Jungheinrich EFG 535, EFG 545, EFG 540, EFG 550 User Manual [de]

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EFG 535 - 550

Operating instructions G

10.09 -

51151559

09.12

EFG 535 EFG 540

EFG 545 EFG 550

Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 Hamburg Manufacturer or agent acting in the European Union

Typ e Op tion Se 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

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.

Z Used before notices and explanations.

t Indicates standard equipment o Indicates optional equipment

09.12 EN

Jungheinrich Aktiengesellschaft

Am Stadtrand 35 22047 Hamburg - Germany

Tel: +49 (0) 40/6948-0

www.jungheinrich.com

09.12 EN

Contents

ACorrect Use and Application...................................................11

1General....................................................................................................11

2Correct application...................................................................................11

3Approved application conditions..............................................................12

4Proprietor responsibilities........................................................................13

5Adding attachments and/or accessories..................................................13

BTruck Description....................................................................15

1Application...............................................................................................15

1.1 Truck models and rated capacity............................................................. 15

2Assemblies and Functional Description...................................................16

2.1 Assembly Overview ................................................................................. 16

2.2 Functional Description ............................................................................. 17

3Technical Specifications..........................................................................19

3.1 Performance data .................................................................................... 19

3.2 Dimensions.............................................................................................. 21

3.3 Weights.................................................................................................... 23

3.4 Mast versions .......................................................................................... 25

3.5 Tyre type.................................................................................................. 27

3.6 Engine Data............................................................................................. 27

3.7 EN norms................................................................................................. 28

3.8 Conditions of use..................................................................................... 29

3.9 Electrical requirements ............................................................................ 29

4Identification points and data plates........................................................30

4.1 Indication Points ...................................................................................... 30

4.2 Data plate ................................................................................................ 32

4.3 Truck capacity plate................................................................................. 33

4.4 Attachment capacity plate ....................................................................... 34

5Stability....................................................................................................34

09.12 EN

CTransport and Commissioning................................................35

1Transport.................................................................................................35

2Truck laden..............................................................................................35

2.1 Centre of gravity of the truck ................................................................... 35

2.2 Lifting the truck by crane ......................................................................... 36

2.3 Loading with another industrial truck ....................................................... 37

3 Securing the truck during transport ......................................................... 38

4Using the Truck for the First Time...........................................................39

DBattery - Servicing, Recharging, Replacement.......................41

1Safety Regulations Governing the Handling of Lead-Acid Batteries.......41

1.1 General notes on handling batteries........................................................ 43

2Battery types............................................................................................44

3Exposing the battery................................................................................45

4Charging the battery................................................................................46

4.1 Charging the battery with a stationary charger........................................ 46

4.2 Charging the battery with a charger socket (o)...................................... 47

5Battery removal and installation..............................................................48

6Closing the battery cover.........................................................................49

EOperation................................................................................51

1 Safety Regulations for the Operation of the Forklift Truck....................... 51

2Displays and Controls..............................................................................53

2.1 Control panel with display unit................................................................. 56

2.2 Side compartment control panel switch (o)............................................ 58

2.3 Instrument panel switches (o)................................................................ 58

2.4 Display..................................................................................................... 59

3Starting up the truck................................................................................61

3.1 Checks and operations to be performed before starting daily operation . 61

3.2 Entry and exit........................................................................................... 63

3.3 Trucks with reduced headroom X (o)..................................................... 63

3.4 Setting up the operator position............................................................... 64

3.5 Seat Belt .................................................................................................. 68

4 Industrial Truck Operation ....................................................................... 69

4.1 Safety regulations for truck operation...................................................... 69

4.2 Preparing the truck for operation ............................................................. 71

4.3 Setting the time........................................................................................ 72

4.4 Parking the truck securely ....................................................................... 73

4.5 Emergency Disconnect............................................................................ 74

4.6 Travel....................................................................................................... 75

4.7 Steering ................................................................................................... 76

4.8 Brakes ..................................................................................................... 77

4.9 Adjusting the forks ................................................................................... 79

4.10 Replacing the forks.................................................................................. 80

4.11 Lifting, transporting and depositing loads ................................................ 81

4.12 Operating the lift mechanism and integrated attachments ...................... 83

4.13 Safety instructions for operating additional attachments ......................... 90

4.14 Operating additional attachments for the SOLO-PILOT .......................... 94

4.15 Operating additional attachments for the Multi Pilot ................................ 96

4.16 Fitting additional attachments.................................................................. 98

5Towing trailers.........................................................................................100

