Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg
Manufacturer or agent acting in the European Union
Typ eOp tionSe rial n o.Yea r of
EFG 535
EFG 540
EFG 545
EFG 550
Additional information
On behalf of
Date
EU Conformity Declaration
The undersigned hereby declare that the powered industrial truck described below in
detail complies with the European Directives 2006/42/EC (Machinery Directive) and
2004/108/EEC (Electromagnetic Compatibility - EMC) including amendments as well
as the legislative decree to incorporate the directives in national law. The signatories
are in each case individually authorized to compile the technical documents.
manufacture
09.12 EN
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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.
The operator manual details different industrial truck models. When operating and
servicing the industrial truck, make sure that the particular section applies to your
truck model.
Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the system. No guarantee of
particular features of the truck should therefore be assumed from the present
operating instructions.
Safety notices and text mark-ups
Safety instructions and important explanations are indicated by the following
graphics:
DANGER!
Indicates an extremely hazardous situation. Failure to comply with this instruction will
result in severe irreparable injury and even death.
WARNING!
Indicates an extremely hazardous situation. Failure to comply with this instruction
may result in severe irreparable injury and even death.
CAUTION!
Indicates a hazardous situation. Failure to comply with this instruction may result in
slight to medium injury.
NOTE
Indicates a material hazard. Failure to comply with this instruction may result in
material damage.
ZUsed before notices and explanations.
tIndicates standard equipment
oIndicates optional equipment
Copyright
Copyright of these operating instructions remains with JUNGHEINRICH AG.
09.12 EN
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Jungheinrich Aktiengesellschaft
Am Stadtrand 35
22047 Hamburg - Germany
Tel: +49 (0) 40/6948-0
www.jungheinrich.com
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Contents
ACorrect Use and Application...................................................11
These operating instructions apply only to Jungheinrich battery models. If using
Z
another brand, refer to the manufacturer's operating instructions.
0506.GB
1
0506.GB
2
ACorrect Use and Application
1General
The industrial truck described in the present operating instructions is designed for
lifting, lowering and transporting load units.
It must be used, operated and serviced in accordance with the present instructions.
Any other type of use is beyond the scope of application and can result in damage to
personnel, the industrial truck or property.
2Correct application
NOTE
The maximum load and load distance are indicated on the load chart 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 rest on the back of the fork carriage and centrally between the forks.
–Lifting and lowering loads.
–Transporting lowered loads over short distances.
–Do not travel with a raised load (>30 cm).
–Do not carry or lift passengers.
–Do push or pull load units.
–Occasional towing of trailer loads.
–When towing trailer loads the load must be secured on the trailer.
–The permissible trailer load must not be exceeded.
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3Approved application conditions
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
–Operation in industrial and commercial environments.
–Permissible temperature range -20°C to +40°C.
–Operation only on secure, level surfaces with sufficient capacity.
–Operation only on routes that are visible and approved by the proprietor.
–Negotiating inclines up to a maximum of 15 %.
–Do not negotiate inclines crosswise or at an angle. Transporting loads downhill.
–Operation in partially public traffic.
WARNING!
Extreme conditions
XSpecial equipment and authorisation are required if the truck is to be constantly
used in extreme conditions, especially in dusty or corrosive atmospheres.
XThe truck is not authorised for use in areas at risk of explosion.
XIn adverse weather conditions (thunder, lightning) the industrial truck must not be
operated outside or in endangered areas.
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4Proprietor responsibilities
For the purposes of the present operating instructions the “proprietor” 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.
The proprietor must ensure that the industrial truck is used only for the purpose for
which it is intended and that there is no danger to life and limb of the user and third
parties. Furthermore, accident prevention regulations, safety regulations and
operating, servicing and repair guidelines must be followed. The proprietor must
ensure that all users have read and understood these operating instructions.
NOTE
Failure to comply with the operating instructions shall invalidate the warranty. The
same applies if improper work is carried out on the truck by the customer or third
parties without the permission of the manufacturer.
5Adding attachments and/or accessories
Adding accessories
The mounting or installation of additional equipment which affects or enhances the
performance of the forklift truck requires the written permission of the manufacturer.
Local authority approval may also need to be obtained.
Local authority approval does not however constitute the manufacturer’s approval.
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14
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BTruck Description
1Application
The EFG 535 - 550 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.
1.1Truck models and rated capacity
The rated capacity depends on the model. The rated capacity can be derived from
the model description.
EFG 535
EFG Model name
5Series
35Rated capacity x 100 kg
The rated capacity does not generally match the permissible capacity. The capacity
can be found on the load chart attached to the rack.
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2Assemblies and Functional Description
2.1Assembly Overview
1
13
12
ItemDescription
1t Driver's seat
2t Overhead guard
3t Mast
4t Steering wheel
5t Control / display unit
6t Lift mechanism control
7t Emergency Disconnect switch
8t Fork tines
9t Fork carriage
10t Battery cover
11t Drive
12t Trailer coupling
13t Counterweight
2
3
4
5
6
7
8
9
10
11
16
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2.2Functional 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 (2) comes in a range of models and protects the driver from
falling objects and other external
influences. All the controls are ergonomically arranged. The steering column and
driver's seat can be adjusted individually.
The controls and warnings on the control and display unit (5) enable the system to be
monitored during operation, thereby ensuring a very high level of safety.
Steering
The steer cylinder of the hydrostatic steering is integrated in the steer axle (12) and
is controlled by the power steering. The steer axle is fully floating in the chassis to
ensure excellent grip even on non-level surfaces.
Wheels
There is a choice of super elastic or fully rubber tyres as well as optional pneumatic
tyres.
Drive system and brakes
The front drive provides maximum traction to the drive wheels at all times. The
hydraulic oil bath multi-plate brakes form the operating brake and are practically
maintenance-free. The transmission encapsulation allows the truck to be used even
in hostile environments. The drive motor also decelerates to a halt. This minimizes
energy consumption.
The parking brake applies approx. 15 seconds when the truck comes to a halt or 1 to
15 seconds (adjustable) after the driver’s seat has been vacated.
The parking brake is automatically released again when the accelerator pedal is
pressed.
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Hydraulic system
A multi-pilot 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. Fork carriage and mast run
on permanently lubricated and hence maintenance-free support rollers.
Attachments
The trucks can be optionally fitted with mechanical and hydraulic attachments.
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3Technical Specifications
All technical details refer to standard trucks.
Values indicated with *) may vary, depending on the
types of equipment used (e.g. mast, cabin, tyres etc.).
ZTechnical data specified in accordance with VDI 2198.
Technical modifications and additions reserved.
3.1Performance data
EFG 535-540
Description
Rated capacity
Q
(where C = 500 mm)
C Load centre of gravity500500mm
Travel speed
w / w.o. load *)
Lift speed
w / w.o. load
Lowering speed
w / w.o. load
Gradeability (30 min)
with / without load *)
Max. gradeability 2) (5 min)
with / without load
Acceleration (10 m)
with / without load *)
Max. operating pressure200200bar
Oil flow for attachments3030l/min
1)
for vertical mast.
2)
The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.
1)
535540
35004000kg
16 / 1715 / 17km/h
0,38 / 0,500,35 / 0,47m/s
0,58 / 0,550,55 / 0,50m/s
8,5 / 14,58 / 13,5%
15,5 / 2514 / 23,5%
4,8 / 4,25,0 / 4,4s
EFG
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EFG 545-550
Description
Rated capacity
Q
(where C = 500 mm)
545550
1)
45004990kg
EFG
C Load centre of gravity500500mm
Travel speed
w / w.o. load *)
Lift speed
w / w.o. load
Lowering speed
w / w.o. load
Gradeability (30 min)
with / without load *)
Max. gradeability 2) (5 min)
with / without load
Acceleration (10 m)
with / without load *)
15 / 16,515 / 16km/h
0,33 / 0,450,31 / 0,45m/s
0,55 / 0,500,55 / 0,50m/s
7 / 126,5 / 12%
12,5 / 21,512 / 21%
5,5 / 4,85,8 / 5,2s
Max. operating pressure200200bar
Oil flow for attachments3030l/min
1)
for vertical mast.
2)
The values shown represent the maximum gradeability to overcome short
differences in height and surface unevenness (surface edges). The truck must not
operate on inclines of more than 15%.
When replacing tyres/rims fitted at the factory, always use original spare parts or tyres
approved by the manufacturer. Otherwise the manufacturer's specification cannot be
guaranteed.
If you have any queries please contact the manufacturer's customer service
department.
