become very hot during operation. Hot components are freely accessible when the panels are open or the covers are removed. Direct contact with hot operating materials can cause scalds.
  • Page 325 CAUTION! Consumables and used parts represent an environmental hazard uDispose of used operating materials and used parts in accordance with the applicable environmental protection regulations. uOil changes may only be performed by the manufacturer's customer service department. uNote the safety regulations when handling these substances. When carrying out maintenance and repair work in the engine compartment, the pedal plate/floor plate must be removed.
  • Page 326 5.8.2 Replacing the hydraulic oil CAUTION! The use of unsuitable hydraulic oils can cause damage Trucks with bio hydraulic oil have a warning notice on the hydraulic reservoir: “Add hydraulic oil only”. uUse only BIO hydraulic oil. Requirements – Industrial truck parked on a level surface. –...
  • Page 327 Requirements – Park the truck on a level surface. – Truck prepared for maintenance and repair work (see page 314). – Floor plate removed (see page 320). Procedure • Place an oil collection container of sufficient capacity (see page 312) underneath to collect any drips that may escape.

  • Page 328: Checking The Gear Oil Level

    Checking the gear oil level CAUTION! Consumables and used parts represent an environmental hazard uDispose of used operating materials and used parts in accordance with the applicable environmental protection regulations. uOil changes may only be performed by the manufacturer's customer service department.

  • Page 329: Automatic Brake In The Axle

    5.9.2 Replacing the gear oil Requirements – Truck parked securely on a level surface. Procedure • Place an oil collection container of sufficient capacity (see page 312) underneath the oil drain plug (270). • Remove the oil drain plug (270) with sealing ring and collect the transmission oil in the oil collection container.
  • Page 330 5.10.1 Checking the Brake Oil Level in the Axle Requirements – Park the truck securely on a level surface –see page 158 Tools and Material Required – Oil pan Procedure • Place the oil pan under the axle. • Unscrew the oil check plug (271). •...
  • Page 331 5.10.2 Changing the Brake Oil NOTICE Warning of viscous brake oil Brake oil can be viscous when the transmission is cold. uChange the brake oil only at operational temperature and when the truck is in a horizontal position. Requirements – Park the truck securely on a level surface –see page 158 Tools and Material Required –...

  • Page 332: Brake

    5.11 Brake 5.11.1 Check the brake oil level WARNING! Malfunctioning brake due to incorrect consumable Using brake fluid can cause the brake to fail. uOnly use authorised brake oil according to the consumables table, see page 312. Procedure • Loosen the nuts and remove the cover (274). •...

  • Page 333: Heater And Air Conditioning

    5.12 Heater and Air Conditioning WARNING! Danger from hot fluids and hot components Operating materials (hydraulic oil) as well as components of the hydraulic system and the drive train become very hot during operation. Hot components are freely accessible when the panels are open or the covers are removed. Direct contact with hot operating materials can cause scalds.

  • Page 334: Adding Window Washer System Fluid

    5.13 Adding window washer system fluid Requirements – Screw cap (277) of the container (277) is opened. Procedure • Fill container (278) with weather-dependent additives (max. 3,5 Liter). Use a funnel or pouring aid to make filling easier. • Wipe away excess fluid. •...

