Jungheinrich EFG 110 Operating Instructions Manual Download | Manualshive

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4

Industrial Truck Operation

4.1

Safety regulations for truck operation

WARNING!

Magnetic fields can cause accidents

Electronic components can be affected or damaged by external magnetic fields. This
can lead to malfunctions or accidents.

u

Do not use or keep magnets or clamping magnets in the immediate vicinity of the
controls.

Travel routes and work areas

Only use lanes and routes specifically designated for truck traffic. Unauthorised third
parties must stay away from work areas. Loads must only be stored in places
specially designated for this purpose.
The truck must only be operated in work areas with sufficient lighting to avoid danger
to personnel and materials. Additional equipment is necessary to operate the truck in
areas of insufficient lighting.

DANGER!

Do not exceed the permissible surface and point loading on the travel lanes.
At blind spots get a second person to assist.
The driver must ensure that the loading dock /dock leveller cannot be removed or
come loose during loading/unloading.

NOTICE

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.

Travel conduct

The  operator  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  operator  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

The operator must not jump off the truck. The operator 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 operator must look in the direction of travel and must always have a clear view
of the route ahead. If the truck is carrying loads that affect visibility, the truck must

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Summary of Contents for EFG 110

Page 1: ...EFG 110 115 10 09 Operating instructions 51151449 10 20 en GB EFG 110k EFG 110 EFG 113 EFG 115 ...

Page 2: ...2 ...

Page 3: ...110 EFG 113 EFG 115 On behalf of Date EU DECLARATION OF CONFORMITY The undersigned hereby declare that the powered truck described in detail complies with the current versions of European Directives 2006 42 EG Machinery Directive and 2014 30 EU Electromagnetic Compatibility EMC The manufacturer is authorised to compile the technical documentation 3 10 20 en GB ...

Page 4: ...4 10 20 en GB ...

Page 5: ...ular 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 hazardou...

Page 6: ...ght Copyright of these operating instructions remains with JUNGHEINRICH AG Jungheinrich Aktiengesellschaft Friedrich Ebert Damm 129 22047 Hamburg Germany Tel 49 0 40 6948 0 www jungheinrich com 6 10 20 en GB ...

Page 7: ... 3 3 Weights 24 3 4 Mast versions 24 3 5 Tyre type 25 3 6 Engine Data 26 3 7 EN norms 27 3 8 Conditions of use 28 3 9 Electrical Requirements 28 3 10 Specifications according to RED guideline Radio Equipment Directive for radio units 29 4 Identification 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 35 5 Stability 36 5...

Page 8: ...5 Restraint systems 80 3 6 Seat Belt 81 4 Industrial Truck Operation 83 4 1 Safety regulations for truck operation 83 4 2 Preparing the truck for operation 86 4 3 Setting the time 87 4 4 Parking the truck securely 88 4 5 Emergency Disconnect 89 4 6 Travel 90 4 7 Steering 92 4 8 Brakes 93 4 9 Adjusting the forks 96 4 10 Replacing the forks 97 4 11 Lifting transporting and depositing loads 98 4 12 O...

Page 9: ...Lifting and jacking up the truck safely 149 5 3 Opening the battery panel 150 5 4 Checking the wheel attachments 152 5 5 Replacing wheels 153 5 6 Hydraulic system 155 5 7 Check the gear oil level 157 5 8 Adding window washer system fluid 158 5 9 Checking electrical fuses 159 5 10 Cleaning 162 5 11 Working on the electrical system 165 5 12 Restoring the truck to service after maintenance and repair...

Page 10: ...10 10 20 en GB ...

Page 11: ...cope of application and may result in damage to personnel the industrial truck or property 2 Correct application NOTICE The maximum load and load distance are indicated on the capacity plate and must not be exceeded The load must rest on the load handler or be lifted by an attachment approved by the manufacturer The load must be fully raised see page 98 11 10 20 en GB ...

Page 12: ...e trailer coupling Z When towing trailers the load must be secured on the trailer The permissible trailer load must not be exceeded The following operations are prohibited Do not travel with a raised load 30 cm Carrying and lifting persons without approved attachments or optional equipment a Pushing or pulling loads with the exception of occasional towing of trailers with the trailer coupling Tran...

Page 13: ...temperature range 20 C to 40 C Operation only on secure level surfaces with sufficient capacity Do not exceed the permissible surface and point load limits on the travel routes Operation only on travel paths that are visible and approved by the operating company Negotiating inclines up to a maximum of 15 Do not travel across or at an angle on inclines Travel with the load facing uphill 3 1 Interna...

Page 14: ...epair guidelines must be followed The operating company must ensure that all users have read and understood these operating instructions NOTICE Failure to comply with the operating instructions invalidates 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 5 Adding attachments and or optional equipm...

Page 15: ...r 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 name EFG110 EFG Model name 1 Series 10 Rated capacity x 100 kg The rated capacity is not generally the same as the permissible capacity The capacity can be found on the capacity plate attached to the truck 15 10 20...

Page 16: ...rection definition The following determinations have been made for travel direction specification 1 2 3 4 The following conventions have been agreed for travel direction specification Item Travel direction 1 Left 4 Reverse 2 Forward 3 Right 16 10 20 en GB ...

Page 17: ...s seat 2 t Overhead guard 3 t Mast 4 t Steering wheel 5 t Control and display unit 6 t Lifting mechanism control 7 t Emergency Disconnect switch 8 t Forks 9 t Fork carriage 10 t Battery cover 11 t Drive 12 t Trailer coupling 13 t Counterweight t Standard equipment 17 10 20 en GB ...

Page 18: ...ereby ensuring a very high level of safety Steering A low steer effort of 15 N as well as a favourable transmission ratio of 5 steering wheel revolutions for an 180 steer angle A hydraulic steer motor actuates the drive wheel via a gear wheel pair Efficient energy deployment through the load sensing system The steering column is adjustable Wheels There is a choice of super elastic or fully rubber ...

Page 19: ... automatically reduces the travel speed as a function of the steer angle 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 th...

Page 20: ...d 1 2 2 The load centre distance D of the load handler is specified as the horizontal distance from the front face and the vertical distance from the upper edge of the load handler Z The capacity plate for standard load handlers specifies valid load centre distances of 500 mm 600 mm and 700 mm The distances d1 and d2 depicted in the illustration between the load handler and the actual centre of gr...

Page 21: ... 60 0 58 0 60 0 58 0 60 0 58 0 60 m s Gradeability 30 min w w o load 8 5 12 8 11 5 7 11 6 5 10 5 Max gradeability 5 mins w w o load 13 18 12 5 17 5 11 16 5 10 16 Acceleration 10 min w w o load 5 1 4 6 5 1 4 6 5 4 4 7 5 6 4 8 s Max operating pressure 160 160 185 210 bar Oil flow for attachments 14 14 14 14 l min 1 for vertical mast 2 The values shown represent the maximum gradeability to overcome s...

