Forklifts
Solutions for forklifts, industrialvehicles and automatedtransport systems

plastics for longer life®

www.igus.eu/forklift

Your technical innovator and cost reducer,

Christian Strauch
Phone: +49 2203 9649-7208
e-mail: cstrauch@igus.net
www.igus.eu/forklift

In this brochure you will find technical components made of high performancepolymers, important for forklifts and other industrial vehicles. We also offer a huge
range of cables for movement in energy chains, used directly on or in the forklift.
Not always visible from outside, but already a proven technology, there are several
places in the forklift where igus® products are already being successfully used.
From igus®, you will receive a technically better solution with a longer service life
or a product that is considerably more cost-effective than components you havepreviously used. Change over now to our plastic bearings for an up to 40% costsaving and a 60% weight saving. From the No. 1 for cables in e-chains®, you will
be supplied with the most cost-effective cable that is guaranteed to do its job orchoose from our 90,000 types of e-chain® for easy and safe energy supply.
For further information and application examples relating to forklifts and industrial
vehicles, go to our website at: www.igus.eu/forklift
Advantages of motion plastics® in forklifts:●● Lubrication-free●● Quiet operation and smooth sliding●● Resistance to dirt●● Long service life●● Corrosion resistance2-3

www.igus.eu/forklift

Reliable and 100%
lubrication-freeigus® solutions for forklifts, industrial vehicles and automated transportsystems. Lubrication and maintenance-free, high service life and lifetime
predictable online!

Less maintenance effort and cost for forklifts thanks to igus® high-performance polymers.
Defects, repairs or downtimes of industrial vehicles for maintenance purposes are costly bothin terms of replacement parts but also expensive downtime. Robust and reliable components
are therefore required to avoid this. The high-performance polymers and cables from igus® havebeen specially developed for dynamic applications and long service life and are able to withstandeven high levels of stress. For example, iglidur® bearings are used in heavy-duty pivots andchainflex® cables are used for extremely small bend radii and large heights in lifting gear.

Benefits of igus® high-performance polymers for industrial vehicles:●● No maintenance or lubrication●● Long service life●● Tested in the test laboratory under realistic conditions●● Predictable service life●● Fast delivery●● UV and weather-resistant●● Especially durable●● Resistant to dirt●● Resistant to vibrations●● Individual custom-made products

In the case ofhigh-performanceequipment for narrow
aisle warehouses,
the driver is also liftedup into the air.

Guaranteemonth guarantee

4-5

chainflex® cables are
braided in bundles
and were developed
especially for use inenergy chains. All cables
with 36 month guarantee.

*Avoid failures, guaranteed – more than 2 billion test strokes and 1.4 million electrical measurements per year. For more than 25 years, igus® has been carrying out tests in the industry's largest
laboratory for moving cables and energy chains.

www.igus.eu/forklift

Always the right solution forforklifts and industrial vehicles

®

Camera:chainflex® CF298

Control panel:
drylin® W

Head rest back adjustment:
drylin® positional system

Sensor:chainflex® CFSPECIAL.182

Steering column bearing:
iglidur ® J

Camera:chainflex® CFSPECIAL.182
Pedals:iglidur ® J

Fork tines:
iglidur ® plate material

Backrest adjustment mechanism:
iglidur ® G

Seat adjustment:
E2.1 e-chain®

Lifting mast bearing:
iglidur ® G

Positioner:
iglidur ® Q2

Brake:
iglidur ® J

6-7

www.igus.eu/forklift

motion plastics
in forklifts –less weight,
longer service life

The special forklift is used to gather
trolleys in a large dairy facility and feedthem into the washing system.
Right hand image: the drylin® W modular
system offer the largest product range ofigus® lubrication and maintenance-freedrylin® linear guides.

8-9

www.igus.eu/forklift

Smooth operating
linear motion –from the steering
wheel to the fork

drylin® linear drives for Jungheinrich special
forklifts
The creative designers in the Jungheinrichplant in Lüneburg Germany, face many different
challenges. This plant is responsible for special
forklifts and modified serial-production devices,and manufactures a variety of industrial trucks thathandle special tasks, such as transport of paperrolls. Lubrication-free linear drives from igus® areused in the special designs as needed – on theoperator workstation and in the load-handlingequipment.

®

In order to supply energy and signals to the
housing of an order picking machine via themoving lifting rack, the Still designers use anigus® chainflex® cable. This cable is not only
suitable for applications with energy chains,
but also an ideal solution when working overroller guides. The EK-X type series of verticalorder pickers are particularly impressive devices in
Still's product range. Their task is to drive to pallets
in the narrow aisles of a high bay warehouse, andthen remove individual boxes. The pickers achieve
heights of up to twelve metres.