EFG 535-550
DescriptionEFG 535-545EFG 550
SE *)250 / 70 R1528 x 12.5 - 15
Full rubber*)28 x 10 x 2228 x 12 x 22
Front tyres
Rear tyres
*) The models listed in the table correspond to the standard version. Other tyres can
be used depending on the truck's equipment.
Pneumatic*)250 / 70 R15-
Tyre pressure bar10-
To rq u e (N m )4 30
SE *)21 x 8 - 9
Full rubber*)21 x 7 - 15 ǩ"
Pneumatic*)250 / 70 R1521 x 8 - 9
Tyre pressure bar1010
To rq u e (N m )2 202 20
3.6Engine Data
DescriptionEFG535-550
Drive motor18 kW
Lift motor23,5 kW
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3.7EN norms
Noise emission level
–75 dB(A)
*+/- 3 dB(A) depending on the truck's equipment
in accordance with 12053 as harmonised with ISO 4871.
ZThe noise emission level is calculated in accordance with standard procedures and
takes into account the noise level when travelling, lifting and when idle. The noise
level is measured at the level of the driver's ear.
Vibration
–0,64 m/s²
in accordance with EN 13059.
ZThe vibration acceleration acting on the body in the operating position is, in
accordance with standard procedures, the linearly integrated, weighted
acceleration in the vertical direction. It is calculated when travelling over thresholds
at constant speed (standard truck version). These recordings were taken on a
single occasion and must not be confused with the human vibrations of the "2002/
44/EC/Vibrations" operator directive. The manufacturer offers a special service to
measure these human vibrations, (see "Human vibration measurement" on
page 167).
Electromagnetic compatibility (EMC)
The manufacturer confirms that the truck adheres to the limits for electromagnetic
emissions and resistance as well as the static electricity discharge test in accordance
with EN 12895 as well as the standardised instructions contained therein.
ZNo changes to electric or electronic components or their arrangement may be
made without the written agreement of the manufacturer.
WARNING!
Medical equipment can be damaged by non-ionised radiation
Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless data
transmission) can affect operators' medical equipment (pacemakers, hearing aids
etc.) and result in malfunctions. Consult with a doctor or the medical equipment
manufacturer to clarify whether it can be used near the industrial truck.
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3.8Conditions of use
Ambient temperature
–operating at -20°C to +40°C
ZSpecial equipment and authorisation are required if the truck is to be constantly
used in conditions of extreme temperature or air humidity fluctuations.
3.9Electrical 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 according to its purpose.
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4Identification points and data plates
4.1Indication Points
ZWarnings and notices such as capacity charts, strap points and data plates must
be legible at all times. Replace if necessary.
1415182021
27
191716
(mm)Q (kg)
D (mm)
1
2
5
1
4
1
1
0
6
2000
3
9
7
2
1
8
28293031
22
23
16
24
25
26
27
30
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Item Component
14 Procedure when truck in danger of tipover notice
Do not stand on load handler / Do not stand under load handler / Risk of
15
trapping when mast extended
16 Strap points for crane lifting
17 Steering column adjustment
18 Do not travel with raised load or mast forward tilt with raised load
19 Max. body size
20 Wear seat belt
21 Lift limit
22 Do not carry passengers warning
23 Read operating instructions
24 Serial number, on chassis below side panel
25 Capacity (or reduced capacity)
26 Mineral oil
27 Jack contact points
28 Data plate
29 Plaque (o)
30 Add hydraulic oil
31 Cylinder internal pressure
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4.2Data plate
3233353436
Item DescriptionItem Description
32 Type38 Year of manufacture
33 Serial number39 Load centre (mm)
34 Rated capacity (kg)40 Output
35 Battery voltage (V)41 Min./max. battery weight (kg)
36 Net weight w.o. battery (kg)42 Manufacturer
37 Option43 Manufacturer’s logo
3837
39
40
41
42
43
ZFor queries regarding the truck or ordering spare parts always quote the truck serial
number (33).
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09.12 EN
4.3Truck capacity plate
CAUTION!
Accident risk from fork replacement
If you replace the forks with ones that differ from the originals, the capacity will
change.
XWhen replacing the forks you must attach an additional capacity plate to the truck.
XTrucks supplied without forks are given a capacity plate for standard forks (length:
1150 mm).
The capacity plate (25) gives the capacity (Q in kg) of the truck for a vertical mast.
The maximum capacity is shown as a table with a given load centre of gravity D (in
mm) and the required lift height H (in mm).
The capacity plate (25) of the truck indicates the truck's capacity with the forks as
originally supplied.
Example of how to calculate the maximum capacity:
h3 (mm)
4250
3600
2900
D (mm) 500600700
850
1105
1250
Q (kg)
850
1105
1250
600
850
850
For a load cente of gravity D of 600 mm and a maximum lift height h3 of 3600 mm the
maximum capacity is Q 1105 kg.
Lift height restriction
The arrow shape markings (44 and 45) on the
inner and outer masts show the driver when the
4445
prescribed lift limits have been reached.
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4.4Attachment capacity plate
The attachment capacity plate is next to the truck's capacity plate and gives the
truck's capacity Q (in kg) in conjunction with the respective attachment. The serial
number for the attachment indicated on the capacity plate must match the data plate
of the attachment.
ZFor loads with a centre of gravity greater than 500 mm, the capacities are reduced
by the difference of the altered centre of gravity.
WARNING!
Loss of stability can cause accidents
Changing the components listed will affect stability.
If the attachment sideshift is off-centre, refer to the capacity data plate with reduced
capacity, (see "Indication Points" on page 30).
5Stability
The truck's stability has been tested according to latest technological standards.
These take into account the dynamic and static tipover forces that can occur if used
correctly.
Stability can also be affected by the following factors:
–Tyre type
–Mast
–Attachment
– Transported load (size, weight and centre of gravity)
WARNING!
Loss of stability can cause accidents
Changing the components listed will affect stability.
If the attachment sideshift is off-centre, refer to the capacity data plate with reduced
capacity, (see "Indication Points" on page 30).
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09.12 EN
CTransport and Commissioning
1Transport
Transport can be carried out in two different ways, depending on the height of the
mast and the local conditions.
–Vertically, with the mast assembled (for low heights)
–Vertically, with the mast dismantled (for large heights), all mechanical connections
and hydraulic lines between the basic truck and the mast separated.
2Truck laden
2.1Centre of gravity of the truck
WARNING!
Altering the centre of gravity can be hazardous
The overall centre of gravity can vary depending on the truck's equipment (especially
the mast version).
XFor masts with a low height the centre of gravity will move towards the
counterweight.
XFor masts with a greater height the centre of gravity will move towards the centre
of the truck.
The picture shows the approximate centre of
gravity location.
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2.2Lifting the truck by crane
CAUTION!
The mast can get damaged
XLoading by crane is only intended for the initial transport before the truck is used
for the first time.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703
DANGER!
Crane slings can tear, resulting in accidents
XOnly use crane lifting gear with sufficient capacity.
XLoading weight = Net weight of truck (+ battery weight for electric trucks).
XThe mast must be tilted back fully.
XThe crane lifting gear on the mast must have a minimum clear length of 2 m.
XCrane slings should be fastened in such a way that they do not come into contact
with any attachments or the overhead guard when lifting.
XDo not stand under a swaying load.
ZTruck net weight: (see "Data plate" on page 32).
Lifting the truck by crane
Requirements
–Park the truck securely, (see "Parking the truck
securely" on page 73).
Procedure
•Secure the crane slings to the attachment
points (46) and (47.
•Raise and load the truck.
•Lower and deposit the truck carefully ((see
"Parking the truck securely" on page 73)).
•Secure the truck with wedges to prevent it from
rolling away.
This concludes the loading by crane.
47
46
36
09.12 EN
2.3Loading with another industrial truck
WARNING!
The truck can be damaged
The truck to be loaded can get damaged when loading with another industrial truck.
XOnly trained specialist personnel should load the truck.
XUse only trucks with sufficient capacity for loading.
XOnly for loading and unloading.
XThe forks of the second industrial truck must be sufficiently long
XTransporting over long distances prohibited.
Loading the truck with a second industrial truck
Requirements
–Park the truck securely, (see "Parking the truck securely" on page73).
Procedure
•Raise the truck with the forks at the side between the axles.
•Raise the truck slightly and make sure it is securely positioned on the forks. If
necessary adjust or secure the forks with stops.
•Carefully load/unload the truck, (see "Lifting, transporting and depositing loads" on
page 81).
•Lower the truck slowly onto the ground and prevent it from rolling away.
The truck is now loaded.
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3Securing the truck during transport
WARNING!
Accidental movement during transport
Improper fastening of the truck and mast during transport can result in serious
accidents.