Page 22: ... α Mast tilt fwd 5 5 5 5 β Mast tilt back 6 6 6 6 L1 Length including forks 2719 2773 2881 2935 mm L2 Headlength 1569 1623 1731 1785 mm b Overall width 990 990 990 990 mm e Fork width 100 100 100 100 mm m1 Ground clearance with load below mast 90 90 90 90 mm m2 Ground clearance centre wheelbase 100 100 100 100 mm Ast Aisle width for pallets 800 x 1200 longit 3020 3074 3182 3236 mm Ast Aisle width ...

Page 23: ...Ast a 2 e a 2 W a c Q h 6 h 7 H 1 h 1 h 3 h 4 h 2 m 1 b L2 L1 y m 2 h 10 x 23 10 20 en GB ...

Page 24: ...m Mast table EFG 110k 110 113 115 VDI 3596 Designation Lift h3 Free lift h2 Retracted height h1 Extended height h4 ZT 2300 150 1650 2850 3000 150 2000 3550 3100 150 2050 3650 3300 150 2150 3850 3600 150 2300 4150 4000 150 2500 4550 4500 150 2800 5050 5000 150 3050 5550 ZZ 2300 1055 1605 2850 3000 1405 1955 3550 3100 1455 2005 3650 3300 1555 2105 3850 3600 1705 2255 4150 4000 1905 2455 4550 DZ 4350...

Page 25: ...tted at the factory only use the manufacturer s original spare parts Otherwise the manufacturer s specifications cannot be ensured If you have any queries contact the manufacturer s customer service department Description EFG 110 EFG 113 EFG 115 Front tyres SE 18 x 7 8 Full rubber 18 x 6 x 12 1 8 Pneumatic 180 70 8 Diagonal 16PR Tyre pressure bar 10 Torque Nm 170 Rear tyres SE 18 x 7 8 Full rubber...

Page 26: ...0k EFG 110 EFG 113 EFG 115 Energy consumption according to EN cycle 2 6 kWh h 2 7 kWh h CO2 equivalent according to EN 16796 1 40 kg h 1 46 kg h Throughput performance 60 t h 76 t h 93 t h Energy consumption at max throughput performance 3 2 kWh h 3 3 kWh h 3 5 kWh h 3 7 kWh h 26 10 20 en GB ...

Page 27: ... a special service to measure these human vibrations see page 171 Z The internal accuracy of the measuring chain for at 21 C at 0 02 m s Further deviations may occur in particular through the positioning of the sensor and different driver weights Electromagnetic compatibility EMC The manufacturer confirms that the truck adheres to the limits for electromagnetic emissions and resistance as well as ...

Page 28: ...y in conditions of extreme temperature or condensing 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 28 10 20 en GB ...

Page 29: ... affected frequency range and the emitted transmission power for each component Component Frequency range Transmission power Radio module ISM Online 433 05 434 79 MHz 10 mW Access module ISM Online 13 56 MHz 100 mW EasyAccess StandAlone 13 56 MHz 100 mW Transponder reader EasyKey 2 4 GHz 67 6 mW Transponder reader EasyKey 5 8 GHz 66 1 mW Indoor outdoor detection 24 00 24 25 GHz 100 mW 29 10 20 en ...

Page 30: ...nts and data plates must be legible at all times Replace if necessary D mm mm Q kg 20 21 28 27 18 26 25 24 23 22 19 18 17 16 15 14 Item Description 14 Capacity or reduced capacity 15 Wear seat belt 16 Do not travel with a raised load or operate the mast forward tilt with a raised load 17 Tipover warning 30 10 20 en GB ...

Page 31: ... risk of trapping with moving mast 20 Serial number on chassis below the battery panel 21 Warning optical radiation Floor Spot 22 Max body size 23 Inspection plaque o 24 Data plate 25 Jacking points 26 Model description 27 Do not carry passengers 28 Observe the operating instructions 31 10 20 en GB ...

Page 32: ...tem Model 29 Rated capacity kg 36 Load centre distance mm 30 Battery voltage V 37 Drive output 31 Net weight w o battery kg 38 Min max battery weight kg 32 Option 39 Manufacturer 33 Model 40 QR code 34 Serial number 41 Manufacturer s logo 35 Year of manufacture Z For queries regarding the truck or when ordering spare parts always quote the truck serial number 34 32 10 20 en GB ...

Page 33: ...or standard forks length 1150 mm The capacity plate 14 gives the capacity Q in kg of the truck for a vertical mast A table indicates the maximum capacity with a given load centre distance D in mm and the required lift height h3 in mm 14 43 42 The truck capacity plate specifies the type and serial number of the truck and indicates the capacity with the fork arms t 42 or the fork extensions o 43 in ...

Page 34: ...ntre distance D of 600 mm and a maximum lift height of h3 3600 mm the max capacity Q is 1105 kg Lift height limits The arrow shaped markings 45 and 46 on the inner and outer masts show the operator when the prescribed lift limits have been reached 45 46 34 10 20 en GB ...

Page 35: ...8 The model name and or serial number for the attachment indicated on the attachment capacity plate must match the data plate of the attachment 48 47 4 4 1 Attachment with More Than 100 mm Side Shift The capacity plate of the attachment with more than 100 mm possible side shift for a current working position in the centre position 49 or pushed out offset to max 100 mm side shift is affixed next to...

Page 36: ...ing position with 100 mm side shift pushed out 50 is affixed separately to the other capacity plates 50 5 Stability The truck s stability has been tested according to latest technological standards These take into account the dynamic and static tipover forces that can occur if used correctly Stability can also be affected by the following factors Tyre type Mast Attachment Transported load size wei...

Page 37: ...of a truck when lifting lowering and transporting loads with large surface areas Light loads must be especially secured when they are subjected to wind forces This will prevent the load from sliding or falling Stop the truck in both cases 37 10 20 en GB ...

Page 38: ...38 10 20 en GB ...

Page 39: ... the basic truck and the mast separated 2 Truck laden 2 1 Centre of gravity of the truck WARNING An altered centre of gravity can result in tipovers when cornering The overall centre of gravity can vary depending on the truck s equipment especially the mast version For trucks without a mast the centre of gravity will move significantly in the direction of the counterweight uDrive carefully and wit...

Page 40: ... tear resulting in accidents uOnly use crane lifting gear with sufficient capacity uLoading weight Net weight of truck battery weight for electric trucks uThe mast must be tilted back fully uThe crane lifting gear on the mast must have a minimum clear length of 2 m uCrane slings should be fastened in such a way that they do not come into contact with any attachments or the overhead guard when lift...

Page 41: ...page 88 Procedure Secure the crane slings to the attachment points 51 and 52 Raise and load the truck Lower and deposit the truck carefully see page 88 Secure the truck with wedges to prevent it from rolling away This concludes the loading by crane 51 52 41 10 20 en GB ...

Page 42: ...ces prohibited NOTICE Pick up the truck only from the left hand side of the truck Make sure that the truck is not picked up from the battery door Loading the truck with a second industrial truck Requirements Park the truck securely see page 88 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 nece...

Page 43: ... loads on road vehicles and handling load securing devices In each case correct measurements must be taken and appropriate safety measures applied uThe truck must be securely fastened when transported on a lorry or a trailer uThe lorry or trailer must have fastening rings uUse wedges to prevent the truck from moving uUse only fastening belts with sufficient strength uUse non slip materials to secu...

