EFG 422-430/425k/425ks/425s 12.

03-

G
Operating Instructions

52020422
07.08
 Foreword
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. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.
Foreword
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. Each chapter
starts with page 1. The page identification consists of a chapter letter and a page
number.
For example: Page B 2 is the second page in chapter B.

The operating instructions detail different truck models. When operating and servicing The operating instructions detail different truck models. When operating and servicing
the truck, make sure that the instructions apply to your truck model. the truck, make sure that the instructions apply to your truck model.

Safety instructions and important explanations are indicated by the following Safety instructions and important explanations are indicated by the following
graphics: graphics:

F Used before safety instructions which must be observed to avoid danger to

personnel. F Used before safety instructions which must be observed to avoid danger to
personnel.

M Used before notices which must be observed to avoid material damage.

M Used before notices which must be observed to avoid material damage.

Z Used before notices and explanations.

Z Used before notices and explanations.

t Used to indicate standard equipment. t Used to indicate standard equipment.

o Used to indicate optional equipment. o Used to indicate optional equipment.

Our trucks are subject to ongoing development. Jungheinrich reserves the right to Our trucks are subject to ongoing development. Jungheinrich reserves the right to
alter the design, equipment and technical features of the truck. No guarantee of alter the design, equipment and technical features of the truck. No guarantee of
particular features of the truck should therefore be inferred from the present operating particular features of the truck should therefore be inferred from the present operating
instructions. instructions.

Copyright Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG. Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft Jungheinrich Aktiengesellschaft

Am Stadtrand 35 Am Stadtrand 35
22047 Hamburg - GERMANY 22047 Hamburg - GERMANY

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

www.jungheinrich.com www.jungheinrich.com
0108.GB

0108.GB
0108.GB

0108.GB
 Table of contents
A Correct use and application of the truck
B Description of the truck
1 Design and application ........................................................................ B 1
2 Description of assembly groups and functions .................................... B 2
2.1 Truck ................................................................................................... B 3
3 Technical data - standard version ....................................................... B 4
3.1 Performance data ................................................................................ B 7
3.2 Weight (all weights in kg) .................................................................... B 8
3.3 Tyres ................................................................................................... B 8
3.4 EN standards ...................................................................................... B 9
3.5 Conditions for application .................................................................... B 9
4 Label positions and identification plates .............................................. B 10
4.1 Identification plate, truck ..................................................................... B 12
4.2 Truck load diagram ............................................................................. B 12
4.3 Fork arm load diagram (basic device) ................................................. B 13
4.4 Attachment load diagram .................................................................... B 13
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Securing the truck during transport ..................................................... C 2
3 Commissioning .................................................................................... C 3
4 Moving the truck with the drive unit inoperative .................................. C 4
5 Steering the truck without its own drive system (o) ............................. C 5
6 Towing the truck .................................................................................. C 5
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Opening the battery hood with support system (o) ............................. D 3
4 Exposing the battery ........................................................................... D 4
5 Charging the battery ............................................................................ D 5
5.1 Charger socket (o) ............................................................................. D 6
6 Removing and installing the battery .................................................... D 7
7 Closing battery cover .......................................................................... D 8
8 Battery discharge indicator, exhaustive discharge protection device,
operating hour meter ........................................................................... D 8
0708.GB
0708.GB
I1
Table of contents
A Correct use and application of the truck
B Description of the truck
1 Design and application ........................................................................ B 1
2 Description of assembly groups and functions .................................... B 2
2.1 Truck ................................................................................................... B 3
3 Technical data - standard version ....................................................... B 4
3.1 Performance data ................................................................................ B 7
3.2 Weight (all weights in kg) .................................................................... B 8
3.3 Tyres ................................................................................................... B 8
3.4 EN standards ...................................................................................... B 9
3.5 Conditions for application .................................................................... B 9
4 Label positions and identification plates .............................................. B 10
4.1 Identification plate, truck ..................................................................... B 12
4.2 Truck load diagram ............................................................................. B 12
4.3 Fork arm load diagram (basic device) ................................................. B 13
4.4 Attachment load diagram .................................................................... B 13
C Transportation and commissioning
1 Transportation by crane ...................................................................... C 1
2 Securing the truck during transport ..................................................... C 2
3 Commissioning .................................................................................... C 3
4 Moving the truck with the drive unit inoperative .................................. C 4
5 Steering the truck without its own drive system (o) ............................. C 5
6 Towing the truck .................................................................................. C 5
D Battery - Servicing, recharging, replacement
1 Safety regulations governing the handling of lead-acid batteries ........ D 1
2 Battery types ....................................................................................... D 2
3 Opening the battery hood with support system (o) ............................. D 3
4 Exposing the battery ........................................................................... D 4
5 Charging the battery ............................................................................ D 5
5.1 Charger socket (o) ............................................................................. D 6
6 Removing and installing the battery .................................................... D 7
7 Closing battery cover .......................................................................... D 8
8 Battery discharge indicator, exhaustive discharge protection device,
operating hour meter ........................................................................... D 8
I1
 E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
2.1 Instrument panel switches ................................................................... E 6
2.2 Control panel switches ........................................................................ E 6
2.3 Multi-function display ........................................................................... E 7
2.4 Control panel (o) ................................................................................. E 9
2.5 Setting the time ................................................................................... E 14
2.6 Warning registration on driver’s display .............................................. E 15
3 Starting up the truck ............................................................................ E 16
3.1 Checks and operations to be performed before starting daily work .... E 16
3.2 Trucks with reduced headroom X (o) .................................................. E 16
3.3 Adjusting the driver’s seat ................................................................... E 17
3.4 Safety restraint belt ............................................................................. E 18
3.5 Safety Restraint System (o) ................................................................ E 20
3.6 Adjusting the steering column ............................................................. E 22
3.7 Preparing the truck for operation ......................................................... E 22
3.8 Trucks with Heating (o) ....................................................................... E 23
4 Industrial Truck Operation ................................................................... E 24
4.1 Safety regulations for truck operation ................................................. E 24
4.2 Travel .................................................................................................. E 26
4.3 Steering ............................................................................................... E 29
4.4 Braking ................................................................................................ E 29
4.5 Operating the lift mechanism and attachments (MULTI-PILOT) ......... E 31
4.6 Operating the lift mechanism and attachments (SOLO-PILOT) .......... E 33
4.7 Operating the lift mechanism and attachments
(multifunction steering wheel) ............................................................. E 35
4.8 Collecting, transporting and depositing loads ..................................... E 36
4.9 Parking the truck securely ................................................................... E 39
4.10 Towing trailers ..................................................................................... E 40
4.11 Tow loads ............................................................................................ E 40
5 Troubleshooting .................................................................................. E 41
I2
E Operation
1 Safety Regulations for the Operation of Forklift Trucks ...................... E 1
2 Controls and Displays ......................................................................... E 2
2.1 Instrument panel switches ................................................................... E 6
2.2 Control panel switches ........................................................................ E 6
2.3 Multi-function display ........................................................................... E 7
2.4 Control panel (o) ................................................................................. E 9
2.5 Setting the time ................................................................................... E 14
2.6 Warning registration on driver’s display .............................................. E 15
3 Starting up the truck ............................................................................ E 16
3.1 Checks and operations to be performed before starting daily work .... E 16
3.2 Trucks with reduced headroom X (o) .................................................. E 16
3.3 Adjusting the driver’s seat ................................................................... E 17
3.4 Safety restraint belt ............................................................................. E 18
3.5 Safety Restraint System (o) ................................................................ E 20
3.6 Adjusting the steering column ............................................................. E 22
3.7 Preparing the truck for operation ......................................................... E 22
3.8 Trucks with Heating (o) ....................................................................... E 23
4 Industrial Truck Operation ................................................................... E 24
4.1 Safety regulations for truck operation ................................................. E 24
4.2 Travel .................................................................................................. E 26
4.3 Steering ............................................................................................... E 29
4.4 Braking ................................................................................................ E 29
4.5 Operating the lift mechanism and attachments (MULTI-PILOT) ......... E 31
4.6 Operating the lift mechanism and attachments (SOLO-PILOT) .......... E 33
4.7 Operating the lift mechanism and attachments
(multifunction steering wheel) ............................................................. E 35
4.8 Collecting, transporting and depositing loads ..................................... E 36
4.9 Parking the truck securely ................................................................... E 39
4.10 Towing trailers ..................................................................................... E 40
4.11 Tow loads ............................................................................................ E 40
0708.GB 5 Troubleshooting .................................................................................. E 41
0708.GB
I2
 F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist EFG ................................................................ F 4
5 Lubrication Schedule ........................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Description of servicing and maintenance operations ......................... F 8
6.1 Prepare truck for the servicing and maintenance operations .............. F 8
6.2 Check attachment of tyres .................................................................. F 8
6.3 Tyre pressure ...................................................................................... F 8
6.4 Check hydraulic oil level ...................................................................... F 9
6.5 Check transmission oil level ................................................................ F 10
6.6 Draining oil .......................................................................................... F 10
6.7 Refilling oil ........................................................................................... F 10
6.8 Changing the hydraulic filter ................................................................ F 10
6.9 Changing the vacuum filter ................................................................. F 11
6.10 Check oil level for brake system ......................................................... F 11
6.11 Restrain safety belt service ................................................................. F 12
6.12 Checking the electric fuses ................................................................. F 13
6.13 Recommissioning after cleaning or maintenance operations .............. F 15
7 Decommissioning the fork lift truck ..................................................... F 15
7.1 Operations to be performed prior to decommissioning ....................... F 15
7.2 Measures to be taken during decommissioning .................................. F 15
7.3 Recommissioning the truck ................................................................. F 16
8 Safety tests to be performed at intervals and after unusual events .... F 16
9 Final de-commissioning, disposal ....................................................... F 16
0708.GB
0708.GB
I3
F Maintenance of the fork lift truck
1 Operational safety and environmental protection ................................ F 1
2 Safety regulations applicable to truck maintenance ............................ F 1
3 Servicing and inspection ..................................................................... F 3
4 Maintenance checklist EFG ................................................................ F 4
5 Lubrication Schedule ........................................................................... F 6
5.1 Fuels, coolants and lubricants ............................................................. F 7
6 Description of servicing and maintenance operations ......................... F 8
6.1 Prepare truck for the servicing and maintenance operations .............. F 8
6.2 Check attachment of tyres .................................................................. F 8
6.3 Tyre pressure ...................................................................................... F 8
6.4 Check hydraulic oil level ...................................................................... F 9
6.5 Check transmission oil level ................................................................ F 10
6.6 Draining oil .......................................................................................... F 10
6.7 Refilling oil ........................................................................................... F 10
6.8 Changing the hydraulic filter ................................................................ F 10
6.9 Changing the vacuum filter ................................................................. F 11
6.10 Check oil level for brake system ......................................................... F 11
6.11 Restrain safety belt service ................................................................. F 12
6.12 Checking the electric fuses ................................................................. F 13
6.13 Recommissioning after cleaning or maintenance operations .............. F 15
7 Decommissioning the fork lift truck ..................................................... F 15
7.1 Operations to be performed prior to decommissioning ....................... F 15
7.2 Measures to be taken during decommissioning .................................. F 15
7.3 Recommissioning the truck ................................................................. F 16
8 Safety tests to be performed at intervals and after unusual events .... F 16
9 Final de-commissioning, disposal ....................................................... F 16
I3
I4
0708.GB

I4

0708.GB
 Appendix Appendix

JH Traction Battery Operating Instructions JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
Z These operating instructions apply only to Jungheinrich battery models. If using
another brand, refer to the manufacturer's operating instructions.
0506.GB

0506.GB

1 1
2
0506.GB

0506.GB
 A Correct use and application of the truck
Z The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) are
included in the scope of delivery for this truck. The guidelines are part of these oper-
Z The „Guidelines for the Correct Use and Application of Industrial Trucks“ (VDMA) are
ating instructions and must always be heeded. National regulations are fully applica-
ble.
The fork-lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these oper-
ating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The operator must ensure that damaged and/or poorly readable
load diagrams are renewed. The fork-lift truck must not be operated in spaces subject
to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres
prevail.
Duties of the user: A „user“ within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork-lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid-
ered the person, who, in accordance with existing contractual agreements between
the owner and the user of the fork-lift truck, is charged with the observance of the op-
erating duties.
The user must ensure that the truck is not abused and only used within its design lim-
its and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
M If these operating instructions are not observed the warranty becomes void. The
same applies if improper works are carried out at the device by the customer and/or
M If these operating instructions are not observed the warranty becomes void. The
third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
Trailing and slipping loads: The truck may only be used for trailing or slipping loads
for which the truck has been approved.
1203.GB
1203.GB
A1
A Correct use and application of the truck
included in the scope of delivery for this truck. The guidelines are part of these oper-
ating instructions and must always be heeded. National regulations are fully applica-
ble.
The fork-lift truck described in these operating instructions is a truck that is suitable
for lifting and transporting loads.
It must be used, operated and maintained according to the information in these oper-
ating instructions. Any other uses are outside the design envelope and can lead to
injury to persons or damage to equipment and property. Above all, overloading
caused by excessively heavy or unbalanced loads must be avoided. The max. admis-
sible load to be picked up is indicated on the identification plate or load diagram label
shown on the truck. The operator must ensure that damaged and/or poorly readable
load diagrams are renewed. The fork-lift truck must not be operated in spaces subject
to fire or explosion hazards, or in spaces where corrosive or very dusty atmospheres
prevail.
Duties of the user: A „user“ within the meaning of these operating instructions is de-
fined as any natural or legal person who either uses the fork-lift truck himself, or on
whose behalf it is used. In special cases (e.g. leasing or renting), the user is consid-
ered the person, who, in accordance with existing contractual agreements between
the owner and the user of the fork-lift truck, is charged with the observance of the op-
erating duties.
The user must ensure that the truck is not abused and only used within its design lim-
its and that all danger to life and limb of the operator, or third parties, is avoided. In
addition to this, it must be ensured that the relevant accident prevention regulations
and other safety-related provisions, as well as the operating, servicing and mainte-
nance guidelines, are observed. The user must also ensure that all persons operating
the truck have read and understood these operating instructions.
same applies if improper works are carried out at the device by the customer and/or
third parties without permission of our Customer Service.
Mounting of attachments: The mounting or installation of any attachments which
will interfere with, or supplement, the functions of the truck is permitted only after writ-
ten approval by the manufacturer has been obtained. If necessary, the approval of
local authorities has to be obtained.
Any approval obtained from local authorities does not, however, make the approval
by the manufacturer unnecessary.
Trailing and slipping loads: The truck may only be used for trailing or slipping loads
for which the truck has been approved.
A1
A2
1203.GB

A2

1203.GB
 B Description of the truck B Description of the truck
1 Design and application 1 Design and application

EFG 422-430 is an electric rider-controlled fork lift truck in four-wheel construction
with front drive which picks up, transports, and lifts its load outside the wheelbase. It
is a cantilevered counterbalance truck which can – due to its load lifting device being
located in front of the lift truck – unload lorries and deliver the load on ramps or in
racks unimpededly. It can be used to stack and transport DIN 15142 pallets,
DIN 15144 lattice box pallet, and other palletised loads.
EFG 422-430 is an electric rider-controlled fork lift truck in four-wheel construction
with front drive which picks up, transports, and lifts its load outside the wheelbase. It
is a cantilevered counterbalance truck which can – due to its load lifting device being
located in front of the lift truck – unload lorries and deliver the load on ramps or in
racks unimpededly. It can be used to stack and transport DIN 15142 pallets,
DIN 15144 lattice box pallet, and other palletised loads.

Truck types and maximum carrying capacity: Truck types and maximum carrying capacity:

Type max. carrying capacity *) Load centre Type max. carrying capacity *) Load centre
EFG 422 2,200 kg 500 mm EFG 422 2,200 kg 500 mm
EFG 425 2,500 kg 500 mm EFG 425 2,500 kg 500 mm
EFG 430 3,000 kg 500 mm EFG 430 3,000 kg 500 mm

*) The load diagrams attached to the trucks are binding for the carrying capacity *) The load diagrams attached to the trucks are binding for the carrying capacity
0708.GB

0708.GB

B1 B1
2 Description of assembly groups and functions 2 Description of assembly groups and functions

1 1

2 2
8 8

7 3 7 3

6 6

5 4 5 4

Item Designation Item Designation

1 t Overhead guard 1 t Overhead guard
2 t Driver seat 2 t Driver seat
3 t Counterweight 3 t Counterweight
4 t Steering axle 4 t Steering axle
5 t Drive axle 5 t Drive axle
6 t Fork arm carriage 6 t Fork arm carriage
7 t Lifting mast 7 t Lifting mast
8 t Steering 8 t Steering
0708.GB

0708.GB
B2 B2
 2.1 Truck
Steering (8): When a load is applied to the driver seat the steering is switched to
Standby. The steering unit runs at a preset idle speed. Depending on the steering re-
quest the steering pump is increased and the travel speed is reduced depending on
the steering arc (“CurveControl”). The steering angle is indicated in the display.
Driver seat (2): The driver seat is a comfort seat and the steering column is adjusta-
ble. There are storage places for documents or personal belongings of the driver. The
MULTI-PILOT combines all hydraulic functions and the travel direction switch in one
single lever. The overhead guard (1) is prepared for a cabin installation and thus can
be easily retrofitted.
Electric/electronic system: Sophisticated three-phase AC technology enables data
transfers with few cables only (CAN bus). Thus we achieve decreased susceptibility
to faults caused be broken cables as well as considerably faster fault isolation. The
complex TC system (Total Control) is designed for simply, safe, and flexible usage.
Depending on the load the driver can select from different operating programmes:
from high-performance to energy-saving. Convenient and very fast fault analysis and
programming can be performed via PC.
Drive and brake system: The front drive offers ideal traction to the drive wheels at
all times.
The hydraulically actuated oil-bath multi-disk brake used a service brake is practically
maintenance-free. The encapsulation in the transmission allows applications even in
aggressive environments. In addition, the lift truck is generatively braked via the travel
motor. Thus the energy consumption is minimised.
After approximately 15 sec standstill of the truck or 1 to 15 sec (adjustable) after the
driver seat is relieved the spring-loaded brake engages.
When actuating the accelerator the spring-loaded brake is automatically disengaged.
Hydraulic system: All functions must be executed sensitively, proportionally, and si-
multaneously (only if this does not impair the safety). For higher efficiency a hydraulic
unit and a steering booster motor function separately from each other. The micro
pressure filter can be changed from the top (without spilling hydraulic oil).
Lifting mast (7): Our goal is optimising the view. The high-strength steel profiles are
narrow, which is especially notable in the three-stage lifting mast with its good view
to the fork arms. The same good results are achieved for the fork arm carriage.
The lifting mast as well as the fork arm carriage move on prelubricated and thus main-
tenance-free cocked support rollers.
0708.GB
0708.GB
B3
2.1 Truck
Steering (8): When a load is applied to the driver seat the steering is switched to
Standby. The steering unit runs at a preset idle speed. Depending on the steering re-
quest the steering pump is increased and the travel speed is reduced depending on
the steering arc (“CurveControl”). The steering angle is indicated in the display.
Driver seat (2): The driver seat is a comfort seat and the steering column is adjusta-
ble. There are storage places for documents or personal belongings of the driver. The
MULTI-PILOT combines all hydraulic functions and the travel direction switch in one
single lever. The overhead guard (1) is prepared for a cabin installation and thus can
be easily retrofitted.
Electric/electronic system: Sophisticated three-phase AC technology enables data
transfers with few cables only (CAN bus). Thus we achieve decreased susceptibility
to faults caused be broken cables as well as considerably faster fault isolation. The
complex TC system (Total Control) is designed for simply, safe, and flexible usage.
Depending on the load the driver can select from different operating programmes:
from high-performance to energy-saving. Convenient and very fast fault analysis and
programming can be performed via PC.
Drive and brake system: The front drive offers ideal traction to the drive wheels at
all times.
The hydraulically actuated oil-bath multi-disk brake used a service brake is practically
maintenance-free. The encapsulation in the transmission allows applications even in
aggressive environments. In addition, the lift truck is generatively braked via the travel
motor. Thus the energy consumption is minimised.
After approximately 15 sec standstill of the truck or 1 to 15 sec (adjustable) after the
driver seat is relieved the spring-loaded brake engages.
When actuating the accelerator the spring-loaded brake is automatically disengaged.
Hydraulic system: All functions must be executed sensitively, proportionally, and si-
multaneously (only if this does not impair the safety). For higher efficiency a hydraulic
unit and a steering booster motor function separately from each other. The micro
pressure filter can be changed from the top (without spilling hydraulic oil).
Lifting mast (7): Our goal is optimising the view. The high-strength steel profiles are
narrow, which is especially notable in the three-stage lifting mast with its good view
to the fork arms. The same good results are achieved for the fork arm carriage.
The lifting mast as well as the fork arm carriage move on prelubricated and thus main-
tenance-free cocked support rollers.
B3
3 Technical data - standard version 3 Technical data - standard version

Z Technical specification details in accordance with VDI 2198.

Technical modifications and additions reserved.
Z Technical specification details in accordance with VDI 2198.
Technical modifications and additions reserved.

EFG EFG EFG EFG EFG EFG

Designation Designation
422 425k 425 422 425k 425
h1 Height with mast retracted 2,200 2,200 2,200 mm h1 Height with mast retracted 2,200 2,200 2,200 mm
h2 Free lift height 150 150 150 mm h2 Free lift height 150 150 150 mm
h3 Lift 3,100 3,100 3,100 mm h3 Lift 3,100 3,100 3,100 mm
h4 Height with mast extended 3,696 3,696 3,696 mm h4 Height with mast extended 3,696 3,696 3,696 mm
h6 Height above overhead guard 2,215 2,215 2215 mm h6 Height above overhead guard 2,215 2,215 2215 mm
h7 Seating height/standing height 1,060 1,060 1,060 mm h7 Seating height/standing height 1,060 1,060 1,060 mm
Seating room H1 1,105 1,105 1,105 Seating room H1 1,105 1,105 1,105
390/ 390/ 390/ 390/ 390/ 390/
h10 Coupling height mm h10 Coupling height mm
550 550 550 550 550 550
L1 Overall length including fork 3,428 3,428 3,572 mm L1 Overall length including fork 3,428 3,428 3,572 mm
L2 Length including fork back 2,278 2,278 2,422 mm L2 Length including fork back 2,278 2,278 2,422 mm
b1 Overall width 1,196 1,196 1,196 mm b1 Overall width 1,196 1,196 1,196 mm
b3 Width of fork arm carriage 1,120 1,120 1,120 mm b3 Width of fork arm carriage 1,120 1,120 1,120 mm
m1 Ground clearance with load under lifting mast 110 110 110 mm m1 Ground clearance with load under lifting mast 110 110 110 mm
m2 Ground clearance at centre of wheelbase 125 125 125 mm m2 Ground clearance at centre of wheelbase 125 125 125 mm
Width of aisle Width of aisle
Ast 3,875 3,875 4,025 mm Ast 3,875 3,875 4,025 mm
with pallets 800 × 1,200 lengthwise with pallets 800 × 1,200 lengthwise
Width of aisle Width of aisle
Ast 3,675 3,675 3,825 mm Ast 3,675 3,675 3,825 mm
with pallets 1,000 × 1,200 crossways with pallets 1,000 × 1,200 crossways
Wa Turning radius 2,050 2,050 2,200 mm Wa Turning radius 2,050 2,050 2,200 mm
x Load distance 4251) 4251) 4251) mm x Load distance 4251) 4251) 4251) mm
y Wheel-base 1,537 1,537 1,681 mm y Wheel-base 1,537 1,537 1,681 mm
1) 1)
= +25 mm DZ mast = +25 mm DZ mast
0708.GB

0708.GB
B4 B4
 EFG EFG EFG EFG EFG EFG
Designation Designation
425ks 425s 430 425ks 425s 430
h1 Height with mast retracted 2,200 2,200 2,200 mm h1 Height with mast retracted 2,200 2,200 2,200 mm
h2 Free lift height 150 150 150 mm h2 Free lift height 150 150 150 mm
h3 Lift 3,100 3,100 3,100 mm h3 Lift 3,100 3,100 3,100 mm
h4 Height with lifting mast extended 3,696 3,696 3,806 mm h4 Height with lifting mast extended 3,696 3,696 3,806 mm
h6 Height above overhead guard 2,215 2,215 2,215 mm h6 Height above overhead guard 2,215 2,215 2,215 mm
h7 Seating height/standing height 1,060 1,060 1,060 mm h7 Seating height/standing height 1,060 1,060 1,060 mm
Seat clearanceH1 1,105 1,105 1,105 Seat clearanceH1 1,105 1,105 1,105
h10 Coupling height 390/550 390/550 390/550 mm h10 Coupling height 390/550 390/550 390/550 mm
L1 Overall length including fork 3,428 3,572 3,577 mm L1 Overall length including fork 3,428 3,572 3,577 mm
L2 Overall length including fork back 2,278 2,422 2,427 mm L2 Overall length including fork back 2,278 2,422 2,427 mm
b1 Overall width 1,196 1,196 1,196 mm b1 Overall width 1,196 1,196 1,196 mm
b3 Width of fork arm carriage 1,120 1,120 1,120 mm b3 Width of fork arm carriage 1,120 1,120 1,120 mm
Ground clearance under lifting mast Ground clearance under lifting mast
m1 110 110 110 mm m1 110 110 110 mm
with load with load
m2 Ground clearance at centre of wheelbase 125 125 125 mm m2 Ground clearance at centre of wheelbase 125 125 125 mm
Width of aisle Width of aisle
Ast 3,875 4,025 4,030 mm Ast 3,875 4,025 4,030 mm
with pallets 800 × 1,200 lengthwise with pallets 800 × 1,200 lengthwise
Width of aisle Width of aisle
Ast 3,675 3,825 3,830 mm Ast 3,675 3,825 3,830 mm
with pallets 1,000 × 1,200 crossways with pallets 1,000 × 1,200 crossways
Wa Turning radius 2,050 2,200 2,200 mm Wa Turning radius 2,050 2,200 2,200 mm
x Load distance 4251) 4251) 4301) mm x Load distance 4251) 4251) 4301) mm
y Wheel-base 1,537 1,681 1,681 mm y Wheel-base 1,537 1,681 1,681 mm
1) 1)
= +25 mm DZ mast = +25 mm DZ mast
0708.GB