XLoading must be carried out by specially trained staff in accordance with
recommendations contained in Guidelines VDI 2700 and VDI 2703 In each case
correct measurements must be made and appropriate safety measures adopted.
XThe truck must be securely fastened when transported on a lorry or a trailer.
XThe loading area must have clamp rings and a wooden floor to secure the retaining
wedges.
XUse wedges to prevent the truck from moving.
XUse only tensioning belts or tie-down straps or with sufficient strength.
Securing with a mast Securing without a mast
3
48
49
12
Securing the truck for transport
Requirements
–Position the truck securely on a lorry or trailer, (see "Parking the truck securely" on
page 73).
Tools and Material Required
–2 tensioning belts with tensioner
–Retaining wedges.
Procedure
•Secure the truck with the tensioning belt(48) at the top cross member of the
mast (3) and the trailer coupling (12) or over the overhead guard (2) and the trailer
coupling (12).
•Tighten the tensioning belt (48) with the tensioner (49).
The truck is now secured for transport.
2
12
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4Using the Truck for the First Time
Safety Instructions for Assembly and Commissioning
WARNING!
Accident risk from incorrect assembly
The assembly of the truck at the application site, commissioning and driver training
must only be performed by the manufacturer's customer service representatives who
have been specially trained for these tasks.
XThe hydraulic lines may only be connected to the basic truck / mast interface when
the mast has been properly assembled.
XOnly then can the truck be started.
XIf several trucks have been delivered, make sure that the serial numbers of the load
handlers, masts and basic trucks always match.
CAUTION!
Only operate the truck with battery current. Rectified AC current will damage the
electronic components. Cable connections to the battery (tow leads) must be less
than 6 m long and have a minimum cross-section of 6 yd² (50 mm²).
Preparing the truck for operation after delivery or transport
Procedure
•Check the equipment is complete.
•Check the hydraulic oil level, (see "Checking the hydraulic oil level" on page154).
•Install the battery if necessary, (see "Battery removal and installation" on page48).
•Charge the battery, (see "Starting up the truck" on page61).
The truck can now be started, (see "Starting up the truck" on page 61).
ZTo operate the truck without its own drive system, (see "Operating the truck without
its own drive system" on page 121).
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09.12 EN
DBattery - Servicing, Recharging,
Replacement
1Safety Regulations Governing the Handling of Lead-Acid
Batteries
Maintenance personnel
Batteries may only be charged, serviced or replaced by trained personnel. This
operator manual and the manufacturer’s instructions concerning batteries and
charging stations must be observed when carrying out the work.
Fire protection
Do not smoke and avoid naked flames when handling batteries. Wherever an
industrial truck is parked for charging there shall be no inflammable material or
lubricants capable of creating sparks within 2 m around the truck. The room must be
ventilated. Fire protection equipment must be on hand.
Battery maintenance
The battery cell covers must be kept dry and clean. Terminals and cable shoes must
be clean, lightly greased with terminal grease and must be securely tightened.
Batteries with non insulated terminals must be covered with a non slip insulating mat.
CAUTION!
Before closing the battery panel make sure that the battery cable cannot be
damaged. There is a risk of short circuits with damaged cables.
09.12 EN
Battery disposal
Batteries may only be disposed of in accordance with national environmental
protection regulations or disposal laws. The manufacturer’s disposal instructions
must be followed.
41
42
09.12 EN
1.1General notes on handling batteries
WARNING!
Batteries can be hazardous
Batteries contain an acid solution which is poisonous and corrosive. Avoid contact
with battery acid at all times.
XDispose of used battery acid in accordance with regulations.
XAlways wear protective clothing and goggles when working with batteries.
XDo not let battery acid come into contact with skin, clothing or eyes. If necessary,
rinse with plenty of clean water.
XIn the event of physical damage (e.g. skin or eye contact with battery acid) call for
a doctor immediately.
XSpilled battery acid should be neutralised immediately with plenty of water.
XOnly batteries with a sealed battery container may be used.
XFollow national guidelines and legislation.
WARNING!
Unsuitable batteries that have not been approved by Jungheinrich for the truck
can be hazardous
The design, weight and dimensions of the battery have a considerable effect on the
operational safety of the truck, in particular its stability and capacity. The use of
unsuitable batteries that have not been approved by Jungheinrich for the truck can
lead to a deterioration of the braking system during energy recovery operations and
also cause considerable damage to the electrical control system. The use of batteries
that have not been approved by Jungheinrich can therefore affect the health and
safety of personnel.
XOnly manufacturer-approved batteries may be used on the truck.
XReplacement of the battery equipment requires the manufacturer's agreement.
XWhen replacing/installing the battery make sure the battery is securely located in
the battery compartment of the truck.
XDo not use batteries that have not been approved by the manufacturer.
09.12 EN
Park the truck securely before carrying out any work on the batteries ((see "Parking
the truck securely" on page 73)).
43
2Battery types
CAUTION!
Always use batteries with insulated covers or live components.
The battery weights are indicated on the battery data plate.
The truck will be equipped with different battery models, depending on the
application. The following table shows which combinations are included as standard:
Truck mo delDe scr ipt ionCapac ity
EFG 53580V - 5PzS700 Ah
EFG 540-55080V - 6PzS840 Ah
Drive battery 80 volts
Dimension (mm)
Truck
EFG 53510288557697841863
EFG 540-
550
L max.B max.H1+/-
2mm
10289997697842178
H2 +/-
2mm
Rated weight
(-5/+8%) in kg
44
09.12 EN
3Exposing the battery
CAUTION!
50
Accident risk when the battery cover is
open
If the battery cover is open there is a risk
of injury if it accidentally closes.
XAfter opening the battery cover engage
the lever (50) to prevent the cover from
accidentally closing.
Exposing the battery
1
51
Requirements
–Park the truck securely, (see "Parking the truck
securely" on page 73).
–Load handler lowered.
–Key switch set to OFF.
–Key removed.
–Set the Emergency Disconnect OFF.
Procedure
•Release the steering column lock(51), push the steering column forward and
secure it in this position.
•Carefully lift up the rear window slightly. Push and hold down on the lever on the
left-hand gas spring (viewed in the travel direction).
•Carefully open up the rear window.
•
•Pull the panel(52) forward until it engages.
•Carefully lift back the battery cover and the
driver’s seat (1) as far as the stop (opening
angle = 90°).
•Engage the lever(50) to prevent the cover
from accidentally closing.
ZOn trucks with a steel cab, before opening the battery cover push the driver’s seat
back and open the rear window.
09.12 EN
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45
4Charging the battery
WARNING!
The gases produced during charging can cause explosions
The battery produces a mixture of nitrogen and hydrogen (electrolytic gas) during
charging. Gassing is a chemical process. This gas mixture is highly explosive and
must not be ignited.
XSwitch the charging station and truck off first before connecting/disconnecting the
charging cable of the battery charging station to/from the battery connector.
XThe charger must be adapted to the battery in terms of voltage and charge
capacity.
XBefore charging, check all cables and plug connections for visible signs of damage.
XVentilate the room in which the truck is being charged.
XThe battery cell surfaces must be exposed during charging to ensure adequate
ventilation.
XDo not smoke and avoid naked flames when handling batteries.
XWherever an industrial truck is parked for charging there shall be no inflammable
material or lubricants capable of creating sparks within 2 m around the truck.
XFire protection equipment must be on hand.
XDo not lay any metallic objects on battery.
XIt is essential to follow the safety regulations of the battery and charger station
manufacturers.
4.1Charging the battery with a stationary charger
Requirements
–Park the truck securely, (see "Parking the
truck securely" on page 73).
–Battery exposed.
–Charger switched off.
–Disconnect the battery connector(53) from the
truck connector (51).
Procedure
•Connect the battery connector(53) to the
charging cable (54) of the stationary charger
and turn on the charger.
The battery is now charged.
53
54
46
09.12 EN
4.2Charging the battery with a charger socket (
o
Charging
WARNING!
The gases produced during charging
can cause explosions
XAlways check the fans each time you
charge.
Requirements
–Truck parked securely, (see "Parking the
truck securely" on page 73).
Procedure
•Connect the charger lead of the battery charger station to the charger socket(55).
)
ZTest the fan. If the fan is not working, open the cover to ventilate the battery
compartment.
•Depending on the battery you may need to attach the water connection(56) to the
battery charger station.
•Switch on the battery charging station and charge the battery in accordance with
the battery and charging station manufacturers’ instructions.
ZAfter charging, test the fans and remove the connector. If the fan is not working,
open the cover to ventilate the battery compartment.
ZUse only chargers with a max. 160 A charging current.
Battery is charged.
55
56
09.12 EN
47
5Battery removal and installation
WARNING!