Page 44: ...red 2 fastening belts with a tensioner Retaining wedges Procedure Secure the truck with the fastening belt 53 at the top cross member of the mast 3 and the trailer coupling 12 or on the overhead guard 2 and the trailer coupling 12 Tighten the fastening belt 53 with the tensioner 54 The truck is now secured for transport 53 3 12 54 12 53 2 44 10 20 en GB ...

Page 45: ...stem Unsuitable cable connections too long insufficient wire cross section to the battery tow cables can overheat setting the truck and battery on fire uThe truck must only be operated with battery current uCable connections to the battery tow leads must be less than 6 m long and have a minimum cross section of 6 yd 50 mm Preparing the truck for operation after delivery or transport Procedure Chec...

Page 46: ...46 10 20 en GB ...

Page 47: ...anufacturer 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 for the truck by the manufacturer can lead to a deterioration of the braking system during energy recovery operations and also cause considerable damage to ...

Page 48: ...r physical defect The batteries are normally charged There is still some residual voltage in a discharged battery This must be considered as a hazardous contact voltage With this kind of defect the battery must not be touched and must not come into contact with metal objects see page 47 48 10 20 en GB ...

Page 49: ... closing the battery cover make sure that the battery cables are not damaged CAUTION The use of unsuitable fire protection equipment can result in acid burns In the event of fire a reaction with the battery acid can occur if water is used to extinguish the fire This can lead to acid burns uUse powder extinguishers uNever extinguish burning batteries with water Do not smoke and avoid naked flames w...

Page 50: ...uck type Description Capacity EFG 110k 24 V 4PzS 500 Ah EFG 110 24 V 5PzS 625 Ah EFG 113 24 V 7PzS 875 Ah EFG 115 24 V 8PzS 1000 Ah 4 Battery dimensions Traction battery 24 V Truck Dimension mm Rated weight 5 8 in kg L max B max H1 2mm H2 2mm EFG 110k 830 273 612 627 380 EFG 110 830 327 612 627 450 EFG 113 830 435 612 627 600 EFG 115 830 489 612 627 690 DANGER If the centre of gravity of the batte...

Page 51: ...or and allow it to cool down Exposing the battery with the SOLO PILOT Requirements Park the truck securely see page 88 Load handler lowered Key switch set to OFF Key removed Set the Emergency Disconnect OFF Procedure Press the lever 56 to unlock the cover 55 and move it forward Carefully lift back the battery cover and the driver s seat as far as the stop opening angle 90 The battery is now expose...

Page 52: ...ase the steering column lock 58 push the steering column forward and secure it in this position Pull the panel 57 forward until it engages Carefully lift back the battery cover and the driver s seat 1 as far as the stop opening angle 90 The battery is now exposed 57 Z On trucks with a rear window canvas cover open the rear window canvas cover before opening the battery cover 58 1 52 10 20 en GB ...

Page 53: ...e only batteries with insulated cells and terminal connectors uPark the truck on a level surface to prevent the battery from sliding out uMake sure the crane slings have sufficient capacity to replace the battery uUse only approved battery replacement devices battery roller stand replacement trolley etc uMake sure the battery is securely located in the truck s battery compartment CAUTION Trapping ...

Page 54: ...trap the crane lifting gear vertically over the recess in the overhead guard to the battery tray Z Hooks must be fitted in such a way that when the crane lifting gear is slackened it does 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 54 10 20 en GB ...

Page 55: ...ting sparks within 2 5 m around the truck uFire protection equipment must be on hand uDo not lay any metallic objects on battery uIt is essential to follow the safety regulations of the battery and charger station manufacturers 7 1 Charging the battery with a stationary charger WARNING Risk of electric shock and fire due to lacking or inappropriate residual current devices A lack of residual curre...

Page 56: ...The battery is now charged 56 10 20 en GB ...

Page 57: ... the battery cover with the driver s seat Move the cover 55 back until it engages The battery cover is now closed 61 Closing the battery cover with the Multi Pilot optional Requirements The battery cable is in the cable guide 61 Procedure Push the cover 57 back with force Engage the lock 62 The battery cover is now closed 57 62 55 57 10 20 en GB ...

Page 58: ...58 10 20 en GB ...

Page 59: ...iliar with the operating instructions Unauthorised use of truck The operator is responsible for the truck during the time it is in use The operator 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 informed immediately of any damage or faults to the truck or attachment Trucks which are unsafe ...

Page 60: ...truck immediately WARNING Falling objects can cause accidents Falling objects can injure the operator while the truck is being operated uThe operator must remain within the protected area of the overhead guard while the truck is being operated Safety devices warning signs and warning instructions Safety devices warning signs see page 30 and warning instructions in the present operating instruction...

Page 61: ...with display unit t Displays the battery capacity service hours errors key warning indicators wheel position and travel direction 65 Steering wheel t Steers the truck 66 soloPILOT t Controls the following functions Fwd rev travel direction Lifting lowering load Mast forward reverse tilt Horn button Sideshifter left right o Auxiliary hydraulics o multiPILOT o 61 10 20 en GB ...

Page 62: ...astened the warning indicator for the belt lock control system illuminates 72 Warning indicator for cab door monitoring If the cab door is not closed the warning indicator for the cab door monitoring illuminates 73 Reverse accelerator twin pedal control o The truck reverses when the accelerator pedal is applied Provides infinitely variable travel speed 74 Forwards accelerator twin pedal control o ...

Page 63: ...72 71 73 69 74 75 70 69 68 67 66 64 65 63 63 10 20 en GB ...

Page 64: ...ator for the cab door monitoring illuminates 76 Travel direction switch not available with twin pedal control t Selects travel direction or neutral 77 Horn button t Activates an audible warning signal 78 Lever t Lever for operating the hydraulic functions 79 Button o Hydraulic auxiliary function control button 80 Additional hydraulic function release button o Activates the additional hydraulic fun...

Page 65: ...80 77 76 79 72 71 65 10 20 en GB ...

Page 66: ...ature Monitors the temperature of the drive motor Performance is reduced if the temperature is excessive 83 Parking brake indicator Comfort feature displayed when the parking brake indicator 83 lights up Truck prevented from rolling away but not parked securely Parking brake is automatically activated after a set time when the truck stops The parking brake is automatically released when the accele...

Page 67: ...ht left indicator lamps activated 90 Service display Service interval exceeded 1000 operating hours or annual FEM test due flashing indicator 91 WARNING WARNING Flashes for faults an audible warning sounds Flashes when battery capacity is less than 10 92 Slow travel button Switches slow travel on and off 93 Program selector Selects the travel program moves up or down a level in the travel program ...

Page 68: ...ment control panel switch o Function Rear window heating Slow travel Beacon Seat heating Work lights Lift cutout override Windscreen washer system 2 3 Instrument panel switches o Function Truck lighting 68 10 20 en GB ...

Page 69: ...errors occur they are displayed alternately at 1 5 second intervals A warning is sounded 97 Battery capacity display Battery discharge status 98 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 69 10 20 en GB ...

Page 70: ...attery charge status is shown through a battery icon 97 in the truck display in 10 increments 100 100 battery capacity 0 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 orde...