0708.GB

B5 B5
B6
0708.GB

B6

0708.GB
 3.1 Performance data 3.1 Performance data

Designation EFG 422 EFG 425k EFG 425 Designation EFG 422 EFG 425k EFG 425
Q Carrying capacity/load 2.2 2.5 2.5 t Q Carrying capacity/load 2.2 2.5 2.5 t
c Load centre 500 500 500 mm c Load centre 500 500 500 mm
Travel speed with/without load 17/18 17/18 17/17 km/h Travel speed with/without load 17/18 17/18 17/17 km/h
Lifting speed Lifting speed
0.46/0.54 0.44/0.54 0.44/0.54 m/s 0.46/0.54 0.44/0.54 0.44/0.54 m/s
with/without load with/without load
Lowering speed Lowering speed
0.58/0.56 0.58/0.56 0.58/0.56 m/s 0.58/0.56 0.58/0.56 0.58/0.56 m/s
with/without load with/without load
Negotiable gradient Negotiable gradient
10/15 8.5/14 7.5/13 % 10/15 8.5/14 7.5/13 %
with/without load S2 30 min. with/without load S2 30 min.
Max. negotiable gradient Max. negotiable gradient
20/31 18/29 17/27 % 20/31 18/29 17/27 %
with/without load S2 5 min. with/without load S2 5 min.
Acceleration time Acceleration time
4.2/3.9 4.3/4,0 4.4/4.1 s 4.2/3.9 4.3/4,0 4.4/4.1 s
with/without load for 10 m with/without load for 10 m

Designation EFG 425ks EFG 425s EFG 430 Designation EFG 425ks EFG 425s EFG 430
Q Carrying capacity/load 2.5 2.5 3.0 t Q Carrying capacity/load 2.5 2.5 3.0 t
c Load centre 500 500 500 mm c Load centre 500 500 500 mm
Travel speed with/without load 20/20 20/20 20/20 km/h Travel speed with/without load 20/20 20/20 20/20 km/h
Lifting speed Lifting speed
0.55/0.60 0.55/0.60 0.50/0.60 m/s 0.55/0.60 0.55/0.60 0.50/0.60 m/s
with/without load with/without load
Lowering speed Lowering speed
0.58/0.56 0.58/0.56 0.58/0.56 m/s 0.58/0.56 0.58/0.56 0.58/0.56 m/s
with/without load with/without load
Negotiable gradient Negotiable gradient
12/19 11/17 10/17 % 12/19 11/17 10/17 %
with/without load S2 30 min. with/without load S2 30 min.
Max. negotiable gradient Max. negotiable gradient
21/35 20/32 18/29 % 21/35 20/32 18/29 %
with/without load S2 5 min. with/without load S2 5 min.
Acceleration time Acceleration time
4.1/3.7 4.1/3.7 4.2/3.8 s 4.1/3.7 4.1/3.7 4.2/3.8 s
with/without load for 10 m with/without load for 10 m
0708.GB

0708.GB

B7 B7
3.2 Weight (all weights in kg) 3.2 Weight (all weights in kg)

Designation EFG 422 EFG 425k EFG 425 Designation EFG 422 EFG 425k EFG 425
Dead weight (incl. battery) 4,300 4,600 4,750 kg Dead weight (incl. battery) 4,300 4,600 4,750 kg
Battery weight 1,558 1,558 1,872 kg Battery weight 1,558 1,558 1,872 kg
Load per axle with load front/rear 5,800/700 6,300/800 6,400/850 kg Load per axle with load front/rear 5,800/700 6,300/800 6,400/850 kg
Load per axle without load front/rear 2,300/2,000 2,300/2,300 2,530/2,220 kg Load per axle without load front/rear 2,300/2,000 2,300/2,300 2,530/2,220 kg

Designation EFG 425ks EFG 425s EFG 430 Designation EFG 425ks EFG 425s EFG 430
Dead weight (incl. battery) 4,600 4,750 5,100 kg Dead weight (incl. battery) 4,600 4,750 5,100 kg
Battery weight 1,558 1,872 1,872 kg Battery weight 1,558 1,872 1,872 kg
Load per axle with load front/rear 6,300/800 6,400/850 7,250/850 kg Load per axle with load front/rear 6,300/800 6,400/850 7,250/850 kg
Load per axle without load front/rear 2,300/2,300 2,530/2,220 2,600/2,500 kg Load per axle without load front/rear 2,300/2,300 2,530/2,220 2,600/2,500 kg

3.3 Tyres 3.3 Tyres

Model EFG 422 EFG 425 EFG 430 Model EFG 422 EFG 425 EFG 430
SE 23 x 9 10 23 x 10 - 12 SE 23 x 9 10 23 x 10 - 12
Tyre size, front Rubber 22 x 8 x 16 22 x 9 x 16 Tyre size, front Rubber 22 x 8 x 16 22 x 9 x 16
Pneumatic 250 / 60 R12 ; 10 bar Pneumatic 250 / 60 R12 ; 10 bar
SE 18 x 7 - 8 SE 18 x 7 - 8
Tyre size, rear Rubber 18 x 6 12 1/8“ Tyre size, rear Rubber 18 x 6 12 1/8“
Pneumatic 180 / 70 R8; 7 bar Pneumatic 180 / 70 R8; 7 bar

Z Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries
please contact your Jungheinrich customer adviser.
Z Permissible tyres: See chapter F “Forklift Truck Maintenance”. For any queries
please contact your Jungheinrich customer adviser.

0708.GB

0708.GB
B8 B8
 3.4 EN standards 3.4 EN standards

Continuous sound pressure: Continuous sound pressure:

EFG 422/425k/425 = 70 dB(A) EFG 422/425k/425 = 70 dB(A)
EFG 425ks/425s/430 = 71 dB(A) EFG 425ks/425s/430 = 71 dB(A)

according to EN 12053 as stipulated in ISO 4871 according to EN 12053 as stipulated in ISO 4871

Z The continuous sound level is a value averaged according to standard regulations,

taking the sound pressure level into account when driving, lifting and idling. The
Z The continuous sound level is a value averaged according to standard regulations,
taking the sound pressure level into account when driving, lifting and idling. The
sound pressure level is measured at the ear. sound pressure level is measured at the ear.

Vibration: EFG 422-430 = 0.45 m/s2 Vibration: EFG 422-430 = 0.45 m/s2

According to EN 13059 According to EN 13059

Z The swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical
Z The swinging acceleration acting on the body in its operating position is, according to
standard regulations, the linear integrated, weighted acceleration in the vertical
plane. It is determined by driving over bumps with a constant speed. plane. It is determined by driving over bumps with a constant speed.
Electromagnetic compatibility (EMC) Electromagnetic compatibility (EMC)

The manufacturer confirms compliance with the limit val-
ues for electromagnetic emission and interference immu-
nity as well as testing of static electricity discharge ac-
cording to EN 12895 and the references to other
standards contained therein.
The manufacturer confirms compliance with the limit val-
ues for electromagnetic emission and interference immu-
nity as well as testing of static electricity discharge ac-
cording to EN 12895 and the references to other
standards contained therein.

Z Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.
Z Electrical or electronic components and their arrangement may only be modified after
written approval by the manufacturer has been obtained.

3.5 Conditions for application 3.5 Conditions for application

Ambient temperature during operation: -20 °C to 40 °C Ambient temperature during operation: -20 °C to 40 °C

Z Industrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5 °C or in cold stores respectively with extreme
Z Industrial trucks must be specially equipped and approved for continuous use in en-
vironments with temperatures below 5 °C or in cold stores respectively with extreme
temperatures or humidity changes. temperatures or humidity changes.
0708.GB

0708.GB

B9 B9
4 Label positions and identification plates 4 Label positions and identification plates

F Warning and information labels such as load diagrams, sling points, and ID plates
must be readable at all times and must be renewed, if necessary. F Warning and information labels such as load diagrams, sling points, and ID plates
must be readable at all times and must be renewed, if necessary.

9 10 9 10

11 11

28 29 28 29
13 13
12 12
14 14
17 15 17 15

16 16

27 17 27 17

18 (mm) Q (kg)
18 (mm) Q (kg)

D (mm) D (mm)

19 19

20 20
26 26
21 21
23 23
25 22 25 22
1 14 1 14
152 152

2000 2000
10 3

10 3
6

6
7 7
9

9
2 8 1 2 8 1

24 24
0708.GB

0708.GB
B 10 B 10
 Item Description Item Description
9 “Lift/lower” notice 9 “Lift/lower” notice
10 “Forward/reverse tilt” notice 10 “Forward/reverse tilt” notice
11 “Maximum body size” notice 11 “Maximum body size” notice
12 “Travel with raised load, mast forward tilt with raised load 12 “Travel with raised load, mast forward tilt with raised load
prohibited” notice prohibited” notice
13 "Attach safety restraint belt" notice 13 "Attach safety restraint belt" notice
14 Lift limit 14 Lift limit
15 “Do not carry passengers” warning 15 “Do not carry passengers” warning
16 Attention: Read operating instructions. 16 Attention: Read operating instructions.
17 Strap points for lifting by crane 17 Strap points for lifting by crane
18 “Capacity” notice 18 “Capacity” notice
19 Serial number, on chassis below side panel 19 Serial number, on chassis below side panel
20 “Mineral oil” notice 20 “Mineral oil” notice
21 Jack contact points 21 Jack contact points
22 Data plate 22 Data plate
23 Test sticker (o) 23 Test sticker (o)
24 “Add hydraulic oil” notice 24 “Add hydraulic oil” notice
25 “Spring-loaded brake” notice 25 “Spring-loaded brake” notice
26 “Procedure when truck in danger of tipover” notice 26 “Procedure when truck in danger of tipover” notice
27 "Do not stand under load handler” / “Do not stand under load 27 "Do not stand under load handler” / “Do not stand under load
handler” / “Risk of trapping when mast extended” combined notice handler” / “Risk of trapping when mast extended” combined notice
28 “Hydraulic function (Multi-Pilot)” notice 28 “Hydraulic function (Multi-Pilot)” notice
29 “Steering column adjustment” notice 29 “Steering column adjustment” notice
0708.GB

0708.GB

B 11 B 11
4.1 Identification plate, truck 4.1 Identification plate, truck
30 41 30 41

31 40 31 40

32 39 32 39

33 38 33 38

34 37 34 37

36 36

35 35

Item Designation Item Designation Item Designation Item Designation

30 Type 36 Manufacturer 30 Type 36 Manufacturer
31 Serial No. 37 Min./max. battery weight in kg 31 Serial No. 37 Min./max. battery weight in kg
32 Rated capacity in kg 38 Drive power in kW 32 Rated capacity in kg 38 Drive power in kW
33 Battery: Voltage V 39 Load centre distance in mm 33 Battery: Voltage V 39 Load centre distance in mm
34 Empty weight without battery in kg 40 Year of manufacture 34 Empty weight without battery in kg 40 Year of manufacture
35 Manufacturer logo 41 Option 35 Manufacturer logo 41 Option

Z In the event of queries relating to the truck or spare part orders, please state the serial
No. (31) of the truck.
Z In the event of queries relating to the truck or spare part orders, please state the serial
No. (31) of the truck.

4.2 Truck load diagram 4.2 Truck load diagram

The truck load diagram indicates the carrying capacity Q kg of the truck with the lifting The truck load diagram indicates the carrying capacity Q kg of the truck with the lifting
mast in vertical position. The table shows the maximum carrying capacity at a stand- mast in vertical position. The table shows the maximum carrying capacity at a stand-
ard load centre distance D (in mm) and the desired lifting height H (in mm). ard load centre distance D (in mm) and the desired lifting height H (in mm).
Example: Example:

4,250 850 850 600 4,250 850 850 600

1,105 1,105 850 1,105 1,105 850
3,600 3,600
1,250 1,250 850 1,250 1,250 850
2,900 2,900

500 600 700 500 600 700

0708.GB

0708.GB
B 12 B 12
 Example for determining the maximum carrying capacity: Example for determining the maximum carrying capacity:

At a load centre distance of D = 600 mm and maximum lifting height H = 3,600 mm At a load centre distance of D = 600 mm and maximum lifting height H = 3,600 mm
the maximum carrying capacity Q = 1,105 kg. the maximum carrying capacity Q = 1,105 kg.

4.3 Fork arm load diagram (basic device) 4.3 Fork arm load diagram (basic device)

The fork arm load diagram indicates the carrying capacity Q of the truck in kg. In the The fork arm load diagram indicates the carrying capacity Q of the truck in kg. In the
diagram the maximum carrying capacity for different load centres D (in mm) is shown. diagram the maximum carrying capacity for different load centres D (in mm) is shown.

4.4 Attachment load diagram 4.4 Attachment load diagram

The attachment load diagram indicates the carrying capacity Q of the truck in connec-
tion with the respective attachment in kg. The attachment serial number indicated in
the load diagram must correspond to the ID plate of the attachment, since the manu-
facturer must state the carrying capacity specially for each attachment. It is indicated
in the same way as the carrying capacity of the truck itself and must be determined
accordingly.
The attachment load diagram indicates the carrying capacity Q of the truck in connec-
tion with the respective attachment in kg. The attachment serial number indicated in
the load diagram must correspond to the ID plate of the attachment, since the manu-
facturer must state the carrying capacity specially for each attachment. It is indicated
in the same way as the carrying capacity of the truck itself and must be determined
accordingly.

The arrow markings (42 and 43) at the The arrow markings (42 and 43) at the
inner respectively outer mast indicate to 42 43 inner respectively outer mast indicate to 42 43
the driver that the lift limitations pre- the driver that the lift limitations pre-
scribed in the load diagram have been scribed in the load diagram have been
reached. reached.
0708.GB

0708.GB

B 13 B 13
B 14
0708.GB

B 14

0708.GB
 C Transportation and commissioning C Transportation and commissioning
1 Transportation by crane 1 Transportation by crane
1 1

M Only lifting gear of adequate capacity

must be used
M Only lifting gear of adequate capacity
must be used
(loading weight = own weight + battery (loading weight = own weight + battery
weight; see identification plate of the weight; see identification plate of the
truck). truck).

– Safe parking of the truck – Safe parking of the truck

(refer to chapter E) (refer to chapter E)
– Fasten hoisting gear at lifting mast – Fasten hoisting gear at lifting mast
crossbeam (1) and at trailer coupling crossbeam (1) and at trailer coupling
(2). (2).

M Transporting by crane is only provided

for transport for first commissioning.
M Transporting by crane is only provided
for transport for first commissioning.
For application conditions that require For application conditions that require
frequent shipment (changing usage lo- frequent shipment (changing usage lo-
cations) it is required to consult the man- cations) it is required to consult the man-
ufacturer. ufacturer.

M Hoisting belts or chains may only be

hooked into the top lug of the counter-
M Hoisting belts or chains may only be
hooked into the top lug of the counter-
weight and the lugs of the end cross- weight and the lugs of the end cross-
head (lifting mast). head (lifting mast).
The lifting mast must be fully tilted back. The lifting mast must be fully tilted back.
The hoisting belt or chain at the mast The hoisting belt or chain at the mast
must have a minimum free length of must have a minimum free length of
2 m. 2 m.

M The crane hoisting gear must be at-

tached in such a way that it cannot touch
M The crane hoisting gear must be at-
tached in such a way that it cannot touch
any attached components or the over- any attached components or the over-
head guard during lifting. head guard during lifting.

2 2
0307.GB

0307.GB

C1 C1
2 Securing the truck during transport 2 Securing the truck during transport

M The fork lift truck must be properly secured with wedges and restraints during trans-
port on a lorry or trailer. The lorry or trailer must be equipped with lashing rings and a
M The fork lift truck must be properly secured with wedges and restraints during trans-
port on a lorry or trailer. The lorry or trailer must be equipped with lashing rings and a
wooden floor. Perform loading with suitably trained specialist staff according to the wooden floor. Perform loading with suitably trained specialist staff according to the
recommendations of VDI 2700 and VDI 2703 guidelines. Correct dimensioning and recommendations of VDI 2700 and VDI 2703 guidelines. Correct dimensioning and
implementation of load securing measures is required for every separate case. implementation of load securing measures is required for every separate case.

Z To lash down the fork lift truck with the lifting mast installed use the eyes on the top
cross beam of the mast and the trailer coupling pin.
Z To lash down the fork lift truck with the lifting mast installed use the eyes on the top
cross beam of the mast and the trailer coupling pin.

Lashing and wedging with the lifting mast installed Lashing and wedging with the lifting mast installed

Z To transport the fork lift truck without lifting mast perform lashing across the overhead
guard front.
Z To transport the fork lift truck without lifting mast perform lashing across the overhead
guard front.

Lashing and wedging without lifting mast Lashing and wedging without lifting mast
0307.GB

0307.GB
C2 C2
 Approximate centre of gravity Approximate centre of gravity

3 Commissioning 3 Commissioning

F Commissioning and instructing drivers may only be performed by appropriately

trained personnel. F Commissioning and instructing drivers may only be performed by appropriately
trained personnel.

M The truck must only be operated on bat-

tery current. Rectified alternate current
M The truck must only be operated on bat-
tery current. Rectified alternate current
will damage the electronics. Cables will damage the electronics. Cables
connected to the battery (trailing cables) connected to the battery (trailing cables)
must be less than 6 meters in length. must be less than 6 meters in length.
In order to prepare the truck for work fol- In order to prepare the truck for work fol-
lowing delivery or transportation, the fol- lowing delivery or transportation, the fol-
lowing operations must be performed: lowing operations must be performed:

– Check equipment for completeness. – Check equipment for completeness.

– Check battery connections and acid – Check battery connections and acid
level (refer to chapter D, section 6). level (refer to chapter D, section 6).
– Bring the truck into service as pre- – Bring the truck into service as pre-
scribed scribed
(refer to chapter E, section 3). (refer to chapter E, section 3).
0307.GB

0307.GB

C3 C3
4 Moving the truck with the drive unit inoperative
In order to move the truck without elec-
tricity supply, the spring-loaded brake
must be disengages as follows:
F Before the driver leaves the truck with
the spring-loaded brake disengaged he
must secure the truck against accidental
rolling away.
– Set lever (1) to position “Disengage
spring-loaded brake”.
– Turn the steering wheel clockwise un-
til pressure builds up in the hydraulics
circuit and the spring-loaded brake is
disengaged. (This can be noticed by
checking whether the brake pedal
functions normally, if the brake is still
engaged you feel an immediate re-
sistance). The drive wheels are no
longer blocked resp. decelerated by
the spring-loaded brake. The foot
brake will still be fully operative. While turning the steering wheel the foot brake
must not be actuated.
M Prior to recommissioning the truck by applying power again, lever (1) must be set to
the right to “Travel position”. The truck is now ready to operate in travel position.
Trucks with Multifunction Steering Wheel (o)
– Set lever (4) to the left position “Release
accumulator brake”
– Carry out a sufficient number of pump
strokes with the lever (5) until pressure
builds up in the hydraulic circuit and the
spring-loaded accumulator brake is
released. The drive wheels are no
longer blocked / braked by the spring-
loaded brake.
M Before starting the truck again with power
supply, the lever (4) must be reset to the
right in the “travel” position. The truck can
only operate in the travel position.
C4
4 Moving the truck with the drive unit inoperative
In order to move the truck without elec-
tricity supply, the spring-loaded brake
must be disengages as follows:
F Before the driver leaves the truck with
the spring-loaded brake disengaged he
3 must secure the truck against accidental 3
rolling away.
– Set lever (1) to position “Disengage
spring-loaded brake”.
– Turn the steering wheel clockwise un-
til pressure builds up in the hydraulics
circuit and the spring-loaded brake is
disengaged. (This can be noticed by
checking whether the brake pedal
functions normally, if the brake is still
engaged you feel an immediate re-
sistance). The drive wheels are no
longer blocked resp. decelerated by
the spring-loaded brake. The foot
brake will still be fully operative. While turning the steering wheel the foot brake
must not be actuated.
M Prior to recommissioning the truck by applying power again, lever (1) must be set to
the right to “Travel position”. The truck is now ready to operate in travel position.
Trucks with Multifunction Steering Wheel (o)
– Set lever (4) to the left position “Release
accumulator brake”
– Carry out a sufficient number of pump
strokes with the lever (5) until pressure
builds up in the hydraulic circuit and the
spring-loaded accumulator brake is
released. The drive wheels are no
longer blocked / braked by the spring-
loaded brake.
M Before starting the truck again with power
supply, the lever (4) must be reset to the
right in the “travel” position. The truck can
4 5 only operate in the travel position. 4 5
0307.GB
0307.GB
C4
 5 Steering the truck without its own drive system (o) 5 Steering the truck without its own drive system (o)

M The truck cannot be steered if the steering hydraulic system or the truck electronics
are damaged.
M The truck cannot be steered if the steering hydraulic system or the truck electronics
are damaged.

To steer the truck without power, apply To steer the truck without power, apply
the steering as follows. 6 the steering as follows. 6
– Turn the EMERGENCY DISCONNECT – Turn the EMERGENCY DISCONNECT
and key switch off. and key switch off.
– Secure the truck to prevent it from – Secure the truck to prevent it from
rolling away rolling away
– Place a spanner on the hex. bolt (6) – Place a spanner on the hex. bolt (6)
and turn the drive to the required and turn the drive to the required
steering position. steering position.

6 Towing the truck 6 Towing the truck

– Connect a tow-rod/towing rope at the trailer coupling of the recovery vehicle and at – Connect a tow-rod/towing rope at the trailer coupling of the recovery vehicle and at
the truck to be towed. the truck to be towed.
– Disconnect the battery plug (observe item D3!). – Disconnect the battery plug (observe item D3!).
– Disengage the parking brake. – Disengage the parking brake.

F There must be a person for steering the truck on the driver seat of the truck to be
towed. Tow the truck at walking speed! F There must be a person for steering the truck on the driver seat of the truck to be
towed. Tow the truck at walking speed!

Z As the steering booster is not switched on, the truck can only be steered with in-
creased effort.
Z As the steering booster is not switched on, the truck can only be steered with in-
creased effort.

M For trucks with a multifunctional steering wheel (o) only authorised persons may only
tow the truck out of the hazard area for slow shunting. The truck can only be moved
M For trucks with a multifunctional steering wheel (o) only authorised persons may only
tow the truck out of the hazard area for slow shunting. The truck can only be moved
using a recovery truck and a tow bar. The emergency steering must be applied as using a recovery truck and a tow bar. The emergency steering must be applied as
described in “Steering the Truck without its own Drive System” described in “Steering the Truck without its own Drive System”
0307.GB

0307.GB

C5 C5
C6
0307.GB

C6

0307.GB
 D Battery - Servicing, recharging, replace-
ment
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per-
formed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when han-
dling batteries. No inflammable substances or spark-generating materials must be
present or stored within a distance of 2 meters of the truck parked for battery recharg-
ing. The location must be well ventilated and fire fighting equipment must be kept
ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-
minals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a non-
skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na-
tional environmental protection regulations or waste disposal provisions. The manu-
facturer’s specifications for the disposal must be heeded.
M Before closing the battery hood, make sure that the battery cable cannot be dam-
aged.
F Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into con-
tact with battery acid. Spilled battery acid must be immediately neutralized.
M Only batteries with closed tray may be used.
0708.GB
0708.GB
D1
D Battery - Servicing, recharging, replace-
ment
1 Safety regulations governing the handling of lead-acid batteries
The truck must be parked and rendered safe before any operations on batteries are
undertaken (refer to chapter E).
Servicing staff: Recharging, servicing and replacing of batteries must only be per-
formed by qualified personnel. The instructions contained in this operating manual,
and the instructions of the manufacturer of the battery and of the battery recharging
station, must be observed when performing the above operations.
Fire protection measures: Smoking and naked flames are not permitted when han-
dling batteries. No inflammable substances or spark-generating materials must be
present or stored within a distance of 2 meters of the truck parked for battery recharg-
ing. The location must be well ventilated and fire fighting equipment must be kept
ready.
Servicing of batteries: The battery cell screw caps must be kept dry and clean. Ter-
minals and cable shoes must be clean, lightly greased with pole grease and must be
securely tightened. Batteries with bare terminal posts must be covered using a non-
skid insulating mat.
Disposal of the battery: Batteries must only be disposed of as stipulated in the na-
tional environmental protection regulations or waste disposal provisions. The manu-
facturer’s specifications for the disposal must be heeded.
M Before closing the battery hood, make sure that the battery cable cannot be dam-
aged.
F Batteries contain dissolved acid which is toxic and caustic. For this reason, protective
clothing and goggles must be worn whenever work is undertaken on batteries. Avoid
physical contact with battery acid.
If clothing, skin or eyes accidentally come into contact with battery acid, liberally flush
the affected parts with clean water. Consult a doctor when skin or eyes come into con-
tact with battery acid. Spilled battery acid must be immediately neutralized.
M Only batteries with closed tray may be used.
D1
2 Battery types 2 Battery types

In dependence on the application, the truck is equipped with different battery types. In dependence on the application, the truck is equipped with different battery types.
The following table shows which standard combinations are possible, similar to The following table shows which standard combinations are possible, similar to
DIN 43535, with indication of the capacity. DIN 43535, with indication of the capacity.