6Optional equipment.................................................................................102

6.1 CanCode keypad..................................................................................... 102

6.2 Assistance systems ................................................................................. 106

6.3 Steel cab.................................................................................................. 108

6.4 Sliding windows ....................................................................................... 108

6.5 Automatic / mechanical folding gate........................................................ 109

6.6 BODYGUARD ......................................................................................... 110

09.12 EN

6.7 Panel door ............................................................................................... 110

6.8 Operator position extension..................................................................... 111

6.9 Adjusting the driver’s seat ....................................................................... 111

6.10 Heating .................................................................................................... 112

6.11 Removable load backrest ........................................................................ 113

6.12 Lift cutout override ................................................................................... 113

6.13 Fire extinguisher ...................................................................................... 114

6.14 Tilt angle display...................................................................................... 114

6.15 Rockinger coupling with hand lever or remote control............................. 115

6.16 Camera system ....................................................................................... 116

6.17 Control layout “N” .................................................................................... 117

7Troubleshooting.......................................................................................118

7.1 Troubleshooting....................................................................................... 118

7.2 Operating the truck without its own drive system .................................... 121

7.3 Emergency lowering ................................................................................ 123

FIndustrial Truck Maintenance..................................................125

1Operational Safety and Environmental Protection...................................125

2Maintenance Safety Regulations.............................................................126

3Servicing and Inspection.........................................................................131

4Maintenance checklist.............................................................................132

4.1 Owner ...................................................................................................... 132

4.2 Customer Service .................................................................................... 135

5Lubricants and Lubrication Schedule......................................................144

5.1 Handling consumables safely.................................................................. 144

5.2 Lubrication Schedule ............................................................................... 146

5.3 Consumables........................................................................................... 147

6Maintenance and repairs.........................................................................149

6.1 Preparing the truck for maintenance and repairs .................................... 149

6.2 Opening the rear panel............................................................................ 149

6.3 Checking the wheel attachments............................................................. 150

6.4 Replacing wheels .................................................................................... 151

6.5 Hydraulic system ..................................................................................... 153

6.6 Replacing the hydraulic oil filter............................................................... 155

6.7 Replacing the ventilation/discharge filter ................................................. 155

6.8 Check the gear oil level ........................................................................... 156

6.9 Replacing the suction filter of the engine fan........................................... 157

6.10 Heating .................................................................................................... 158

6.11 Adding window washer system fluid........................................................ 158

6.12 Checking electrical fuses......................................................................... 159

6.13 Seat belt maintenance............................................................................. 161

6.14 Restoring the truck to service after maintenance and repairs ................. 162

7Decommissioning the industrial truck......................................................163

7.1 Prior to decommissioning ........................................................................ 164

7.2 During decommissioning ......................................................................... 164

7.3 Restoring the truck to service after decommissioning ............................. 165

8 Safety tests to be performed at intervals and after unusual incidents ..... 166

9Final de-commissioning, disposal............................................................167

10 Human vibration measurement ............................................................... 167

09.12 EN

Appendix

JH Traction Battery Operating Instructions

These operating instructions apply only to Jungheinrich battery models. If using

another brand, refer to the manufacturer's operating instructions.

0506.GB

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.

09.12 EN

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.

09.12 EN

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.

09.12 EN

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.

1.1 Truck 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

35 Rated 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.

09.12 EN

2Assemblies and Functional Description

2.1 Assembly Overview

Item Description

1 t Driver's seat 2 t Overhead guard 3 t Mast 4 t Steering wheel 5 t Control / display unit 6 t Lift mechanism control 7 t Emergency Disconnect switch 8 t Fork tines 9 t Fork carriage

10 t Battery cover

11 t Drive 12 t Trailer coupling 13 t Counterweight

09.12 EN

2.2 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 (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.