Accident risk during battery removal and installation
Due to the battery weight and acid there is a risk of trapping or scalding when the
battery is removed and installed.
XNote the "Safety regulations for handling acid batteries" section in this chapter.
XWear safety shoes when removing and installing the battery.
XUse only batteries with insulated cells and terminal connectors.
XPark the truck on a level surface to prevent the battery from sliding out.
XMake sure the crane slings have sufficient capacity to replace the battery.
XUse only approved battery replacement devices (battery roller stand, replacement
trolley etc.).
XMake sure the battery is securely located in the truck's battery compartment.
CAUTION!
Trapping hazard
Trapping hazard when replacing the battery.
XWhen replacing the battery do not reach between the battery and the chassis.
XWear safety shoes.
Battery removal and installation
Requirements
–Park the truck securely, (see "Parking the truck securely" on page73).
–Battery exposed, (see "Exposing the battery" on page45).
–Battery disconnected.
Tools and Material Required
–Crane lifting gear
Procedure
•Attach the crane lifting gear through the
overhead guard recess so that it is vertical
above the battery container.
ZHooks must be fitted in such a way that when
the crane lifting gear is slackened, they do not
fall onto the battery cells.
•With the crane lifting gear raise the battery
above the chassis in the right hand travel
direction and then move it out sideways.
The battery is now removed.
48
09.12 EN
6Closing the battery cover
Closing the battery cover
Requirements
–The battery cable is in the cable guide(56).
Procedure
•Pull up the lever(50) preventing the battery
cover from accidentally closing.
•Close the battery cover slowly
•
•Push the cover(52) back with force.
•Engage the lock(57).
•Carefully bring the rear window down and lock
it.
The battery cover is now closed.
50
52
57
09.12 EN
49
50
09.12 EN
EOperation
1Safety Regulations for the Operation of the
Forklift Truck
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.
Driver's rights, responsibilities and rules of behaviour
The driver must be informed of his duties and responsibilities and be instructed in the
operation of the truck and shall be familiar with the operating instructions. The driver
shall be afforded all due rights.
Unauthorised use of truck
The driver is responsible for the truck during the time it is in use. The driver must
prevent unauthorised persons from driving or operating the truck. Do not carry
passengers or lift other people.
Damage and faults
The supervisor must be immediately informed of any damage or faults to the truck or
attachment. Trucks which are unsafe for operation (e.g. wheel or brake problems)
must not be used until they have been rectified.
Repairs
The driver must not carry out any repairs or alterations to the truck without the
necessary training and authorisation to do so. The driver must never disable or adjust
safety mechanisms or switches.
09.12 EN
51
Hazardous area
WARNING!
Risk of accidents / injury in the hazardous area of the truck
The hazardous area is defined as the area in which a person is at risk due to truck
movement, lifting operations, the load handler (e.g. forks or attachments) or the load
itself. This also includes areas which can be reached by falling loads or lowering
operating equipment.
XInstruct unauthorised people to leave the hazardous area.
XGive a warning signal with plenty of time for people to leave.
XIf unauthorised personnel are still within the hazardous area stop the truck
immediately.
DANGER!
Accident risk
XThe driver must remain within the protected area of the overhead guard while the
truck is being operated.
Safety devices and warning labels
Safety devices, warning signs ((see "Indication Points" on page 30)) and warning
instructions in the present operating instructions must be strictly observed.
CAUTION!
Reduced headroom can cause injuries
XTrucks with reduced headroom are equipped with a warning label within the driver's
line of sight. The max. recommended body size indicated on this sign must be
observed.
XThe headroom is also reduced when you wear a protective helmet.
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09.12 EN
2Displays and Controls
Item Control /
Display
58Parking brake levertApplies / releases parking brake
59Steering wheeltSteers the t ruck.
60Control panel with display
unit
61SOLO-PILOTtOperates the following functions:
MULTI-PILOTo
62Key switchtSwitches control current on and off.
ISM access module*oSwitches the truck on.
Code lock*
errors, key warning indicators, wheel
position and travel direction.
–Fwd/rev. travel direction
–Lift/lower load handler
–Mast forward / reverse tilt
–Horn button
– Sideshifter left / right (o)
–Auxiliary hydraulics (o)
Removing the key prevents the truck from
being switched on by unauthorized
personnel.
Switches power supply on and off.
tSwitches electric options on and off
oApplying the accelerator pedal reverses the
truck.
The travel speed is infinitely controlled.
oApplying the accelerator pedal moves the
truck forwards.
The travel speed is infinitely controlled.
Z*If the truck is equipped with an ISM access module or Can Code refer to the “ISM
Access Module” or "CanCode" operator manuals.
09.12 EN
53
605859
61
62
63
64
65
66
67
54
63
68
09.12 EN
Item Control /
Function
Display
69Travel direction switch
t Selects travel direction / neutral position.
(not available with dual
pedal control)
70Lever t Lever for operating the hydraulic functions.
71Hornt Activates an audible warning.
72Additional hydraulic
function release button
o Activates the additional hydraulic functions
or hydraulics that require
acknowledgement.
73Buttono Hydraulic auxiliary function control button.
71
706971
69
70
707169
72
73
69
72
71
09.12 EN
55
2.1Control panel with display unit
The control panel display unit shows the operating data, the battery charge, the
service hours and error details and information. Pictograms in the left top section of
the control panel act as warning indicators.
7682778378
7974807581
84
85
86
Item Control /
87
Function
88
Display
74Controller
overtemperature indicator
–Lights up to indicate controller
overtemperature
–Performance is continually reduced in
relation to the temperature
75Drive motor
overtemperature
indicator
76Parking brake warning
indicator
–Monitors the temperature of the drive motor
–Performance is reduced if the temperature is
77Truck in operation indicator – Key switch ON
78Insufficient brake fluid– The brake fluid level can be checked through
sensors on the brake fluid reservoir
79Hourmeter / time toggle
switch
–Truck key switch ON service hours
– "Eff" service hours can be switched ON or
OFF via a code
–Time display
80Pump motor, power
steering
overtemperature indicator
–Monitors the temperature of the pump motor
and the power steering motor
–Performance is reduced if the temperature is
excessive
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09.12 EN
Item Control /
Function
Display
81Seat switch warning
indicator
Seat switch not closed
– Truck operational, but driver’s seat not
occupied
82Travel direction display
–Right / left indicator lamps activated
indicator lamp
83Service display– Service interval exceeded (1000 service
hours) or annual FEM test due (flashing
indicator).
84WARNINGWARNING
– Flashes for faults, an audible warning
sounds
–Flashes when battery capacity is less than
10%
85Crawl speed button– Switches crawl mode on and off
86Program selector– Selects the travel program (moves up or
down a level in the travel program list.)
87Operating program display – Displays the selected travel program (1 to 5)
88Set button– Confirms the entries
7682778378
7974807581
09.12 EN
87
84
85
86
88
57
2.2Side compartment control panel switch (
o
o
Function
Slow travel
Seat heating
Lift cutout override
Rear window heating
Rear windscreen wiper
–Press 1x > intermittent,
– 2x > fast,
–3x > off
–Hold down on the button > Switch on the windscreen washing
system
Front windscreen wipers
–Press 1x > intermittent,
– 2x > fast,
–3x > off
–Hold down on the button > Switch on the windscreen washing
system
Beacon
)
Work lights
2.3Instrument panel switches (
Function
Parking light
Warning indicator
Truck lighting
58
)
09.12 EN
2.4Display
899190
ItemFunction
89Hourmeter display
Error display:
–If an error (Err) or a warning (Inf) occurs, the error or
info code is displayed.
–If several errors occur they are displayed alternately at
1.5 second intervals. A warning is sounded.
90Battery capacity display
–Battery discharge status
91Travel direction and wheel position display
–Indicates the pre-selected travel direction (forward or
reverse) or the position of the steered wheels.
–Flashing direction arrow = no travel direction selected
09.12 EN
59
2.4.1 Battery discharge indicator
NOTE
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.
XThis adjustment should only be made by the manufacturer’s service department.
XThe battery discharge indicator shows the battery’s residual capacity.
XCharge battery, (see "Charging the battery" on page 46).
The battery charge status is shown on the truck display via a battery symbol (90) in
the truck's display in 10% increments (100% = 100% battery capacity, 0% display =
20% battery capacity).
2.4.2 Battery discharge monitor
If the residual capacity falls below the required level, lifting is inhibited and the travel
speed is reduced. An message appears in the display. Lifting is only released when
the battery connected is at least 40% charged.
ZIn order to complete the lift cycle, the key switch must be turned off and on again.
Lifting is then enabled for 30 to 40 seconds.