EFG 422 80 V - 4PzW - battery 480 Ah EFG 422 80 V - 4PzW - battery 480 Ah
80 V - 4PzS - battery 560 Ah 80 V - 4PzS - battery 560 Ah
EFG 425k 80 V - 4PzW - battery 480 Ah EFG 425k 80 V - 4PzW - battery 480 Ah
80 V - 4PzS - battery 560 Ah 80 V - 4PzS - battery 560 Ah
80 V - 4PzS - battery 600 Ah 80 V - 4PzS - battery 600 Ah
EFG 425/430 80 V - 5PzW - battery 600 Ah EFG 425/430 80 V - 5PzW - battery 600 Ah
80 V - 5PzS - battery 700 Ah 80 V - 5PzS - battery 700 Ah
80 V - 5 PzS - battery 750 Ah 80 V - 5 PzS - battery 750 Ah

The battery weight is indicated on the rating plate of the battery. The battery weight is indicated on the rating plate of the battery.

F Battery weight and dimensions have a considerable influence on the stability of the
truck. For this reason, the dimensions and weight of the batteries must correspond to
the following table and drawing. Operation of the truck with non-conforming batteries
is only allowed with prior approval by the manufacturer.
F Battery weight and dimensions have a considerable influence on the stability of the
truck. For this reason, the dimensions and weight of the batteries must correspond to
the following table and drawing. Operation of the truck with non-conforming batteries
is only allowed with prior approval by the manufacturer.

similar to similar to
Drive battery 80 V Drive battery 80 V
DIN 43535 DIN 43535
Dimension (mm) Nom. weight Dimension (mm) Nom. weight
Truck Truck
L max. B max. H1 +/- 2 mm H2 +/- 2 mm (-5/+8%)in kg L max. B max. H1 +/- 2 mm H2 +/- 2 mm (-5/+8%)in kg
480 - 560 480 - 560
EFG 422 1028 711 769 784 1558 EFG 422 1028 711 769 784 1558
Ah Ah
EFG 425k/ 480 - 600 EFG 425k/ 480 - 600
1028 711 769 784 1558 1028 711 769 784 1558
425ks Ah 425ks Ah
EFG 425/ 600 - 750 EFG 425/ 600 - 750
1028 855 769 784 1863 1028 855 769 784 1863
425s/430 Ah 425s/430 Ah

0708.GB

0708.GB
D2 D2
 3 Opening the battery hood with support system (o)
M If the truck is equipped with a safety restraint system, the battery panel can only be
opened if the safety gates are in the home position (horizontal), the gate on the
M If the truck is equipped with a safety restraint system, the battery panel can only be
driver’s side folded inward and secured with the locking knob.
– For the automatic restraint system (ERS), engage the locking knob (2) and fold the
gate in.
– With the ERS-AS automatic restraint system, the gate is automatically folded and
maintained in the right position.
See Chapter E “Safety Restraint System”.
2 2
Mechanical restraint system with electronic control (HRS-E with folding gate)
To open the battery panel fold the left restraint gate down and in. After closing the
battery panel fold the gate out and up.
Electronic Restraint System (ERS with folding gate)
To open the battery panel manually fold down the gate and lock it with the locking
knob (2). Fold the gate in.
After closing the battery panel (charging completed) fold the gate out, unlock the
locking knob (2) and manually fold the gate up.
Electronic safety restraint system with automatic closing (ERS-AS with gate)
When the battery panel is opened the gate automatically flips to the home position
(horizontal position, see chapter E, “Safety Restraint System (Automatic) Operating
Instructions” and automatically locks. Fold the gate in by hand.
When closing the battery panel fold the gate out, the gate automatically opens and
unlocks.
0708.GB
0708.GB
D3
3 Opening the battery hood with support system (o)
opened if the safety gates are in the home position (horizontal), the gate on the
driver’s side folded inward and secured with the locking knob.
– For the automatic restraint system (ERS), engage the locking knob (2) and fold the
gate in.
– With the ERS-AS automatic restraint system, the gate is automatically folded and
maintained in the right position.
See Chapter E “Safety Restraint System”.
Mechanical restraint system with electronic control (HRS-E with folding gate)
To open the battery panel fold the left restraint gate down and in. After closing the
battery panel fold the gate out and up.
Electronic Restraint System (ERS with folding gate)
To open the battery panel manually fold down the gate and lock it with the locking
knob (2). Fold the gate in.
After closing the battery panel (charging completed) fold the gate out, unlock the
locking knob (2) and manually fold the gate up.
Electronic safety restraint system with automatic closing (ERS-AS with gate)
When the battery panel is opened the gate automatically flips to the home position
(horizontal position, see chapter E, “Safety Restraint System (Automatic) Operating
Instructions” and automatically locks. Fold the gate in by hand.
When closing the battery panel fold the gate out, the gate automatically opens and
unlocks.
D3
4 Exposing the battery
F Park and lock the truck (see chapter E).
– Release steering column lock (1),
push steering column forward and se-
cure in this position.
F F
Pay special attention when unlatching
and latching the control valve cover.
With MULTI PILOT or multifunction
steering wheel:
– Pull control valve cover (2) forward un-
til it engages.
– Carefully fold back battery cover with
driver's seat (3).
With SOLOPILOT:
– Unlatch control valve cover (2) by
pressing lever (4) and swivel forward.
– Carefully fold back battery cover with
driver's seat.
F Connecting and disconnecting the bat-
tery plug and socket is only permitted
with the main switch and charger
switched off.
– Unplug battery connector (5).
– If necessary, remove any insulating
mats from the battery.
D4
4 Exposing the battery
F Park and lock the truck (see chapter E).
– Release steering column lock (1),
push steering column forward and se-
cure in this position.
1 1
Pay special attention when unlatching
and latching the control valve cover.
With MULTI PILOT or multifunction
steering wheel:
3 – Pull control valve cover (2) forward un- 3
2 2
til it engages.
– Carefully fold back battery cover with
driver's seat (3).
With SOLOPILOT:
2 – Unlatch control valve cover (2) by 2
pressing lever (4) and swivel forward.
– Carefully fold back battery cover with
driver's seat.
4 4
F Connecting and disconnecting the bat-
tery plug and socket is only permitted
with the main switch and charger
switched off.
– Unplug battery connector (5).
– If necessary, remove any insulating
mats from the battery.
5 5
0708.GB
0708.GB
D4
 5 Charging the battery 5 Charging the battery

– Expose the battery (refer to chapter D, section 3). – Expose the battery (refer to chapter D, section 3).

F Connecting and disconnecting battery and charger is only permitted with the charger
switched off.
F Connecting and disconnecting battery and charger is only permitted with the charger
switched off.
The surface of the battery cells must be uncovered during charging operation, to The surface of the battery cells must be uncovered during charging operation, to
guarantee sufficient aeration. Do not put any metal objects on the battery. guarantee sufficient aeration. Do not put any metal objects on the battery.

M Check all cable and plug connections for visible damages prior to charging.
M Check all cable and plug connections for visible damages prior to charging.

– Connect charging cable of the battery – Connect charging cable of the battery
charging station to battery plug (5). charging station to battery plug (5).
– Charge the battery according to the in- – Charge the battery according to the in-
structions of the battery and charger structions of the battery and charger
manufacturer. manufacturer.

F All safety instructions as provided by the

battery supplier and battery charger sup- F All safety instructions as provided by the
battery supplier and battery charger sup-
plier must be strictly observed. During plier must be strictly observed. During
charging, the battery cover must remain charging, the battery cover must remain
open at all times, so that any gas gener- open at all times, so that any gas gener-
ated by the charging process can volatil- ated by the charging process can volatil-
ise. No not use any open fire or light. ise. No not use any open fire or light.
Explosion hazard! Explosion hazard!
0708.GB

0708.GB

D5 D5
5.1 Charger socket (o) 5.1 Charger socket (o)

– Park the truck securely (see chapter E) – Park the truck securely (see chapter E)

F Always connect and disconnect the battery and charger when the charger is switched
off.
F Always connect and disconnect the battery and charger when the charger is switched
off.

– Connect the charger lead of the bat- – Connect the charger lead of the bat-
tery charger station to the charger tery charger station to the charger
socket (6). socket (6).
– Depending on the battery you may – Depending on the battery you may
need to connect the water (5) to the need to connect the water (5) to the
battery charger station. battery charger station.
The charging process is monitored elec- The charging process is monitored elec-
trically. The truck is automatically pre- 6 trically. The truck is automatically pre- 6
vented from being operated and a fan vented from being operated and a fan
inside the truck is activated to ventilate inside the truck is activated to ventilate
the battery. 5 the battery. 5

F Always check the fans each time you

charge.
5 6 F Always check the fans each time you
charge.
5 6

– Switch on the battery charging station and charge the battery in accordance with – Switch on the battery charging station and charge the battery in accordance with
the battery and charging station manufacturers’ instructions. the battery and charging station manufacturers’ instructions.

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

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

F It is essential to follow the safety regulations of the battery and charging station man-
ufacturers. The fan must be in permanent operation during charging to allow the F It is essential to follow the safety regulations of the battery and charging station man-
ufacturers. The fan must be in permanent operation during charging to allow the
charging gases to dissipate. Do not use fire or naked flames. Risk of explosion! charging gases to dissipate. Do not use fire or naked flames. Risk of explosion!

0708.GB

0708.GB
D6 D6
 6 Removing and installing the battery 6 Removing and installing the battery

M The battery must not be lifted above the collision guard at the rear wall, otherwise the
ventilator or seat hood may be damaged.
M The battery must not be lifted above the collision guard at the rear wall, otherwise the
ventilator or seat hood may be damaged.

– Exposing the battery – Exposing the battery

(refer to chapter D, Section 3). (refer to chapter D, Section 3).
– Pull out side wall (6, 7). – Pull out side wall (6, 7).

F To prevent short-circuits, batteries with exposed poles or cell connectors must be

covered using a rubber mat. When changing batteries with the aid of a crane, ensure
that the crane is of adequate capacity (the battery weight is indicated on the battery
identification plate at the battery trough). The crane hoisting gear is routed through
the recess at the overhead guard and must exert vertical pulling action, so that the
battery trough is not crushed. The hooks must be fastened in such a way that they
cannot fall onto the battery cells when the crane hoisting gear is slackened.
– Attach the hoisting gear at the battery efg v d04 mitte
trough.
– Lift the battery by means of the hoist-
ing gear to the right over the frame and
then swivel it outwards to the side.
F To prevent short-circuits, batteries with exposed poles or cell connectors must be
covered using a rubber mat. When changing batteries with the aid of a crane, ensure
that the crane is of adequate capacity (the battery weight is indicated on the battery
identification plate at the battery trough). The crane hoisting gear is routed through
the recess at the overhead guard and must exert vertical pulling action, so that the
battery trough is not crushed. The hooks must be fastened in such a way that they
cannot fall onto the battery cells when the crane hoisting gear is slackened.
– Attach the hoisting gear at the battery efg v d04 mitte
trough.
– Lift the battery by means of the hoist-
ing gear to the right over the frame and
then swivel it outwards to the side.

– Replacing the battery is done in re- – Replacing the battery is done in re-
verse order. verse order.

F When replacing the battery, make sure only to use the same type as replacement.
After reinstallation of the battery, visually check all cables and connectors for dam- F When replacing the battery, make sure only to use the same type as replacement.
After reinstallation of the battery, visually check all cables and connectors for dam-
age. All covers and side doors must be securely closed. age. All covers and side doors must be securely closed.

F During replacement/installation of the battery, pay attention that the battery is tight in
the battery box of the truck. F During replacement/installation of the battery, pay attention that the battery is tight in
the battery box of the truck.
0708.GB

0708.GB

D7 D7
7 Closing battery cover 7 Closing battery cover

With MULTI PILOT or multifunction With MULTI PILOT or multifunction

steering wheel:: steering wheel::

– Pull control valve cover forward and – Pull control valve cover forward and
simultaneously unlatch it by pressing 8 simultaneously unlatch it by pressing 8
lever (8). Control valve cover moves lever (8). Control valve cover moves
back by itself. back by itself.
With SOLOPILOT: With SOLOPILOT:

– After closing the battery cover, swivel – After closing the battery cover, swivel
control valve cover to the back until it control valve cover to the back until it
engages. engages.

8 Battery discharge indicator, exhaustive discharge protection device, operating 8 Battery discharge indicator, exhaustive discharge protection device, operating
hour meter hour meter

Battery discharge indicator: The charging condition of the battery is indicated on Battery discharge indicator: The charging condition of the battery is indicated on
the information and service display. the information and service display.

M The standard setting of the battery discharge indicator / discharge monitor is made
using standard batteries.
M The standard setting of the battery discharge indicator / discharge monitor is made
using standard batteries.
When using maintenance-free batteries, the display must be readjusted. The setting When using maintenance-free batteries, the display must be readjusted. The setting
must be performed by customer service engineers. If this setting is not performed, the must be performed by customer service engineers. If this setting is not performed, the
battery might suffer damage caused by exhaustive discharge. battery might suffer damage caused by exhaustive discharge.

When reaching the last 10 % of the available capacity, the warning symbol flashes. When reaching the last 10 % of the available capacity, the warning symbol flashes.

When a battery is discharged to the permissible discharge level, the battery symbol When a battery is discharged to the permissible discharge level, the battery symbol
is displayed empty. is displayed empty.

Battery discharge monitor: As soon as the capacity falls below the residual battery Battery discharge monitor: As soon as the capacity falls below the residual battery
capacity, the lifting function will be switched off. This is indicated by a message dis- capacity, the lifting function will be switched off. This is indicated by a message dis-
played on the information and service display. played on the information and service display.

In order to complete the lifting process, the key switch must be switched off and on In order to complete the lifting process, the key switch must be switched off and on
again, which enables lifting for another 30 to 40 seconds. again, which enables lifting for another 30 to 40 seconds.

Z Lifting will only become possible again after the battery has been recharged to at least
40 %.
Z Lifting will only become possible again after the battery has been recharged to at least
40 %.

Operating hour meter: The operating hours are indicated next to the charging state Operating hour meter: The operating hours are indicated next to the charging state
of the battery. The service hours are counted when the truck is switched on and the of the battery. The service hours are counted when the truck is switched on and the
seat switch is closed. seat switch is closed.
0708.GB

0708.GB
D8 D8
 E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation The forklift 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, obligations and responsibilities: The driver must be: informed of
his rights and duties; trained in the operation of the forklift truck; and familiar with the
contents of these operating instructions. The driver shall be afforded all due rights.
Safety shoes must be worn with pedestrian operated trucks.
Unauthorised use of truck: The driver is responsible for the truck during the time it
is in use. He shall 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 forklift truck. 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 industrial truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
Hazardous area: A 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.
F Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, warning shall be sounded in good time. If unauthorised
personnel are still within the hazardous area the truck shall be brought to a halt
immediately.
Safety devices and warning signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
M Trucks with reduced headroom are equipped with a warning sign within the driver's
line of sight. The max. recommended body size indicated on this sign must be
observed.
0707.GB
0707.GB
E1
E Operation
1 Safety Regulations for the Operation of Forklift Trucks
Driver authorisation The forklift 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, obligations and responsibilities: The driver must be: informed of
his rights and duties; trained in the operation of the forklift truck; and familiar with the
contents of these operating instructions. The driver shall be afforded all due rights.
Safety shoes must be worn with pedestrian operated trucks.
Unauthorised use of truck: The driver is responsible for the truck during the time it
is in use. He shall 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 forklift truck. 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 industrial truck
without the necessary training and authorisation to do so. The driver must never
disable or adjust safety mechanisms or switches.
Hazardous area: A 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.
F Unauthorised persons must be kept away from the hazardous area. Where there is
danger to personnel, warning shall be sounded in good time. If unauthorised
personnel are still within the hazardous area the truck shall be brought to a halt
immediately.
Safety devices and warning signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
M Trucks with reduced headroom are equipped with a warning sign within the driver's
line of sight. The max. recommended body size indicated on this sign must be
observed.
E1
2 Controls and Displays 2 Controls and Displays

Item Control / Function Item Control / Function

Display Display
1 Steering wheel t Steers the truck with 5 full turns from left to right. 1 Steering wheel t Steers the truck with 5 full turns from left to right.
2 Multi-function display t Displays the main travel, lift parameters, warning 2 Multi-function display t Displays the main travel, lift parameters, warning
displays, error messages and service displays, as displays, error messages and service displays, as
well as battery discharge and elapsed hour display. well as battery discharge and elapsed hour display.
3 Parking brake (toggle t Only apply manually when operating brakes fail. 3 Parking brake (toggle t Only apply manually when operating brakes fail.
switch) Normally the parking brake (spring-loaded switch) Normally the parking brake (spring-loaded
accumulator brake) automatically applies when the accumulator brake) automatically applies when the
truck is idle. truck is idle.
Visual display: Visual display:
Red = Parking brake applied Red = Parking brake applied
Green = Parking brake released Green = Parking brake released
4 Steering column stop t To adjust and fix the steering column to the required 4 Steering column stop t To adjust and fix the steering column to the required
distance. distance.
5 Key switch t Switches current on and off. Removing the key 5 Key switch t Switches current on and off. Removing the key
prevents the truck from being switched on by prevents the truck from being switched on by
unauthorised personnel. unauthorised personnel.
6 Accelerator pedal t The travel speed is infinitely controlled. 6 Accelerator pedal t The travel speed is infinitely controlled.
7 Brake pedal t Brakes the truck. 7 Brake pedal t Brakes the truck.
8 Travel direction switch o Sets the required travel direction. 8 Travel direction switch o Sets the required travel direction.
MULTI PILOT o Controls the lifting mast functions. MULTI PILOT o Controls the lifting mast functions.
Horn o Triggers a warning signal. Horn o Triggers a warning signal.
Auxiliary hydraulics (ZH3) o Toggles from ZH2 to ZH3 Auxiliary hydraulics (ZH3) o Toggles from ZH2 to ZH3
9 Optional equipment o e.g. display for work lights on 9 Optional equipment o e.g. display for work lights on
switch switch
10 EMERGENCY t Switches power supply on and off. 10 EMERGENCY t Switches power supply on and off.
DISCONNECT isolator DISCONNECT isolator
11 For dual pedal control: o The truck travels in reverse direction when applied 11 For dual pedal control: o The truck travels in reverse direction when applied
“Reverse” accelerator The travel speed is infinitely controlled. “Reverse” accelerator The travel speed is infinitely controlled.
pedal pedal
12 For dual pedal control: o Brakes the truck. 12 For dual pedal control: o Brakes the truck.
Brake pedal Brake pedal
13 For dual pedal control: o The truck travels forward when applied 13 For dual pedal control: o The truck travels forward when applied
“Forward” accelerator The travel speed is infinitely controlled. “Forward” accelerator The travel speed is infinitely controlled.
pedal pedal
14 Travel direction switch t Sets the required travel direction. 14 Travel direction switch t Sets the required travel direction.
15 Horn t Triggers a warning signal. 15 Horn t Triggers a warning signal.
16 SOLO-PILOT t Lifts / lowers the forks 16 SOLO-PILOT t Lifts / lowers the forks
Lift - Lower Lift - Lower
17 SOLO-PILOT t Tilts the forks forward / backward. 17 SOLO-PILOT t Tilts the forks forward / backward.
Mast - tilt Mast - tilt
18 SOLO-PILOT o Moves the forks to the right / left. 18 SOLO-PILOT o Moves the forks to the right / left.
Auxiliary hydraulics (ZH1) Auxiliary hydraulics (ZH1)
Sideshift Sideshift
19 SOLO-PILOT o Used for hydraulic attachments. 19 SOLO-PILOT o Used for hydraulic attachments.
Auxiliary hydraulics (ZH2) Auxiliary hydraulics (ZH2)
20 Toggle switch o Toggles from ZH2 to ZH3 20 Toggle switch o Toggles from ZH2 to ZH3
Auxiliary hydraulics (ZH3) Auxiliary hydraulics (ZH3)
0707.GB

0707.GB
t = Standard equipment o = Optional Equipment t = Standard equipment o = Optional Equipment

E2 E2
 Truck with MULTI PILOT Truck with MULTI PILOT
1 2 1 2
4 4
5 3 5 3

10 9 8 7 6 10 9 8 7 6

Twin pedal control Twin pedal control

11 11

12 12

13 13

Truck with SOLO PILOT Truck with SOLO PILOT

14 15 16 17 18 19 14 15 16 17 18 19

20 20

10 10
0707.GB

0707.GB

E3 E3
 Truck with MULTIPILOT / Fingertip multifunction armrest (o) Truck with MULTIPILOT / Fingertip multifunction armrest (o)

Item Control / Function Item Control / Function

Display Display
21 Control panel o Displays the main travel, lift parameters, 21 Control panel o Displays the main travel, lift parameters,
warning displays, error messages and service warning displays, error messages and service
displays, as well as battery discharge and displays, as well as battery discharge and
elapsed hour display. elapsed hour display.
22 EMERGENCY o Switches power supply on and off. 22 EMERGENCY o Switches power supply on and off.
DISCONNECT DISCONNECT
23 Key switch o Switches current on and off. Removing the key 23 Key switch o Switches current on and off. Removing the key
prevents the truck from being switched on by prevents the truck from being switched on by
ISM o unauthorised personnel. ISM o unauthorised personnel.
24 Fingertip o Same operation as for Solopilot items 16; 17; 24 Fingertip o Same operation as for Solopilot items 16; 17;
18; 19 18; 19

16 17 18 19 16 17 18 19

21 21
24 24

22 22

23 23

0707.GB

0707.GB
E4 E4
 Trucks with Multifunction Steering Wheel (o) Trucks with Multifunction Steering Wheel (o)

Item Control / Function Item Control / Function

Display Display
21 Control panel o Displays the main travel, lift parameters, 21 Control panel o Displays the main travel, lift parameters,
warning displays, error messages and service warning displays, error messages and service
displays, as well as battery discharge and displays, as well as battery discharge and
elapsed hour display. elapsed hour display.
22 EMERGENCY o Switches power supply on and off. 22 EMERGENCY o Switches power supply on and off.
DISCONNECT DISCONNECT
23 Key switch o Switches current on and off. Removing the key 23 Key switch o Switches current on and off. Removing the key
prevents the truck from being switched on by prevents the truck from being switched on by
ISM o unauthorised personnel. ISM o unauthorised personnel.
25 Auxiliary hydraulics o Used for hydraulic attachments. 25 Auxiliary hydraulics o Used for hydraulic attachments.
(ZH2) (ZH2)
26 Mast - tilt t Tilts the forks forward / backward. 26 Mast - tilt t Tilts the forks forward / backward.
27 Toggle switch o Toggles from ZH1 to ZH3 27 Toggle switch o Toggles from ZH1 to ZH3
Auxiliary hydraulics Auxiliary hydraulics
(ZH3) Z when changing from ZH1 to ZH3, the
ZH3 function is operated with button 29.
(ZH3) Z when changing from ZH1 to ZH3, the
ZH3 function is operated with button 29.
28 Lift - Lower t Lifts / lowers the forks 28 Lift - Lower t Lifts / lowers the forks
29 Auxiliary hydraulics (ZH1) o Moves the forks to the right / left. 29 Auxiliary hydraulics (ZH1) o Moves the forks to the right / left.
Sideshift Sideshift
30 Height adjuster Adjusts and sets the steering column at the required 30 Height adjuster Adjusts and sets the steering column at the required
height. height.
31 Horn t Sends a warning signal. 31 Horn t Sends a warning signal.
32 Travel direction switch t Sets the required travel direction. 32 Travel direction switch t Sets the required travel direction.