09.12 EN

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.

09.12 EN

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.).

Z Technical data specified in accordance with VDI 2198.

Technical modifications and additions reserved.

3.1 Performance data

EFG 535-540

Description

Rated capacity

(where C = 500 mm)

C Load centre of gravity 500 500 mm

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 pressure 200 200 bar

Oil flow for attachments 30 30 l/min

for vertical mast.

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%.

535 540

3500 4000 kg

16 / 17 15 / 17 km/h

0,38 / 0,50 0,35 / 0,47 m/s

0,58 / 0,55 0,55 / 0,50 m/s

8,5 / 14,5 8 / 13,5 %

15,5 / 25 14 / 23,5 %

4,8 / 4,2 5,0 / 4,4 s

EFG

09.12 EN

EFG 545-550

Description

Rated capacity

(where C = 500 mm)

545 550

4500 4990 kg

EFG

C Load centre of gravity 500 500 mm

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 / 16,5 15 / 16 km/h

0,33 / 0,45 0,31 / 0,45 m/s

0,55 / 0,50 0,55 / 0,50 m/s

7 / 12 6,5 / 12 %

12,5 / 21,5 12 / 21 %

5,5 / 4,8 5,8 / 5,2 s

Max. operating pressure 200 200 bar

Oil flow for attachments 30 30 l/min

for vertical mast.

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%.

09.12 EN

3.2 Dimensions

EFG 535-540

Description

535 540

a/2 Safety distance 100 100 mm

h1Mast height retracted* 2228 2405 mm

h2Free lift* 150 150 mm

h3Lift* 3100 3000 mm

h4Mast height extended* 3883 3830 mm

h6Overhead guard height* 2320 2320 mm

h7Seat height* 1165 1165 mm

h10Coupling height 390/500 390/500 mm

Į Mast tilt, fwd. 6 6 °

ȕ Mast tilt, back 8 8 °

L1Length including forks* 3975 3980 mm

L2Headlength* 2830 2830 mm

b1Overall width* 1340 1340 mm

b3Fork width* 1120 1260 mm

Ground clearance with load below

mast

120 120 mm

m2Ground clearance centre wheelbase 160 160 mm

Working aisle width

Ast

800 x 1200 longitudinal pallets

Working aisle width

Ast

1000 x 1200 traverse pallets

4180 4360 mm

3980 4160 mm

Wa Turning radius 2300 2450 mm

xLoad distance 510 * 510 * mm

yWheelbase 1855 2000 mm

EFG

09.12 EN

EFG 545-550

Description

a/2 Safety distance 100 100 mm

h1Mast height retracted* 2405 2405 mm

h2Free lift* 150 150 mm

h3Lift* 3000 3000 mm

h4Mast height extended* 3830 3830 mm

h6Overhead guard height* 2320 2320 mm

h7Seat height* 1165 1165 mm

h10Coupling height 390/500 390/500 mm

Į Mast tilt, fwd. 6 6 °

ȕ Mast tilt, back 8 8 °

L1Length including forks* 3980 3980 mm

L2Headlength* 2830 2830 mm

b1Overall width* 1340 1340 mm

b3Fork width* 1120 1260 mm

Ground clearance with load below

mast

m2Ground clearance centre wheelbase 160 160 mm

Working aisle width

Ast

800 x 1200 longitudinal pallets

Working aisle width

Ast

1000 x 1200 traverse pallets

Wa Turning radius 2450 2450 mm

xLoad distance 510 * 510 * mm

yWheelbase 2000 2000 mm

545 550

120 120 mm

4360 4360 mm

4160 4160 mm

EFG

3.3 Weights

Z All dimensions in kg.