Page 71: ...n accidents If damage or other truck or attachment optional equipment defects are discovered during the following checks the truck must be taken out of service until it has been repaired uReport any defects immediately to your supervisor uMark defective truck and take out of service uDo not return the industrial truck to service until you have identified and rectified the fault 71 10 20 en GB ...

Page 72: ...isplay unit Belt lock control symbol see page 61 lights up when the belt is not locked Test the function of the display unit Cabin door monitoring symbol see page 61 lights up when the summer door the folding gate or the cabin door is not closed properly o Test the seat switch when the driver s seat is vacated it should not be possible to activate the hydraulic functions Test the restraint system ...

Page 73: ...nnections Check the battery latch is present and working On trucks with lateral battery removal check the left and right stops 101 in the battery compartment for damage Check the fluid level of the windscreen washing system see page 158 101 73 10 20 en GB ...

Page 74: ...ion o 3 3 Trucks with reduced headroom o CAUTION An unsuitable workplace can damage your health Failure to observe the recommended body size can cause stress and endanger the operator and may lead to lasting ill health due to an unhealthy posture and excessive strain on the operator uThe operating company must ensure that truck operators do not exceed the maximum body size indicated uThe operating...

Page 75: ... 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 uDo not adjust the driver s seat while travelling ...

Page 76: ...o a higher weight Move the weight adjustment lever 103 down and up to set the seat to a lower weight Z The driver s weight is correctly set when the arrow is in the middle of the display window 104 The minimum or maximum weight setting is reached when you can feel a return stroke on the lever After setting the weight fully fold back in the weight adjustment lever 103 The driver s weight is now set...

Page 77: ...river s seat must be locked in position uDo not adjust the driver s seat while travelling Procedure Sit on the driver s seat Pull up the driver s seat locking lever106 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 106 in position The seat position is now correctly set 106 77 10 20 en GB ...

Page 78: ...nt Pull the backrest up and lock it in place to extend the backrest Push the backrest down and lock it in place to shorten the backrest Adjusting the swivel seat o Procedure Pull the locking lever 107 back while simultaneously turning the seat to the required position Allow the lock to engage The swivel seat is adjusted and locked in position Z Operate the truck only when the swivel seat is locked...

Page 79: ...rea Position 1 increasing warping in upper lumbar vertebrae area Position 2 increasing warping in lower lumbar vertebrae area The lumbar support is now adjusted Switching the seat heating on and off o Procedure Press the seat heating switch 108 Switch setting 1 Seat heating on Switch setting 0 Seat heating off 108 109 79 10 20 en GB ...

Page 80: ...lt the armrest up or down Re tighten the screw 110 Loosen the screw 111 and set the armrest vertical Re tighten the screw 111 Loosen the screw 112 and set the armrest horizontal Re tighten the screw 112 The armrest is now positioned 110 111 112 3 5 Restraint systems Restraint systems Approved restraint systems Seat belt see page 81 Folding gate Summer door see page 123 Z At least one of these rest...

Page 81: ... 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 Belt lock control system The truck is fitted with a belt lock control system If the belt is not locked properly the following may occur The warning indicator f...

Page 82: ...at belt Procedure Check the attachment points for wear and damage Check the cover for damage Pull the belt out fully from the retractor and check for damage loose seams fraying and nicks Test the belt buckle and make sure the belt returns correctly into the retractor Check the automatic locking system Procedure Park the truck on a level surface Jerk the seat belt out suddenly Z The locking system ...

Page 83: ...NOTICE 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 Travel conduct The operator 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 operator must always observe an ...

Page 84: ... At a distance D of 4000 mm between the rear of the load Y and a person or obstacle the non visible area A must not be larger than 1085 mm If the height C impairs visibility to the extent that A 1085 mm is exceeded the truck must travel in the opposite direction to the load direction Depending on the operating conditions and application of the truck the operating company or its representative is o...

Page 85: ...pears on the display unit uIn emergencies use the service brake via the brake pedal for braking Negotiating lifts loading ramps and docks Lifts may only be negotiated 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...

Page 86: ...clockwise as far as it will go to the I position Test the brake pedal and parking brake parking brake indicator 83 lights up and parking brake lever 63 applied Truck is operational The display 113 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 ...

Page 87: ...rst digit flashes Press the up down key 93 to increase or decrease the flashing digit Use the SET 95 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 87 10 20 en GB ...

Page 88: ...ast and load handler uTilt the mast forward uAlways apply the parking brake lever before parking the truck uChoose a place to park where no other people are at risk of injury from lowering forks uDo not park and abandon a truck on an incline 63 113 67 114 Parking the Truck Securely with the Parking Brake Lever Procedure Pull the parking brake lever 114 back Turn the key in the key switch 67 to the...

Page 89: ...nd take it out of service uDo not return the truck to service until you have identified and rectified the fault Operating the emergency disconnect switch Procedure Press the emergency disconnect switch 75 All electrical travel steering and hydraulic functions are cut out 75 Releasing the Emergency Disconnect Procedure Press the rocker in s and pull the Emergency Disconnect switch 75 up until you f...

Page 90: ...d uTilt the mast back and raise the fork carriage approx 200 mm uMake sure you have sufficient visibility when reversing Travel Requirements Truck prepared for operation see page 86 Procedure Release the parking brake lever 63 Select the travel direction with the travel direction switch 76 Select the travel speed if necessary to do this press the slow travel button 115 Raise the fork carriage appr...

Page 91: ...accelerator pedal 116 to reverse The travel speed is governed by the accelerator 116 The truck travels in the direction selected 63 116 118 117 Changing direction during travel Procedure Set the travel direction switch 76 to the opposite direction while travelling For the twin pedal version apply the accelerator pedal in the opposite direction to the travel direction 116 or 118 The truck decelerat...

Page 92: ...re 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 The truck travels in the required travel direction 92 10 20 en GB ...

Page 93: ...struct people to leave the hazardous area uThe operator must perform test braking WARNING Danger of accidents due to regenerative braking fault Regenerative braking faults can result in extended stopping distances and accidents particularly when travelling on inclines Other persons can be injured in the truck s hazardous area uKeep all persons out of the hazardous area during travel operations uIn...

Page 94: ...ring travel will cause the truck to decelerate This may cause the load to slide off the fork arms There is a greater risk of accidents and injury The parking brake has the following function Park the truck securely parking brake lever 63 applied Pulling the parking brake lever 63 disables travel the truck is secured Pushing the parking brake button 114 and the parking brake lever 63 forward releas...

Page 95: ...arking brake is now released Pull the parking brake lever 63 back the parking brake is now applied The truck is now secure 114 63 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 95 10 20 en GB ...

Page 96: ...ing hazard There is a trapping hazard when you perform this operation uWear work gloves and safety shoes Adjusting the forks Requirements Park the truck securely see page 88 Procedure Lift up the locking lever 119 Push the forks 120 into the correct position on the fork carriage 121 Z To lift the load securely the forks 120 must be spread as far apart as possible and positioned centrally with resp...

Page 97: ...ing them down from the fork carriage uAfter replacing the forks fit the retaining bolts 100 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 100 Loosen the fork stop 99 Carefully push the forks off the fork carriage The forks are now dismantled f...