32 32
31 31
21 21

22 22

27 27
23 23
30 29 28 26 25 30 29 28 26 25
0707.GB

0707.GB

E5 E5
2.1 Instrument panel switches 2.1 Instrument panel switches

Function Function

Hazard warning switch Hazard warning switch

“Beacon / parking light” switch “Beacon / parking light” switch

Windscreen wiper / washer system switch Windscreen wiper / washer system switch
Position 1 “Windscreen wiper on” Position 1 “Windscreen wiper on”
Position 2 “Washing system on” Position 2 “Washing system on”

2.2 Control panel switches 2.2 Control panel switches

Function Function

“Lift cutout” override switch “Lift cutout” override switch

“Inching” switch “Inching” switch

“Seat heater” switch “Seat heater” switch

“Truck lighting” switch (parking light / dimmed headlights) “Truck lighting” switch (parking light / dimmed headlights)

“Work lights” switch “Work lights” switch

0707.GB

0707.GB
E6 E6
 2.3 Multi-function display 2.3 Multi-function display

The multi-function display shows the operating data, the battery charge, the service The multi-function display shows the operating data, the battery charge, the service
hours and error details and information. Graphic illustrations on the multi-function hours and error details and information. Graphic illustrations on the multi-function
display act as warning indicators. display act as warning indicators.
34 36 38 40 42 34 36 38 40 42
33 35 37 39 41 33 35 37 39 41

43 43

44 44

45 45
50 49 48 50 49 48

47 46 47 46

Item Display Item Display

33 Service hours / time toggle switch 33 Service hours / time toggle switch
34 Controller overtemperature 34 Controller overtemperature
35 Pump motor overtemperature 35 Pump motor overtemperature
36 Drive motor overtemperature 36 Drive motor overtemperature
37 Seat switch / belt lock control (o) 37 Seat switch / belt lock control (o)
38 Parking brake applied 38 Parking brake applied
39 Travel direction indicator (o) 39 Travel direction indicator (o)
40 Truck operational (key switch “ON”) 40 Truck operational (key switch “ON”)
41 Service display / UVV display 41 Service display / UVV display
42 Brake fluid level too low 42 Brake fluid level too low
43 Lights up for errors or when battery capacity is less than 10% 43 Lights up for errors or when battery capacity is less than 10%
44 Crawl speed switch 44 Crawl speed switch
45 Program selector 45 Program selector
46 SET key 46 SET key
47 Operating program display (programs 1 to 5) 47 Operating program display (programs 1 to 5)
48 Travel direction and wheel position display 48 Travel direction and wheel position display
49 Battery capacity display 49 Battery capacity display
50 Time and service hours or diagnostics and error display 50 Time and service hours or diagnostics and error display
0707.GB

0707.GB

E7 E7
2.3.1 Warning displays, buttons and switches 2.3.1 Warning displays, buttons and switches

The following conditions are displayed or switched on: The following conditions are displayed or switched on:

Item Display / Function Item Display / Function

33 Hourmeter – Time Toggle Switch 33 Hourmeter – Time Toggle Switch
– Service hours during which truck key switch is ON – Service hours during which truck key switch is ON
– EFF service hours can be switched ON or OFF via a code. – EFF service hours can be switched ON or OFF via a code.
– Time display – Time display
34 Controller overtemperature 34 Controller overtemperature
– Lights up to indicate controller overtemperature – Lights up to indicate controller overtemperature
– Performance is continually reduced in relation to the temperature – Performance is continually reduced in relation to the temperature
35 Pump motor, steering booster overtemperature 35 Pump motor, steering booster overtemperature
– Monitors the temperature of the pump motor and the steering booster – Monitors the temperature of the pump motor and the steering booster
– Performance is reduced if the temperature is excessive – Performance is reduced if the temperature is excessive
36 Drive motor overtemperature 36 Drive motor overtemperature
– Monitors the temperature of the drive motor – Monitors the temperature of the drive motor
– Performance is reduced if the temperature is excessive – Performance is reduced if the temperature is excessive
37 Seat switch / belt lock control (o) 37 Seat switch / belt lock control (o)
– Seat switch not closed – Seat switch not closed
– Truck operational, but driver’s seat not occupied – Truck operational, but driver’s seat not occupied
– Truck operational, belt lock not closed – Truck operational, belt lock not closed
38 Parking brake applied 38 Parking brake applied
– Truck operational, parking brake applied – Truck operational, parking brake applied
39 Travel direction indicator o 39 Travel direction indicator o
– For lighting with a flashing indicator system – For lighting with a flashing indicator system
40 Truck operational 40 Truck operational
– Key switch ON – Key switch ON
41 Service display / UVV display 41 Service display / UVV display
– Service interval exceeded (1000 service hours) or annual UVV test due – Service interval exceeded (1000 service hours) or annual UVV test due
(flashing indicator). (flashing indicator).
42 Insufficient brake fluid 42 Insufficient brake fluid
– The brake fluid level can be checked through sensors on the brake fluid – The brake fluid level can be checked through sensors on the brake fluid
reservoir. reservoir.
43 WARNING 43 WARNING
– Lights up to indicate error – Lights up to indicate error
– Flashes when battery capacity is less than 10% – Flashes when battery capacity is less than 10%
44 Crawl speed switch 44 Crawl speed switch
– Travel speed max. 6 km/h (adjustable) – Travel speed max. 6 km/h (adjustable)
45 Program selector 45 Program selector
– Up and down keys – Up and down keys
46 SET key 46 SET key
– Selects special functions – Selects special functions
47 Operating program display 47 Operating program display
– Displays the selected travel program (1 to 5) – Displays the selected travel program (1 to 5)
0707.GB

0707.GB
E8 E8
 2.3.2 Displays 2.3.2 Displays

Item Function Item Function

48 Travel direction and wheel position display 48 Travel direction and wheel position display
– Indicates the pre-selected travel direction (forward or reverse) or the – Indicates the pre-selected travel direction (forward or reverse) or the
position of the steered wheels. position of the steered wheels.
49 Battery capacity display in % 49 Battery capacity display in %
Indicates the available residual capacity. Indicates the available residual capacity.
0% display = battery 80% discharged. 0% display = battery 80% discharged.
For a 10% display the warning indicator flashes (42). For a 10% display the warning indicator flashes (42).
At 0% capacity lifting is cut out after 30 to 40 seconds. At 0% capacity lifting is cut out after 30 to 40 seconds.
50 Operating hours display / Error display 50 Operating hours display / Error display
– Operating hours display: – Operating hours display:
– eff: shows the overall working time – eff: shows the overall working time
Error display: Error display:
– if an error (Err) or a warning (Inf) occurs, the operating hour display – if an error (Err) or a warning (Inf) occurs, the operating hour display
disappears. The error code is displayed. disappears. The error code is displayed.
– If several errors occur they are displayed alternately at 1.5 second intervals, – If several errors occur they are displayed alternately at 1.5 second intervals,
and a warning is sounded. and a warning is sounded.

2.4 Control panel (o) 2.4 Control panel (o)

The control panel display shows the operating data, the battery charge, the service The control panel display shows the operating data, the battery charge, the service
hours and error details and information. Graphic illustrations on the control panel act hours and error details and information. Graphic illustrations on the control panel act
as warning indicators. as warning indicators.

51 53 55 57 59 61 63 65 51 53 55 57 59 61 63 65
52 54 56 58 60 62 64 66 52 54 56 58 60 62 64 66

67 67
km/h
68 km/h
68
69 69
70 70
71 71
72 72
73 73
75 76 77 78 75 76 77 78

74 79 74 79
82 81 80 82 81 80

83 84 85 86 83 84 85 86
0707.GB

0707.GB

E9 E9
2.4.1 Control panel displays 2.4.1 Control panel displays

Item Display Item Display

51 No function 51 No function

52 No function 52 No function

53 No function 53 No function

54 Crawl speed control light 54 Crawl speed control light

55 No function 55 No function

Travel direction indicator Travel direction indicator

56 56
– For lighting with a flashing indicator system – For lighting with a flashing indicator system
Parking brake applied Parking brake applied
57 57
– Truck operational, parking brake applied – Truck operational, parking brake applied
Truck operational Truck operational
58 58
– Key switch ON – Key switch ON

59 No function 59 No function

Seat switch / belt lock control o) Seat switch / belt lock control o)
– Seat switch not closed – Seat switch not closed
60 60
– Truck operational, but driver’s seat not occupied – Truck operational, but driver’s seat not occupied
– Truck operational, belt lock not closed – Truck operational, belt lock not closed

61 No function 61 No function

Service Display Service Display

62 – Service interval exceeded (1000 service hours) or annual UVV test 62 – Service interval exceeded (1000 service hours) or annual UVV test
due (flashing indicator). due (flashing indicator).
Controller overtemperature Controller overtemperature
63 – Lights up to indicate controller overtemperature 63 – Lights up to indicate controller overtemperature
– Performance continually reduces with respect to the temperature – Performance continually reduces with respect to the temperature

64 No function 64 No function

65 No function 65 No function

WARNING WARNING
66 – Lights up to indicate error 66 – Lights up to indicate error
– Flashes when battery capacity is less than 10% – Flashes when battery capacity is less than 10%
0707.GB

0707.GB
67 Driver’s display 67 Driver’s display

E 10 E 10
 2.4.2 Control panel buttons 2.4.2 Control panel buttons

51 53 55 57 59 61 63 65 51 53 55 57 59 61 63 65
52 54 56 58 60 62 64 66 52 54 56 58 60 62 64 66

67 67
km/h
68 km/h
68
69 69
70 70
71 71
72 72
73 73
75 76 77 78 75 76 77 78

74 79 74 79
82 81 80 82 81 80

83 84 85 86 83 84 85 86

Item Function Item Function

68 Selects travel program (go up to other modes) 68 Selects travel program (go up to other modes)

69 Hourmeter / time toggle switch 69 Hourmeter / time toggle switch

SET button SET button

70 70
– Selects special functions – Selects special functions

71 Selects travel program (go down to other modes) 71 Selects travel program (go down to other modes)

Parking brake Parking brake

72 72
Applies / releases parking brake Applies / releases parking brake
Crawl speed switch Crawl speed switch
73 73
– Travel speed max. 6 km/h (adjustable). – Travel speed max. 6 km/h (adjustable).

74 Option not used 74 Option not used

75 Switches roof window wipers on and off, interval setting 75 Switches roof window wipers on and off, interval setting

76 Switches windscreen washing system on and off. 76 Switches windscreen washing system on and off.
0707.GB

0707.GB

E 11 E 11
 Item Function Item Function

77 Switches window wipers on and off, interval setting 77 Switches window wipers on and off, interval setting

78 Switches warning indicator system on and off. 78 Switches warning indicator system on and off.

79 Switches front headlights on and off. 79 Switches front headlights on and off.

80 Switches rear headlights on and off. 80 Switches rear headlights on and off.

81 Switches dipped lights on and off. 81 Switches dipped lights on and off.

82 Switches parking light on and off. 82 Switches parking light on and off.

83 Switches rear window heating on and off. 83 Switches rear window heating on and off.

84 Switches seat heating on and off. 84 Switches seat heating on and off.

85 Switches the beacon on and off. 85 Switches the beacon on and off.

86 “Lift cutout” override button 86 “Lift cutout” override button

0707.GB

0707.GB
E 12 E 12
 2.4.3 Displays 2.4.3 Displays
87 87

88 88
km/h km/h

91 90 89 91 90 89

Item Function Item Function

87 Battery capacity display 87 Battery capacity display
– Battery discharge status – Battery discharge status
88 Profile number (travel / lift profile 1, 2, 3, 4 and 5) 88 Profile number (travel / lift profile 1, 2, 3, 4 and 5)
89 Hourmeter display 89 Hourmeter display
– Time display – Time display
– Residual time display with on-board battery – Residual time display with on-board battery
(hours : minutes) (hours : minutes)
90 Error display: 90 Error display:
– if an error (Err) or a warning (Inf) occurs, the operating hour display – if an error (Err) or a warning (Inf) occurs, the operating hour display
disappears. disappears.
– If several errors occur they are displayed alternately at 1.5 second intervals. – If several errors occur they are displayed alternately at 1.5 second intervals.
A warning is sounded. A warning is sounded.
– eft: shows the overall working time – eft: shows the overall working time
91 Travel direction, speed and wheel position display 91 Travel direction, speed and wheel position display
– Indicates the pre-selected travel direction (forward or reverse) or the – Indicates the pre-selected travel direction (forward or reverse) or the
position of the steered wheels. position of the steered wheels.
0707.GB

0707.GB

E 13 E 13
2.5 Setting the time 2.5 Setting the time

Normal operating mode Normal operating mode

Press the “h/time” (69) and up (68) Press the “h/time” (69) and up (68)
keys simultaneously keys simultaneously

The time appears on The time appears on

the display. the display.
The first digit flashes. The first digit flashes.

Use the up (68) / down (71) key Use the up (68) / down (71) key
to increase or decrease to increase or decrease
the flashing digit. the flashing digit.
Use the SET (62) key to Use the SET (62) key to
jump to the next figure. After the last jump to the next figure. After the last
digit the value is digit the value is
accepted. accepted.

km/h 68 km/h 68
69 69
70 70
71 71
0707.GB

0707.GB
E 14 E 14
 2.6 Warning registration on driver’s display 2.6 Warning registration on driver’s display

Display Meaning Display Meaning

INFO 02 - No direction selected when truck powered up, no wheel INFO 02 - No direction selected when truck powered up, no wheel
position displayed position displayed
-Travel direction changed to neutral setting during operation, -Travel direction changed to neutral setting during operation,
wheel position display alternates between forward and wheel position display alternates between forward and
reverse. reverse.
INFO 05 (Optional setting for travel cutout input) INFO 05 (Optional setting for travel cutout input)
Lift cutout active / independent of other conditions Lift cutout active / independent of other conditions
INFO 16 (Optional setting for travel cutout input) INFO 16 (Optional setting for travel cutout input)
Travel cutout active / independent of other conditions Travel cutout active / independent of other conditions
INFO 35 Accelerator pedal zero position INFO 35 Accelerator pedal zero position
-Message can be adjusted to suit preference – either the zero -Message can be adjusted to suit preference – either the zero
position is only checked after power up or after every transition position is only checked after power up or after every transition
of the seat switch from the open to closed position. of the seat switch from the open to closed position.
INFO 36 Hydraulics zero position INFO 36 Hydraulics zero position
-Message can be adjusted to suit preference - message -Message can be adjusted to suit preference - message
displayed or not. displayed or not.
INFO 40 Overtemperature INFO 40 Overtemperature
Traction or lift controller above 83°C. Traction or lift controller above 83°C.
Traction or lift controller above 145 °C. Traction or lift controller above 145 °C.
INFO 90 Travel with handbrake on INFO 90 Travel with handbrake on
-Accelerator pedal applied while the handbrake switch is set to -Accelerator pedal applied while the handbrake switch is set to
parking position. parking position.
INFO 96 Hydraulics zero position on power up INFO 96 Hydraulics zero position on power up
-a hydraulic function applied during power up -a hydraulic function applied during power up
-the hydraulic function applied will not be performed. -the hydraulic function applied will not be performed.
0707.GB

0707.GB

E 15 E 15
3 Starting up the truck 3 Starting up the truck

F Before commissioning or operating the truck, and before raising a load, the driver
must ensure that there is nobody in the hazardous area and that the truck is safe to F Before commissioning or operating the truck, and before raising a load, the driver
must ensure that there is nobody in the hazardous area and that the truck is safe to
operate. operate.

3.1 Checks and operations to be performed before starting daily work 3.1 Checks and operations to be performed before starting daily work

Before starting the truck the driver must ensure it is safe to operate. Before starting Before starting the truck the driver must ensure it is safe to operate. Before starting
work, check for example that work, check for example that

– the operating and parking brakes or the automatic brake (Emergency Stop) are – the operating and parking brakes or the automatic brake (Emergency Stop) are
working working
– the fork tine retainer preventing the tines from moving is not defective – the fork tine retainer preventing the tines from moving is not defective
– the load handler does not show visible signs of damage (bent, cracks or heavy – the load handler does not show visible signs of damage (bent, cracks or heavy
wear) wear)
– the warning device is working – the warning device is working

3.2 Trucks with reduced headroom X (o) 3.2 Trucks with reduced headroom X (o)

M Failure to comply with the recommended

body size may result in overload and
M Failure to comply with the recommended
body size may result in overload and
constitute a danger to the driver, constitute a danger to the driver,
possibly resulting in permanent damage possibly resulting in permanent damage
caused by an unhealthy posture and caused by an unhealthy posture and
excessive physical exertions on the part excessive physical exertions on the part
of the driver. of the driver.
The owner must ensure that the truck The owner must ensure that the truck
operator does not exceed the maximum operator does not exceed the maximum
body size indicated. body size indicated.
The owner must also check that the The owner must also check that the
drivers can sit normally, in an upright drivers can sit normally, in an upright
position without having to exert himself. position without having to exert himself.
0707.GB

0707.GB
E 16 E 16
 3.3 Adjusting the driver’s seat 3.3 Adjusting the driver’s seat

Z To achieve optimal seat cushioning, the driver’s seat must be adapted to the driver’s
weight.
Z To achieve optimal seat cushioning, the driver’s seat must be adapted to the driver’s
weight.
The driver’s seat must be adapted to the driver’s weight. The driver’s seat must be adapted to the driver’s weight.

Adjusting the driver's weight: Adjusting the driver's weight:

– Pull the “driver’s seat” weight adjuster – Pull the “driver’s seat” weight adjuster
(92) in the direction of the arrow as far (92) in the direction of the arrow as far
as the stop and then return it. as the stop and then return it.

Z The previous weight setting is reset to

the minimum value. The seat
Z The previous weight setting is reset to
the minimum value. The seat
suspension can be set from 50 kg to suspension can be set from 50 kg to
130kg 130kg

– Move the “driver’s seat” weight 95 – Move the “driver’s seat” weight 95
adjuster (92) again in the direction of adjuster (92) again in the direction of
the arrow until the corresponding 94 the arrow until the corresponding 94
weight marking on the “driver’s seat” 93 weight marking on the “driver’s seat” 93
weight display (93) is reached. Now 92 weight display (93) is reached. Now 92
return the “driver’s seat” weight return the “driver’s seat” weight
adjuster. adjuster.
– Sit on the driver’s seat. – Sit on the driver’s seat.

Adjusting the backrest: Adjusting the backrest:

– Lift up the backrest adjuster (94) and – Lift up the backrest adjuster (94) and
adjust the backrest tilt. adjust the backrest tilt.
– Release the backrest tilt adjuster (94) – Release the backrest tilt adjuster (94)
to lock the backrest in position. to lock the backrest in position.

Adjusting the seat position: Adjusting the seat position:

– Pull up the longitudinal adjuster (95) – Pull up the longitudinal adjuster (95)
and push the driver’s seat forwards or and push the driver’s seat forwards or
backwards to the desired position. 95 backwards to the desired position. 95
– Engage driver’s seat lock (95) in 94 – Engage driver’s seat lock (95) in 94
position again. 93 position again. 93
– 92 – 92

F The driver’s seat must be securely locked in the desired position. The driver’s seat
setting must not be changed during travel. F The driver’s seat must be securely locked in the desired position. The driver’s seat
setting must not be changed during travel.

Z The procedure for adjusting the driver’s seat applies to standard models. For other
models, follow the manufacturer’s setting instructions. When adjusting the seat make
Z The procedure for adjusting the driver’s seat applies to standard models. For other
models, follow the manufacturer’s setting instructions. When adjusting the seat make
sure that all controls are within easy reaching distance. sure that all controls are within easy reaching distance.
0707.GB

0707.GB

E 17 E 17
3.4 Safety restraint belt 3.4 Safety restraint belt

F Put on the safety restraint belt each time before starting the industrial truck.
The belt protects against serious injury. F Put on the safety restraint belt each time before starting the industrial truck.
The belt protects against serious injury.

Protect the belt from contamination (e.g. cover it when the truck is idle) and clean it Protect the 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 regularly. Frozen belt locks or pulleys must be thawed out and dried to prevent them
from freezing up again. from freezing up again.

Z The dry temperature of the warm air should not exceed +60 °C.
Z The dry temperature of the warm air should not exceed +60 °C.

F Do not alter the belt setting.

This will increase the risk of malfunctioning.
F Do not alter the belt setting.
This will increase the risk of malfunctioning.
– Always replace the safety restraint belt after an accident. – Always replace the safety restraint belt after an accident.
– Only original spare parts must be used for retrofits or repairs. – Only original spare parts must be used for retrofits or repairs.

F Damaged or non-operational belts must only be replaced by contractual dealers or

branches. F Damaged or non-operational belts must only be replaced by contractual dealers or
branches.

Procedure in unusual situations Procedure in unusual situations

F If the truck is about to tip over, under no

circumstances should you the restraint
F If the truck is about to tip over, under no
circumstances should you the restraint
belt and try to jump out. belt and try to jump out.
Jumping increases the risk of injury. Jumping increases the risk of injury.

Correct procedure: Correct procedure:

– Lean your upper body over the – Lean your upper body over the
steering wheel. steering wheel.

– Grip the steering wheel with both – Grip the steering wheel with both
hands and brace feet. hands and brace feet.

– Lean your body against the opposite – Lean your body against the opposite
direction of fall direction of fall
0707.GB

0707.GB
E 18 E 18
 Restraint belt operating instructions Restraint belt operating instructions

Before starting the truck carefully pull Before starting the truck carefully pull
the belt out of the pulley, pull it tightly the belt out of the pulley, pull it tightly
across your body and over your thigh, across your body and over your thigh,
and engage it in the lock. and engage it in the lock.

F The belt must not be twisted when

fastened.
F The belt must not be twisted when
fastened.
When operating the truck (e.g. travelling, When operating the truck (e.g. travelling,
lifting, lowering, etc.), sit as far back as lifting, lowering, etc.), sit as far back as
possible so that your back is against the possible so that your back is against the
backrest. backrest.

The automatic locking retractor allows The automatic locking retractor allows
sufficient freedom of movement on the sufficient freedom of movement on the
seat. seat.

F Sitting at the front edge of the seat

affords less protection, as the belt is too F Sitting at the front edge of the seat
affords less protection, as the belt is too
long. long.

Z The belt is only to be used to secure one

person.
Z The belt is only to be used to secure one
person.

– After using the belt, push the red – After using the belt, push the red
button and manually guide the tongue button and manually guide the tongue
back to the retractor. back to the retractor.

Z The automatic blocking system can be triggered if the seat belt tongue strikes the
housing. This will prevent the belt from being extracted.
Z The automatic blocking system can be triggered if the seat belt tongue strikes the
housing. This will prevent the belt from being extracted.

Deactivating the blocking system: Deactivating the blocking system:

– Apply force to pull the belt 10mm – 15mm out of its housing. – Apply force to pull the belt 10mm – 15mm out of its housing.
– Feed the belt back in to undo the automatic blocking system. – Feed the belt back in to undo the automatic blocking system.
The belt can now be extracted again. The belt can now be extracted again.

Starting the industrial truck on steep slopes Starting the industrial truck on steep slopes

The automatic blocking system locks the belt in the retractor when the truck is 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 positioned on a steep slope. This prevents the belt from being pulled out of the
retractor. retractor.

Z Carefully drive the truck off the slope and then put on the belt.
Z Carefully drive the truck off the slope and then put on the belt.
0707.GB

0707.GB

E 19 E 19
3.5 Safety Restraint System (o) 3.5 Safety Restraint System (o)

F Never use the truck with a non-functional restraint system.

F Never use the truck with a non-functional restraint system.

F The restraint system must be checked by authorised specialist personnel after an

accident.
F The restraint system must be checked by authorised specialist personnel after an
accident.

F Do not alter the restraint system.

F Do not alter the restraint system.

F When the driver’s seat is occupied,

maintain a 90 mm gap between the gate 96
F When the driver’s seat is occupied,
maintain a 90 mm gap between the gate 96
(96) and the seat to ensure safety. (96) and the seat to ensure safety.

Procedure in unusual situations Procedure in unusual situations

F If the truck is in danger of tipping over, do not try to jump out. This will only increase
the risk of injury.
F If the truck is in danger of tipping over, do not try to jump out. This will only increase
the risk of injury.

Correct procedure Correct procedure

– Lean your upper body over the steering wheel. – Lean your upper body over the steering wheel.
– Grip the steering wheel with both hands and brace feet. – Grip the steering wheel with both hands and brace feet.
– Tilt your body in the opposite direction of fall. – Tilt your body in the opposite direction of fall.
0707.GB

0707.GB
E 20 E 20
 3.5.1 Safety restraint system (automatic) operating instructions (o) 3.5.1 Safety restraint system (automatic) operating instructions (o)

F Test the restraint system before starting the truck.

F Test the restraint system before starting the truck.
The stop knob (97) must not be The stop knob (97) must not be
engaged. engaged.

– Sit down on the seat – Sit down on the seat

97 97
– Turn the key switch “On”. – Turn the key switch “On”.
After releasing the parking brake the two After releasing the parking brake the two
safety gates (LH and RH) close and lock safety gates (LH and RH) close and lock
automatically. automatically.

Make sure the safety gates are free to 98 Make sure the safety gates are free to 98
move. move.
After parking the truck and applying the After parking the truck and applying the
handbrake, the safety gates open handbrake, the safety gates open
automatically. automatically.

The key switch should only be turned to “0” and removed when the safety gates have The key switch should only be turned to “0” and removed when the safety gates have
been opened. been opened.
If the event of a power failure, the restraint system can be unlocked by pulling the If the event of a power failure, the restraint system can be unlocked by pulling the
knob (98). The safety gates can be moved back manually. knob (98). The safety gates can be moved back manually.

Electronic Safety Restraint Sysetm (ERS with folding gate) Electronic Safety Restraint Sysetm (ERS with folding gate)
Electronic Safety Restraint System with automatic closing (ERS-AS with Electronic Safety Restraint System with automatic closing (ERS-AS with
folding gate) folding gate)

When the truck is switched off and the handbrake applied the safety gates are folded When the truck is switched off and the handbrake applied the safety gates are folded
up. After powering up the truck (Emergency Disconnect, key switch) and releasing up. After powering up the truck (Emergency Disconnect, key switch) and releasing
the handbrake, the safety gates automatically close (horizontal position). When the the handbrake, the safety gates automatically close (horizontal position). When the
parking brake is applied the safety gates open automatically. parking brake is applied the safety gates open automatically.

3.5.2 Safety restraint system (mechanical) operating instructions (o) 3.5.2 Safety restraint system (mechanical) operating instructions (o)

F Test the restraint system before starting the truck.

F Test the restraint system before starting the truck.

To open, push the left hand restraint gate in and at the same time lift it up, when the To open, push the left hand restraint gate in and at the same time lift it up, when the
gate is released it automatically drops down and locks. gate is released it automatically drops down and locks.

Mechanical restraint system with electronic control (HRS-E with folding gate) Mechanical restraint system with electronic control (HRS-E with folding gate)
To open, push the left safety gate in. The gate opens automatically through spring To open, push the left safety gate in. The gate opens automatically through spring
pressure. To close, push the safety gate down. The closed gate is monitored by pressure. To close, push the safety gate down. The closed gate is monitored by
switches. switches.

Z The truck will not travel with an open safety gate.

Z The truck will not travel with an open safety gate.
0707.GB

0707.GB

E 21 E 21
3.6 Adjusting the steering column 3.6 Adjusting the steering column

– Loosen the steering column lock (4)
and push the steering column forward
or back into the desired position.
– Retighten the steering column.
– Loosen the steering column lock (4)
2 and push the steering column forward 2
4 4
or back into the desired position.
5 5
– Retighten the steering column.

Height adjuster (o) Height adjuster (o)

Pull the lever (30) up and set the 99 Pull the lever (30) up and set the 99
steering wheel to the required height. steering wheel to the required height.

