14e04k10 Jung-Efg 425-S50 - Instructions

INSTALLATION INSTRUCTIONS
JUNGHEINRICH
EFG 425, 430k, 430, S30,
535k, 540k, 540, S40,
545k, 545, 550, S50
.
JUNGHEINRICH
EFG 425 – S50
SAFETY INSTRUCTIONS
READ PROPERLY COMPLETE ASSEMBLY INSTRUCTIONS
BEFORE STARTING OF ASSEMBLY
Warning: Failure to heed all safety and operating instructions

and warnings regarding use of this product can result in
serious bodily injury.
Install all parts indicated in assembly instructions. Failure to

fully assemble product before use could result in personal
injury.
Assembly of product requires use of hand or power tools. If

you are not experienced in using these types of tools, have
product dealer do the install for you.
Some parts contain sharp edges, wear protective gloves if

2 necessary. Always keep your assembly area clean, uncluttered
and well lit.
Keep visitors and children a safe distance away from the

assembly area. Visitors should wear the same safety
equipment described under.
Never operate your UTV with the cab doors open. Failure to
properly latch the doors before moving the vehicle could
result in serious injury.
Dress for safety. DO NOT wear loose clothing, gloves, neckties

or jewelry if using power tools to assemble this product. Insert
all nut covers after you finish installation.
Never drive your UTV with the cab front window in open
position.
Failure of improperly latched/locked front window before

driving the vehicle could result in serious injury.
DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz
Za Olšávkou 391 Fax: +420 572 520 071 www.dfk.cz/podpora-vzv
Uherské Hradiště 686 01 E-mail: dfk@dfk.cz password: 78a6xu6mj8G
Czech Republic
JUNGHEINRICH
EFG 425 – S50
MAINTENANCE AND CLEANING

To clean polycarbonate surface use soapy water solution or
other subtle means.
Dirt and dust wash by gently water stream and swipe only
with wet or damp means in the direction from top to bottom.
The recommended frequency of cleaning of polycarbonate

part is about 1 time per month or according to the actual
degree of pollution.
Do not use detergents that could scratch the surface plates

(abrasives, harsh fabrics, etc.).
Do not use solvents or alkaline detergents or cleaners with

ammonia (ammonium hydroxide).
Do not remove the impurities from the surface of the razor 3

blades or other sharp items.
Do not clean cabin, when the polycarbonate plates are heated

by the sun.
Do not use the squeegee. It could be scratched surface plates.
Do not clean the water current strength greater than 50 bar

(WAP).
The manufacturer is not responsible for scratching the surface

in case of failure to comply with the above instructions.
All bolted connections of cab must be by user at regular

intervals checked and tightened.
It is necessary to check the air filter of the heater regularly,

depending on the dust environment in which the vehicle is
operated.
Czech Republic
JUNGHEINRICH
EFG 425 – S50
PREPARATION FOR INSTALLATION

Uninstall all additional systems from the forklift frame (work lights,
rear mirrors, drink holders etc.)
CAB PREVIEW

Czech Republic
JUNGHEINRICH
EFG 425 – S50
ELECTROINSTALLATION 1
Do not manipulate with electrical wiring connected to the battery!
You will need Jungheinrich mechanick to approval electroinstalation
functions (wipers, washers and heater) in control unit.
Open red marked right side door.
Disconect battery plug.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Unmount marked side cover.
Unmount the central stop button cover.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Remove original cover and mount included diffuser.
7
Mount power supply harness relays onto the heater holder (green
marked). Connect harness to the heater (red marked).

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Mount the heater under the central stop button using the original
holes on the vehicle frame.
Fix heater air hose onto the bottom diffuser by aluminium tape
8 (green marked).

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Cut a red marked hole into the central stop button cover. Insert
heater control panel and mark four green marked holes.
Put heater control panel away and drill four marked holes Ø 4mm.
Remove self adhesive tape cover.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Stick heater control panel onto the central stop button cover and fix
by screwing screws into the drilled holes at back side.
Connect power suply harness to the ventilator and heater switches.
VENTILATOR
10 SWITCH
HEATER
SWITCHES

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Connect positive pole cable of power suply harness to the screw

terminal. Fix air hoses to the heater with aluminium tape.
POSITIVE POLE 80V
Connect negative pole cable of power suply harness to the screw 11

terminal.
ORIGINAL FUSE BOX
NEGATIVE POLE
VIEW ONTO THE FUSE BOX

UNDER THE FLOOR

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Insert 10A fuses to the slots: 7F3, 7F4, 7F11.

View onto the original fuse box cover with fuse position description.
Mount central stop button cover back.
12

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Unmount rear red marked cover.
13

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Mount voltage convertor of the heater harness onto the original

bolts by nuts.
Route washer hose and heater relay connector to the heater unit and
connect heater relay connector with power supply harness.
14 TO THE POWER SUPPLY HARNESS
Mount relay and fuse of the heater harness onto the original bolts by
nut.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Connect heater, wiper and washer harness plugs to the original

sockets.
Harness plug Vehicle socket
Heater relay connector XB35 XS35
Convertor supply connector 80V XB171 XS171
Rear wiper harness XB156 XS156
Washer harness XB154 XS154
15
Route washer harness through the original hole (green arrow). Route
rear wiper harness and washer hose up, through the vehicle frame
(blue arrow).