Page 98: ...lume For rectangular loads with an even weight distribution over the entire volume the load centre distance is in the middle i e half the length half the height and half the width of the load WARNING Risk of accident due to unsecured and incorrectly positioned loads Before lifting a load the operator must make sure that it has been correctly palletised and does not exceed the truck s rated capacit...

Page 99: ... 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 is outside the storage area Make sure you have enough clear space to reverse into 99 10 20 en GB ...

Page 100: ...th care 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 Depositing a load Requirements Storage location suitable for storing the load Procedure Set the mast vertical Drive the truck carefully up to the storage location Press the Lower load handler button unt...

Page 101: ...If people do not leave the hazardous area despite the warning prevent the truck from being used by unauthorised people uOnly carry loads that have been correctly secured and positioned Use suitable precautions to prevent parts of the load from tipping or falling down uDo not exceed the maximum loads specified on the capacity plate uDo not stand underneath a raised load handler uDo not stand on the...

Page 102: ...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 page 86 Procedure Pull the Solo Pilot lever 123 in direction R to tilt the mast back Push the Solo Pilot lever 123 in direction V to tilt the mast forward The mast is now tilted back forward V R 123 Z When t...

Page 103: ...s Requirements Truck prepared for operation see page 86 Procedure Press the toggle switch 125 and at the same time pull the SOLO PILOT 122 in direction Z the forks will move towards each other Press the toggle switch 125 and at the same time push the SOLO PILOT 122 in direction A the forks will spread apart The forks are now positioned V R 125 122 Synchronising the alignment of the fork tines with...

Page 104: ... are now synchronised 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 104 10 20 en GB ...

Page 105: ...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 page 86 Procedure Push the Multi Pilot lever 126 in direction V to tilt the mast forward Push the Multi Pilot lever 126 in direction R to tilt the mast back The mast is now tilted back forward V R 126 Z When the limi...

Page 106: ...i Pilot forward and to the left The mast is now tilted back forward Positioning the integrated sideshifter option Requirements Truck prepared for operation see page 86 Procedure Press the 128 button to move the load handler to the right from the driver s viewpoint Press the 127 button to move the load handler to the left from the driver s viewpoint The sideshifter is now positioned 128 127 Z When ...

Page 107: ...sing the alignment of the fork tines with an integrated fork positioner optional equipment Requirements Truck prepared for operation see page 86 The fork tines are no longer aligned Procedure Press the 129 button and at the same time turn the MULTI PILOT 126 anti clockwise the forks will spread apart Press the 129 button and at the same time turn the MULTI PILOT 126 anti clockwise the forks will m...

Page 108: ...age and failure of the attachment as well as the load falling or becoming damaged uOnly use attachments that are suitable for the operating pressure and oil flow available at the hydraulic port see page 20 CAUTION Risk of slipping and environmental damage due to leaked hydraulic oil When using attachments that are not suitable for the operating pressure and oil flow available overload may give ris...

Page 109: ...only be added to trucks which have a button to enable additional hydraulic functions uClamping attachments must only be operated on trucks will auxiliary hydraulics ZH1 ZH2 or ZH3 uWhen connecting the attachment make sure that the hydraulic lines of the attachment are connected to the right ports see page 116 Safety instructions for rotary attachments WARNING A non centred load centre of gravity c...

Page 110: ...st be released by the acknowledgement button Safety instructions for rotary attachments WARNING A non centred load centre of gravity can result in accidents When using rotary devices and non centred loads the centre of gravity can be displaced from the centre with a high risk of accidents uAdapt the travel speed to the load uLift the load from the centre WARNING Risk of accidents due to falling lo...

Page 111: ...educed residual capacity can result in accidents Transporting hanging loads can reduce the stability of the truck uAdapt the travel speed to the load less than walking pace uSecure swinging loads for example with lifting slings uReduce the residual capacity and have it certified by a expert uIf the truck is to be operated with hanging loads proof of sufficient safety distance under local operating...

Page 112: ... of dirt and foreign bodies near the entry opening point Clean the fork extensions as required Z The weight of the fork extensions reduces the residual capacity of the truck When determining the residual capacity the increased load distance must be taken into account see the data plate and capacity plate of the fork extension WARNING Risk of accidents due to falling loads In the case of an incorre...

Page 113: ...achments 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 124 is assigned the function of the attachment Levers that are not required are void For connections see page 116 Procedure Operating the hydraulic port ZH1 Move the lever 124 in directi...

Page 114: ...f the attachment Unused levers have no function For connections see page 116 Procedure Operating the hydraulic port ZH1 Move the lever 124 in direction V or R Operating the hydraulic port ZH2 Press the toggle switch 125 and at the same time move the lever 122 in the V or R direction The attachment s function is performed V R 125 122 124 114 10 20 en GB ...

Page 115: ...nt Unused buttons have no function For connections see page 116 Procedure Operating hydraulic port ZH1 Press the 128 button or the 127 button 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 buttons 128 127 and the lever 126 are assigned the function of the attachment Levers that are not required are void F...

Page 116: ...eners are positioned correctly and securely and make sure they are complete uBefore starting make sure the attachment is working correctly WARNING Hydraulic ports for clamping attachments uClamping attachments may only be added to trucks which have a button to enable additional hydraulic functions uOn trucks with auxiliary hydraulics ZH2 the clamping function should only be attached to the couplin...

Page 117: ...sure the pilot is correctly labelled and adjust if necessary 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 ...

Page 118: ...er service department can correctly connect the attachment adjust the controls and actuation directions on the pilot to the connections and directions of movement of the attachment and label the pilot accordingly 118 10 20 en GB ...

Page 119: ...dicated on the capacity plate see page 30 If a load is also transported on the load handler the trailer load must be reduced by the same amount uDo not exceed the maximum speed of 5 km h uA special trailer coupling must be used for frequent trailer operation uDo not use supporting loads uTowing must only be performed on level secure travel routes uThe owner must test trailer operation with the per...

Page 120: ...iller must be horizontal tilted down by no more than 10 and never facing up Attaching the trailer Requirements Truck and trailer are on a level surface Trailer prevented from rolling away Procedure Push the tow pin 130 down and turn it 90 Pull the tow pin up and insert the tiller of the trailer into the opening Z Reverse the truck for coupling until the tow pin of the coupling and the hole in the ...

Page 121: ...g 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 6 1 1 Access Control The truck is only released for operation if The operator is seated He is wearing the seat b...

Page 122: ...he following checks Lift the empty load handler beyond the reference lift height and check if the slow travel indicator lights up 6 1 3 Lift Control This option includes Drive Control and also monitors and controls the mast functions Tilt speed reduction as a function of the lift height from approx 1 5 m lift height When the load handler is lowered below the limit height the tilt speed increases a...

Page 123: ...s with multiple restraint systems the use of the seat belt is not always mandatory However the manufacturer recommends the additional use of the seat belt since the seat belt also prevents injuries caused by a rear end collision for example Trucks with Bodyguard monitoring may experience the following situations if the Bodyguard is not locked The warning indicator for cab door monitoring see page ...