3.7 Preparing the truck for operation 3.7 Preparing the truck for operation

– Unlock the isolator (10). 10 – Unlock the isolator (10). 10

– Push in the rocker (s) and pull it up (r) – Push in the rocker (s) and pull it up (r)
until you feel the isolator engaging (o) until you feel the isolator engaging (o)
on trucks with multifunction armrest on trucks with multifunction armrest
unlock the EMERGENCY unlock the EMERGENCY
DISCONNECT (22). DISCONNECT (22).
– Insert the key in the key switch (5) and – Insert the key in the key switch (5) and
turn it clockwise as far as it will go to turn it clockwise as far as it will go to
the “I” position. the “I” position.

– Test the horn (99).. – Test the horn (99)..

F Test the electric, hydraulic and parking

brakes.
F Test the electric, hydraulic and parking
brakes.
30 30

– The truck is now operational. The – The truck is now operational. The
information and service display (2) / information and service display (2) /
control panel (21) shows the available 99 21 control panel (21) shows the available 99 21
battery capacity. battery capacity.

Z When you have

EMERGENCY DISCONNECT and
applied the 22 Z When you have
EMERGENCY DISCONNECT and
applied the 22

turned the key switch to the right, the turned the key switch to the right, the
truck carries out a self test for approx. truck carries out a self test for approx.
3-4 seconds (tests the controllers and 3-4 seconds (tests the controllers and
motors). During this time the truck motors). During this time the truck
cannot move. If the accelerator pedal is cannot move. If the accelerator pedal is
applied during this time, the display will applied during this time, the display will
0707.GB

0707.GB
show "Zero drive sens”. show "Zero drive sens”.

E 22 E 22
 3.8 Trucks with Heating (o) 3.8 Trucks with Heating (o)

F Covering the heater is prohibited due to severe risk of burning.

F Covering the heater is prohibited due to severe risk of burning.

– Set switch (100) to level I or II to – Set switch (100) to level I or II to

switch on the heating column. switch on the heating column.

Z If the switch (100) is set to the middle

position, the heating is off.
Z If the switch (100) is set to the middle
position, the heating is off.
100 100
– Set switch 101 to level I or II to switch – Set switch 101 to level I or II to switch
the fan on. 101 the fan on. 101

M The fan must be on in heating mode.

M The fan must be on in heating mode.

– Set the desired temperature on the 102 – Set the desired temperature on the 102
rotary button (102). rotary button (102).
0707.GB

0707.GB

E 23 E 23
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
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.
Driving 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. It is forbidden to lean out of or reach beyond the working and operating
area.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. When carrying loads which affect visibility, these must
be stored at the rear of the truck. If this is not possible, a second person must walk in
front of the truck as a lookout.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. 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.
Negotiating lifts and docks: Lifts and docks must only be used 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.
Type of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Do not carry loads unless they are positioned safely and
carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from
tipping or falling down.
0707.GB
E 24
4 Industrial Truck Operation
4.1 Safety regulations for truck operation
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.
Driving 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. It is forbidden to lean out of or reach beyond the working and operating
area.
Travel visibility: The driver must look in the direction of travel and must always have
a clear view of the route ahead. When carrying loads which affect visibility, these must
be stored at the rear of the truck. If this is not possible, a second person must walk in
front of the truck as a lookout.
Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted if
such roads are clean and have a non-slip surface and providing such journeys are
safely undertaken in accordance with the technical specifications for the truck in
question. 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.
Negotiating lifts and docks: Lifts and docks must only be used 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.
Type of loads to be carried: The operator must make sure that the load is in a
satisfactory condition. Do not carry loads unless they are positioned safely and
carefully. Use suitable precautions, e.g. a load guard, to prevent parts of the load from
tipping or falling down.
0707.GB
E 24
 Towing trailers or the truck itself being towed are only permitted occasionally, on
secure, level routes, with a maximum deviation of +/- 1% and at a max. speed of 5
km/h. Do not permanently operate the truck with trailers.
When the truck is pulling there must be no load on the forks.
Do not exceed the maximum trailer load specified for the forklift truck for trailers with
or without brakes. The specified trailer load only applies for the auxiliary coupling in
the counterbalance of the forklift. If a different trailer coupling is used on the truck, the
instructions of the coupling manufacturer must be observed..
After coupling and before starting the driver must ensure that the trailer coupling
cannot become detached.
Trucks pulling a load must be operated in such a manner that the trailing vehicle is
driven safely and can be stopped at all times.
0707.GB
0707.GB
E 25
Towing trailers or the truck itself being towed are only permitted occasionally, on
secure, level routes, with a maximum deviation of +/- 1% and at a max. speed of 5
km/h. Do not permanently operate the truck with trailers.
When the truck is pulling there must be no load on the forks.
Do not exceed the maximum trailer load specified for the forklift truck for trailers with
or without brakes. The specified trailer load only applies for the auxiliary coupling in
the counterbalance of the forklift. If a different trailer coupling is used on the truck, the
instructions of the coupling manufacturer must be observed..
After coupling and before starting the driver must ensure that the trailer coupling
cannot become detached.
Trucks pulling a load must be operated in such a manner that the trailing vehicle is
driven safely and can be stopped at all times.
E 25
4.2 Travel 4.2 Travel

F Travelling in electromagnetic fields beyond the permitted limits can result in random
truck motion. F Travelling in electromagnetic fields beyond the permitted limits can result in random
truck motion.
Immediately apply the EMERGENCY DISCONNECT, brake with the service brake Immediately apply the EMERGENCY DISCONNECT, brake with the service brake
and apply the parking brake. and apply the parking brake.
Determine the cause of the fault and if necessary inform the manufacturer’s service Determine the cause of the fault and if necessary inform the manufacturer’s service
department. department.

Safety functions Safety functions

Z If the driver’s seat is not occupied (safety belt o) not closed) or if the driver’s weight
is set too high, travel is interrupted by the safety switch (see Section 3 “Setting the
Z If the driver’s seat is not occupied (safety belt o) not closed) or if the driver’s weight
is set too high, travel is interrupted by the safety switch (see Section 3 “Setting the
Driver’s Weight”). Occupying the driver’s seat and applying the accelerator pedal Driver’s Weight”). Occupying the driver’s seat and applying the accelerator pedal
releases the spring-loaded brake. releases the spring-loaded brake.
The travel speed reduces as a function of the steering angle. However, the driver is The travel speed reduces as a function of the steering angle. However, the driver is
still responsible for adapting the travel speed to the conditions of the travel route, the still responsible for adapting the travel speed to the conditions of the travel route, the
work area and the load. work area and the load.

F Do not drive the truck unless the panels

are closed and properly locked. F Do not drive the truck unless the panels
are closed and properly locked.
Travel routes must be free of obstacles. Travel routes must be free of obstacles.

– Raise the fork carriage approx. – Raise the fork carriage approx.
200 mm so that the fork tines are clear 200 mm so that the fork tines are clear
of the ground. of the ground.
– Tilt the mast fully backward: – Tilt the mast fully backward:

Z Depending on the truck model, the travel

direction switch (103/14/32) can be fitted 103 14 Z Depending on the truck model, the travel
direction switch (103/14/32) can be fitted 103 14
to the to the
v v
– MULTI-PILOT Fig. (1) or – MULTI-PILOT Fig. (1) or
r r
– the SOLO-PILOT Fig. (2) or – the SOLO-PILOT Fig. (2) or

(1) (2) (1) (2)

– the multifunction steering wheel – the multifunction steering wheel

Fig. (3) or 32 14 Fig. (3) or 32 14

– the fingertip Fig. (4) – the fingertip Fig. (4)

. .

Z There is no travel direction switch on

trucks with a twin pedal.
Z There is no travel direction switch on
trucks with a twin pedal.
0707.GB

0707.GB
(3) (4) (3) (4)

E 26 E 26
 Forward travel (single pedal)
F Make sure that the travel area is clear.
– Release the parking brake (3)
– Push the travel direction switch ( 103 /
14 / 32) on the MULTI-PILOT / SOLO-
PILOT /multifunction steering wheel
forward
– Slowly apply the accelerator pedal (6)
Forward travel (twin pedal)
F Make sure that the travel area is clear
– Release the parking brake (3)
– Slowly apply the accelerator pedal
(13)
F Do not move the MULTI-PILOT to travel.
Changing direction (single pedal)
F Before setting off in the opposite
direction, make sure that the reverse
travel area is clear.
– Take your foot off the accelerator
pedal (6).
– Applying the brake pedal (7), bring the truck to a halt.
– Push/pull the travel direction switch (103 / 14 / 32 ) back.
– Slowly apply the accelerator pedal until you reach the required travel speed.
Changing direction (twin pedal)
F Before setting off in the opposite direction, make sure that the reverse travel area is
clear.
– Take your foot off the accelerator
pedal (13).
– Applying the brake pedal (12), bring
the truck to a halt.
– Slowly apply the accelerator pedal
(11) until you reach the required travel
speed.
0707.GB
103 Forward travel (single pedal) 103
F Make sure that the travel area is clear.
– Release the parking brake (3)
R V – Push the travel direction switch ( 103 / R V
14 / 32) on the MULTI-PILOT / SOLO-
PILOT /multifunction steering wheel
7 forward 7
– Slowly apply the accelerator pedal (6)
6 Forward travel (twin pedal) 6
F Make sure that the travel area is clear
– Release the parking brake (3)
3 3
– Slowly apply the accelerator pedal
(13)
F Do not move the MULTI-PILOT to travel.
Changing direction (single pedal)
F Before setting off in the opposite
direction, make sure that the reverse
travel area is clear.
– Take your foot off the accelerator
pedal (6).
– Applying the brake pedal (7), bring the truck to a halt.
– Push/pull the travel direction switch (103 / 14 / 32 ) back.
– Slowly apply the accelerator pedal until you reach the required travel speed.
Changing direction (twin pedal)
F Before setting off in the opposite direction, make sure that the reverse travel area is
clear.
– Take your foot off the accelerator
pedal (13).
– Applying the brake pedal (12), bring
the truck to a halt.
– Slowly apply the accelerator pedal
(11) until you reach the required travel
speed.
0707.GB
E 27 E 27
 Accelerating (single pedal) Accelerating (single pedal)

– Slowly apply the accelerator pedal (6)
until the truck starts to move. 103
– Continue to depress the accelerator
(6).
The motor speed and travel speed
increase the more you apply the
accelerator.
– Slowly apply the accelerator pedal (6)
until the truck starts to move. 103
– Continue to depress the accelerator
(6).
The motor speed and travel speed
R V increase the more you apply the R V
accelerator.
7 7

6 6

Accelerating (twin pedal) Accelerating (twin pedal)

– Slowly press the accelerator pedal (11
or 13) depending on the direction
selected, until the truck starts to move.
– Continue to depress the respective
accelerator pedal (11/13). The motor
speed and travel speed increase the
more you apply the accelerator.
– Slowly press the accelerator pedal (11
or 13) depending on the direction
selected, until the truck starts to move.
11 – Continue to depress the respective 11
accelerator pedal (11/13). The motor
12 speed and travel speed increase the 12
more you apply the accelerator.
13 13

Braking Braking

F The braking pattern depends largely on the ground conditions. The driver must take
this into consideration when handling the truck. Brake with care to prevent the load
F The braking pattern depends largely on the ground conditions. The driver must take
this into consideration when handling the truck. Brake with care to prevent the load
from slipping. from slipping.
If you are travelling with an attached load you must increase the braking distance. If you are travelling with an attached load you must increase the braking distance.

– Take your foot off the accelerator pedal (6) (11/13) and if necessary gently apply – Take your foot off the accelerator pedal (6) (11/13) and if necessary gently apply
the brake pedal (7/12) (see also Section 4.4). 0707.GB
the brake pedal (7/12) (see also Section 4.4).

0707.GB
E 28 E 28
 4.3 Steering 4.3 Steering

M Very minimal steering effort is required for the electric steering, therefore turn the
steering wheel sensitively.
M Very minimal steering effort is required for the electric steering, therefore turn the
steering wheel sensitively.

Negotiating right hand bends Negotiating right hand bends

– Turn the steering wheel clockwise to match the desired steering radius. – Turn the steering wheel clockwise to match the desired steering radius.

Negotiating left hand bends Negotiating left hand bends

– Turn the steering wheel anti-clockwise to match the desired steering radius. – Turn the steering wheel anti-clockwise to match the desired steering radius.

4.4 Braking 4.4 Braking

There are four ways of braking: There are four ways of braking:

– Service brake – Service brake

– Coasting brake – Coasting brake
– Reversing brake – Reversing brake
– Parking brake – Parking brake
7 7
– Spring-loaded brake – Spring-loaded brake
6 6
Service brake: 3 Service brake: 3
– Depress the brake pedal (7/12) until – Depress the brake pedal (7/12) until
you feel the brake pressure. you feel the brake pressure.

Z The service brake acts on the drive

wheels via the multi-plates.
Z The service brake acts on the drive
wheels via the multi-plates.

Coasting brake: Coasting brake:

– Take your foot off the accelerator 11 – Take your foot off the accelerator 11
pedal (6) (11/13). The truck brakes pedal (6) (11/13). The truck brakes
regeneratively via the traction regeneratively via the traction
controller. 12 controller. 12

Z This operating method reduces energy

consumption.
13
Z This operating method reduces energy
consumption.
13
0707.GB

0707.GB

E 29 E 29
 Reversing brake (single pedal) Reversing brake (single pedal)

– Set the travel direction switch (103/14/32) to the opposite direction while travelling. – Set the travel direction switch (103/14/32) to the opposite direction while travelling.
The truck brakes regeneratively via the traction controller until it starts to travel in The truck brakes regeneratively via the traction controller until it starts to travel in
the opposite direction. the opposite direction.

Z Depending on the truck model, the travel

direction switch (103/14/32) can be fitted 103 14 Z Depending on the truck model, the travel
direction switch (103/14/32) can be fitted 103 14
to the to the
v v
– MULTI-PILOT Fig. (1) or – MULTI-PILOT Fig. (1) or
r r
– the SOLO-PILOT Fig. (2) or – the SOLO-PILOT Fig. (2) or

(1) (2) (1) (2)

– the multifunction steering wheel – the multifunction steering wheel

Fig. (3) or 32 14 Fig. (3) or 32 14

– the fingertip Fig. (4) – the fingertip Fig. (4)

. .

Z There is no travel direction switch on

trucks with a twin pedal. Z There is no travel direction switch on
trucks with a twin pedal.
(3) (4) (3) (4)
Reversing brake (twin pedal) Reversing brake (twin pedal)
During travel, depress the accelerator pedal (11/13) for the opposite direction. The During travel, depress the accelerator pedal (11/13) for the opposite direction. The
truck brakes regeneratively via the traction controller until it starts to travel in the truck brakes regeneratively via the traction controller until it starts to travel in the
opposite direction. opposite direction.

Parking brake: Parking brake:

– Apply the parking brake – Apply the parking brake

F The parking brake actuates a black and white valve, braking cannot be performed
with any degree of sensitivity. F The parking brake actuates a black and white valve, braking cannot be performed
with any degree of sensitivity.

Z The parking brake acts mechanically on the drive wheels via the multi-plates.
Z The parking brake acts mechanically on the drive wheels via the multi-plates.

F The parking brake will keep the truck with the maximum permissible load, on a clean
ground surface, on a 15 % incline. F The parking brake will keep the truck with the maximum permissible load, on a clean
ground surface, on a 15 % incline.

Spring-loaded brake Spring-loaded brake

The spring-loaded brake applies approx. 30 seconds (adjustable) after the truck
comes to a halt, and approx. 1 to 5 seconds (adjustable) after the driver’s seat has
been vacated.
When you stop on the ramp the truck is held electrically until the spring-loaded brake
applies.
When you set off, before the spring-loaded brake is released, a torque builds up on
the drive motor to prevent the truck from rolling back.
0707.GB
The spring-loaded brake applies approx. 30 seconds (adjustable) after the truck
comes to a halt, and approx. 1 to 5 seconds (adjustable) after the driver’s seat has
been vacated.
When you stop on the ramp the truck is held electrically until the spring-loaded brake
applies.
When you set off, before the spring-loaded brake is released, a torque builds up on
the drive motor to prevent the truck from rolling back.

0707.GB
E 30 E 30
 4.5 Operating the lift mechanism and 4.5 Operating the lift mechanism and
8 8
attachments (MULTI-PILOT) attachments (MULTI-PILOT)

F The Multipilot must only be operated

from the driver’s seat. The driver must
F The Multipilot must only be operated
from the driver’s seat. The driver must
be instructed in how to handle the lift be instructed in how to handle the lift
mechanism and the attachments. mechanism and the attachments.

Push the Multipilot in the desired Push the Multipilot in the desired
direction, depending on the hydraulic direction, depending on the hydraulic
function. function.

Lifting/lowering the fork carriage Lifting/lowering the fork carriage

110 104 105 110 104 105
– Move the MULTI-PILOT (8) back – Move the MULTI-PILOT (8) back
(107) to raise the fork carriage. (107) to raise the fork carriage.
– Move the MULTI-PILOT (8) forward – Move the MULTI-PILOT (8) forward
(104) to lower the fork carriage. (104) to lower the fork carriage.
109 MP-Symbole 106 109 MP-Symbole 106

Tilting the mast forward / backward Tilting the mast forward / backward

F When tilting the mast back, ensure no

part of your body is between the mast
108 107 F When tilting the mast back, ensure no
part of your body is between the mast
108 107
and the front panel. and the front panel.

– Move the Multipilot (8) to the left (109) – Move the Multipilot (8) to the left (109)
to tilt the fork carriage back. 104 to tilt the fork carriage back. 104
– Move the Multipilot (8) to the right – Move the Multipilot (8) to the right
(106) to tilt the fork carriage forward. (106) to tilt the fork carriage forward.

107 107
Twin operation Twin operation

– To simultaneously lower the fork – To simultaneously lower the fork

carriage and tilt the mast forward,
move the Multipilot forward and to the
right (105).
– To simultaneously raise the fork
carriage and tilt the mast back, move
the MULTI-PILOT back and to the left
(108).
– To simultaneously raise the fork
carriage and tilt the mast back, move
the MULTI-PILOT forward and to the
left (110).
0707.GB
carriage and tilt the mast forward,
move the Multipilot forward and to the
right (105).
– To simultaneously raise the fork
carriage and tilt the mast back, move
109 106 the MULTI-PILOT back and to the left 109 106
(108).
– To simultaneously raise the fork
carriage and tilt the mast back, move
the MULTI-PILOT forward and to the
left (110).

0707.GB

E 31 E 31
4.5.1 Controlling Attachments (Multipilot) (o) 4.5.1 Controlling Attachments (Multipilot) (o)

F Note the manufacturer’s operating instructions and the capacity of the attachment.
Do not lift other people with the lifting device. F Note the manufacturer’s operating instructions and the capacity of the attachment.
Do not lift other people with the lifting device.

Auxiliary Controller I Auxiliary Controller I

(Integrated Sideshift) (Integrated Sideshift)
111 111
– Press the button (1110) on the 112 – Press the button (1110) on the 112
Multipilot to push the fork carriage to Multipilot to push the fork carriage to
the left. the left.
– Press the button (112) on the – Press the button (112) on the
Multipilot to push the fork carriage to Multipilot to push the fork carriage to
113 113
the right. the right.

Auxiliary Controller II Auxiliary Controller II

Z The MULTI-PILOT can be turned

to activate a hydraulic attachment.
Z The MULTI-PILOT can be turned
to activate a hydraulic attachment.
Read the manufacturer’s operating Read the manufacturer’s operating
instructions when operating attach- instructions when operating attach-
ments. ments.

Auxiliary Controller III Auxiliary Controller III

For auxiliary controller III press the For auxiliary controller III press the
key (113) on the MULTI-PILOT key (113) on the MULTI-PILOT
(e.g. locking). (e.g. locking).

Controlling the speed of the lifting device Controlling the speed of the lifting device
You control the hydraulic cylinder speed by moving the MULTI-PILOT. You control the hydraulic cylinder speed by moving the MULTI-PILOT.

When the MULTI-PILOT is released it automatically reverts to neutral and the lifting When the MULTI-PILOT is released it automatically reverts to neutral and the lifting
device remains in the position it has reached. device remains in the position it has reached.

M Always apply the MULTI-PILOT sensitively, never with a sudden jerk. Release the
Multipilot as soon as the lifting device reaches its limit position.
M Always apply the MULTI-PILOT sensitively, never with a sudden jerk. Release the
Multipilot as soon as the lifting device reaches its limit position.
0707.GB

0707.GB
E 32 E 32
 4.6 Operating the lift mechanism and 4.6 Operating the lift mechanism and
attachments (SOLO-PILOT) 20 attachments (SOLO-PILOT) 20

F The SOLO-PILOT must only be

operated from the driver’s seat. The
F The SOLO-PILOT must only be
operated from the driver’s seat. The
driver must be instructed in how to driver must be instructed in how to
operate the lifting unit and the operate the lifting unit and the
attachments. attachments.

Lifting/lowering the fork carriage Lifting/lowering the fork carriage

– Pull the SOLO-PILOT (16) back to 16 17 18 19 – Pull the SOLO-PILOT (16) back to 16 17 18 19
raise the fork carriage. raise the fork carriage.
– Press the SOLO PILOT (16) to the – Press the SOLO PILOT (16) to the
front to lower the fork carriage. front to lower the fork carriage.

Titing the mast forward / backward Titing the mast forward / backward

F When tilting the mast back, ensure no

part of your body is between the mast F When tilting the mast back, ensure no
part of your body is between the mast
and the front panel. and the front panel.

– Pull the SOLO-PILOT (17) back to tilt – Pull the SOLO-PILOT (17) back to tilt
the mast back. the mast back.
– Push the SOL-PILOT (17) forward to tilt the mast forward. – Push the SOL-PILOT (17) forward to tilt the mast forward.

4.6.1 Controlling Attachments (SOLO-PILOT) (o) 4.6.1 Controlling Attachments (SOLO-PILOT) (o)

F Note the manufacturer’s operating instructions and the capacity of the attachment.
Do not lift other people with the lifting device.
F Note the manufacturer’s operating instructions and the capacity of the attachment.
– Pull the auxiliary hydraulics control lever ZH1 (18) backwards or push it forward to
control the attachment (e.g. sideshift).
– Pull the auxiliary hydraulics control lever ZH2 (19) backwards or push it forward to
control the attachment (e.g. fork positioner).
– You can use button (20) to toggle the ZH2 control lever (19) to auxiliary hydraulics
ZH3.
The auxiliary hydraulics ZH3 can only be activated when the button (20) is pressed
and the control lever is in the neutral position. To control the attachment, pull the
SOLO-PILOT ZH2 lever (19) back or push it forward. The auxiliary hydraulics ZH3
are deactivated when the button (20) is released and the control lever has returned
to the neutral position.
Moving the lever controls the lift speed of the hydraulic cylinder.
When the lever is released it automatically reverts to neutral and the lifting device
remains in the position it has reached.
Do not lift other people with the lifting device.
– Pull the auxiliary hydraulics control lever ZH1 (18) backwards or push it forward to
control the attachment (e.g. sideshift).
– Pull the auxiliary hydraulics control lever ZH2 (19) backwards or push it forward to
control the attachment (e.g. fork positioner).
– You can use button (20) to toggle the ZH2 control lever (19) to auxiliary hydraulics
ZH3.
The auxiliary hydraulics ZH3 can only be activated when the button (20) is pressed
and the control lever is in the neutral position. To control the attachment, pull the
SOLO-PILOT ZH2 lever (19) back or push it forward. The auxiliary hydraulics ZH3
are deactivated when the button (20) is released and the control lever has returned
to the neutral position.
Moving the lever controls the lift speed of the hydraulic cylinder.
When the lever is released it automatically reverts to neutral and the lifting device
remains in the position it has reached.

M Always apply the control lever sensitively, never with a sudden jerk. Release the
control lever as soon as the lifting device reaches the limit position.
M Always apply the control lever sensitively, never with a sudden jerk. Release the
control lever as soon as the lifting device reaches the limit position.
0707.GB

0707.GB

E 33 E 33
 Integrated Sideshift (o) Integrated Sideshift (o)

The fork carriage can be moved sideways using the integrated sideshift. The fork carriage can be moved sideways using the integrated sideshift.
– Pull the auxiliary hydraulics control lever ZH1 (18) back = sideshift right. – Pull the auxiliary hydraulics control lever ZH1 (18) back = sideshift right.
– Push the auxiliary hydraulics control lever ZH1 (18) forward = sideshift left. – Push the auxiliary hydraulics control lever ZH1 (18) forward = sideshift left.
Integrated fork positioner (o) Integrated fork positioner (o)

The integrated fork positioner allows the distance between the forks to be set. The integrated fork positioner allows the distance between the forks to be set.

– Pull the auxiliary hydraulics control lever ZH2 (19) back = forks together. – Pull the auxiliary hydraulics control lever ZH2 (19) back = forks together.
– Push the auxiliary hydraulics control lever ZH2 (19) forward = forks apart. – Push the auxiliary hydraulics control lever ZH2 (19) forward = forks apart.

Z The fork positioner can be synchronised to ensure the forks are even. The forks must
be spread apart as far as the stop and then brought back together.
Z The fork positioner can be synchronised to ensure the forks are even. The forks must
be spread apart as far as the stop and then brought back together.

Other Attachments Other Attachments

Additional equipment can only be attached with written permission from the Additional equipment can only be attached with written permission from the
manufacturer, see chapter A “Attaching Accessories”. Always follow the manufacturer, see chapter A “Attaching Accessories”. Always follow the
manufacturer’s operating instructions when using other attachments. manufacturer’s operating instructions when using other attachments.

The control levers of the attachments must be indicated by symbols to illustrate the The control levers of the attachments must be indicated by symbols to illustrate the
function of the attachment. function of the attachment.