Guarantee

month guarantee

The energy cables and signal cables in thelift frame, which are up to 12m in length,
are guided via guide rollers and move eachtime that the mast is lifted or lowered.

10-11

www.igus.eu/forklift

Energy supplied
perfectly withchainflex in ­rollerguides

®

High reliability and freedom from maintenanceare of great importance in automated transport
vehicles, because flexibility and operational
efficiency are paramount for 24/7 operation.
Maintenance-free igus® solutions reduce costs
in procurement and operation and increase plantavailability.

Reliable operation with minimal maintenanceis a major advantage of FTS.
With maintenance-free and lubrication-freedrylin® ZLW toothed belt axes, this advantage
is used here at Knapp's lifting platform.

12-13

www.igus.eu/forklift

Linear solutions
for automatedtransport systems:
drylin ZLW®

●● Maintenance-free●● Lubrication-free●● Cost-effective
www.igus.eu/iglidur

iglidur plain bearings anddrylin lead screws in lifting
unit: lightweight and quiet®

®

●● Maintenance-free●● Cost-effective●● Lightweight
www.igus.eu/drylin

www.igus.eu/forklift

iglidur plain bearing in scissor
lift: cost-effective and durable

iglidur PRT slewing ring
bearing in rotary unit: torsional
rigidity and low friction®

●● Maintenance-free●● Compact design●● Lightweight
www.igus.eu/PRT
14-15

®

●● From stock or machined special parts and sizes in 3 to 5 days●● Standard plastic bar stock: round bars and plate materials●● Predictable service life
www.igus.eu/barstock

drylin W curved guide system:
follow the curve, with flexibility®

●● drylin® W carriage on curved rail●● Variable profile directions●● Torque-resistant alternative to curved tube profiles
www.igus.eu/curved

iglidur J in steering columns
and pedals®

●● Excellent wear resistance on virtually all shafts●● Very low coefficients of friction●● Cost-effective and maintenance-free
www.igus.eu/iglidur

16-17

www.igus.eu/forklift

iglidur materials in fork tines:
lubrication-free and clean®

●● Easy movement with roller support●● Wide range of sizes and options●● For exact re-positioning
www.igus.eu/drylin

E2 micro e-chain in seatadjustment mechanism:very small bend radii andinner heights®

●● Safe cable guidance●● Easy to open and quick assembly●● Quiet operation, stable and cost-effective
www.igus.eu/E2.1

Guarantee

chainflex cables in thecontrol panel: for thesmallest installation spaces®

month guarantee●● For extremely small radii and installation spaces either indoor or outdoor●● For hanging applications and high tensile strain●● All chainflex® cables with a 36 month guarantee* and numerous certifications – tested
www.igus.eu/chainflex
18-19

www.igus.eu/forklift

drylin pre-defined positional
systems in head-rests: lightweight, defined positioning*Avoid failures, guaranteed – more than 2 billion test strokes and 1.4 million electrical measurements per year. For morethan 25 years, igus® has been carrying out tests in the industry's largest laboratory for moving cables and energy chains.

®

●● Most popular iglidur ® plain bearing worldwide●● High wear resistance●● Resistance to dust and dirt
www.igus.eu/iglidur

e-spool on scanners: compact
and reliable cable guidance●● For telescopic/retractable applications, energy, data and other media in one system●● Always provides the correct length and tension of the energy supply system●● Space-saving alternative to zig-zag solutionwww.igus.eu/e-spool

e-chain in special forklifts: safeand reliable cable guidance®

●● Cable protection for constricted installation spaces●● Very easy to open from the inside or outside●● Excellent mechanical stability
www.igus.eu/E2.120-21

www.igus.eu/forklift

iglidur G in tipping devices:lightweight and cost-effective

www.igus.eu/forklift

iglidur Q2 in positioners: highstrength and maintenance-free®

●● Resistant to high frequency shocks and vibrations●● Extreme wear-resistant●● No 'stick slip'
www.igus.eu/iglidur

chainflex in lifting gear:
guided by rollers®

Guarantee●● For extremely small radii and installation spaces either indoor or outdoor●● For hanging applications and high tensile strain●● With 36 month guarantee*, upon request
www.igus.eu/chainflex*Avoid failures, guaranteed – more than 2 billion test strokes and 1.4 million electrical measurements
per year. For more than 25 years, igus® has been carrying out tests in the industry's largest laboratory for moving cables and energy chains.