Page 124: ...the manufacturer strongly recommends the additional use of the seat belt since the seat belt also prevents injuries caused by a rear end collision for example Trucks with summer door monitoring may experience the following situations if the summer door is not locked The warning indicator for cab door monitoring see page 61 lights up After max 30 seconds an acoustic signal sounds Travel cut off is ...

Page 125: ...ckrest from the fork carriage and put it down securely Fit the fork retaining screws 133 Load backrest assembly Procedure Attach the load backrest to the top rail of the fork carriage Fit the bolts and tighten them with a torque wrench Z Tightening torque 85 Nm 125 10 20 en GB ...

Page 126: ...lift cutout override button see page 68 Pull the control lever 122 Lift cutout is deactivated until the button is pressed again or the fork carriage is lowered below the height limit setting 122 6 6 Fire extinguisher Procedure Open the fasteners 134 Pull the fire extinguish out of its bracket Z To operate refer to the illustrations on the fire extinguisher 134 126 10 20 en GB ...

Page 127: ...ith the control sleeve 139 Rockinger coupling operation attaching trailers Procedure Prevent the trailer from rolling away Adjusting the trailer pull rod to the height of the coupling Pull the hand lever 137 remote control 136 o up Z The remote control 136 o is located in the overhead guard depending on the truck model Slowly reverse the truck until the coupling engages Push the hand lever 137 rem...

Page 128: ... 144 143 Using the camera system Press the button 144 on the monitor to switch the camera system on or off Press the button 143 to lighten or darken the screen day night settings Press the button 140 to open the menu Z Pressing the button several times changes the menu item contrast brightness colour saturation language video light reflection or quits the menu Adjusting the menu items Press the bu...

Page 129: ...ments NOTICE uThe lift lower and tilt speeds are determined by the inclination of the Multipilot Do not deposit the load handler suddenly to avoid damaging the load and the racking Lifting Procedure Push the Multipilot to the right direction H to raise the load Push the Multipilot to the left direction S to lower the load Tilting CAUTION Trapping hazard from inclined mast uWhen tilting the mast ba...

Page 130: ...to the light beam of the Floor Spot uDo not adjust the position and alignment of the Floor Spot on the truck The Floor Spot serves as an auxiliary device and with the travel direction selected projects a coloured dot on the floor at a distance of 4 4 5 m When the truck travels forward the coloured dot is in front of the truck When reversing it is behind the truck 130 10 20 en GB ...

Page 131: ... 780 nm blue light can potentially damage the retina of the human eye uCheck that the warning notice Caution Potentially dangerous optical radiation is present and legible and replace if necessary uDo not look directly into the light beam of the Floor Spot uWhen performing maintenance and repairs take the Floor Spot out of service e g by disconnecting the battery and secure it against unintentiona...

Page 132: ... fault the following information is essential Truck serial number Event message from the display unit if applicable Error description Current location of truck Info messages Display Meaning Info 03 Traction or lift controller temperature above 83 C Info 35 Accelerator pedal zero position Message can be set via parameters either the zero position is only checked after power up or after every change...

Page 133: ... if necessary Check the fuses Load cannot be lifted Truck not operational Hydraulic oil level too low Battery discharge monitor has switched off Faulty fuse Load is too heavy Carry out all measures listed under Truck does not start Check hydraulic oil level Charge the battery Check the fuses o Note the maximum capacity see page 33 Fault displays Truck not operational Press the EMERGENCY DISCONNECT...

Page 134: ...o not park the truck with the parking brake released uOne person must be seated in the recovery truck to steer it and one person must be seated on the towed truck 52 Towing the truck Requirements Park the truck securely Disconnect the battery Procedure Connect the pull rod to the trailer coupling 52 of the towing truck and attach it to the truck to be towed Release the parking brake see page 94 To...

Page 135: ...rt any defects immediately to your supervisor uTag out and decommission a faulty lift truck uOnly return the truck to service when you have identified and rectified the fault Emergency mast lowering Solo Pilot Requirements Load handler is not in the rack Turn the Emergency Disconnect switch and key switch off Disconnect the battery Remove the panel press the lever 56 to unlock the cover 55 and mov...

Page 136: ...lumn forward and pull the cover 57 forward until it engages Procedure Slowly turn the emergency lowering valve 145 the mast and load handler will lower Turn the emergency lowering valve 145 in the opposite direction as far as the stop the lowering process stops The mast is now lowered 145 57 WARNING Only return the truck to service when you have identified and rectified the fault 136 10 20 en GB ...

Page 137: ...fety size accuracy and material The installation or use of non original spare parts can negatively affect the specified properties of the product and impair safety The manufacturer cannot be held liable for damage caused by the use of non original spare parts The product related electronic spare parts catalogue can be found at www jungheinrich de spare parts search by entering the serial number Z ...

Page 138: ...d there is no successor to the business operating companies must however Ensure that the changes to be made are planned tested and performed by a specialist engineer in industrial trucks taking safety into account Keep permanent records of the construction tests and completion of changes Carry out and have authorised the respective changes to the capacity data plates decals and stickers as well as...

Page 139: ...o the following target groups Customer Services Customer Services are specially trained in the use of the truck and are able to carry out maintenance and repairs independently Customer Services are aware of the relevant standards guidelines and safety regulations as well as potential risks Operating company The maintenance personal of the operating company has the technical expertise and experienc...

Page 140: ...truck s stability and increases the stopping distance uWhen replacing tyres make sure the truck is not skewed uAlways replace tyres in pairs i e left and right at the same time Z When replacing rims and tyres fitted at the factory only use the manufacturer s original spare parts Otherwise the manufacturer s specifications cannot be ensured If you have any queries contact the manufacturer s custome...

Page 141: ...ft chains with high pressure steam jets or chemical cleaning agents uImmediately after cleaning dry the lift chain with compressed air and apply a chain spray uLift chains must be unloaded when lubricated to do this fully lower the load handler uLubricate a lift chain with particular care around the pulleys WARNING Diesel fuel can be hazardous uDiesel fuel can cause irritation if it comes into con...

Page 142: ...or immediately in the event of an injury uDo not touch pressurised hydraulic hoses uReport any defects immediately to your supervisor uMark defective truck and take it out of service uDo not return the industrial truck to service until you have identified and rectified the fault NOTICE Testing and replacing hydraulic hoses Hydraulic hoses can become brittle through age and must be checked at regul...

Page 143: ...arked containers uAlways fill consumables in clean containers uDo not mix up different grades of consumable The only exception to this is when mixing is expressly stipulated in the Operating Instructions CAUTION Spilled consumables can cause slipping and endanger the environment Risk of slipping from spilled consumables The risk is greater when combined with water uDo not spill consumables uSpille...

Page 144: ... when handling oil uAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has come into contact with your skin rinse your skin with water uIf oil has come into contact with your eyes rinse them with water and seek medical assistance immediately uReplace oil soaked clothing and sh...

Page 145: ...A E D 0 4l N 4 15 l G g Contact surfaces c Hydraulic oil drain plug s Grease nipple b Gear oil filler neck Hydraulic oil filler neck a Gear unit oil drain plug t Brake fluid filler neck o Gear oil control screw 145 10 20 en GB ...