M Only use attachments that have CE approval. The reduced residual capacity must be
re-calculated and indicated by a separate capacity plate.
M Only use attachments that have CE approval. The reduced residual capacity must be
re-calculated and indicated by a separate capacity plate.

0707.GB

0707.GB
E 34 E 34
 4.7 Operating the lift mechanism and 4.7 Operating the lift mechanism and
attachments (multifunction steering attachments (multifunction steering
wheel) wheel)

F The multifunction steering wheel must only

be operated from the driver’s seat. The F The multifunction steering wheel must only
be operated from the driver’s seat. The
driver must be instructed in how to operate driver must be instructed in how to operate
the lifting unit and the attachments. the lifting unit and the attachments.

Lifting/lowering the fork carriage Lifting/lowering the fork carriage

27 27
– Pull the button (28) to raise the fork – Pull the button (28) to raise the fork
carriage. 29 29
28 28
26 26
25 25 carriage. 29 29
28 28
26 26
25 25
– Push the button (28) to lower the fork – Push the button (28) to lower the fork
carriage. carriage.

Tilting the mast forward / backward Tilting the mast forward / backward

F When tilting the mast back, ensure no part of your body is between the mast and the
front panel. F When tilting the mast back, ensure no part of your body is between the mast and the
front panel.

– Pull the button (26) to tilt the mast back. – Pull the button (26) to tilt the mast back.
– Push the button (26) to tilt the mast forward. – Push the button (26) to tilt the mast forward.

Controlling attachments Controlling attachments

F Note the manufacturer’s operating instructions and the capacity of the attachment.
Do not lift other people with the lifting device. F Note the manufacturer’s operating instructions and the capacity of the attachment.
Do not lift other people with the lifting device.

– Pull or push the auxiliary hydraulics button ZH1 (29) to control the attachment
(e.g. sideshift).
– Pull or push the auxiliary hydraulics button ZH2 (25) to control the attachment
(e.g. fork positioner).
– You can use the toggle switch (27) to toggle from auxiliary hydraulics ZH1 (29) to
the auxiliary hydraulics ZH3. When the auxiliary hydraulics ZH3 are activated, an
LED on the toggle switch (27) lights up. Pull or push the auxiliary hydraulics button
(29) to control the attachment. When the toggle switch (27) is pressed again the
auxiliary hydraulics ZH3 are deactivated.
The distance moved by the button controls the lift speed of the hydraulic cylinder.
When the button is released it automatically reverts to neutral and the lifting
mechanism remains in the position it has reached.
– Pull or push the auxiliary hydraulics button ZH1 (29) to control the attachment
(e.g. sideshift).
– Pull or push the auxiliary hydraulics button ZH2 (25) to control the attachment
(e.g. fork positioner).
– You can use the toggle switch (27) to toggle from auxiliary hydraulics ZH1 (29) to
the auxiliary hydraulics ZH3. When the auxiliary hydraulics ZH3 are activated, an
LED on the toggle switch (27) lights up. Pull or push the auxiliary hydraulics button
(29) to control the attachment. When the toggle switch (27) is pressed again the
auxiliary hydraulics ZH3 are deactivated.
The distance moved by the button controls the lift speed of the hydraulic cylinder.
When the button is released it automatically reverts to neutral and the lifting
mechanism remains in the position it has reached.

M Apply the buttons sensitively and avoid sudden movements. Release the button as
soon as the lifting mechanism reaches the limit position.
M Apply the buttons sensitively and avoid sudden movements. Release the button as
soon as the lifting mechanism reaches the limit position.
0707.GB

0707.GB

E 35 E 35
4.8 Collecting, transporting and depositing loads 4.8 Collecting, transporting and depositing loads

M Before lifting a load, the driver must ensure that it is correctly palletised and that the
capacity of the truck is not exceeded.
M Before lifting a load, the driver must ensure that it is correctly palletised and that the
capacity of the truck is not exceeded.
Note the load chart. Note the load chart.

Adjusting the forks Adjusting the forks

F Adjust the forks in such a way that both

are equally distanced from the outer
edge of the fork carriage and the load
centre of gravity lies in the middle of the
forks.
114 F Adjust the forks in such a way that both
are equally distanced from the outer 114
edge of the fork carriage and the load
centre of gravity lies in the middle of the
forks.

– Raise the locking lever (115). – Raise the locking lever (115).
– Push the forks (114) to the correct – Push the forks (114) to the correct
position on the fork carriage (116). position on the fork carriage (116).
– Turn the locking lever down and move – Turn the locking lever down and move
the fork tine until it engages in a slot. the fork tine until it engages in a slot.

116 115 116 115

Lifting a load Lifting a load
– Carefully approach the load to be – Carefully approach the load to be
lifted. lifted.
– Apply the parking brake (3). 3 – Apply the parking brake (3). 3

– Set the mast vertical. – Set the mast vertical.

– Raise the forks to the correct height for – Raise the forks to the correct height for
the load. the load.
0707.GB

0707.GB
E 36 E 36
 – Drive the truck with forks spread as far
apart as possible underneath the load.
F At least two thirds of their length must
extend into the load.
– Apply the parking brake (3). Raise the
fork carriage until the load rests freely
on the forks.
– Set the travel direction switch (92) to
reverse and release the parking
brake.
F Make sure you have enough space to
reverse into.
– Reverse carefully and slowly until the
load is outside the storage area.
F xDo not stand underneath a raised load.
Do not reach through the mast.
– Tilt the mast fully backward:
– Lower the load as far as is absolutely
necessary for transport (ground
clearance approx. 150...200mm).
F When transporting loads, the mast must
be tilted back and the forks lowered as
far as possible.
0707.GB
– Drive the truck with forks spread as far
apart as possible underneath the load.
F At least two thirds of their length must
extend into the load.
– Apply the parking brake (3). Raise the
fork carriage until the load rests freely
on the forks.
– Set the travel direction switch (92) to
reverse and release the parking
brake.
103 F Make sure you have enough space to
reverse into.
103
– Reverse carefully and slowly until the
load is outside the storage area.
F xDo not stand underneath a raised load.
Do not reach through the mast.
3 – Tilt the mast fully backward: 3
– Lower the load as far as is absolutely
necessary for transport (ground
clearance approx. 150...200mm).
F When transporting loads, the mast must
be tilted back and the forks lowered as
far as possible.
0707.GB
E 37 E 37
 Transporting a load Transporting a load

F If the load is stacked so high that it affects forward visibility, then reverse.
F If the load is stacked so high that it affects forward visibility, then reverse.
– Gently accelerate with the accelerator – Gently accelerate with the accelerator
pedal (6) and slowly brake with the pedal (6) and slowly brake with the
brake pedal (7). Be ready to brake at brake pedal (7). Be ready to brake at
all times. all times.
– Adapt your travel speed to the – Adapt your travel speed to the
conditions of the route and the load conditions of the route and the load
you are transporting. you are transporting.
– Watch out for other traffic at crossings – Watch out for other traffic at crossings
and passageways. and passageways.
– Always travel with a lookout at – Always travel with a lookout at
blindspots. blindspots.

F On slopes and inclines always carry the

load facing uphill, never approach at an F On slopes and inclines always carry the
load facing uphill, never approach at an
angle or turn. angle or turn.

Depositing a load Depositing a load

– Drive the truck carefully up to the load – Drive the truck carefully up to the load
handler. 7 handler. 7
– Apply the parking brake (3). – Apply the parking brake (3).
– Set the mast vertical. – Set the mast vertical.
– Raise the forks to the correct height for – Raise the forks to the correct height for
the load handler. 6 the load handler. 6
– Release the parking brake. – Release the parking brake.
3 3
– Carefully enter the load handler. – Carefully enter the load handler.
– Slowly lower the load until the forks – Slowly lower the load until the forks
are free. are free.

M Avoid depositing the load suddenly to

avoid damaging the load and the load
M Avoid depositing the load suddenly to
avoid damaging the load and the load
handler. handler.

F You can only tilt forward when the load

handler is raised in front of or above the F You can only tilt forward when the load
handler is raised in front of or above the
stack. stack.
0707.GB

0707.GB
E 38 E 38
 4.9 Parking the truck securely 4.9 Parking the truck securely

F When you leave the truck it must be securely parked even if you only intend to leave
it for a short time. F When you leave the truck it must be securely parked even if you only intend to leave
it for a short time.

– Drive the truck onto a level surface. – Drive the truck onto a level surface.
– Apply the parking brake (3). – Apply the parking brake (3).
5 5
– Fully lower the load forks and tilt the – Fully lower the load forks and tilt the
mast forward. mast forward.

F Never park and abandon a truck with a

raised load. F Never park and abandon a truck with a
raised load.

– Press the isolator (10) down – Press the isolator (10) down
– Turn the key in the key switch (5) – Turn the key in the key switch (5)
to “0”. to “0”.
– Remove the key from the key – Remove the key from the key
switch (5). 10 switch (5). 10

M Avoid parking the truck in areas below

15° C, as this will render the hydraulic
M Avoid parking the truck in areas below
15° C, as this will render the hydraulic
fluids extremely viscous and 3 fluids extremely viscous and 3
consequently the hydraulic functions consequently the hydraulic functions
harder to operate. harder to operate.
Never operate a cold pump at full speed. Never operate a cold pump at full speed.
Heat up the oil by repeatedly tilting and/ Heat up the oil by repeatedly tilting and/
or lifting slowly. or lifting slowly.
The LCD display may fail temporarily. As The LCD display may fail temporarily. As
the temperature rises the display will the temperature rises the display will
appear again. appear again.
0707.GB

0707.GB

E 39 E 39
4.10 Towing trailers 4.10 Towing trailers

The truck can occasionally be used to tow a light trailer on a dry, level and well The truck can occasionally be used to tow a light trailer on a dry, level and well
maintained surface. maintained surface.

Z The max. tow load is the capacity indicated on the capacity data plate (see decals
diagram in chapter B).
Z The max. tow load is the capacity indicated on the capacity data plate (see decals
diagram in chapter B).

The tow load consists of the weight of the trailer and the stated capacity. The tow load consists of the weight of the trailer and the stated capacity.
If a load is transported on the forks, the tow load must be reduced by the same If a load is transported on the forks, the tow load must be reduced by the same
amount. amount.

F Important notes for safe towing

F Important notes for safe towing
– A truck must not be continually operated with trailers. – A truck must not be continually operated with trailers.
– No supporting loads are permitted. – No supporting loads are permitted.
– The maximum speed is 5 km/h. – The maximum speed is 5 km/h.
– Towing must only be performed on level, secure travel routes. – Towing must only be performed on level, secure travel routes.
– Follow the instructions of the coupling manufacturer if using special trailer – Follow the instructions of the coupling manufacturer if using special trailer
couplings. couplings.
– The owner must test trailer operation with the permissible tow load by means of a – The owner must test trailer operation with the permissible tow load by means of a
trial run under the applicable operating conditions in the field. trial run under the applicable operating conditions in the field.
Attaching the trailer Attaching the trailer
117 117
– Push the tow pin (117) down and turn – Push the tow pin (117) down and turn
it 90 degrees. it 90 degrees.
– Pull the tow pin up and insert the tiller – Pull the tow pin up and insert the tiller
of the trailer vehicle into the opening. of the trailer vehicle into the opening.
– Insert the tow pin, push it down, turn it – Insert the tow pin, push it down, turn it
90 degrees and engage it. 90 degrees and engage it.

4.11 Tow loads 4.11 Tow loads

M Before coupling, the driver must ensure

the maximum trailer load is not
M Before coupling, the driver must ensure
the maximum trailer load is not
exceeded. 0707.GB exceeded.

0707.GB
E 40 E 40
 5 Troubleshooting 5 Troubleshooting

This chapter is designed to help the user identify and rectify basic faults or the results This chapter is designed to help the user identify and rectify basic faults or the results
of incorrect operation. When locating a fault, proceed in the order shown in the table. of incorrect operation. When locating a fault, proceed in the order shown in the table.

Fault Probable Cause Action Fault Probable Cause Action

Truck does – Battery connector – Check the battery connector and connect if Truck does – Battery connector – Check the battery connector and connect if
not travel. not necessary. not travel. not necessary.
plugged in plugged in
– Main switch – Release isolator – Main switch – Release isolator
pressed. pressed.
– Key switch – Set key switch to “I” – Key switch – Set key switch to “I”
in “0” position in “0” position
– Battery charge too – Check battery charge, charge battery if – Battery charge too – Check battery charge, charge battery if
low necessary low necessary
– Faulty fuse – Check fuses – Faulty fuse – Check fuses
Load cannot be – Truck not – Carry out all measures listed under “Truck Load cannot be – Truck not – Carry out all measures listed under “Truck
lifted operational does not travel” lifted operational does not travel”
– Hydraulic oil level – Check the hydraulic oil level – Hydraulic oil level – Check the hydraulic oil level
too low too low
– Faulty fuse – Check fuses – Faulty fuse – Check fuses
– Battery charge too – Check battery charge, charge battery if – Battery charge too – Check battery charge, charge battery if
low necessary low necessary
Error message – Truck not – Press EMERGENCY DISCONNECT Error message – Truck not – Press EMERGENCY DISCONNECT
displayed operational isolator or turn key switch to 0, after approx. displayed operational isolator or turn key switch to 0, after approx.
– Software failure 3 seconds try to perform the desired – Software failure 3 seconds try to perform the desired
operation again operation again

Z If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer’s service department, as any further troubleshooting can only be
Z If the fault cannot be rectified after carrying out the remedial procedure, notify the
manufacturer’s service department, as any further troubleshooting can only be
performed by specially trained and qualified service personnel. performed by specially trained and qualified service personnel.
0707.GB

0707.GB

E 41 E 41
E 42
0707.GB

E 42

0707.GB
 F Maintenance of the fork lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
F Modifications of fork lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
M Only original spare parts have been certified by our quality assurance service. To en-
sure safe and reliable operation of the fork lift truck, only spare parts of the manufac-
turer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the
manufacturer has external technicians trained especially for these assignments. We
thus recommend signing a maintenance contract with the relevant service location of
the manufacturer.
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tip-
ping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength.
Z Jacking point see chapter B.
F When work has to be performed under the raised fork or under the jacked up truck,
suitable measures must be taken to prevent any dropping, tilting or slipping of the fork
or truck. When lifting the truck, the instructions contained in chapter “Transportation
and commissioning” have to be observed.
When performing work on the parking brake, the truck must be secured against mov-
ing.
Cleaning operations: No inflammable liquids must be used when cleaning the fork
lift truck. Prior to commencing cleaning operations, all safety measures that are re-
quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-oper-
ated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com-
pressed air and non-conducting, antistatic brushes must be used for the cleaning of
electric or electronic assemblies.
0708.GB
0708.GB
F1
F Maintenance of the fork lift truck
1 Operational safety and environmental protection
The checks and servicing operations contained in this chapter must be performed in
accordance with the intervals as indicated in the servicing checklists.
F Modifications of fork lift truck assemblies, especially of the safety installations, are not
permitted. On no account must the operational speeds of the truck be changed.
M Only original spare parts have been certified by our quality assurance service. To en-
sure safe and reliable operation of the fork lift truck, only spare parts of the manufac-
turer must be used. Used parts, oils and fuels must be disposed of in accordance with
the applicable environmental protection regulations. For oil changes, the oil service
of the manufacturer is available to you.
Upon completion of any checking and servicing activities, the operations contained in
the section “Recommissioning” must be performed (refer to chapter F).
2 Safety regulations applicable to truck maintenance
Servicing and maintenance personnel: The fork lift truck must only be serviced and
maintained by trained personnel of the manufacturer. The service organization of the
manufacturer has external technicians trained especially for these assignments. We
thus recommend signing a maintenance contract with the relevant service location of
the manufacturer.
Lifting and jacking up: When a fork lift truck is to be lifted, the lifting gear must only
be secured to the points specially provided for this purpose. When the truck is to be
jacked up, suitable measures must be taken to prevent the truck from slipping or tip-
ping over (use of wedges, wooden blocks). Work underneath the raised load lifting
device must only be carried out when the fork is immobilised and supported by a
chain of adequate strength.
Z Jacking point see chapter B.
F When work has to be performed under the raised fork or under the jacked up truck,
suitable measures must be taken to prevent any dropping, tilting or slipping of the fork
or truck. When lifting the truck, the instructions contained in chapter “Transportation
and commissioning” have to be observed.
When performing work on the parking brake, the truck must be secured against mov-
ing.
Cleaning operations: No inflammable liquids must be used when cleaning the fork
lift truck. Prior to commencing cleaning operations, all safety measures that are re-
quired to prevent sparking (e.g. by short-circuits) have to be taken. For battery-oper-
ated fork lift trucks, the battery plug must be removed. Only weak indraft, weak com-
pressed air and non-conducting, antistatic brushes must be used for the cleaning of
electric or electronic assemblies.
F1
M If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis-
sioning” must be performed.
Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork lift trucks, the truck must also be depow-
ered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components,
these have to be removed from the fork lift truck before any welding operations are
undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, all truck-specific settings have to be retained.
Wheels: The quality of wheels affects the stability and performance of the truck.
When replacing wheels fitted at the factory, only use manufacturer’s original spare
parts. Otherwise the truck's rated performance cannot be ensured.
When replacing wheels, ensure that the truck does not slew (e.g. always replace
wheels in pairs, i.e. left and right wheels at the same time).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubri-
cation is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication.
The chain tensioners must be adjusted in such a manner that they can adapt them-
selves to the pulling direction of the chain. Pretensioning the tensioner head against
the mounting is not allowed. A minimum distance of 20 mm must be kept.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy-
draulic components, also renew the hoses in this hydraulic system.
0708.GB
F2
M If the fork lift truck is to be cleaned using a water jet or a high-pressure cleaner, all
electric and electronic components must be carefully covered beforehand because
moisture can lead to incorrect functioning.
Cleaning by means of a steam jet is not permitted.
Upon completion of cleaning work, the operations detailed in the section “Recommis-
sioning” must be performed.
Work on the electric system: Work on the electric system of the truck must only be
performed by personnel specially trained for such operations. Before commencing
any work on the electric system, all measures required to prevent electric shocks
have to be taken. For battery-operated fork lift trucks, the truck must also be depow-
ered by removing the battery plug.
Welding operations: To prevent any damage to electric or electronic components,
these have to be removed from the fork lift truck before any welding operations are
undertaken.
Settings: When repairing or replacing hydraulic, electric or electronic components or
assemblies, all truck-specific settings have to be retained.
Wheels: The quality of wheels affects the stability and performance of the truck.
When replacing wheels fitted at the factory, only use manufacturer’s original spare
parts. Otherwise the truck's rated performance cannot be ensured.
When replacing wheels, ensure that the truck does not slew (e.g. always replace
wheels in pairs, i.e. left and right wheels at the same time).
Lift chains: The lift chains wear rapidly if not lubricated. The intervals in the service
checklist apply to normal duty. If requirements are higher (dust, temperature), lubri-
cation is required more often. The specified chain spray must be used as specified.
The external application of grease does not provide sufficient lubrication.
The chain tensioners must be adjusted in such a manner that they can adapt them-
selves to the pulling direction of the chain. Pretensioning the tensioner head against
the mounting is not allowed. A minimum distance of 20 mm must be kept.
Hydraulic hoses: The hoses must be renewed every six years. When replacing hy-
draulic components, also renew the hoses in this hydraulic system.
0708.GB
F2
 3 Servicing and inspection 3 Servicing and inspection

Thorough and expert servicing is one of the most important preconditions for safe Thorough and expert servicing is one of the most important preconditions for safe
operation of the forklift truck. Failure to perform regular servicing can lead to truck operation of the forklift truck. Failure to perform regular servicing can lead to truck
failure and poses a potential hazard to personnel and equipment. failure and poses a potential hazard to personnel and equipment.

M The application conditions of an industrial truck have a considerable impact on the

wear of the service components.
M The application conditions of an industrial truck have a considerable impact on the
wear of the service components.
We recommend that a Jungheinrich customer service adviser carries out an We recommend that a Jungheinrich customer service adviser carries out an
application analysis on site to work out specific service intervals to prevent damage application analysis on site to work out specific service intervals to prevent damage
due to wear. due to wear.
The service intervals listed are based on single shift operation under normal The service intervals listed are based on single shift operation under normal
operating conditions. They must be reduced accordingly if the truck is to be used in operating conditions. They must be reduced accordingly if the truck is to be used in
conditions where there is heavy dust, temperature fluctuations or multiple shifts. conditions where there is heavy dust, temperature fluctuations or multiple shifts.

The following maintenance check list gives the tasks and times at which they should The following maintenance check list gives the tasks and times at which they should
be carried out. Maintenance intervals are defined as: be carried out. Maintenance intervals are defined as:

W = Every 50 service hours or at least weekly W = Every 50 service hours or at least weekly
A = Every 500 service hours A = Every 500 service hours
B = Every 1000 service hours, or at least six months B = Every 1000 service hours, or at least six months
C = Every 2000 service hours, or at least annually C = Every 2000 service hours, or at least annually

Z W service intervals are to be performed by the customer.

Z W service intervals are to be performed by the customer.
In the run-in period - after approx. 100 service hours - or after repair work, the owner In the run-in period - after approx. 100 service hours - or after repair work, the owner
must check the wheel nuts/bolts and re-tighten if necessary. must check the wheel nuts/bolts and re-tighten if necessary.
0708.GB

0708.GB

F3 F3
4 Maintenance checklist EFG 4 Maintenance checklist EFG

Maintenance intervals Maintenance intervals

Standard = t W A B C Standard = t W A B C

Chassis/ 1.1 Check all load bearing components for damage t Chassis/ 1.1 Check all load bearing components for damage t
Superstructure 1.2 Check screw connections t Superstructure 1.2 Check screw connections t
1.3 Check trailer coupling t 1.3 Check trailer coupling t
1.4 Check overhead guard for damage and make sure it is secure t 1.4 Check overhead guard for damage and make sure it is secure t
1.5 Test seat belt operation and check for damage t 1.5 Test seat belt operation and check for damage t
1.6 Test restraint system (option) operation and check for t 1.6 Test restraint system (option) operation and check for t
damage damage
1.7 Check overhead guard for damage and make sure it is secure t 1.7 Check overhead guard for damage and make sure it is secure t
Drive: 2.1 Check transmission for noise and leakage t Drive: 2.1 Check transmission for noise and leakage t
2.2 Check transmission oil level t 2.2 Check transmission oil level t
2.3 Check pedal mechanism, adjust and lubricate if necessary t 2.3 Check pedal mechanism, adjust and lubricate if necessary t
2.4 Change transmission oil t 2.4 Change transmission oil t
Wheels: 3.1 Check wheels for wear and damage t Wheels: 3.1 Check wheels for wear and damage t
3.2 Check air pressure t 3.2 Check air pressure t
3.3 Check suspension and attachment t 3.3 Check suspension and attachment t
3.4 Replace wheel bearing grease fillings for front and rear t 3.4 Replace wheel bearing grease fillings for front and rear t
wheels and re-adjust the wheel bearings. wheels and re-adjust the wheel bearings.
Steering: 4.1 Test operation of hydraulic components and check for leaks t Steering: 4.1 Test operation of hydraulic components and check for leaks t
4.2 At the latest after 500 hours lubricate all bearings points on 4.2 At the latest after 500 hours lubricate all bearings points on
the steering axle (wheel bearings, steering knuckle pins, the steering axle (wheel bearings, steering knuckle pins,
t t
steering lever) in accordance with the lubrication schedule steering lever) in accordance with the lubrication schedule
using a trade standard grease gun. using a trade standard grease gun.
4.3 Check steering axle, axle knuckle and stops for wear and t 4.3 Check steering axle, axle knuckle and stops for wear and t
deformation deformation
4.4 Clean the steering angle sensor with compressed air t 4.4 Clean the steering angle sensor with compressed air t
Brake system: 5.1 Test operation and settings t Brake system: 5.1 Test operation and settings t
5.2 Check brake mechanism, adjust and lubricate if necessary t 5.2 Check brake mechanism, adjust and lubricate if necessary t
5.3 Check brake lines, connections and oil level for the brake t 5.3 Check brake lines, connections and oil level for the brake t
system system
5.4 Replace brake system mineral oil t 5.4 Replace brake system mineral oil t
5.5 Measure the holding force of the spring-loaded brake t 5.5 Measure the holding force of the spring-loaded brake t
5.6 Check the brake oil level (mineral oil) t 5.6 Check the brake oil level (mineral oil) t
Hydr. system: 6.1 Check connections for leaks and damage t Hydr. system: 6.1 Check connections for leaks and damage t
6.2 Check ventilation and aeration filter at hydraulics tank t 6.2 Check ventilation and aeration filter at hydraulics tank t
6.3 Check oil level t 6.3 Check oil level t
6.4 Check hydraulic cylinders for leaks, damage, and t 6.4 Check hydraulic cylinders for leaks, damage, and t
secure attachment secure attachment
6.5 Check hose line for correct function and damage t 6.5 Check hose line for correct function and damage t
6.6 Change filter cartridge (hydraulic oil and aeration filter) t 6.6 Change filter cartridge (hydraulic oil and aeration filter) t
6.7 Change hydraulic oil t 6.7 Change hydraulic oil t
6.8 Check pressure relief valves for correct function t 6.8 Check pressure relief valves for correct function t
6.9 Change vacuum filter (steering) t 6.9 Change vacuum filter (steering) t
0708.GB

0708.GB
F4 F4
 Maintenance intervals Maintenance intervals
Standard = t W A B C Standard = t W A B C