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Rear wiper harness and washer hose.
16
Insert pins into the rear wiper motor conector.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Mount washer tank holder onto the vehicle frame. Insert washer tank
and connect washer motors connectors and washer hoses.
17

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Unmount dashboard cover and connect front wiper harness plug to

the original socket.
18

Czech Republic
JUNGHEINRICH
EFG 425 – S50
FRONT PANEL
Loosen the holders bolts and turn them down.
Place front panel onto the vehicle frame.
19

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Turn holders to the correct orientation and tighten the bolts.
20

Czech Republic
JUNGHEINRICH
EFG 425 – S50
RIGHT PANEL
Loosen the holders bolts and turn them down.
21
Place right panel onto the vehicle frame.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Turn holders to the correct orientation and tighten the bolts.
22

Czech Republic
JUNGHEINRICH
EFG 425 – S50
LEFT DOOR
Mount hinges onto the vehicle frame by screwing bolts into the
original holes.
23

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Place washers onto the hinges pins. Lubricate hinges pins. Place door
onto the hinges.
24

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Slightly loosen the hinges bolts. Center door into the best position.
Tighten hinges bolts hard.
25

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Mount two bolts with washers into the original holes.
26
Insert door stop holder between the bolts washers and vehicle frame.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Mount third bolt with washer into the original hole. Tighten all three
bolts.
Adjust the door stop pin and pin holder to the best locking position.
You can hear two metallic clicks during closing the door slowly, if you
have door stop adjusted correctly. 27

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Mount gas spring joint into the original hole.
28
Mount gas spring.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
REAR PANEL
Place rear panel onto the vehicle frame.
29
Fix rear panel onto the vehicle frame by screwing bolts into the
original holes.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
ROOF
Unmount roof panel holders.
Place roof panel onto the vehicle frame.

30

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Place holders back to the correct position and tighten the bolts.
31

Czech Republic
JUNGHEINRICH
EFG 425 – S50
ELECTROINSTALLATION 2
Mount front and rear wipers.
32
Connect rear wiper motor and insert connector under the wiper
cover. Connect washer hose to the washer nozzle on the wiper arm.

Czech Republic
JUNGHEINRICH
EFG 425 – S50
Connect front wiper motor. Connect washer hose to the washer

nozzle on the wiper arm.
33

Czech Republic
JUNGHEINRICH
EFG 425 – S50
34

Czech Republic
Declaration of Conformity
DFK Cab, s.r.o.

Za Olšávkou 391
686 01 Uherské Hradiště
Česká republika / Czech Republic

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INSTALLATION INSTRUCTIONS

Warning: Failure to heed all safety and operating instructions

Install all parts indicated in assembly instructions. Failure to

Assembly of product requires use of hand or power tools. If

Some parts contain sharp edges, wear protective gloves if

Keep visitors and children a safe distance away from the

Dress for safety. DO NOT wear loose clothing, gloves, neckties

Failure of improperly latched/locked front window before

MAINTENANCE AND CLEANING

The recommended frequency of cleaning of polycarbonate

Do not use detergents that could scratch the surface plates

Do not use solvents or alkaline detergents or cleaners with

Do not remove the impurities from the surface of the razor 3

Do not clean cabin, when the polycarbonate plates are heated

Do not use the squeegee. It could be scratched surface plates.

Do not clean the water current strength greater than 50 bar

The manufacturer is not responsible for scratching the surface

All bolted connections of cab must be by user at regular

It is necessary to check the air filter of the heater regularly,

PREPARATION FOR INSTALLATION

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Disconect battery plug.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Unmount marked side cover.

Unmount the central stop button cover.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Remove original cover and mount included diffuser.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Connect power suply harness to the ventilator and heater switches.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Connect positive pole cable of power suply harness to the screw

POSITIVE POLE 80V

Connect negative pole cable of power suply harness to the screw 11

ORIGINAL FUSE BOX

VIEW ONTO THE FUSE BOX

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Insert 10A fuses to the slots: 7F3, 7F4, 7F11.

Mount central stop button cover back.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Unmount rear red marked cover.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Mount voltage convertor of the heater harness onto the original

14 TO THE POWER SUPPLY HARNESS

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Connect heater, wiper and washer harness plugs to the original

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Rear wiper harness and washer hose.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Unmount dashboard cover and connect front wiper harness plug to

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Place front panel onto the vehicle frame.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Turn holders to the correct orientation and tighten the bolts.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

Turn holders to the correct orientation and tighten the bolts.

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz

DFK Cab, s.r.o. Tel: +420 572 520 061,3 www.dfk.cz