Page 146: ...280 400ml Chain spray Chains N 50 468 784 1l 4 15 l Transmission oil EP 80 Transmission 1 Valid for temperatures 5 30 C 2 Valid for temperatures 20 5 C 3 Valid for temperatures 30 50 C Z The trucks are factory equipped with a special manufacturer s hydraulic oil the Jungheinrich hydraulic oil with a blue colouration or the Plantosyn 46 HVI bio hydraulic oil This special hydraulic oil can only be o...

Page 147: ...c oil The same applies to changing from the manufacturer s hydraulic oil to Plantosyn 46 HVI bio hydraulic oil Do not mix the Plantosyn 46 HVI bio hydraulic oil with the manufacturer s hydraulic oil or one of the named alternative hydraulic oils Grease guidelines Code Saponification Dew point C Worked penetration at 25 C NLG1 class Application temperature C E Lithium 185 265 295 2 35 120 147 10 20...

Page 148: ...ty measures must be taken to avoid accidents when carrying out maintenance and repairs The following preparations must be made Procedure Park the truck securely see page 88 Fully lower the load handler Disconnect the battery to prevent the truck from being switched on accidentally 148 10 20 en GB ...

Page 149: ...hen raising the truck take appropriate measures to prevent it from slipping or tipping over e g wedges wooden blocks Raising and jacking up the truck securely Requirements Prepare the truck for maintenance and repairs see page 148 Tools and Material Required Jack Hard wooden blocks Procedure Place the jack against the contact point Z Jack contact point see page 30 Raise the truck Support the truck...

Page 150: ...ey switch set to OFF Key removed Set the Emergency Disconnect OFF Procedure Press the lever 56 to unlock the cover 55 and move it forward Carefully lift back the battery cover and the driver s seat as far as the stop opening angle 90 The battery cover is now open The fuses and other electrical components can now be reached 55 56 150 10 20 en GB ...

Page 151: ...8 push the steering column forward and secure it in this position Pull the panel 57 forward until it engages Carefully lift back the battery cover and the driver s seat 1 as far as the stop opening angle 90 The battery cover is now open The fuses and other electrical components can now be reached 58 1 57 Z On trucks with a rear window canvas cover open the rear window canvas cover before opening t...

Page 152: ...placing the tyres check the wheel nuts are secure after 10 service hours uAlways use tyres of the same make model and profile Checking the mounting of wheels Requirements Prepare the truck for maintenance and repairs see page 148 Tools and Material Required Torque wrench Procedure Torque the wheel nuts 146 crosswise with a torque wrench tightening torques see page 25 The mounting of wheels is now ...

Page 153: ...WARNING Falling wheels can cause injury uThe wheels of the truck are very heavy A single wheel can weigh up to 150 kg uAlways replace wheels with a suitable tool and protective equipment Removing the wheels Requirements Prepare the truck for maintenance and repairs see page 148 Tools and Material Required Jack Hard wooden blocks Mounting lever Torque wrench Procedure Place the jack against the con...

Page 154: ...he wheel attachment Remove the hard wooden blocks Lower the truck Torque the wheel attachment 146 crosswise with a torque wrench tightening torques see page 25 The wheel has now been fitted 146 Z When using pneumatic tyres check the air pressure for the air pressure see page 25 154 10 20 en GB ...

Page 155: ... contact with hot motor parts uDo not smoke when handling hydraulic oil uAvoid contact and digestion If you swallow oil do not induce vomiting but seek medical assistance immediately uSeek fresh air after breathing in oil fumes or vapours uIf oil has come into contact with your skin rinse your skin with water uIf oil has come into contact with your eyes rinse them with water and seek medical assis...

Page 156: ... Park the truck on a level surface Prepare the truck for maintenance and repairs see page 148 Battery cover open see page 150 Procedure Unscrew the air filter and dipstick 147 Visually inspect the hydraulic oil level on the dipstick Z If the reservoir is sufficiently full the hydraulic oil level will be at the top mark max If necessary add hydraulic oil up to the level indicated 20 mm on the dipst...

Page 157: ...ts are an environmental hazard Used parts and consumables must be disposed of in accordance with the applicable environmental protection regulations To change the oil contact the manufacturer s customer service department who have been specially trained for this task uNote the safety regulations when handling these materials Check the gear oil level Requirements Park the truck securely see page 88...

Page 158: ...tick 151 The oil is now drained 151 152 149 150 Adding oil Procedure Insert the oil drain plug 152 Remove the cap 149 Turn the steering axle wheel until the filler bore 150 is visible Unscrew the oil control screw 151 and add new gear oil in the filler hole 150 The oil has now been added 5 8 Adding window washer system fluid Procedure Make sure there is sufficient window fluid in the container 153...

Page 159: ...mage components The use of incorrect fuses can damage the electrical system and result in fire The safety and functionality of the truck cannot be ensured uUse only fuses with the prescribed rated current see page 160 Checking electrical fuses Requirements Prepare the truck for maintenance and repairs see page 148 Procedure Open the battery panel see page 150 Remove the electrical system cap Check...

Page 160: ...ion Electric circuit Rating type 154 1F Drive motor fuse 250 A 155 2F1 Hydraulic motor fuse 250 A 156 F3 1 Control fuse 24 V 40 A 157 1F9 Travel lift electronics fuse 10 A 158 4F1 Horn control fuse 10 A 159 F4 Main contactor control fuse 5 A 160 10 20 en GB ...

Page 161: ...ntrol fuse seat heating 10 A 163 4F6 Fuse brake light 10 A 164 4F4 Control fuse warning beacon 5 A 165 5F6 Control fuse front rear windscreen wiper and rear windscreen heater 10 A 166 F1 1 Fuse indicator relay 5 A 167 5F5 2 Control fuse reversing light 5 A 168 5F4 Control fuse RH tail light 5 A 169 5F4 1 Control fuse LH tail light 5 A 170 5F5 Control fuse RH lighting 5 A 171 5F5 1 Control fuse LH ...

Page 162: ...ure washer by the marked points to avoid damaging them see page 30 uDo not clean the truck with pressurised water NOTICE Risk of damage when cleaning the truck with a high pressure cleaner Cleaning with a high pressure cleaner can cause discolouration or other damage on coated or painted surfaces uDo not clean the truck with hot water or steam jets uDo clean the truck using acidic or aggressive cl...

Page 163: ... pre wipe the roof window uIf necessary rub the roof window dry using a clean soft cotton cloth uReplace the roof window in the case of damage scratched surfaces poor visibility or discolouration Cleaning the truck Requirements Truck prepared for maintenance and repair work see page 148 Tools and Material Required Water based solvents Sponge or cloth Procedure Clean the surface of the truck with w...

Page 164: ...ctrical system assemblies Requirements Truck prepared for maintenance and repair work see page 148 Tools and Material Required Compressor with water separator Non conductive antistatic brush Procedure Expose the electrical system see page 150 Clean the electrical system assemblies with weak suction or compressed air use a compressor with a water separator and a non conductive anti static brush Fit...

Page 165: ...ly discharged approx 10 minutes after disconnecting the electrical system from the battery Before starting maintenance on the electrical system uOnly suitably trained electricians may work on the truck s electrical system uBefore working on the electrical system take all precautionary measures to avoid electric shocks uPark the truck securely see page 88 uDisconnect the battery uRemove any rings m...