2.4.3 Hourmeter
The service hours are counted when the truck is switched on and the seat switch is
closed.
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09.12 EN
3Starting up the truck
3.1Checks and operations to be performed before starting daily
operation
WARNING!
Damage and other truck or attachment (special equipment) defects can result
in accidents.
If damage or other truck or attachment (special equipment) defects are discovered
during the following checks, the truck must be taken out of service until it has been
repaired.
XReport any defects immediately to your supervisor.
XTag out and decommission a faulty lift truck.
XOnly return the truck to service when you have identified and rectified the fault.
09.12 EN
61
Checks before daily operation
Procedure
•Visually inspect the entire truck (in particular wheels,
wheel bolts and load handler) for damage.
• Check the fork stop (92) and fork retainer (93).
•Visually inspect the hydraulic system in the visible
92
area for damage and leaks.
•Make sure the driver’s seat is locked in position.
93
• Test the horn and reversing buzzer (o) where
applicable.
•Check that the load chart and warning labels are
legible.
•Test the controls and displays.
•Test the steering.
•Check the steer angle display (o), turn the steering wheel in both directions as far
as the stop and check that the wheel position is displayed on the control panel.
• Make sure the load chains are evenly tensioned.
•Test the seat belt. (The belt should block if extracted suddenly.)
•Test the seat switch. When the driver’s seat is vacated it should not be possible to
activate the hydraulics.
•Test the restraint system (o).
•Test the Drive Control (o).
•Raise the fork carriage without load beyond the reference point on the mast. The
slow travel symbol lights up on the display.
•Slowly apply the accelerator pedal on a clear route with good visibility. The
maximum speed should be reduced to walking pace (3 km/h).
•Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.
•Check the accelerator pedal can move freely while the parking brake is applied and
the truck is idling, by pressing it several times.
•Visually inspect the battery attachment and cable connections.
•Check the battery lock is present and working.
•
•On trucks with lateral battery removal, check
the left and right stops (94) in the battery
compartment for damage.
•Check the fluid level of the window washer
system, (see "Adding window washer system
fluid" on page 158).
62
94
09.12 EN
3.2Entry and exit
o
Procedure
•Open the cab door (o)
•To enter and exit the cab, hold onto the handle
(95).
95
ZAn additional step is provided for the driver position extension (
3.3Trucks with reduced headroom X (
WARNING!
An unsuitable workplace can damage
your health
Failure to observe the recommended
body size can cause stress and endanger
the driver and may lead to lasting ill health
due to an unhealthy posture and
excessive strain on the driver.
XThe owner must ensure that truck
operators do not exceed the maximum
body size indicated.
XThe owner must check that the drivers
can sit in a normal and upright position
without having to strain.
)
)
o
09.12 EN
63
3.4Setting up the operator position
WARNING!
Accident risk
XDo not adjust the driver’s seat while travelling.
Procedure
•Before starting to travel, adjust the driver’s seat, steering column and armrest (if
necessary) so that all the controls are within reach and can be applied without
having to strain.
•Adjust the visibility aid equipment (mirrors, camera systems etc.) so that the
working environment can be clearly seen.
3.4.1 Adjusting the driver’s seat
WARNING!
Risk of accidents and damage to health
An incorrectly adjusted driver’s seat can result in accidents and damage to health.
XDo not adjust the driver’s seat while travelling.
XThe driver’s seat should lock in position after adjustment.
XCheck and adjust the individual driver’s seat setting before starting to use the truck.
XHold the weight setting lever (96) only by the recess, do not reach through
underneath the lever.
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09.12 EN
Adjusting the driver's weight
NOTE
To achieve optimal seat cushioning the
driver’s seat must be set to the driver’s
weight.
Set the driver's weight when the seat is
occupied.
Procedure
•Fold out the weight adjustment lever
(96) as far as it will go in the arrow
direction
•Move the weight adjustment lever (96) up and down to set the seat to a higher
weight.
•Move the weight adjustment lever (96) up and down to set the seat to a lower
weight.
97
96
9998
100 101
ZThe driver's weight is correct when the arrow is in the middle of the display window
(97). The minimum or maximum weight setting is reached when you can feel a
return stroke on the lever.
• After setting the weight, move the lever (96) back in full.
The driver’s weight is now set.
Adjusting the backrest
Procedure
•Sit on the driver’s seat.
•Pull the lever (99) to adjust the backrest.
•Adjust the backrest tilt.
•Release the lever (99) again. The backrest is locked.
The backrest is now set.
ZHold the weight setting lever (96) only by the recess, never reach through
underneath the lever.
09.12 EN
65
Adjusting the seat position
o
96
CAUTION!
97
An unsecured driver's seat can cause
injury
An unsecured driver's seat can slide out of
its guide during travel, resulting in
accidents.
The driver's seat must be locked in
X
position.
Do not adjust the driver’s seat while
X
travelling.
9998
Procedure
•Sit on the driver’s seat.
•Pull up the driver’s seat locking lever98 in the direction of the arrow.
•Push the driver’s seat forwards or backwards to the desired position
•Engage the driver’s seat locking lever (98) in position.
The seat position is now correctly set.
Switching the seat heating on and off
Procedure
•Press the seat heating switch (100).
Switch setting 1 = Seat heating on.
Switch setting 0 = Seat heating off.
100 101
Adjusting the lumbar vertebrae support (
Procedure
•Turn the hand wheel (101) to the required position.
Position 0 = no warping in lumbar vertebrae area.
Position 1 = increasing warping in upper lumbar vertebrae area.
Position 2 = increasing warping in lower lumbar vertebrae area.
The lumbar vertebrae support is now set.
66
)
09.12 EN
3.4.2 Adjusting the steering column
51
Adjusting the steering column
Procedure
•Release the steering column stop (51).
•Set the steering column to the required position (height and angle).
•Fix the steering column stop (51) in position.
The steering column is now positioned.
3.4.3 Adjusting the arm rest
102103
09.12 EN
Adjusting the arm rest
Procedure
•Pull up the lock (103) and hold it in this position.
•Move the armrest (102) vertically and horizontally.
•Release the lock (103) at the desired position.
•Push the armrest slightly forward or back until it locks in position.
The armrest is now positioned.
67
3.5Seat Belt
DANGER!
Travelling without a seat belt increases the risk of injury.
If the seat belt is not worn or is modified, personal injury can result.
XAlways put on the seat belt before starting the industrial truck.
XDo not modify the seat belt.
XDamaged or non-operational seat belts must be replaced by trained personnel.
XSeat belts must always be replaced after an accident.
XOnly original spare parts must be used for retrofits or repairs.
ZProtect the seat belt from contamination (e.g. cover it when the truck is idle) and
clean it regularly. Frozen belt locks or pulleys must be thawed out and dried to
prevent them from freezing up again.
The temperature of the warm air should not exceed +60 °C!
Starting the industrial truck on steep slopes
The automatic blocking system locks the belt in the retractor when the truck is
positioned on a steep slope. This prevents the belt from being pulled out of the
retractor.
ZCarefully drive the truck off the slope and then put on the belt.
68
09.12 EN
4Industrial Truck Operation
4.1Safety regulations for truck operation
WARNING!
Electromagnetic influence can result in accidents
Strong magnets can cause electronic components such as Hall sensors to become
damaged, resulting in accidents.
XDo not use magnets in the operating area of the truck. Exceptions to this rule are
commercial, weak clamping magnets for attaching notices.
Travel routes and work areas
Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.
DANGER!
Do not exceed the permissible surface and spot load limits on the travel routes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock / ramp cannot move or come loose
during loading / unloading.
Travel conduct
The driver must adapt the travel speed to local conditions. The truck must be driven
at slow speed when negotiating bends or narrow passageways, when passing
through swing doors and at blind spots. The driver must always observe an adequate
braking distance between the forklift truck and the vehicle in front and must be in
control of the truck at all times. Abrupt stopping (except in emergencies), rapid U turns
and overtaking at dangerous or blind spots are not permitted. Do not lean out or reach
beyond the working and operating area.
Do not use a mobile phone or walkie-talkie without a handsfree device while
operating the truck.
Hazardous situations
If the truck is about to tip over, do not loosen the seat belt. The driver must not jump
off the truck. The driver must lean his upper body over the steering wheel and hold
on with both hands. Tilt your body in the opposite direction of fall.
Travel visibility
The driver must look in the direction of travel and must always have a clear view of
the route ahead. Loads that affect visibility must be positioned at the rear of the truck.
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 driver. Proceed only
at walking pace and with particular care. Stop the truck as soon as you lose eye
contact.