  • Page 335: Checking The Electrical Fuses

    5.14 Checking the electrical fuses WARNING! Risk of accidents due to electrical current Make sure the electrical system is voltage-free before starting work on it. uPark the truck securely (see page 158). uPress the emergency disconnect switch. u Equipped with lithium-ion battery (o): Disconnect the truck-side control line from the connection on the battery tray or the interface converter (o) on the battery.
  • Page 336 Checking electrical fuses Requirements – Prepare the truck for maintenance and repair work (see page 314). Procedure • Remove the rear cover by undoing the mounting screws – see page 319. • Equipment with comfort charging socket (o): Disconnect connector XB334. •...
  • Page 337 5.14.1 Fuse ratings Main fuses Designation Type / rating Electrical circuit SF56 Mega 120V / 650A Main fuse FKS 80V / 20A UL SIO power supply FKS 80V / 30A UL 80 V heater supply 7F11 FKS 80V / 30A UL 80 V auxiliary-converter supply FKS 80V / 30A UL Air-conditioning system...
  • Page 338 9F67 2F14 1F13 2F19 1F14 9F63 4F10 9F66 5F20 Control fuses for the drive section Description Type / rating Electrical circuit Release valve FK1 MINI, 32V/4A UL Lift 2 valve 9F67 FK1 MINI, 32V/4A UL Axle cooling fan ZH1/4 left/forwards valve ZH1/4 right/backwards valve ZH2/3 right/backwards valve 2F14...
  • Page 339 Description Type / rating Electrical circuit Steering actual value sensor Battery door and comfort charging flap FK1 MINI, 32V/4A UL sensor Parking brake sensor FK1 MINI, 32V/2A UL Internal supply of the logic 9F63 FK1 MINI, 32V/7.5A UL Oil-cooler fan FK1 MINI, 32V/20A UL Control for options modules 24V supply 4F10...
  • Page 340 1 2 3 4 Control fuses for the cabin section: Electrical circuit 0 (standby) Description Value (A) Consumer (24 V) F17.1 Truck terminal Light switch for search lighting, left parking light, left tail light Front left and right indicators, rear left and right indicators 5F4.1 Right parking light, right tail light...
  • Page 341 1 2 3 4 Control fuses for the cabin section: Electrical circuit 1 Designation Rating (A) Consumer (24 V) Front left and right work lights, rear left and right work lights Horn, rear windscreen heater, options 5F5.3 Right dipped light, right brake light Third-party truck terminal Reversing buzzer, warning indicator, front 5F13...
  • Page 342 5.14.1.1 Optional Equipment Depending on the truck equipment, additional fused components may be connected in the cabin section near the control unit. All fuses are of the following type: FK1 MINI 32 V / UL. The status of each fuse circuit is indicated by an LED on the module. In the event of a defective fuse, the associated LED goes out.
  • Page 343 Description Rating (A) Consumer (24 V) 9F17.1 Fuse circuit 1 (condenser fan 9M11) 9F17.2 Fuse circuit 2 (condenser fan 9M12) 9F17.3 Fuse circuit 3 (relay control) 9F17.4 Fuse circuit 4 9F17.5 Fuse circuit 5 9F17.6 Fuse circuit 6 9F17.7 Fuse circuit 7, electrically isolated Assignment of status LED to the respective fuse circuit...
  • Page 344 Auxiliary inputs and outputs module (9U26 NxT CIO) Description Rating (A) Consumer (24 V) 9F36.1 Digital output 1 9F36.2 Digital output 2 9F36.3 Consumer 1, e. g. Floor-Stripes 9F36.4 Consumer 2 9F36.5 Consumer 3 9F36.6 Consumer 4 9F36.7 Current controller output 1/2 Assignment of status LED to the respective fuse circuit 1 2 3 4 External operating components module (9U16 NxT SCI)
  • Page 345 Voltage converter 7U6 - 24V / 24V Description Rating (A) Consumer F3.1 7.5 A Option Voltage converter 7U13 - 24V / 24V Description Rating (A) Consumer 15 A Option...
  • Page 346 Control auxiliary converter U30 and U30.1 - 80V / 24V Description Rating (A) Consumer F3.1 25 A NxT SIO...