EFG 535-550

Net weight (including battery)

Front axle load (without lifting load)

Front axle load (with lifting load)

Rear axle load (without lifting load)

09.12 EN

Description EFG

535 540 545 550

5800 6600 6950 7300

3000 3700 3700 3700

8350 9700 10400 11200

2800 2900 3250 3600

EFG 535-550

Description EFG

Rear axle load (with lifting load)

535 540 545 550

950 900 1050 1100

09.12 EN

3.4 Mast versions

Z All dimensions in mm

EFG 535-540

VDI 3596 Description

Special trucks are not included in this overview.

Lift h

Free lift h

EFG 535 EFG 540 EFG 535 EFG 540 EFG 535 EFG 540

2750 3000 2405 3830 3100 2228 3883 3500 2428 2655 4283 4330 4000 2678 2905 4783 4830 4500 2978 3155 5283 5330 5000 3228 3405 5783 5830 5500 3655 6330 6000 3905 6830 6500 4155 7330 2700 1376 2080 3404 2950 1501 2205 3654 3450 1751 2455 4154 3950 2001 2705 4654 4450 2251 2955 5154 4950 2501 3205 5654 5450 2751 3455 6154 3800 1376 2080 5405 4175 1501 2205 4879 4700 1430 2193 5463 4925 1751 2405 5629 5000 1530 2293 5763 5300 1871 2580 6004 5500 1730 2493 6263 5675 2001 2705 6379 6000 1930 2693 6763 6425 2251 2955 7159 6500 2130 2893 7263 7175 2521 3205 7879

150

Height

mast

retracted h

Height

mast

extended h

2280 3580

09.12 EN

EFG 545-550

VDI 3596 Description

Lift h

Free lift h

EFG 545 EFG 550 EFG 545 EFG 550 EFG 545 EFG 550

2750 3000 2405 2405 3830 3830 3500 2655 2655 4330 4330 4000 2905 2905 4830 4830

4500 3155 3155 5330 5330

150 5000 3405 3405 5830 5830 5500 3655 3655 6330 6330 6000 3905 3905 6830 6830 6500 4155 4155 7330 7330 2700 1376 1227 2080 2080 3404 3553 2950 1501 1352 2205 2205 3654 3803 3450 1751 1602 2455 2455 4154 4303

3950 2001 1852 2705 2705 4654 4803 4450 2251 2102 2955 2955 5154 5303 4950 2501 2352 3205 3205 5654 5803 5450 2751 2602 3455 3455 6154 6303 3800 1376 1227 2080 2080 5405 4653 4175 1501 1352 2205 2205 4879 5023 4925 1751 1602 2405 2405 5629 5773

5300 1871 1727 2580 2580 6004 6153 5675 2001 1852 2705 2705 6379 6523 6425 2251 2102 2955 2955 7159 7273 7175 2521 2352 3205 3205 7879 8023

Special trucks are not included in this overview.

Height

mast

retracted h

Height

mast

extended h

2280 2280 3580 3580

09.12 EN

3.5 Tyre type

NOTE

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

Description EFG 535-545 EFG 550

SE *) 250 / 70 R15 28 x 12.5 - 15

Full rubber*) 28 x 10 x 22 28 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 bar 10 -

To rq u e (N m ) 4 30

SE *) 21 x 8 - 9

Full rubber*) 21 x 7 - 15 ǩ"

Pneumatic*) 250 / 70 R15 21 x 8 - 9

Tyre pressure bar 10 10

To rq u e (N m ) 2 20 2 20

3.6 Engine Data

Description EFG535-550

Drive motor 18 kW Lift motor 23,5 kW

09.12 EN

3.7 EN 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.

Z The 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.

Z The 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.

Z No 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.

09.12 EN

3.8 Conditions of use

Ambient temperature

–operating at -20°C to +40°C

Z Special equipment and authorisation are required if the truck is to be constantly

used in conditions of extreme temperature or air humidity fluctuations.

3.9 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 according to its purpose.

09.12 EN

4Identification points and data plates

4.1 Indication Points

Z Warnings and notices such as capacity charts, strap points and data plates must

be legible at all times. Replace if necessary.