09.12 EN
69
Negotiating slopes and inclines
Negotiating slopes or inclines up to 15% is only permitted if they are specifically
designed as travel routes, are clean and have a non-slip surface and providing they
can be safely travelled along in accordance with the truck's technical specifications.
The truck must always be driven with the load unit facing uphill. The industrial truck
must not be turned, operated at an angle or parked on inclines or slopes. Inclines
must only be negotiated at slow speed, with the driver ready to brake at any moment.
Particular care is required when travelling near slopes and quay walls.
Negotiating lifts and docks
Lifts may only be entered if they have sufficient capacity, are suitable for driving on
and authorised for truck traffic by the owner. The driver must satisfy himself of the
above before entering these areas. The truck must enter lifts with the load in front and
must take up a position which does not allow it to come into contact with the walls of
the lift shaft. People travelling in the lift with the forklift truck must only enter the lift
after the truck has come to a halt and must exit the lift before the truck. The driver
must ensure that the loading ramp / bridge cannot move or come loose during loading
/ unloading.
Type of loads to be carried
The operator must make sure that the load is in a satisfactory condition. Loads must
always be positioned safely and carefully. Use suitable precautions to prevent parts
of the load from tipping or falling down. Prevent liquid loads from sloshing out.
Inflammable liquids (e.g. fused metal etc.) may only be transported with suitable
auxiliary equipment. Contact your authorized Jungheinrich customer adviser.
ZFor safety instructions on the nature of loads to be carried with attachments,(see
"Lifting, transporting and depositing loads" on page 81).
Towing trailers
The truck may only be used occasionally to tow trailers, (see "Towing trailers" on
page 100)
70
09.12 EN
4.2Preparing the truck for operation
104
62
65
Switching on the truck
Requirements
–For checks and operations to be performed before starting daily operation, (see
"Checks and operations to be performed before starting daily operation" on
page 61).
Procedure
• Unlock the Emergency Disconnect switch (65) to do this
•Press the rocker in (s) and pull it up until you feel the Emergency Disconnect
switch engaging.
• Insert the key in the key switch (62) and turn it clockwise as far as it will go to the
“I” position.
•Test the brake pedal and parking brake.
The truck is now ready for operation. The display (104) shows the remaining battery
capacity.
ZWhen you have pulled the EMERGENCY DISCONNECT and turned the key switch
to the right, the truck carries out a self test for approx. 3-4 seconds (tests the
controllers and motors). During this time the truck cannot move or lift. If the
accelerator or a lift mechanism lever is applied during this time, an information
message will be displayed.
09.12 EN
71
4.3Setting the time
79
86
88
Setting the time
Procedure
•Press the “h/time”(79) and up(86) keys simultaneously.
•The time is displayed. The first digit flashes.
Press the up/down key (86) to increase or decrease the flashing digit.
•Use the SET(88) key to toggle to the next digit. After the last digit the number is
accepted.
The time is now set.
ZKeep pressing the Up and Down keys to set the time and to change between 24
hour and 12 display (SET HOUR 24 H <-> SET HOUR 12 H).
72
09.12 EN
4.4Parking 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.
XAlways park the truck on a level surface. In special cases the truck may need to be
secured with wedges.
XAlways fully lower the mast and load handler.
XTilt the mast forward.
XSelect a place to park where no other people are at risk of injury from lowering
forks.
XDo not park and abandon the truck on an incline.
105
Parking the truck securely
Procedure
•Pull the parking brake lever (105) back.
• Turn the key in the key switch (62) to the “0” position.
•Remove the key from the key switch (62).
•Press the Emergency Disconnect switch (65) down.
The truck is now parked securely.
62
65
09.12 EN
73
4.5Emergency Disconnect
CAUTION!
Accident risk
Applying the Emergency Disconnect switch during travel will cause the truck to brake
to a halt at maximum force. This may cause the load to slide off the forks. There is a
higher risk of accidents and injury!
The operation of the Emergency Disconnect button must not be affected by any
objects placed in its way.
Applying the Emergency Disconnect
Procedure
ZDo not use the Emergency Disconnect (65) as
a service brake.
•Press the Emergency Disconnect(65) down.
All electrical functions are deactivated. The truck
brakes to a halt.
65
Releasing the Emergency Disconnect
Procedure
• Press the rocker in (s) and pull it up until you feel the Emergency Disconnect (65)
switch engaging.
All electrical functions are enabled and the truck is operational again (assuming the
truck was not operational before the Emergency Disconnect was pressed).
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09.12 EN
4.6Travel
WARNING!
Improper travel can result in accidents
XDo not get up from the driver’s seat during travel.
XDo not drive the truck unless your are wearing a seat belt and the panels and doors
are properly locked.
XMake sure that the travel area is clear.
XAdapt the travel speed to the conditions of the route, the work area and the load.
XTilt the mast back and raise the fork carriage approx. 200 mm.
XMake sure you have enough visibility when reversing.
Travel
Requirements
–Truck prepared for operation, (see "Preparing
the truck for operation" on page 71).
Procedure
•Release the parking brake lever(58).
•Select the travel direction
with the travel direction switch (69).
•Select the travel speed if necessary, to do this
press the slow travel button (106).
•Raise the fork carriage approx. 200 mm.
•Tilt the mast back.
•Apply the accelerator pedal(64). The travel
speed is governed by the accelerator (64).
The truck travels in the direction selected.
58
69
64106
09.12 EN
75
Dual pedal (optional equipment)
Requirements
–Truck prepared for operation, (see "Preparing
the truck for operation" on page 71).
Procedure
ZFor trucks with a dual pedal the travel direction
is selected via the accelerator pedals (68;67).
When the driver leaves the truck, the truck is
automatically set to “Neutral”.
•Release the parking brake(58).
•Raise the fork carriage approx. 200 mm.
•Tilt the mast back.
•
•Apply the accelerator pedal (68) to travel
forward. The travel speed is governed by the
accelerator (68).
•Apply the accelerator pedal (67) to reverse.
The travel speed is governed by the
accelerator (67).
The truck travels in the direction selected.
4.7Steering
Requirements
–Truck ready for operation, (see "Preparing the truck for operation" on page71)
Procedure
•To negotiate a right-hand bend:
•Turn the steering wheel clockwise to match the desired steering radius.
•To negotiate a left-hand bend:
•Turn the steering wheel anti-clockwise to match the desired steering radius.
67
63
68
58
76
09.12 EN
4.8Brakes
The truck can brake in three different ways:
–Service brake
–Reversing brake
–Coasting brake
and for safe parking:
–Parking brake
WARNING!
Accident risk
The brake pattern of the truck depends largely on the ground conditions.
XThe driver must be aware of travel route conditions and them into account when
braking.
XBrake with care to prevent the load from slipping.
XAllow for increased braking distance when travelling with an attached load.
XUse the service brake in emergencies.
Braking with the service brake
Procedure
•Depress the brake pedal (63) until you feel the brake pressure.
The truck decelerates depending on the brake pedal position.
WARNING!
Immediately after the battery has been charged the brake power of the reversing and
coasting brakes may reduce of their own accord after long periods of application, e.g.
ramp operation.
XThe driver must instruct people to leave the hazardous area.
XThe driver must perform test braking.
09.12 EN
Braking with the reversing brake
Procedure
•Set the travel direction switch (69) to the
opposite direction while travelling.
The truck decelerates until it starts to travel in the
opposite direction.
69
6364
77
Braking with the coasting brake
Procedure
•Take your foot off the accelerator pedal (64).
The truck decelerates.
Parking brake
Procedure
•Push the parking brake lever(58) down, the
parking brake is now released.
•Push the parking brake lever(58) up, the
parking brake is now applied.
The truck is now secure.
58
ZThe parking brake will hold the truck with maximum load on a clean ground surface,
on inclines of up to 15%.
Do not park and exit the truck on inclines.
78
09.12 EN
4.9Adjusting the forks
WARNING!
Unsecured and incorrectly adjusted
forks can cause accidents
Before adjusting the forks make sure the
retaining bolts (93) are fitted.
XAdjust the forks so that both forks are
equidistant from the outside edge of the
fork carriage.
XEngage the locking pin in a groove to
prevent the forks from moving
accidentally.
XThe load centre of gravity must be
located centrally between the forks.
Adjusting the forks
Requirements
–Park the truck securely, (see "Parking the
truck securely" on page 73).
Procedure
•Lift up the locking lever (107).
•Push the forks (108) into the correct position
on the fork carriage (109).
107
108
109
ZTo lift the load securely, the forks (108) must
be spread as far apart as possible and
positioned centrally with respect to the fork
carriage. The load centre of gravity must be centrally aligned between the forks
(108).