  • Page 347: Connector Overview

    5.15 Connector overview 5.15.1 Operator position Connection Description 1B12 Accelerator pedal 1B19 Brake pedal sensor 2U13 multiPILOT Left-hand combi tail light Right-hand combi tail light Left-hand combi light Right-hand combi light 3U10 Steering setpoint device Control unit display Horn Buzzer 4H3/4H3.1 Beacon / strobe light 5E11...
  • Page 348 Connection Description X5S3 Indicator switch connector X7S9 Interface, seat occupancy switch/seat belt lock switch/seat heating/compressor X9M2.1 Rear wiper motor interface X9M7 Fan heater connector XB527 Interface, accelerator pedal/foot switch XS500 Chassis on-board power supply interface XS501 CCU power supply interface XS502 CUST interface XS503...
  • Page 349 5E19 5E20 5E22 5E21 XS528 X9M2.1 XS525 9M2.1 5E11 5E12 2U13 XS507 XS511 XS510 XS509 XS504 XS506 XS503 XS513 7S82 XS508 XS502 XS505 XS512 XS500 XS501 X7S9...
  • Page 350 X9M7 X5S3 XU28 9M2.2 X3U10 7U6/7U13/9U26/9U27/9U16 XB527 7S40 1B12 1B19...
  • Page 351 5.15.2 Drive section Connection Description 1B28 Right-hand drive motor combined sensor 1B28.1 Left-hand drive motor combined sensor 1B29 Pressure switch for parking brake Right-hand drive motor Left-hand drive motor 1U27 SIO control I/O chassis 1U28 TMC travel/lift control 2B54 Lift motor speed/temperature Hydraulic motor 2Y106 Lift valve...
  • Page 352 Connection Description XB331 TMC interface XS300 Chassis on-board power supply interface XS302 Chassis on-board power supply interface XS302.1 Valve block interface XS303 Additional converter IN interface XS304 Cabin heating interface XS305 Mast module interface XS329 Overhead guard on-board power supply interface XS330 SIO supply interface XS331...
  • Page 353 7B13 2Y106 2Y29 X9M.1 7Y47 1B29 2Y94 2Y115 XS331 2Y87 X1B28.1 2Y95 2Y114 XB331 2Y93 XS302.1 X1B28 X9M1.3 X2B54 1U28 U30.1 9M23 9M24 1U27 7U6/7U13/9U26/9U27/9U16...
  • Page 354 XS501 XS501 XS330 X9B69 XS304 XS333 XS305 XS300 XS303 XS329 XS302 XS302 X3U9 9M1.3 2B54 9M1.1 1B28.1 1B28...

  • Page 355: Cleaning

    5.16 Cleaning Cleaning tasks may only take place in the designated locations, which adhere to the stipulations of the country of use. The cleaning interval must be adapted to the operating conditions of the truck. Before setting off, ensure that the field of view is clear! CAUTION! Risk of injury due to falling from the truck Do not climb on the truck, there is a risk of becoming stuck, slipping and falling.
  • Page 356 Cleaning the truck Requirements – Truck prepared for maintenance and repair work (see page 314). Tools and Material Required – Water-based solvents – Clean sponges, rags, cotton cloths or paper towels Procedure • Clean the surface of the truck with water-based solvents and water. Use clean sponges, rags, cotton cloths or paper towels for cleaning purposes.
  • Page 357 5.16.1 Cleaning the roof window NOTICE Risk of damage to the roof window Dry cleaning, cleaning with paper towels or cleaning with dirty or large-fibre cleaning cloths can scratch the polycarbonate roof window. The static charge caused by dry cleaning can attract more dust to the roof window. The use of unsuitable cleaning agents can also damage the roof window.
  • Page 358 5.16.2 Cleaning the electrical system assemblies NOTICE Risk of electrical-system damage Cleaning the electronic system assemblies (controllers, sensors, motors etc.) with water can damage the electrical system. uDo not clean the electrical system with water. uClean the electrical system with weak suction or compressed air (use a compressor with a water trap) and a non-conductive, anti-static brush.

  • Page 359: Restoring The Truck To Service After Maintenance And Repairs

    5.17 Restoring the truck to service after maintenance and repairs Procedure • Thoroughly clean the truck, see page 355. • Lubricate the truck according to the lubrication diagram, see page 310. • Clean the battery, grease the terminals and connect the battery. •...

  • Page 360: 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 361: During Decommissioning

    During decommissioning NOTICE Full discharge can damage the battery Self-discharge can cause the battery to fully discharge. Full discharge shortens the useful life of the battery. uCharge the battery at least every 2 months. Charge the battery, see page 94. Restoring the truck to service after decommissioning Procedure •...

  • Page 362: 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 363: Maintenance, Inspection And Changing Of Maintenance Parts Requiring Replacement

    G Maintenance, Inspection and Changing of Maintenance Parts Requiring Replacement WARNING! Risk of accidents during repair and maintenance work Maintenance, service and repair work may only be carried out when the truck is de-energised. uPark the truck securely (see page 158). uPress the emergency disconnect switch.