14 15 18 20 21

191716

(mm) Q (kg)

D (mm)

2000

28293031

09.12 EN

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

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

09.12 EN

4.2 Data plate

32 33 3534 36

Item Description Item Description

32 Type 38 Year of manufacture 33 Serial number 39 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 Option 43 Manufacturer’s logo

3837

Z For queries regarding the truck or ordering spare parts always quote the truck serial

number (33).

09.12 EN

4.3 Truck 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) 500 600 700

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

44 45

prescribed lift limits have been reached.

09.12 EN

4.4 Attachment 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.

Z For 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).

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

2.1 Centre 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.

09.12 EN

2.2 Lifting 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.

Z Truck 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.

09.12 EN

2.3 Loading 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.

09.12 EN

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

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.

09.12 EN

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).

Z To operate the truck without its own drive system, (see "Operating the truck without

its own drive system" on page 121).

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.

09.12 EN

1.1 General 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)).

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 del De scr ipt ion Capac ity

EFG 535 80V - 5PzS 700 Ah

EFG 540-550 80V - 6PzS 840 Ah

Drive battery 80 volts

Dimension (mm)

Truck

EFG 535 1028 855 769 784 1863

EFG 540-

550

L max. B max. H1+/-

2mm

1028 999 769 784 2178

H2 +/-

2mm

Rated weight

(-5/+8%) in kg

09.12 EN

3Exposing the battery

CAUTION!

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

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.

Z On trucks with a steel cab, before opening the battery cover push the driver’s seat

back and open the rear window.

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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.

4.1 Charging 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.

09.12 EN

4.2 Charging the battery with a charger socket (

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).

)

Z Test 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.

Z After charging, test the fans and remove the connector. If the fan is not working,

open the cover to ventilate the battery compartment.

Z Use only chargers with a max. 160 A charging current.

Battery is charged.

09.12 EN

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.

Z Hooks 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.

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.

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

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.

09.12 EN

2Displays and Controls

Item Control /

Display

58 Parking brake lever t Applies / releases parking brake 59 Steering wheel t Steers the t ruck. 60 Control panel with display

unit

61 SOLO-PILOT t Operates the following functions:

MULTI-PILOT o

62 Key switch t Switches control current on and off.

ISM access module* o Switches the truck on. Code lock*

63 Brake pedal t Provides infinitely variable braking control. 64 Accelerator pedal t Infinite travel speed control 65 Emergency Disconnect

switch

66 Side compartment

control panel

67 “Reverse” accelerator

double pedal control

68 “Forward” accelerator

twin pedal control

Function

t Displays the battery capacity, service hours,

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.

t Switches electric options on and off

o Applying the accelerator pedal reverses the

truck. The travel speed is infinitely controlled.

o Applying 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

6058 59

09.12 EN

Item Control /

Function

Display

69 Travel direction switch

t Selects travel direction / neutral position.

(not available with dual pedal control)

70 Lever t Lever for operating the hydraulic functions. 71 Horn t Activates an audible warning. 72 Additional hydraulic

function release button

o Activates the additional hydraulic functions

or hydraulics that require acknowledgement.

73 Button o Hydraulic auxiliary function control button.

7069 71

70 7169

09.12 EN

2.1 Control 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

Item Control /

Function

Display

74 Controller

overtemperature indicator

–Lights up to indicate controller

overtemperature

–Performance is continually reduced in

relation to the temperature

75 Drive motor

overtemperature indicator

76 Parking brake warning

indicator

–Monitors the temperature of the drive motor –Performance is reduced if the temperature is

excessive Parking brake activated –Truck operational, parking brake applied

77 Truck in operation indicator – Key switch ON 78 Insufficient brake fluid – The brake fluid level can be checked through

sensors on the brake fluid reservoir

79 Hourmeter / time toggle

switch

–Truck key switch ON service hours – "Eff" service hours can be switched ON or

OFF via a code –Time display

80 Pump 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

09.12 EN

Item Control /

Function

Display

81 Seat switch warning

indicator

Seat switch not closed – Truck operational, but driver’s seat not

occupied

82 Travel direction display

–Right / left indicator lamps activated

indicator lamp

83 Service display – Service interval exceeded (1000 service

hours) or annual FEM test due (flashing

indicator).