Electr. 7.1 Check function of instruments and indicators t Electr. 7.1 Check function of instruments and indicators t
system: 7.2 Check cables for secure connection and damage t system: 7.2 Check cables for secure connection and damage t
7.3 Check cable guides for function and damage t 7.3 Check cable guides for function and damage t
7.4 Check the warning devices and safety circuits for correct t 7.4 Check the warning devices and safety circuits for correct t
function function
7.5 Check contactor t 7.5 Check contactor t
7.6 Check fuses for correct amperage t 7.6 Check fuses for correct amperage t
7.7 Clean installation space of electronics and cooling fins t 7.7 Clean installation space of electronics and cooling fins t
7.8 Read out and clear error memory t 7.8 Read out and clear error memory t
Electric 8.1 Check the motor for secure attachment t Electric 8.1 Check the motor for secure attachment t
motors: 8.2 Check fan for correct function t motors: 8.2 Check fan for correct function t
8.3 Clean motor cooling fins t 8.3 Clean motor cooling fins t
Battery: 9.1 Check battery cables for damage and replace, if t Battery: 9.1 Check battery cables for damage and replace, if t
necessary necessary
9.2 Check acid density, acid level, and cell voltage t 9.2 Check acid density, acid level, and cell voltage t
9.3 Check terminals for secure attachment and apply t 9.3 Check terminals for secure attachment and apply t
grease grease
9.4 Clean battery plug connections, check for tight seat t 9.4 Clean battery plug connections, check for tight seat t
Mast: 10.1 Apply grease to the tracks and the side contact surface of the t Mast: 10.1 Apply grease to the tracks and the side contact surface of the t
guide rollers in the mast sections. guide rollers in the mast sections.
10.2 Check lift chains for wear and adjust. t 10.2 Check lift chains for wear and adjust. t
10.3 Lubricate lift chains and check tension. t 10.3 Lubricate lift chains and check tension. t
10.4 Check mast attachment t 10.4 Check mast attachment t
10.5 Check tilt cylinder suspension and attachment t 10.5 Check tilt cylinder suspension and attachment t
10.6 Check forks and fork carriage for wear and damage t 10.6 Check forks and fork carriage for wear and damage t
10.7 Visually inspect rollers, slide pieces and stops t 10.7 Visually inspect rollers, slide pieces and stops t
Test mast tilt angle. t Test mast tilt angle. t
10.8 10.8
Make sure both tilt cylinders extend evenly. Make sure both tilt cylinders extend evenly.
Check mast play and if necessary adjust lateral play using t Check mast play and if necessary adjust lateral play using t
10.9 10.9
spacers. spacers.
General 11.1 Test electrical system for frame leakage in accordance with t General 11.1 Test electrical system for frame leakage in accordance with t
Measurements: VDI 2511 Measurements: VDI 2511
11.2 Test travel speed and braking distance t 11.2 Test travel speed and braking distance t
11.3 Test lift and lowering speeds t 11.3 Test lift and lowering speeds t
Demonstration 12.1 Test run with rated load t Demonstration 12.1 Test run with rated load t
12.2 After carrying out maintenance, present the truck to the t 12.2 After carrying out maintenance, present the truck to the t
supervisor. supervisor.
0708.GB

0708.GB

F5 F5
5 Lubrication Schedule 5 Lubrication Schedule

G G
-A -A
t-D t-D

g-E g-E

-A -A
s-E s-E
c c

b-N a b-N a

b-N b-N

g Glide surfaces
s Lubricator nipple
Hydraulic oil filler pipe
c Hydraulic oil drain plug
b Transmission oil filler pipe g Glide surfaces b Transmission oil filler pipe
a Transmission oil drain plug s Lubricator nipple a Transmission oil drain plug
Filler pipe for brake system Filler pipe for brake system
t Hydraulic oil filler pipe t
mineral oil mineral oil
c Hydraulic oil drain plug
0708.GB

0708.GB
F6 F6
 5.1 Fuels, coolants and lubricants 5.1 Fuels, coolants and lubricants

Handling consumption type material: Consumption type material must always be Handling consumption type material: Consumption type material must always be
handled properly. Manufacturer's instructions to be observed. handled properly. Manufacturer's instructions to be observed.

F Improper handling is injurious to health, life, and environment. Consumption type ma-
terials must be stored in adequate containers. They might be inflammable and, there- F Improper handling is injurious to health, life, and environment. Consumption type ma-
terials must be stored in adequate containers. They might be inflammable and, there-
fore, must not come into contact with hot components or open fire. fore, must not come into contact with hot components or open fire.

When filling in consumption type materials use clean containers only. It is prohibited When filling in consumption type materials use clean containers only. It is prohibited
to mix consumption type materials of different grades or qualitiies resp., except if mix- to mix consumption type materials of different grades or qualitiies resp., except if mix-
ing is expressively prescribed in these operating instructions. ing is expressively prescribed in these operating instructions.

Avoid spilling. Spilt liquid must be removed immediately using a suitable binding Avoid spilling. Spilt liquid must be removed immediately using a suitable binding
agent, and the mixture of consumption type material and binding agent is to be dis- agent, and the mixture of consumption type material and binding agent is to be dis-
posed of according to the regulations. posed of according to the regulations.

Code Order-no. Quantity Designation Used for Code Order-no. Quantity Designation Used for
50426072 Renolin 321) HLPD 50426072 Renolin 321) HLPD
50429647 Renolin 222) HLPD Hydraulic system 50429647 Renolin 222) HLPD Hydraulic system
A 50124051 34.5 l HV 68 3) A 50124051 34.5 l HV 68 3)
51082888 Plantosyn 46 HVI 51082888 Plantosyn 46 HVI
(BIO hydraulic oil) (BIO hydraulic oil)
D 50429647 0.25 l Renolin 22 Hydraulic brake system D 50429647 0.25 l Renolin 22 Hydraulic brake system
Lubricating grease Front and rear wheel - Lubricating grease Front and rear wheel -
E 50055726 E 50055726
KP 2 K3) wheel bearing KP 2 K3) wheel bearing
G 29201280 Chain spray Chains G 29201280 Chain spray Chains
Shell Donax TC 50 Shell Donax TC 50
N 50137755 2x approx. 3 l Transmission N 50137755 2x approx. 3 l Transmission
Universal Universal

F The trucks are filled at the factory with H-LPD 32 hydraulic oil or Plantosyn 46 HVI
BIO hydraulic oil.
F The trucks are filled at the factory with H-LPD 32 hydraulic oil or Plantosyn 46 HVI
BIO hydraulic oil.
You cannot change from “Plantosyn 46 HVI” BIO hydraulic oil to H-LPD 32. The same You cannot change from “Plantosyn 46 HVI” BIO hydraulic oil to H-LPD 32. The same
applies to changing from H-LPD 32 hydraulic oil to Plantosyn 46 HVI BIO hydraulic oil. applies to changing from H-LPD 32 hydraulic oil to Plantosyn 46 HVI BIO hydraulic oil.
Furthermore you cannot mix H-LPD 32 hydraulic oil with Plantosyn 46 HVI BIO Furthermore you cannot mix H-LPD 32 hydraulic oil with Plantosyn 46 HVI BIO
hydraulic oil. hydraulic oil.

Grease data Grease data

Code Saponification Drop point Worked NLG1 class Usage Code Saponification Drop point Worked NLG1 class Usage
°C penetraton at temperature °C °C penetraton at temperature °C
25 ° C 25 ° C
E Lithium 185 265-295 2 -35/+120 E Lithium 185 265-295 2 -35/+120
1) valid for temperature -5/+30 °C 1) valid for temperature -5/+30 °C
2) 2)
valid for temperature -20/-5 °C valid for temperature -20/-5 °C
3) 3)
valid for temperature +30/+50 °C valid for temperature +30/+50 °C
0708.GB

0708.GB

F7 F7
6 Description of servicing and maintenance operations 6 Description of servicing and maintenance operations

6.1 Prepare truck for the servicing and maintenance operations 6.1 Prepare truck for the servicing and maintenance operations

All required safety measures must be taken to prevent any accidents in the course of All required safety measures must be taken to prevent any accidents in the course of
the servicing and maintenance operations. The following preparatory operations the servicing and maintenance operations. The following preparatory operations
must be performed: must be performed:

– Expose the batteries (refer to chapter D). – Expose the batteries (refer to chapter D).

6.2 Check attachment of tyres 6.2 Check attachment of tyres

– Park and lock the truck (refer to chap- – Park and lock the truck (refer to chap-
ter E). ter E).
– Crosswise tighten the wheel nuts (1) – Crosswise tighten the wheel nuts (1)
with a torque wrench. with a torque wrench.

Torque Torque
Wheels/Drive axle 6-hole Wheel rim Wheels/Drive axle 6-hole Wheel rim
MA = 330 Nm MA = 330 Nm

Wheels/Drive axle 10-hole Wheel rim Wheels/Drive axle 10-hole Wheel rim
1 1
MA = 220 Nm MA = 220 Nm

Wheels/Steering axle MA = 170 Nm Wheels/Steering axle MA = 170 Nm

6.3 Tyre pressure 6.3 Tyre pressure

Wheels/Drive axle 10 bar Wheels/Drive axle 10 bar

Wheels/Steering axle 7 - 8 bar Wheels/Steering axle 7 - 8 bar

0708.GB

0708.GB
F8 F8
 6.4 Check hydraulic oil level 6.4 Check hydraulic oil level

M The load lifting device must be completely lowered.

M The load lifting device must be completely lowered.

– Prepare truck for the servicing and – Prepare truck for the servicing and
maintenance operations 2 maintenance operations 2
(refer to section 6.1). (refer to section 6.1).
– Unscrew air filter with dipstick (2). – Unscrew air filter with dipstick (2).

– Visually check hydraulic oil level at – Visually check hydraulic oil level at
dipstick (3). dipstick (3).

Z If the tank is sufficiently filled the hydrau-

lic level must be readable at the upper
Z If the tank is sufficiently filled the hydrau-
lic level must be readable at the upper
marking (4). marking (4).

3 3

max. max.

min. 4 min. 4

f09unten f09unten
– If required, refill hydraulic oil up to the required level (10 mm at dipstick (3) corre- – If required, refill hydraulic oil up to the required level (10 mm at dipstick (3) corre-
spond to approximately 1 l hydraulic oil). spond to approximately 1 l hydraulic oil).

M Do not overfill hydraulic tank above the upper marking, as this may result in malfunc-
tions and damages of the system.
M Do not overfill hydraulic tank above the upper marking, as this may result in malfunc-
tions and damages of the system.

Used consumption-type materials must be disposed of in accordance with the appli- Used consumption-type materials must be disposed of in accordance with the appli-
cable environmental protection regulations. cable environmental protection regulations.

F Trucks with bio hydraulic oil have a warning notice on the

hydraulic reservoir: “Fill only with hydraulic oil”. Use only bio F Trucks with bio hydraulic oil have a warning notice on the
hydraulic reservoir: “Fill only with hydraulic oil”. Use only bio
hydraulic oil, see “Lubricants” section. hydraulic oil, see “Lubricants” section.
0708.GB

0708.GB

F9 F9
6.5 Check transmission oil level 6.5 Check transmission oil level

F Transmission oil must not be spilt into

the soil; therefore, place an oil pan under F Transmission oil must not be spilt into
the soil; therefore, place an oil pan under
the transmission. the transmission.

– Park and lock the truck (refer to chap- – Park and lock the truck (refer to chap-
ter E). ter E).
– Unscrew oil drain plug (5a). – Unscrew oil drain plug (5a).
– Check transmission oil level, if re- – Check transmission oil level, if re-
quired, refill transmission oil. quired, refill transmission oil.

Z The filling level must reach to the lower

edge of oil check hole (5a). 5 Z The filling level must reach to the lower
edge of oil check hole (5a). 5
5a 5a
M Do not refill transmission oil up to oil
check hole (5).
6
5 M Do not refill transmission oil up to oil
check hole (5).
6
5
5a 5a
F Used consumption-type materials must
be disposed of in accordance with the
6
F Used consumption-type materials must
be disposed of in accordance with the
6

applicable environmental protection regulations. applicable environmental protection regulations.

6.6 Draining oil 6.6 Draining oil

– Drain the oil when the oil is at operating temperature. – Drain the oil when the oil is at operating temperature.
– Place an oil pan under the unit. – Place an oil pan under the unit.
– Unscrew oil drain plug (6) and drain transmission oil. – Unscrew oil drain plug (6) and drain transmission oil.

6.7 Refilling oil 6.7 Refilling oil

– Renew sealing washer and screw in oil drain plug. – Renew sealing washer and screw in oil drain plug.
– Unscrew oil check screw. – Unscrew oil check screw.
– Refill new transmission oil with oil filling plug (5) removed up to the lower edge of – Refill new transmission oil with oil filling plug (5) removed up to the lower edge of
oil check hole (5a). oil check hole (5a).

6.8 Changing the hydraulic filter 6.8 Changing the hydraulic filter

The hydraulic filter is located to the left of 7 The hydraulic filter is located to the left of 7
the tilting cylinder and can be accessed the tilting cylinder and can be accessed
after removing the bottom plate. after removing the bottom plate.

– Unscrew hydraulic filter cap (7). – Unscrew hydraulic filter cap (7).
– Replace the filter cartridge, if the – Replace the filter cartridge, if the
O-ring is damaged, the O-ring must O-ring is damaged, the O-ring must
also be replaced. Lightly oil the O-ring also be replaced. Lightly oil the O-ring
before installation. before installation.
– Screw in the cap again. – Screw in the cap again.
0708.GB

0708.GB
F 10 F 10
 6.9 Changing the vacuum filter
The vacuum filter (10) for the steering
system is located in the hydraulic tank.
Remove hydraulic tank cover and screw
off vacuum filter.
6.10 Check oil level for brake system
M The brake fluid tank can be seen from the right side when the steering column is tilted
back.
To refill or change the mineral oil the cover (8) must be removed.
M Do not use conventional brake fluid, refill only with prescribed mineral oil!
– Park and lock the truck (refer to chap-
ter E).
– Remove cover (8) after loosening the
screws.
– Visually check the oil level at the ex-
pansion tank (9) and refill transmis-
sion oil, if required (refer to section
5.1).
Z The oil level must be visible between
markings “Min” and “Max”.
M Used consumption-type materials must
be disposed of in accordance with the
applicable environmental protection reg-
ulations.
0708.GB
6.9 Changing the vacuum filter
10 The vacuum filter (10) for the steering 10
system is located in the hydraulic tank.
Remove hydraulic tank cover and screw
off vacuum filter.
6.10 Check oil level for brake system
M The brake fluid tank can be seen from the right side when the steering column is tilted
back.
To refill or change the mineral oil the cover (8) must be removed.
M Do not use conventional brake fluid, refill only with prescribed mineral oil!
– Park and lock the truck (refer to chap-
9 ter E). 9
8 – Remove cover (8) after loosening the 8
screws.
– Visually check the oil level at the ex-
pansion tank (9) and refill transmis-
sion oil, if required (refer to section
5.1).
Z The oil level must be visible between
markings “Min” and “Max”.
M Used consumption-type materials must
be disposed of in accordance with the
applicable environmental protection reg-
ulations.
0708.GB
F 11 F 11
6.11 Restrain safety belt service 6.11 Restrain safety belt service

The driver must check condition and correct operation of the safety restraint belt on The driver must check condition and correct operation of the safety restraint belt on
daily basis before using the industrial truck. Early detection of malfunctions is only daily basis before using the industrial truck. Early detection of malfunctions is only
possible through regular checks. possible through regular checks.

– Pull out belt completely and check for unravelling. – Pull out belt completely and check for unravelling.
– Check the function of the belt buckle for correct retraction of the belt into the retrac- – Check the function of the belt buckle for correct retraction of the belt into the retrac-
tor tor
– Check cover for damage – Check cover for damage

Testing the automatic blocking retractor: Testing the automatic blocking retractor:
– Park the industrial truck on a horizontal surface – Park the industrial truck on a horizontal surface
– Pull out the belt with a jerk – Pull out the belt with a jerk

M The automatic blocking system must lock the belt in the retractor.
M The automatic blocking system must lock the belt in the retractor.

– Open motor hood approximately 30 degrees – Open motor hood approximately 30 degrees

M The automatic blocking system must lock the belt in the retractor
M The automatic blocking system must lock the belt in the retractor

F Do not operate the industrial truck when the safety restraint belt is defective; have the
belt exchanged immediately! F Do not operate the industrial truck when the safety restraint belt is defective; have the
belt exchanged immediately!

0708.GB

0708.GB
F 12 F 12
 6.12 Checking the electric fuses 6.12 Checking the electric fuses

– Prepare the truck for the servicing and maintenance operations
(refer to section 6.1).
– Open the battery cover or unscrew the electronics cover.
– Unscrew the cap.
– Check the fuses according to the table for correct amperage and condition.
– Prepare the truck for the servicing and maintenance operations
(refer to section 6.1).
– Open the battery cover or unscrew the electronics cover.
– Unscrew the cap.
– Check the fuses according to the table for correct amperage and condition.

F To avoid damages at the electrical system, only fuses with the appropriate ratings
must be used.
F To avoid damages at the electrical system, only fuses with the appropriate ratings
must be used.
1 2 3 456 7 1 2 3 456 7

8 8
9 9

10 10
11 11

12 12

Item Designation Electric circuit Rating / type Item Designation Electric circuit Rating / type
1 Option 1 Option
2 F3.1 Control circuit fuse, DC/DC converter 24 V 10 A 2 F3.1 Control circuit fuse, DC/DC converter 24 V 10 A
3 6F5 Control circuit fuse 12 V 3 A 3 6F5 Control circuit fuse 12 V 3 A
4 F1.2 Control circuit fuse 80 V 10 A 4 F1.2 Control circuit fuse 80 V 10 A
5 F2.1 Control circuit fuse 80 V 10 A 5 F2.1 Control circuit fuse 80 V 10 A
6 1F9 Control circuit fuse, electronic system 80 V 3 A 6 1F9 Control circuit fuse, electronic system 80 V 3 A
7 3F1 Steering booster motor 30 A 7 3F1 Steering booster motor 30 A
8 2F1 Control circuit fuse, hydraulic system 250 A 8 2F1 Control circuit fuse, hydraulic system 250 A
9 1F Control-circuit fuse, travelling 250 A/355 A 9 1F Control-circuit fuse, travelling 250 A/355 A
10 F1 Overall control circuit fuse 30 A 10 F1 Overall control circuit fuse 30 A
11 5F2 Control circuit fuse, DC/DC converter (op- 24 V 10 A 11 5F2 Control circuit fuse, DC/DC converter (op- 24 V 10 A
tion) tion)
12 5F2 Control circuit fuse, DC/DC converter (op- 24 V 15 A 12 5F2 Control circuit fuse, DC/DC converter (op- 24 V 15 A
0708.GB

0708.GB

tion) tion)

F 13 F 13
 electric fuses electric fuses

1 2 3 4 5 6 7 1 2 3 4 5 6 7

8 8

9 9
10 10

13 13

11 11

12 12

Item Designation Electric circuit Rating / type Item Designation Electric circuit Rating / type
1 Option 1 Option
2 F3.1 Control circuit fuse, DC/DC converter 24 V 10 A 2 F3.1 Control circuit fuse, DC/DC converter 24 V 10 A
3 F4 Control circuit fuse 32 V 5 A 3 F4 Control circuit fuse 32 V 5 A
4 F1.2 Control circuit fuse 80 V 10 A 4 F1.2 Control circuit fuse 80 V 10 A
5 F2.1 Control circuit fuse 80 V 10 A 5 F2.1 Control circuit fuse 80 V 10 A
6 1F9 Control circuit fuse, electronic system 80 V 3 A 6 1F9 Control circuit fuse, electronic system 80 V 3 A
7 F1 Overall control circuit fuse 30 A 7 F1 Overall control circuit fuse 30 A
8 2F10 Control circuit fuse, hydraulic system 250 A / 355 A 8 2F10 Control circuit fuse, hydraulic system 250 A / 355 A
9 1F Control-circuit fuse, travelling 250 A / 355 A 9 1F Control-circuit fuse, travelling 250 A / 355 A
10 F8 Main fuse 425 A 10 F8 Main fuse 425 A
11 5F2 Control circuit fuse, DC/DC converter (op- 24 V 10 A 11 5F2 Control circuit fuse, DC/DC converter (op- 24 V 10 A
tion) tion)
12 5F2 Control circuit fuse, DC/DC converter (op- 24 V 15 A 12 5F2 Control circuit fuse, DC/DC converter (op- 24 V 15 A
tion) tion)
13 3F1 Steering booster motor 30 A 13 3F1 Steering booster motor 30 A
0708.GB

0708.GB
F 14 F 14
 6.13 Recommissioning after cleaning or maintenance operations
Recommissioning of the truck following the performance of cleaning or maintenance
work is permitted only after the following operations have been performed:
– Check the horn for proper functioning.
– Check the master switch for correct functioning.
– Check the brake for correct functioning.
– Lubricate truck according to lubrication schedule.
7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be
parked in a frost-free and dry location and all measures to be taken before, during and
following decommissioning must be performed as detailed below.
M During decommissioning, the fork lift truck must be jacked up, ensuring that the
wheels are clear of the ground. Only this measure will ensure that wheels and wheel
bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional meas-
ures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck.
– Check the brakes for correct function.
– Check the hydraulic oil level and top up if required (refer to chapter F).
– Apply a thin film of oil or grease to all parts not protected by a paint coating.
– Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
– Recharge the battery (refer to chapter D).
– Disconnect and clean the battery. Apply pole grease to the battery poles.
Z In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
M Battery-operated fork lift trucks:
Regular recharging of the battery is very important; otherwise, exhaustive depletion
of the battery caused by self-discharging would occur. Owing to sulfatisation, this will
result in the destruction of the battery.
0708.GB
0708.GB
F 15
6.13 Recommissioning after cleaning or maintenance operations
Recommissioning of the truck following the performance of cleaning or maintenance
work is permitted only after the following operations have been performed:
– Check the horn for proper functioning.
– Check the master switch for correct functioning.
– Check the brake for correct functioning.
– Lubricate truck according to lubrication schedule.
7 Decommissioning the fork lift truck
If the fork lift truck is to be decommissioned for more than two months, it must be
parked in a frost-free and dry location and all measures to be taken before, during and
following decommissioning must be performed as detailed below.
M During decommissioning, the fork lift truck must be jacked up, ensuring that the
wheels are clear of the ground. Only this measure will ensure that wheels and wheel
bearings do not suffer damage.
If the fork lift truck is to be decommissioned for more than 6 months, additional meas-
ures must be discussed with the Service Department of the manufacturer.
7.1 Operations to be performed prior to decommissioning
– Thoroughly clean the fork lift truck.
– Check the brakes for correct function.
– Check the hydraulic oil level and top up if required (refer to chapter F).
– Apply a thin film of oil or grease to all parts not protected by a paint coating.
– Grease the fork lift truck as detailed in the lubrication chart (refer to chapter F).
– Recharge the battery (refer to chapter D).
– Disconnect and clean the battery. Apply pole grease to the battery poles.
Z In addition to this, all instructions given by the battery supplier must be observed.
– Spray all exposed electrical contacts with a suitable contact spray.
7.2 Measures to be taken during decommissioning
Every 2 months:
– Recharge the battery (refer to chapter D).
M Battery-operated fork lift trucks:
Regular recharging of the battery is very important; otherwise, exhaustive depletion
of the battery caused by self-discharging would occur. Owing to sulfatisation, this will
result in the destruction of the battery.
F 15
7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck.
– Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the
battery.
– Recharge the battery (refer to chapter D).
– Check if the gear oil contains condensed water and change if required.
– Check if the hydraulic oil contains condensed water and change if required.
– Start up the fork lift truck (refer to chapter E).
Z Battery-operated fork lift trucks:
If switching troubles are experienced in the electric system, spray the exposed con-
tacts with contact spray and remove any oxide layer on the contacts of the operating
controls by repeated operation.
F Perform several brake tests immediately after recommissioning the truck.
8 Safety tests to be performed at intervals and after unusual events
Z Perform a safety check in accordance with national regulations. Jungheinrich recom-
mends the truck be checked to FEM guideline 4.004. Jungheinrich has a safety de-
partment with trained personnel, able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess
the condition of the truck from purely a safety viewpoint, without regard to operational
or economic circumstances. The inspector shall be sufficiently instructed and expe-
rienced to be able to assess the condition of the truck and the effectiveness of the
safety mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by pos-
sible improper use. A test report shall be provided. The test results must be kept for
at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z Final, correct de-commissioning or disposal of the truck must be performed in
accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
0708.GB
F 16
7.3 Recommissioning the truck
– Thoroughly clean the fork lift truck.
– Lubricate the fork lift truck according to the lubrication chart (refer to chapter F).
– Clean the battery. Grease the pole screws using pole grease and reconnect the
battery.
– Recharge the battery (refer to chapter D).
– Check if the gear oil contains condensed water and change if required.
– Check if the hydraulic oil contains condensed water and change if required.
– Start up the fork lift truck (refer to chapter E).
Z Battery-operated fork lift trucks:
If switching troubles are experienced in the electric system, spray the exposed con-
tacts with contact spray and remove any oxide layer on the contacts of the operating
controls by repeated operation.
F Perform several brake tests immediately after recommissioning the truck.
8 Safety tests to be performed at intervals and after unusual events
Z Perform a safety check in accordance with national regulations. Jungheinrich recom-
mends the truck be checked to FEM guideline 4.004. Jungheinrich has a safety de-
partment with trained personnel, able to carry out inspections.
The truck must be inspected at least annually or after any unusual event by a qualified
inspector (be sure to comply with national regulations). The inspector shall assess
the condition of the truck from purely a safety viewpoint, without regard to operational
or economic circumstances. The inspector shall be sufficiently instructed and expe-
rienced to be able to assess the condition of the truck and the effectiveness of the
safety mechanisms based on the technical regulations and principles governing the
inspection of forklift trucks.
A thorough test of the truck must be undertaken with regard to its technical condition
from a safety aspect. The truck must also be examined for damage caused by pos-
sible improper use. A test report shall be provided. The test results must be kept for
at least the next 2 inspections.
The owner is responsible for ensuring that faults are immediately rectified.
Z A test plate is attached to the truck as proof that it has passed the safety inspection.
This plate indicates the due date for the next inspection.
9 Final de-commissioning, disposal
Z Final, correct de-commissioning or disposal of the truck must be performed in
accordance with the regulations of the country of use. In particular, regulations
governing the disposal of batteries, fuels and electronic and electrical systems must
be observed.
0708.GB
F 16
 Instructions for use Instructions for use
Jungheinrich traction battery Jungheinrich traction battery
Table of contents Table of contents
1 Jungheinrich traction battery 1 Jungheinrich traction battery
with positive tubular plates type EPzS and EPzB ..........................................2-6 with positive tubular plates type EPzS and EPzB ..........................................2-6

Type plate Jungheinrich traction battery............................................7 Type plate Jungheinrich traction battery............................................7

Instruction for use Instruction for use

Aquamatic/BFS III water refilling system ......................................................8-12 Aquamatic/BFS III water refilling system ......................................................8-12

2 Jungheinrich traction battery 2 Jungheinrich traction battery

Maintenance free traction batteries with positive tubular plates type EPzV Maintenance free traction batteries with positive tubular plates type EPzV
and EPzV-BS ............................................................................................13-17 and EPzV-BS ............................................................................................13-17

Type plate Jungheinrich traction battery............................................17 Type plate Jungheinrich traction battery............................................17
0506.GB

0506.GB

1 1
1 Jungheinrich traction battery 1 Jungheinrich traction battery

with positive tubular plates type EPzS and EPzB with positive tubular plates type EPzS and EPzB

Rating Data Rating Data

1. Nominal capacity C5: See type plate 1. Nominal capacity C5: See type plate
2. Nominal voltage: 2,0 V x No of cells 2. Nominal voltage: 2,0 V x No of cells
3. Discharge current:: C5/5h 3. Discharge current:: C5/5h
4. Nominal S.G. of electrolyte* 4. Nominal S.G. of electrolyte*
Type EPzS: 1,29 kg/l Type EPzS: 1,29 kg/l
Type EPzB: 1,29 kg/l Type EPzB: 1,29 kg/l
5. Rated temperature: 30° C 5. Rated temperature: 30° C
6. Nominal electrolyte level: up to electrolyte level mark „max.“ 6. Nominal electrolyte level: up to electrolyte level mark „max.“

* Will be reached within the first 10 cycles. * Will be reached within the first 10 cycles.