  • Page 364: Maintenance Contents Efg 425K-435 / S30

    Maintenance Contents EFG 425k-435 / S30 Issued on: 2024-04-15 10:30 Owner To be performed every 50 service hours, but at least once a week. 1.1.1 Maintenance contents 1.1.1.1 Standard equipment Brakes Test the brake. Hydraulic operations Lubricate the load chains. Lubricate the contact surfaces of the mast.
  • Page 365 Electrical system Warning and safety equipment in accordance with the operating instructions Functionality of display and controls Test emergency disconnect switch and check for damage Power supply Compare the information (battery voltage, battery weight) on the battery data plate with the information on the truck data plate.

  • Page 366: Customer Service

    Work lights Electrical system Test lighting and check for damage Electrical heating Chassis/structure Test the heater Weather protection Chassis/structure Test doors and check for damage Optional electrical equipment Electrical system Test optional electrical equipment and check for damage Optional equipment Chassis/structure Test optional equipment such as mirrors, storage compartments, handles, windscreen wipers and windscreen washing systems, etc.
  • Page 367 1.2.1 Maintenance contents 1.2.1.1 Standard equipment Brakes Test the brake. Correct the brake fluid level via the check hole in the brake housing. Electrical system Clean the fan. Perform insulation inspection. Travel Correct the transmission oil level or grease filling of the transmission. Hydraulic operations Adjust the slide pieces.
  • Page 368 Side shift Hydraulic operations Adjust the axial play of the front and rear rollers. Clean and grease attachment bearings, guides and stops. Test the side shift adjustment. Telescopic forks Hydraulic operations Adjust the attachment. Clean and grease attachment bearings, guides and stops. Adjust the pistons and piston rods.
  • Page 369 Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage. Correct the battery-acid level using demineralised water. Lead-acid battery Electrical system Perform insulation inspection. Power supply Clean the battery. Clean and grease the battery terminals. Measure acid density and battery voltage.
  • Page 370 Chassis/structure Check chassis connections and screw connections are securely attached and check for damage Check labels for legibility, completeness and plausibility Check driver's seat for damage Check driver's seat is securely attached and test adjustment mechanism Test seat belt monitoring and check for damage Check doors or covers for damage Check mast is securely attached Check mast bearings for wear...
  • Page 371 1.2.2.2 Optional Equipment Electrolyte recirculation Power supply Hose connections and pump for correct function Aquamatic Power supply Aquamatic plug, hose connections and float for functionality and sealing Flow indicator for functionality and sealing Battery refill system Power supply Refill system for functionality and leaks Boom Hydraulic operations Check the attachment is securely attached to the truck and check the load-bearing...
  • Page 372 Hydraulic operations Check attachment bearings, guides and stops for wear and damage Check hydraulic connections are securely attached and check for leaks Check cylinder seals for leaks and damage Check cylinder rods and their bushings for wear and damage Side shift Hydraulic operations Test attachment and check for damage Check the attachment is securely attached to the truck and check the load-bearing...
  • Page 373 Trailer coupling Chassis/structure Test trailer coupling stop or tow mechanism stop and check for damage Seat heating Electrical system Check connections and cables are securely attached and check for insulation damage and other signs of damage Shock sensor/data recorder Electrical system Check shock sensor/data recorder is securely attached and check for damage Radio data System components...
  • Page 374 Access module Electrical system Check access module is securely attached, test and check for damage Electrical heating Chassis/structure Test the heater Weather protection Chassis/structure Test window heating and check for damage Test doors and check for damage Optional electrical equipment Electrical system Fuses for correct ratings Test optional electrical equipment and check for damage...
  • Page 375 Restraint system / HRS-E-DUO Electrical system Check connections and cables are securely attached and check for insulation damage and other signs of damage Chassis / structure The secure seating of the electrical connections and for damage. Check restraint system is complete, test and check for damage Test restraint sensor system and check for damage Restraint system / summer door Chassis/structure...
  • Page 376 1.2.3.2 Optional Equipment Cold store application maintenance part service hours months Hydraulic oil 2000...

This manual is also suitable for:

Efg 425kEfg 430Efg 430kEfg s30Efg 435

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