Page 166: ...onverter on the battery Insert the truck side control line into the connection on the battery trough Equipped with lithium ion battery o with interface converter on the battery Pull the battery forward Insert the control line into the battery connection at the top of the battery or the inside of the trough Slide the battery back in Connect the battery to the truck Close the battery connector lock ...

Page 167: ...decommissioning as described hereafter When the truck is out of service it must be jacked up so that all the wheels are clear of the ground This is the only way of ensuring that the wheels and wheel bearings are not damaged Z Jack up the truck see page 149 If the truck is to be out of service for more than 6 months agree further measures with the manufacturer s customer service department 167 10 2...

Page 168: ... page 145 Charge the battery see page 55 Disconnect and clean the battery Clean the terminal screws grease them with terminal grease and screw them into the connection thread to prevent short circuits Z In addition follow the battery manufacturer s instructions 6 2 During decommissioning NOTICE Full discharge can damage the battery Self discharge can cause the battery to fully discharge Full disch...

Page 169: ...ter on the battery Insert the truck side control line into the connection on the battery trough Equipped with lithium ion battery o with interface converter on the battery Pull the battery forward Insert the control line into the battery connection at the top of the battery or the inside of the trough Slide the battery back in Connect the battery to the truck Close the battery connector lock Tight...

Page 170: ...d inspector The manufacturer offers a safety inspection service which is performed by personnel specifically trained for this purpose A complete test must be carried out on the technical condition of the truck with regard to safety The truck must also be examined thoroughly for damage The operating company is responsible for ensuring that faults are rectified immediately 170 10 20 en GB ...

Page 171: ...trained personnel in accordance with the procedures as specified by the manufacturer 9 Human vibration measurement Z Vibrations that affect the operator over the course of the day are known as human vibrations Excessive human vibrations will cause the operator long term health problems The European 2002 44 EC Vibration operator directive has therefore been established to protect operators To help ...

Page 172: ...172 10 20 en GB ...

Page 173: ...inspection and replacement intervals are based on single shift operation under normal operating conditions The intervals must be reduced accordingly if more stringent requirements are placed on the equipment e g use in conditions of extreme dust temperature fluctuations or multiple shifts uTo prevent damage due to wear the manufacturer recommends an on site application analysis to agree on appropr...

Page 174: ... 1 1 Owner To be performed every 50 service hours but at least once a week 1 1 1 Maintenance contents 1 1 1 1 Standard equipment Brakes Test the function of the brakes Hydraulic operations Lubricate the load chains Correct the hydraulic oil level 174 10 20 en GB ...

Page 175: ...achment Telescopic forks Hydraulic operations Clean and lubricate the attachment Wiper washer system Chassis structure Correct the fill level of the windscreen washer reservoir Pneumatic tyres Travel Correct the tyre pressure Lead acid battery international Power supply Correct the battery acid level using demineralised water Lead acid battery Power supply Correct the battery acid level using demi...

Page 176: ...seating of the battery connector and for damage Travel Wheels for wear and damage Chassis structure Labels are legible complete and plausible Doors or covers for damage The function of the battery panel gas strut and for damage The function of the driver s seat restraint system and for damage The secure seating of the overhead guard and or the cab for damage Hydraulic operations Check cylinders hy...

Page 177: ...g Chassis structure The function of the doors and for damage Optional equipment Chassis structure The function of optional equipment such as mirrors storage compartments grips windscreen wipers and washing systems etc and for damage Strobe light beacon Electrical system Strobe light warning beacon for function and damage Lead acid battery international Power supply Battery and battery components f...

Page 178: ... Carry out a chassis insulation resistance test Travel Correct the oil level or grease filling of the transmission Hydraulic operations Adjust the slide pieces Adjust the load chains Lubricate the load chains Lubricate the running surfaces of the mast Test emergency lowering Correct the hydraulic oil level Test and adjust the pressure relief valve Where two tilt cylinders with the same stroke are ...

Page 179: ...retainer to protect against accidental displacement and unhinging are present and function correctly Clean and lubricate the attachment The axial play of the front and rear rollers Sideshifter Hydraulic operations Clean and lubricate the attachment Test the side shift adjustment Telescopic forks Hydraulic operations Clean and lubricate the attachment Wiper washer system Chassis structure Correct t...

Page 180: ... international Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using demineralised water Lead acid battery Power supply Clean and grease the battery terminals Clean the battery Measure the acid density and battery voltage Correct the battery acid level using demineralised water 180 10 20 en GB ...

Page 181: ...or and for damage Travel Drivetrain bearings for wear and damage Transmission for noise and leaks Wheel bearings and attachment for wear and damage Wheels for wear and damage Chassis structure The secure seating of the chassis and screw connections and for damage Labels are legible complete and plausible Driver s seat for damage The secure seating of the driver s seat and the function of the adjus...

Page 182: ...t rollers and their running surfaces for wear and damage Running surfaces of the mast for wear and damage Check cylinders hydraulic connections pipes and hoses for leaks and damage The function of the hydraulic system The secure seating of the hydraulic connections hoses and pipes and for leaks and damage The forks or load handler for wear and damage Piston rod screw depth and counter fixing clamp...

Page 183: ...ing blocks are complete and for wear and damage The function of the attachment and for damage The secure seating of the hydraulic connections and for leaks Cylinder rods and their bushings for wear and damage Cylinder seals for leaks and damage Clamping device Hydraulic operations The function of the acknowledgement button Attachment bearings guides and stops for wear and damage Sliding blocks are...

Page 184: ...ent to the truck and the load bearing components for secure fit and damage The function of the attachment and for damage Cylinder seals for leaks and damage Hydraulic connections hoses and pipes are secure and for leaks and damage The pistons and piston rods for wear and damage Crane hook Hydraulic operations Proper securing of the attachment to the truck and the load bearing components for secure...

Page 185: ...n and secure seating of the camera and for damage The function and secure seating of the monitor and for damage Work lights Electrical system The function of the lighting and for damage Fire extinguisher Additional services The fire extinguisher is present and secure and check the inspection interval Weigher sensors switches Electrical system The weighing system for damage Access module Electrical...

Page 186: ...amage Strobe light beacon Electrical system Strobe light warning beacon for function and damage Overhead guard cover Chassis structure Overhead guard cover is present and secure and for damage Audible warning devices Electrical system Buzzer warning alarm is secure and functions correctly and for damage Belt lock control Chassis structure The function of the seat belt monitoring and for damage Aut...

Page 187: ...s complete and functions correctly and for damage Connections and cables are secure and for insulation damage and other damage Restraint system SUN protector Chassis structure Restraint system is complete and functions correctly and for damage Lead acid battery international Power supply The secure seating of the battery battery cables and cell connectors and for damage The presence of safety labe...

Page 188: ...ance parts at the specified intervals 1 2 3 1 Standard equipment maintenance part service hours months Brake fluid 2000 24 Hydraulic oil 2000 12 Hydraulic system breather filter 2000 12 Hydraulic oil filter 2000 12 Hydraulic oil filter seal kit 2000 12 Transmission oil 1000 12 188 10 20 en GB ...

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