•Pay attention to the operation instruction and fix them close to the battery! •Pay attention to the operation instruction and fix them close to the battery!
•Work on batteries to be carried out by skilled personnel only! •Work on batteries to be carried out by skilled personnel only!

•Use protective glasses and clothes when working on batteries! •Use protective glasses and clothes when working on batteries!
•Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN •Pay attention to the accident prevention rules as well as DIN EN 50272-3, DIN
50110-1! 50110-1!

•No smoking! •No smoking!

•Do not expose batteries to naked flames, glowing embers or sparks, as it may •Do not expose batteries to naked flames, glowing embers or sparks, as it may
cause the battery to explode! cause the battery to explode!

•Acid splashes in the eyes or on the skin must be washed with water. In case of •Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately! accident consult a doctor immediately!
•Clothing contaminated by acid should be washed in water. •Clothing contaminated by acid should be washed in water.

•Risk of explosion and fire, avoid short circuits! •Risk of explosion and fire, avoid short circuits!

•Electrolyte is highly corrosive! •Electrolyte is highly corrosive!

•Batteries and cells are heavy! •Batteries and cells are heavy!
•Ensure secure installation! Use only suitable handling equipment e.g. lifting gear •Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616. in accordance with VDI 3616.

•Dangerous electrical voltage! •Dangerous electrical voltage!

•Caution! Metal parts of the battery are always live. Do not place tools or other me- •Caution! Metal parts of the battery are always live. Do not place tools or other me-
tal objects on the battery! tal objects on the battery!
0506.GB

0506.GB
2 2
 Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
steel
M 10 23 ± 1 Nm
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-
scharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-
ded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
0506.GB
0506.GB
provision must be made for venting of the charging gases.
3 3
Ignoring the operation instructions, repair with non-original parts or using additives for
the electrolyte will render the warranty void.
For batteries in classes I and II the instructions for maintaining the appropriate
protection class during operation must be complied with (see relevant certificate).
1. Commissioning filled and charged batteries. For commissioning of unfilled
batteries see separate instructions!
The battery should be inspected to ensure it is in perfect physical condition.
The charger cables must be connected to ensure a good contact, taking care that the
polarity is correct. Otherwise battery, vehicle or charger could be damaged.
The specified torque loading for the polscrews of the charger cables and connectors
are:
steel
M 10 23 ± 1 Nm
The level of the electrolyte must be checked. If it is below the antisurge baffle or the
top of the separator it must first be topped up to this height with purified water.
The battery is then charged as in item 2.2.
The electrolyte should be topped up to the specified level with purified water.
2. Operation
DIN EN 50272-3 «Traction batteries for industrial trucks» is the standard which ap-
plies to the operation traction batteries in industrial trucks.
2.1 Discharging
Be sure that all breather holes are not sealed or covered.
Electrical connections (e.g. plugs) must only be made or broken in the open circuit
condition.
To achieve the optimum life for the battery, operating discharges of more than 80%
of the rated capacity should be avoided (deep discharge).
This corresponds to an electrolyte specific gravity of 1.13 kg/l at the end of the di-
scharge. Discharged batteries must be recharged immediately and must not be left
discharged. This also applies to partially discharged batteries.
2.2 Charging
Only direct current must be used for charging. All charging procedures in accordance
with DIN 41773 and DIN 41774 are permitted. Only connect the battery assigned to
a charger, suitable for the size of battery, in order to avoid overloading of the electric
cables and contacts, unacceptable gassing and the escape of electrolyte from the
cells.
In the gassing stage the current limits given in DIN EN 50272-3 must not be excee-
ded. If the charger was not purchased together with the battery it is best to have its
suitability checked by the manufacturers service department. When charging, proper
provision must be made for venting of the charging gases.
 Battery container lids and the covers of battery compartments must be opened or re-
moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batte-
ries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-
tentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flamma-
bility due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out follo-
wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-
pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-
peratures shorten the life of the battery, lower temperatures reduce the capacity avai-
lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-
perature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher tempe-
ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
0506.GB
4 4
Battery container lids and the covers of battery compartments must be opened or re-
moved. The vent plugs should stay on the cells and remain closed.
With the charger switched off connect up the battery, ensuring that the polarity is cor-
rect. (positive to positive, negative to negative). Now switch on the charger. When
charging the temperature of the electrolyte rises by about 10°C, so charging should
only begin if the electrolyte temperature is below 45°C. The electrolyte temperature
of batteries should be at least +10°C before charging otherwise a full charge will not
be achieved.
A charge is finished when the specific gravity of the electrolyte and the battery voltage
have remained constant for two hours. Special instructions for the operation of batte-
ries in hazardous areas. This concerns batteries which are used in accordance with
EN 50014, DIN VDE 0170/0171 Ex (in areas with a firedamp hazard) or Ex II (in po-
tentially explosive areas). During charging and subsequent gassing the container lids
must be removed or opened so that the explosive mixture of gases loses its flamma-
bility due to adequate ventilation. The containers for batteries with plate protection
packs must not be closed until at least half an hour after charging has past.
2.3 Equalising charge
Equalising charges are used to safeguard the life of the battery and to maintain its
capacity. They are necessary after deep discharges, repeated incomplete recharges
and charges to an IU characteristic curve. Equalising charges are carried out follo-
wing normal charging. The charging current must not exceed 5 A/100 Ah of rated ca-
pacity (end of charge - see point 2.2).
Watch the temperature!
2.4 Temperature
An electrolyte temperature of 30°C is specified as the rated temperature. Higher tem-
peratures shorten the life of the battery, lower temperatures reduce the capacity avai-
lable. 55°C is the upper temperature limit and is not acceptable as an operating tem-
perature.
2.5 Electrolyte
The rated specific gravity (S. G.) of the electrolyte is related to a temperature of 30°C
and the nominal electrolyte level in the cell in fully charged condition. Higher tempe-
ratures reduce the specified gravity of the electrolyte, lower temperatures increase it.
The temperature correction factor is -0.0007 kg/l per °C, e.g. an electrolyte specific
gravity of 1.28 kg/l at 45°C corresponds to an S.G. of 1.29 kg/l at 30°C.
The electrolyte must conform to the purity regulations in DIN 43530 part 2.
0506.GB
 3. Maintenance
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-
tery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and re-
corded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
0506.GB
0506.GB
5 5
3. Maintenance
3.1 Daily
Charge the battery after every discharge. Towards the end of charge the electrolyte
level should be checked and if necessary topped up to the specified level with purified
water. The electrolyte level must not fall below the anti-surge baffle or the top of the
separator or the electrolyte „min“ level mark.
3.2 Weekly
Visual inspection after recharging for signs of dirt and mechanical damage. If the bat-
tery is charged regularly with a IU characteristic curve an equalising charge must be
carried out (see point 2.3).
3.3 Monthly
At the end of the charge the voltages of all cells or bloc batteries should be measured
with the charger switched on, and recorded. After charging has ended the specific
gravity and the temperature of the electrolyte in all cells should be measured and re-
corded.
If significant changes from earlier measurements or differences between the cells or
bloc batteries are found further testing and maintenance by the service department
should be requested.
3.4 Annually
In accordance with DIN VDE 0117 at least once per year, the insulation resistance of
the truck and the battery must be checked by an electrical specialist.
The tests on the insulation resistance of the battery must be conducted in accordance
with DIN EN 60254-1.
The insulation resistance of the battery thus determined must not be below a value of
50 Ω per Volt of nominal voltage, in compliance with DIN EN 50272-3.
For batteries up to 20 V nominal voltage the minimum value is 1000 Ω.
4. Care of the battery
The battery should always be kept clean and dry to prevent tracking currents. Clea-
ning must be done in accordance with the ZVEI code of practice «The Cleaning of
Vehicle Traction batteries».
Any liquid in the battery tray must be extracted and disposed of in the prescribed man-
ner. Damage to the insulation of the tray should be repaired after cleaning, to ensure
that the insulation value complies DIN EN 50272-3 and to prevent tray corrosion. If it
is necessary to remove cells it is best to call in our service department for this.
 5. Storage 5. Storage

If batteries are taken out of service for a lengthy period they should be stored in the If batteries are taken out of service for a lengthy period they should be stored in the
fully charged condition in a dry, frost-free room. To ensure the battery is always ready fully charged condition in a dry, frost-free room. To ensure the battery is always ready
for use a choice of charging methods can be made: for use a choice of charging methods can be made:
1. a monthly equalising charge as in point 2.3 1. a monthly equalising charge as in point 2.3

2. float charging at a charging voltage of 2.23 V x the number of cells. The storage 2. float charging at a charging voltage of 2.23 V x the number of cells. The storage
time should be taken into account when considering the life of the battery. time should be taken into account when considering the life of the battery.

6. Malfunctions 6. Malfunctions

If malfunctions are found on the battery or the charger our service department should If malfunctions are found on the battery or the charger our service department should
be called in without delay. The measurements taken in point 3.3 will facilitate fault fin- be called in without delay. The measurements taken in point 3.3 will facilitate fault fin-
ding and their elimination. ding and their elimination.

A service contract with us will make it easier to detect and correct faults in good time. A service contract with us will make it easier to detect and correct faults in good time.

Back to the manufacturer! Back to the manufacturer!

Batteries with this sign must be recycled. Batteries with this sign must be recycled.

Batteries which are not returned for the recycling process must be Batteries which are not returned for the recycling process must be
disposed of as hazardous waste! disposed of as hazardous waste!

We reserve the right make technical modification. We reserve the right make technical modification.

0506.GB

0506.GB
6 6
 7. Type plate, Jungheinrich traction battery 7. Type plate, Jungheinrich traction battery

1 2 1 2

2/3 Typ
Type
Baujahr
Year of manufacture 6 2/3 Typ
Type
Baujahr
Year of manufacture 6
4 Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
4
5 4 Serien-Nr.
Serial-Nr.
3
Lieferanten Nr.
Supplier No.
4
5
10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

5
11 10 Nennspannung
Nominal Voltage
5
Kapazität
Capacity
6

5
11
12
7
Zellenzahl
Number of Cells
Batteriegewicht min/max
Battery mass min/max
8
13 12
7
Zellenzahl
Number of Cells
Batteriegewicht min/max
Battery mass min/max
8
13

9 9

7 Jungheinrich AG, D-22047 Hamburg, Germany Jungheinrich AG, D-22047 Hamburg, Germany
Hersteller
Manufacturer 7 Hersteller
Manufacturer

Pb Pb 1 Pb Pb 1
8 8
9 9
14 14

Item Designation Item Designation Item Designation Item Designation

1 Logo 8 Recycling symbol 1 Logo 8 Recycling symbol
2 Battery designation 9 Dustbin/material 2 Battery designation 9 Dustbin/material
3 Battery type 10 Nominal battery voltage 3 Battery type 10 Nominal battery voltage
4 Battery number 11 Nominal battery capacity 4 Battery number 11 Nominal battery capacity
5 Battery tray number 12 Number of battery cells 5 Battery tray number 12 Number of battery cells
6 Delivery date 13 Battery weight 6 Delivery date 13 Battery weight
7 Battery manufacturer's logo 14 Safety instructions and warnings 7 Battery manufacturer's logo 14 Safety instructions and warnings

* CE mark is only for batteries with a nominal voltage greater than 75 volt. * CE mark is only for batteries with a nominal voltage greater than 75 volt.
0506.GB

0506.GB

7 7
 Aquamatic/BFS III water refilling system for Jungheinrich traction battery with Aquamatic/BFS III water refilling system for Jungheinrich traction battery with
EPzS and EPzB cells with tubular positive plates EPzS and EPzB cells with tubular positive plates
Aquamatic plug arrangement for the Operating Instructions Aquamatic plug arrangement for the Operating Instructions

Cell series* Aquamatic plug type (length) Cell series* Aquamatic plug type (length)
EPzS EPzB Frötek (yellow) BFS (black) EPzS EPzB Frötek (yellow) BFS (black)
2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm 2/120 – 10/ 600 2/ 42 – 12/ 252 50,5 mm 51,0 mm
2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm 2/160 – 10/ 800 2/ 64 – 12/ 384 50,5 mm 51,0 mm
– 2/ 84 – 12/ 504 50,5 mm 51,0 mm – 2/ 84 – 12/ 504 50,5 mm 51,0 mm
– 2/110 – 12/ 660 50,5 mm 51,0 mm – 2/110 – 12/ 660 50,5 mm 51,0 mm
– 2/130 – 12/ 780 50,5 mm 51,0 mm – 2/130 – 12/ 780 50,5 mm 51,0 mm
– 2/150 – 12/ 900 50,5 mm 51,0 mm – 2/150 – 12/ 900 50,5 mm 51,0 mm
– 2/172 – 12/1032 50,5 mm 51,0 mm – 2/172 – 12/1032 50,5 mm 51,0 mm
– 2/200 – 12/1200 56,0 mm 56,0 mm – 2/200 – 12/1200 56,0 mm 56,0 mm
– 2/216 – 12/1296 56,0 mm 56,0 mm – 2/216 – 12/1296 56,0 mm 56,0 mm
2/180 – 10/900 – 61,0 mm 61,0 mm 2/180 – 10/900 – 61,0 mm 61,0 mm
2/210 – 10/1050 – 61,0 mm 61,0 mm 2/210 – 10/1050 – 61,0 mm 61,0 mm
2/230 – 10/1150 – 61,0 mm 61,0 mm 2/230 – 10/1150 – 61,0 mm 61,0 mm
2/250 – 10/1250 – 61,0 mm 61,0 mm 2/250 – 10/1250 – 61,0 mm 61,0 mm
2/280 – 10/1400 – 72,0 mm 66,0 mm 2/280 – 10/1400 – 72,0 mm 66,0 mm
2/310 – 10/1550 – 72,0 mm 66,0 mm 2/310 – 10/1550 – 72,0 mm 66,0 mm

* The cell series comprise cells with two to ten (twelve) positive plates, e.g. column * The cell series comprise cells with two to ten (twelve) positive plates, e.g. column
EPzS. 2/120 - 10/600. EPzS. 2/120 - 10/600.

These are cells with the positive plate 60Ah. The type designation of a cell is e.g. These are cells with the positive plate 60Ah. The type designation of a cell is e.g.
2 EPzS 120. 2 EPzS 120.
length

length
stroke

stroke
length

length
stroke

stroke
Aquamatic plug with Aquamatic plug BFS III with Aquamatic plug with Aquamatic plug BFS III with
diagnostics hole diagnostics hole diagnostics hole diagnostics hole

Non-adherence to the operating instructions, repairs carried out with non-original Non-adherence to the operating instructions, repairs carried out with non-original
spare parts, unauthorised interference, and the use of additives for the electrolytes spare parts, unauthorised interference, and the use of additives for the electrolytes
(alleged improvement agents) will invalidate any claim for warranty. (alleged improvement agents) will invalidate any claim for warranty.

When using batteries which comply with I and II, it is important to follow the in- When using batteries which comply with I and II, it is important to follow the in-
structions on maintaining the respective protection class during operation (see asso- structions on maintaining the respective protection class during operation (see asso-
ciated certification). ciated certification).
0506.GB

0506.GB
8 8
 Diagrammatic view Diagrammatic view

Equipment for the Equipment for the

water refilling system water refilling system

1. Water tank 1. Water tank

2. Level switch 2. Level switch
3. Discharge point with ball 3. Discharge point with ball
valve valve
4. Discharge point with sole- 4. Discharge point with sole-

at least 3 m

at least 3 m
noid valve noid valve
5. Charger 5. Charger
6. Sealing coupler 6. Sealing coupler
7. Closing nipple 7. Closing nipple
8. Ion exchange cartridge with 8. Ion exchange cartridge with
conductance meter and conductance meter and
solenoid valve solenoid valve
9. Connection for untreated 9. Connection for untreated
water water
10. Charging lead 10. Charging lead

1. Design 1. Design

The Aquamatic/BFS battery water refilling systems are used for automatically adjus-
ting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte den-
sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-
matic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application
The Aquamatic/BFS battery water refilling systems are used for automatically adjus-
ting the nominal electrolyte level. Venting holes are provided for letting off the gases
which arise during charging. In addition to the optical level indicator, the plug systems
also have a diagnostics hole for measuring the temperature and the electrolyte den-
sity. All battery cells of the design series EPzS; EPzB can be equipped with the Aqua-
matic/BFS filling systems. The water can be refilled by means of a central sealing
coupler through the hose connections in the individual Aquamatic/BFS plugs.
2. Application

The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose con-
nections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.
The Aquamatic/BFS battery water refilling system is used in traction batteries for
forklift trucks. The water refilling system is provided with a central water connection
for the water supply. Soft PVC hose is used for this connection and for the hose con-
nections for the individual plugs. The hose ends are put onto the hose connection
sleeves located on the T or < pieces.

3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS sys-
tem, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.
0506.GB
3. Function
The quantity of water required in the refilling process is controlled by the valve located
in the plug in combination with the float and the float rods. In the Aquamatic System
the existing water pressure at the valve turns off the water supply and ensures that
the valve closes securely. When the maximum filling level is reached in the BFS sys-
tem, the float and the float rods through a lever system close the valve with five times
the buoyant force and consequently interrupt the water supply reliably.

0506.GB

9 9
 4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of fil-
ling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-
ter feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
0506.GB
10
4. Filling (manual/automatic)
The batteries should be filled with battery water as soon as possible before the battery
charging comes to an end; this ensures that the refilled water quantity is mixed with
the electrolyte. In normal operation it is usually sufficient to fill once a week.
5. Connection pressure
The water refilling unit is to be operated in such a way that the water pressure in the
water pipe is between 0.3 bars and 1.8 bars. The Aquamatic System has an operating
pressure range of between 0.2 bars and 0.6 bars. The BFS system has an operating
pressure range of 0.3 bars to 1.8 bars. Deviations from the pressure ranges impair
the system's functional reliability. This wide pressure range permits three types of fil-
ling.
5.1 Falling water
The height of the tank is chosen to suit whichever water refilling system is used. For
the Aquamatic System the installation height is 2 m to 6 m and for the BFS system
the installation height is 3 m to 18 m over the battery surface.
5.2 Pressurised water
The pressure-reducing valve in the Aquamatic System is set from 0.2 bars to 0.6 bars
and from 0.3 bars to 1.8 bars in the BFS system.
5.3 Water Refill Trolley (serviceMobil)
The submergible pump located in the ServiceMobil's tank generates the necessary
filling pressure. No difference in height is permitted between the standing level of the
ServiceMobil and the standing level of the battery.
6. Filling duration
The length of time needed to fill the batteries depends on the conditions under which
the battery is used, the ambient temperatures and the type of filling and/or the filling
pressure. The filling time is approx. 0.5 to 4 minutes. Where filling is manual, the wa-
ter feed pipe must be separated from the battery after filling.
7. Water quality
Only refilling water which conforms in quality to DIN 43530 part 4 may be used to fill
the batteries. The refilling unit (tank, pipelines, valves etc.) may not contain any kind
of dirt which could impair the functional reliability of the Aquamatic/BFS plug. For
safety reasons it is recommendable to insert a filter element (optional) with a max.
passage opening of 100 to 300 µm into the battery's main supply pipe.
0506.GB
10
 8. Battery hose connections 8. Battery hose connections

Hose connections for the individual plugs are laid along the existing electric circuit. Hose connections for the individual plugs are laid along the existing electric circuit.
No changes may be made. No changes may be made.

9. Operating temperature 9. Operating temperature

The temperature limit for battery operation is set at 55° C. Exceeding this temperature The temperature limit for battery operation is set at 55° C. Exceeding this temperature
damages the batteries. The battery filling systems may be operated within a tempe- damages the batteries. The battery filling systems may be operated within a tempe-
rature range of > 0° C to a maximum of 55° C. rature range of > 0° C to a maximum of 55° C.

CAUTION: CAUTION:
Batteries with automatic water refilling systems may only be operated in rooms Batteries with automatic water refilling systems may only be operated in rooms
with temperatures > 0° C (as there is otherwise a danger that the systems may with temperatures > 0° C (as there is otherwise a danger that the systems may
freeze). freeze).
9.1 Diagnostics hole 9.1 Diagnostics hole

To be able to measure the acid density and temperature easily, the water refilling sys- To be able to measure the acid density and temperature easily, the water refilling sys-
tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a tems must have a diagnostics hole with a 6.5 mm-diameter (Aquamatic plugs) or a
7.5 mm-diameter (BFS plugs). 7.5 mm-diameter (BFS plugs).

9.2 Float 9.2 Float

Different floats are used depending on the cell design and type. Different floats are used depending on the cell design and type.

9.3 Cleaning 9.3 Cleaning

The plug systems may only be cleaned with water. No parts of the plugs may come The plug systems may only be cleaned with water. No parts of the plugs may come
in contact with soap or fabrics which contain solvents. in contact with soap or fabrics which contain solvents.

10. Accessories 10. Accessories

10.1 Flow indicator 10.1 Flow indicator

To monitor the filling process, a flow indicator can be inserted into the water feed pipe To monitor the filling process, a flow indicator can be inserted into the water feed pipe
on the battery side. During the filling process, the paddlewheel is turned by the flowing on the battery side. During the filling process, the paddlewheel is turned by the flowing
water. When the filling process ends, the wheel stops and this indicates the end of water. When the filling process ends, the wheel stops and this indicates the end of
the filling process. (ident no.: 50219542). the filling process. (ident no.: 50219542).

10.2 Plug lifter 10.2 Plug lifter

Only the appertaining special-purpose tool may be used to disassemble the plug sys- Only the appertaining special-purpose tool may be used to disassemble the plug sys-
tems (plug lifter). The greatest of care must be employed when prising out the plug to tems (plug lifter). The greatest of care must be employed when prising out the plug to
prevent any damage to the plug systems. prevent any damage to the plug systems.
0506.GB

0506.GB

11 11
 10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres-
sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-
ry's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-
tral supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
0506.GB
12
10.2.1 Clamping ring tool
The clamping ring tool is used to push on a clamping ring to increase the contact pres-
sure of the hose connection on the plugs' hose couplings and to loosen it again.
10.3 Filter element
For safety reasons a filter element (ident no.: 50307282) can be fitted into the batte-
ry's main supply pipe for supplying battery water. This filter element has a maximum
passage cross-section of 100 to 300 µm and is designed as a bag filter.
10.4 Sealing coupler
The water is supplied to the water refilling systems (Aquamatic/BFS) through a cen-
tral supply pipe. This is connected to the water supply system at the battery charging
station by means of a sealing coupler system. On the battery side a closing nipple
(ident no.: 50219538) is mounted and the customer must place a sealing coupler
construction on the water supply side (obtainable under ident. no.: 50219537).
11. Functional data
PS - self-sealing pressure: Aquamatic > 1.2 bars
BFS system none
D - rate of flow in the opened valve when the pressure is 0.1 bars: 350 ml/min
D1 - maximum permissible leakage rate in the closed valve when the pressure is at
0.1 bars: 2 ml/min
T - permissible temperature range: 0° C to a maximum of 65° C
Pa - operating pressure range: 0.2 to 0.6 bars in the Aquamatic system and
operating pressure range: 0.3 to 1.8 bars in the BFS system.
0506.GB
12