•Lift the locking lever down (107) and move the forks until the locking pin engages
in a slot.
The forks are now adjusted.
93
09.12 EN
79
4.10 Replacing the forks
WARNING!
Unsecured forks can cause injury
You can injure your legs when replacing the forks.
XNever pull the forks towards your body.
XAlways push the forks away from your body.
XSecure heavy forks with lifting slings and a crane before pushing them down from
the fork carriage.
XAfter replacing the forks fit the retaining bolts (93) and make sure the bolts are
seated correctly. Retaining bolt torque: 85 Nm.
Replacing the forks
Requirements
–Load handler lowered and forks not touching
the ground.
Procedure
•Disassemble the retaining bolts (93).
•Loosen the fork stop (92).
•Carefully push the forks off the fork carriage.
The forks are now dismantled from the fork
carriage and can be replaced.
92
93
80
09.12 EN
4.11 Lifting, transporting and depositing loads
WARNING!
Unsecured and incorrectly positioned loads can cause accidents
Before lifting a load unit the driver must make sure that it has been correctly palletised
and does not exceed the truck’s capacity.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XOnly carry loads that have been correctly secured and positioned. Use suitable
precautions to prevent parts of the load from tipping or falling down.
XDo not transport loads other than on the authorised load handler.
XDamaged loads must not be transported.
XIf the stacked load obscures forward visibility, then you must reverse the truck.
XMake sure you have enough visibility when reversing.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XDo not reach through the mast.
XCheck the fork spread before lifting the load and adjust if necessary.
XInsert the forks as far as possible underneath the load.
Lifting load units
Requirements
–Load unit correctly palletised.
–Fork spread for the pallet checked and adjusted if necessary.
–Load unit weight matches the truck's capacity.
–Forks evenly loaded for heavy loads.
Procedure
•Drive the truck carefully up to the pallet.
•Set the mast vertical.
•Slowly insert the forks into the pallet until the fork shank touches the pallet.
•Raise the load handler.
•Reverse carefully and slowly until the load unit is outside the storage area. Make
sure you have enough clear space to reverse into.
09.12 EN
NOTE
Loads must not be deposited on travel or escape routes, in front of safety
mechanisms or operating equipment that must be accessible at all times.
Transporting load units
Requirements
–Load unit correctly lifted.
–Load handler lowered for transport (approx. 150 - 200 mm above the ground).
81
–Mast tilted back fully.
Procedure
•Accelerate and decelerate gradually.
•Adapt your travel speed to the conditions of the route and the load you are
transporting.
•Watch out for other traffic at crossings and passageways.
•Always travel with a lookout at blind spots.
•On slopes and inclines always carry the load facing uphill, never approach at an
angle or turn.
Depositing load units
Requirements
–Warehouse location suitable for storing the load.
Procedure
•Set the mast vertical.
•Drive carefully up to the storage location.
•Carefully lower the load handler so that the forks are clear of the load.
ZAvoid depositing the load to avoid damaging the load and the load handler.
•Lower the load handler.
• Carefully remove the forks from the pallet.
The load unit is lowered.
82
09.12 EN
4.12 Operating the lift mechanism and integrated attachments
WARNING!
Accident risk when operating the lifting device and integrated attachments
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. This also includes areas which can be
reached by falling loads or lowering operating equipment.
Apart from the operator (in the normal operating position) there should be no other
people in the truck's hazardous area.
XInstruct other people to move out of the hazardous area of the truck. Stop working
with the truck if people do not leave the hazardous area.
XThe truck must be prevented from being used by unauthorised people if people do
not leave the hazardous area despite the warning.
XOnly carry loads that have been correctly secured and positioned. Use suitable
protection measure to prevent parts of the load from tipping or falling down.
XNever exceed the maximum loads specified in the capacity chart.
XNever stand underneath a raised load handler.
XDo not stand on the load handler.
XDo not lift other people on the load handler.
XDo not reach through the mast.
XThe controls should only be operated from the driver’s seat, and never suddenly.
XThe driver must be instructed in how to operate the lifting device and the
attachments.
09.12 EN
83
4.12.1 Operating the lift mechanism with the SOLO PILOT
S
V
Lifting and lowering
Requirements
–To prepare the truck for operation, (see
"Preparing the truck for operation" on
page 71)
Procedure
•Pull the Solo-Pilot lever(110) in direction H to
raise the load.
•Push the Solo-Pilot lever(110)in direction S
to lower the load.
The load is now raised / lowered.
110
H
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
Tilting the mast forward / backward
Requirements
–To prepare the truck for operation, (see
"Preparing the truck for operation" on
page 71)
Procedure
•Pull the Solo-Pilot lever (111) in direction R to
tilt the mast back.
•Push the Solo-Pilot lever (111) in direction V
to tilt the mast forward.
The mast is now tilted back / forward.
111
R
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
09.12 EN
84
Positioning the integrated sideshift (option)
A
Requirements
–Truck prepared for operation, (see "Preparing
V
112
R
the truck for operation" on page 71).
Procedure
•Pull the SOLO-PILOT lever(112) in direction
R to move the load handler to the right (from
the driver’s viewpoint).
•Push the SOLO-PILOT lever(112) in direction
V to move the load handler to the left (from the
driver’s viewpoint).
The sideshifter is now positioned.
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
Positioning the forks with an integrated fork
positioner (option)
110
CAUTION!
Do not use the fork positioner to clamp
Z
loads.
Requirements
–Truck prepared for operation, (see "Preparing
the truck for operation" on page 71).
113
Procedure
•Press the toggle switch(113) and at the same time pull the SOLO-PILOT(110) in
direction Z: the forks will move towards each other.
•Press the toggle switch(113) and at the same time push the SOLO-PILOT(110) in
direction A: the forks will spread apart.
The forks are now positioned.
09.12 EN
85
Synchronising the alignment of the fork
A
tines with an integrated fork positioner
(optional equipment)
Requirements
–Truck prepared for operation, (see "Preparing
the truck for operation" on page 71).
–The fork tines are no longer aligned.
Procedure
•Press the toggle switch(113) and at the same
time push the SOLO-PILOT (110) in direction
A and spread the fork tines apart as far as
they will go.
•Press the toggle switch(113) and at the same time pull the SOLO-PILOT(110) in
direction Z and bring the fork tines as close to each other as they will go.
The fork tines are now synchronised.
110
Z
113
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
09.12 EN
86
4.12.2 Operating the lift mechanism with the Multi Pilot
Lifting and lowering
Requirements
–To prepare the truck for operation, (see
"Preparing the truck for operation" on
page 71)
Procedure
•Pull the Multi-Pilot (61) in direction H to raise
the load.
•Push the Multi Pilot (61) in direction S to lower
the load.
The load is now raised / lowered.
S
61
H
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
Tilting the mast forward / backward
Requirements
–Truck prepared for operation, (see "Preparing
the truck for operation" on page 71).
Procedure
•Push the Multi-Pilot lever (61) in direction V to
tilt the mast forward.
•Push the Multi-Pilot lever (61) in direction R to
tilt the mast back.
The mast is now tilted back / forward.
V
R
61
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
09.12 EN
87
Positioning the integrated sideshift (option)
Requirements
–Truck ready for operation, (see "Preparing the
truck for operation" on page 71)
Procedure
•Press the button (114) to the left to move the
load handler to the left (from the driver's
viewpoint).
•Press the button (114) to the right to move the
load handler to the right (from the driver's
viewpoint).
The sideshifter is now positioned.
114
61
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
Positioning the forks with an integrated fork
adjuster (option)
CAUTION!
Do not use the fork adjuster to clamp
loads.
Requirements
–Truck prepared for operation, (see "Preparing
the truck for operation" on page 71).
Procedure
•Press the button(115) and at the same time press the button(72), the forks will
spread apart.
•Pull the button(115) and at the same time press the button(72), the forks will move
together.
The forks are now positioned.
115
72
88
09.12 EN
Synchronising the alignment of the fork tines
with an integrated fork adjuster (optional
equipment)
Requirements
–Truck prepared for operation, (see "Preparing
the truck for operation" on page 71).
–The fork tines are no longer aligned.
Procedure
•Press the button(115) and at the same time
press the button (72), the forks will spread
apart.
•Pull the button(115) and at the same time press the button (72), the forks will move
together.
The fork tines are now synchronised.
115
72
ZWhen the limit position for the operation has been reached (there will be a noise
from the pressure relief valve) release the lever. The lever will revert automatically
to neutral.
09.12 EN
89
4.13 Safety instructions for operating additional attachments
ZOptionally, trucks can be fitted with one or more auxiliary hydraulic functions to
operate attachments. The auxiliary hydraulics are indicated with ZH1, ZH2 and
ZH3.