PRT slewing ring bearingsin drawbars: robust andmaintenance-free●● Ready-to-install and maintenance-free solution●● Tough and corrosion-resistant for high loads●● For use in changing environments
www.igus.eu/PRT
22-23

month guarantee®

●● Smooth running due to low coefficient of friction●● Reliable and maintenance-free●● Resistant to dirt
www.igus.eu/iglidur

drylin SHT: optimum integration
into forklift motion®

●● Body material made of stainless steel, aluminium, zinc or plastic●● Lubrication-free polymer bearings and nuts●● Three shaft materials available
www.igus.eu/drylin

drylin WJRM in door holders:­ergonomic operator control®

●● Quiet operation●● Dirt-resistant●● Corrosion-free
www.igus.eu/drylin-hybrid24-25

www.igus.eu/forklift

iglidur G in lifting device:
for reliable and safe lifting3D printing service - forunique parts made fromhigh-performance plastics
In two simple steps 3D-printed component - with instant price.
We print custom components using lubrication-free, wear-resistant iglidur®
high-performance plastics. Upload the drawing in the STEP (STP) format, check the360° view and select the filament material. Upon order, it is printed and shipped –depending on the complexity – from 24 hours.
Proven strength when compared to machined and injection-moulded parts.
3D print materials from igus® are robust and composed of wear-resistant materials
made of iglidur® high-performance plastics, which are especially suited for moving
applications. They guarantee a long service life as well as a high wear resistance ofcustom-made parts.

Online 3D printing service: easy, fast, transparent

www.igus.eu/tribo-printing
26-27

www.igus.eu/forklift

Prototypes, very small
batches, special purpose
machineryReady to install andindustrially harnessed:
www.readychain.eu
Always the right harness for your application. Ready-to-fit readychain®
e-chain system® configured and delivered in 3-8 days.
Possible due to the large selection of energy chains for all kinds of motion, cables
for e-chains® with 36 month guarantee plus the relevant connectors. Reduce
the number of suppliers and orders by 75%. Maximise machine uptime. Systemguarantee – depending on the application.

●● Service for fast, error-free installation●● Specialised assembly team
www.igus.eu/assembly

Basic for forklifts

Samplese-chain® with fitted cables – strain
relief in the system

Standarde-chain® with cables andrelevant connectorsStandard plus

Harnessed e-chain systems® withassociated sheet metal parts

Premium●● We can provide support in the construction
phase of your machinewww.igus.eu/sampling

Engineering

Ready-to-install complete systemwith transport rack

The type of harnessing
most frequently used inforklifts
Basice-chain® with cables andrelevant connectors
www.igus.eu/RCbasic●● Customised products●● Many solutions from the "modular
construction system"
28-29 www.igus.eu/engineeringwww.igus.eu/forklift

AssemblyExtensivetestdatabase●● Vertical mast with 60mm guide roller●● 720,484 strokes with chainflex® CF9

Tested ...

Tested ...

●● Cable test in the climate chamber●● Tested in motion in energy chain down
to -40°C●● More than 250 tests conducted in parallel in58 test facilities●● Constant load test●● Tests of wear and coefficient of friction●● Test of functioning, service life, strength andfailure scenarios

30-31

Tested ...

From more than 15,000 tests
performed per year, we havecreated what is probably theworld's largest test database.
This database gives us the ability
to always select the right productfor your specific application.
Individual tests for your industry
are also possible.

●● More than 3 billion test cycles per year●● Special test set-ups for specific industries●● Further information atwww.igus.eu/frontloadertest

www.igus.eu/test

www.igus.eu/forklift

Tested ...

Buy online - 24hrs!

Visit our industry web pages for more information, products, application
examples and useful online tools. Quickly find and configure products andcalculate service life – all online. With the help of our product finders, you can quickly
find the right article and obtain an exact prediction of service life. All online tools alsoenable you to reduce process costs. igus® delivers from stock in 24-48 hours!

Always the right solution for forklifts.
igus® is certified in accordance withISO 9001:2015 and IATF 16949:2016
in the field of energy supply
systems, cables and harnessing, as
well as plastic bearings.

igus® GmbHSpicher Str. 1a51147 Cologne, Germany
Phone +49 2203 9649-800
Fax+49 2203 9649-222
info@igus.dewww.igus.eu© 2018 igus® GmbH

Published by igus® GmbH, Germany
MAT0074086.20 Issue 10/2018
Subject to technical alterations.

www.igus.eu/forklift/24