84 WARNING WARNING

– Flashes for faults, an audible warning

sounds –Flashes when battery capacity is less than

10%

85 Crawl speed button – Switches crawl mode on and off 86 Program selector – Selects the travel program (moves up or

down a level in the travel program list.)

87 Operating program display – Displays the selected travel program (1 to 5) 88 Set button – Confirms the entries

7682778378

7974807581

09.12 EN

2.2 Side compartment control panel switch (

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

2.3 Instrument panel switches (

Function

Parking light

Warning indicator

Truck lighting

)

09.12 EN

2.4 Display

89 9190

Item Function

89 Hourmeter 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.

90 Battery capacity display

–Battery discharge status

91 Travel 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

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.

Z In 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.

09.12 EN

3Starting up the truck

3.1 Checks 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

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

area for damage and leaks.

•Make sure the driver’s seat is locked in position.

• 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).

09.12 EN

3.2 Entry and exit

Procedure

•Open the cab door (o)

•To enter and exit the cab, hold onto the handle (95).

Z An additional step is provided for the driver position extension (

3.3 Trucks 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.

)

09.12 EN

3.4 Setting 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.

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.

9998

100 101

Z The 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.

Z Hold the weight setting lever (96) only by the recess, never reach through

underneath the lever.

09.12 EN

Adjusting the seat position

CAUTION!

An unsecured driver's seat can cause injury

An unsecured driver's seat can slide out of its guide during travel, resulting in accidents.

The driver's seat must be locked in

position. Do not adjust the driver’s seat while

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.

)

09.12 EN

3.4.2 Adjusting the steering column

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

102 103

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.

3.5 Seat 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.

Z Protect 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.

Z Carefully drive the truck off the slope and then put on the belt.

09.12 EN

4Industrial Truck Operation

4.1 Safety 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!

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

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.

Z For 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)

09.12 EN

4.2 Preparing the truck for operation

104

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.

Z When 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

4.3 Setting the time

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.

Z Keep 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).

09.12 EN

4.4 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.

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.

09.12 EN

4.5 Emergency 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

Z Do 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.

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).

09.12 EN

4.6 Travel

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.

64106

09.12 EN

Dual pedal (optional equipment)

Requirements

–Truck prepared for operation, (see "Preparing

the truck for operation" on page 71).

Procedure

Z For 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.

4.7 Steering

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.

09.12 EN

4.8 Brakes

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.

63 64

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.

Z The 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.

09.12 EN

4.9 Adjusting 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

Z To 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.

09.12 EN

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.

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).

–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.

Z Avoid 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.

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

4.12.1 Operating the lift mechanism with the SOLO PILOT

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

Z When 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

Z When 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

Positioning the integrated sideshift (option)

Requirements

–Truck prepared for operation, (see "Preparing

112

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.

Z When 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

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

Synchronising the alignment of the fork

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

113

Z When 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

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.

Z When 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.

Z When 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

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

Z When 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

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

Z When 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

4.13 Safety instructions for operating additional attachments

Z Optionally, 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.

Z If 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.

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.

Safety instructions for clamping attachments (e.g. baling clamps, barrel clamps, grabs etc.)

WARNING!

Falling loads can cause accidents

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

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.

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

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

Z Depending 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

09.12 EN

4.14.2 Solo Pilot with control of ZH1 and ZH2 hydraulic ports

Z Depending 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

Z Depending 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

113

110

113

112

116

09.12 EN

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

Z Depending 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

Z Depending 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

09.12 EN

4.15.3 Multi Pilot with control of ZH1, ZH2 and ZH3 hydraulic ports

Z Depending 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

09.12 EN

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.

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.

Z 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.

09.12 EN

Jungheinrich EFG 535, EFG 545, EFG 540, EFG 550 User Manual [de]

Specifications and Main Features

Frequently Asked Questions

User Manual