Auxiliary hydraulic functions for exchangeable equipment are fitted with
replacement couplings on the fork carriage. To fit exchangeable equipment (see
"Fitting additional attachments" on page 98).
DANGER!
Attaching exchangeable equipment can result in accidents.
Other people can be damaged by attaching exchangeable equipment. Use only
exchangeable equipment which has been deemed safe after a risk analysis carried
out by the owner.
XOnly use attachments with a CE mark.
XOnly use attachments that have been designed by the attachment manufacturer for
use with the respective industrial truck.
XOnly use attachments that have been fitted for the purpose by the owner.
XMake sure the operator has been instructed in the use of the attachment and that
he uses it for its correct purpose.
XRe-assess the residual capacity of the truck and if it has been altered, attach an
additional capacity plate to the truck.
XNote the attachment manufacturer’s operating instructions.
XOnly use attachments that do not restrict visibility in the travel direction.
ZIf visibility in the travel direction is impaired, the owner must carry out a risk analysis
to assess whether the truck needs to be fitted with auxiliary equipment such as a
camera system or mirrors. If such equipment is used, spend sufficient time
practicing travelling with them.
90
09.12 EN
Safety instructions for sideshifter and fork adjuster attachments
WARNING!
When using multi fork adjusters (multi pallet clamps), restricted visibility and reduced
lateral tilt resistance can result in accidents.
XAdapt the travel speeds to the visibility and load.
XMake sure you have enough visibility when reversing.
This can result in malfunctions and the load can fall accidentally.
XClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
XClamping attachments must only be operated on trucks will auxiliary hydraulics
ZH1, ZH2 or ZH3.
XWhen connecting the attachment make sure that the hydraulic lines of the
attachment are connected to the right ports, (see "Fitting additional attachments"
on page 98).
Safety instructions for rotary attachments
WARNING!
A non-centred 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.
XAdapt the travel speed to the load.
XLift the load from the centre.
09.12 EN
91
Safety instructions for telescopic attachments
WARNING!
Accident risk from increased tipover hazard and reduced residual capacity
There is a greater tipover risk with extended telescopic attachments (e.g. reach
carriages, telescopic forks, telescopic crane booms).
XOnly use the telescopic function for stacking and retrieving.
XAlways retract the attachment fully during transport.
XAdapt the travel speed to changed load centre of gravity.
Safety instructions for attachments when transporting suspended loads
WARNING!
Swinging loads and a reduced residual capacity can result in accidents.
Transporting hanging loads can reduce the stability of the truck.
XAdapt the travel speed to the load, less than walking pace.
XSecure swinging loads for example with lifting slings.
XReduce the residual capacity and have it certified by a expert.
XIf the truck is to be operated with hanging loads, proof of sufficient safety distance
under local operating conditions must be obtained from a specialist assessor.
Safety instructions for using loading buckets as attachments
WARNING!
Greater mast loading can cause accidents.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 61), in
particular attention check the fork carriage, mast rails and mast rollers for damage.
92
09.12 EN
Safety notices for fork extensions:
WARNING!
Unsecured and excessive fork extensions can cause accidents.
XFor fork extensions with an open cross sectional area, only carry loads that are
resting along the entire length of the fork extension.
XOnly use fork extensions with the same fork cross section and minimum fork length
of the truck and which comply with the details on the fork extension data plate.
XThe basic fork length must be at least 60% of the length of the fork extension.
XLock the fork extensions onto the basic forks.
XWhen carrying out the daily checks and operations before starting, (see "Checks
and operations to be performed before starting daily operation" on page 61), also
check the fork extension lock.
XMark any fork extensions with an incomplete or faulty lock and take them out of
service.
XDo not use trucks with an incomplete or faulty fork extension lock. Replace the fork
extension.
XOnly restore the fork extension to service when the fault has been rectified.
XUse only fork extensions which have no dirt or foreign bodies near the entry
opening point. Clean the fork extensions as required.
09.12 EN
93
4.14 Operating additional attachments for the SOLO-PILOT
WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
XMark the controls with symbols that indicate their function.
XSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.
4.14.1 Solo Pilot with control of ZH1 hydraulic port
ZDepending on the attachments used the
lever (112) is assigned the function of the
attachment. Levers that are not required are
void. For connections (see "Fitting additional
attachments" on page 98).
Procedure
•Operating the hydraulic port ZH1:
Move the lever (112) in direction V or R.
The attachment’s function is performed.
112
V
R
94
09.12 EN
4.14.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports
ZDepending on the attachments used the lever
/ button (110, 112, 113) is assigned the
function of the attachment. Levers that are
not required are void. For connections (see
"Fitting additional attachments" on page 98).
Procedure
•Operating the hydraulic port ZH1:
Move the lever (112) in direction V or R.
•Operating the hydraulic port ZH2:
Press the toggle switch (113) and at the same
time move the lever (110) in the V or R
direction.
The attachment’s function is performed.
4.14.3 Solo Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports
ZDepending on the attachments used the
levers / buttons (110, 112, 113, 116) are
assigned the respective functions. Levers that
are not required are void. For connections
(see "Fitting additional attachments" on
page 98).
Procedure
•Operating the hydraulic port ZH1:
Move the lever (112) in direction V or R.
•Operating the hydraulic port ZH2:
Move the lever (116) in direction V or R.
•Operating the hydraulic port ZH3:
Press the toggle switch (113) and at the same
time move the lever (110) in the V or R direction.
The attachment’s function is performed.
110
V
R
113
110
V
R
113
112
112
116
09.12 EN
95
4.15 Operating additional attachments for the Multi Pilot
WARNING!
Incorrect symbols can cause accidents
Symbols on controls that do not depict the function of the attachments can cause
accidents.
XMark the controls with symbols that indicate their function.
XSpecify the attachments’ direction of movement in accordance with ISO 3691-1 so
that they match the controls’ direction of movement.
4.15.1 Multi Pilot with control of ZH1 hydraulic port
ZDepending on the attachments used the
button (114) is assigned the function of the
attachment. Levers that are not required are
void. For connections (see "Fitting additional
attachments" on page 98).
Procedure
•Operating hydraulic port ZH1:
Press the button (114) to the left or right.
The attachment performs its operation.
4.15.2 Multi Pilot with control of ZH1 and ZH2 hydraulic ports
ZDepending on the attachments used the lever
/ button (114,115,72) is assigned the function
of the attachment. Levers that are not required
are void. For connections (see "Fitting
additional attachments" on page 98).
Procedure
•Operating hydraulic port ZH1:
Press the button (114) to the left or right.
•Operating hydraulic port ZH2:
Push or pull the lever (115) and at the same
time press the button (72).
The attachment performs its operation.
115
114
114
72
96
09.12 EN
4.15.3 Multi Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports
ZDepending on the attachments used the levers
/ buttons (114, 115, 72) are assigned the
respective functions. Levers that are not
required are void. For connections (see
"Fitting additional attachments" on page 98).
Procedure
•Operating hydraulic port ZH1:
Press the button (114) to the left or right.
•Operating hydraulic port ZH2:
Push or pull the lever (115).
•Operating the hydraulic port ZH3:
Push or pull the lever (115) and at the same
time press the button (72).
The attachment performs its operation.
115
114
72
09.12 EN
97
4.16 Fitting additional attachments
WARNING!
Incorrectly connected attachments can cause accidents.
Attachments with incorrectly connected hydraulic attachments can result in
accidents.
XAttachments must only be assembled and commissioned by trained, specialist
personnel.
XNote the attachment manufacturer’s operating instructions.
XBefore commissioning, check the fasteners are positioned correctly and securely
and make sure they are complete.
XBefore commissioning, make sure the attachment is working correctly.
Connecting attachments hydraulically
Requirements
–Non-pressurised hydraulic hoses.
– The exchange ports on the truck are marked ZH1, ZH2 and ZH3.
–Attachment directions of movement defined to match the controls’ direction of
movement.
Procedure
•Non-pressurised hydraulic hoses
•Switch off the truck and wait a few minutes.
•Attach the plug connector and engage it in position.
•Mark the controls with symbols that indicate their function.
The attachment is now hydraulically connected.
98
09.12 EN
WARNING!
Hydraulic ports for clamping attachments
XClamping attachments may only be added to trucks which have a button to enable
additional hydraulic functions.
XOn trucks with auxiliary hydraulics ZH2 the clamping function should only be
attached to the coupling pair marked ZH2.
XOn trucks with auxiliary hydraulics ZH3 the clamping function should only be
attached to the coupling pair marked ZH3.
ZSpilled 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.
09.12 EN
99
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