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Operating Instructions

50468482

ETV 110-116

G

07.12

12.05 -

ETV 112ETV 114ETV 116

ETV 110

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Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 HamburgManufacturer or authorized representative in the Community

Additional information

Authorised signatory

Date

G EU Declaration of Conformity

The signatories hereby certify that the specified powered industrial truck conforms tothe EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magne-tic Compatibility, EMC) including their amendments as translated into national legisla-tion of the member countries. The signatories are individually empowered in each caseto compile the technical documentation.

Type Option Serial No. Year of ConstructionETV 110ETV 112ETV 114ETV 116

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1009

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Declaration of Conformity

Jungheinrich AG, Am Stadtrand 35, D-22047 HamburgManufacturer or authorized representative in the Community

Additional information

Authorised signatory

Date

G EU Declaration of Conformity

The signatories hereby certify that the specified powered industrial truck conforms tothe EU Directive 2006/42/EC (Machine Directive) and 2004/108/EEC (Electro-Magne-tic Compatibility, EMC) including their amendments as translated into national legisla-tion of the member countries. The signatories are individually empowered in each caseto compile the technical documentation.

Type Option Serial No. Year of ConstructionETV 110ETV 112ETV 114ETV 116

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0903

.GBImportant notes on transporting and mounting load lifting devicesto reach trucks

Transport

Depending on the overall height of the lifting mast and the local conditions transportcan be performed in three different ways

– Standing, with the lifting mast mounted (for trucks with low overall height)– Standing, with martially mounted lifting mast tilted towards the overhead guard (for

trucks with medium overall height). Hydraulic line for the lifting function is interrup-ted.

– Standing, with the lifting mast dismounted (for trucks with large overall height)

Safety Instructions for Assembly and Commissioning

f The assembly of the truck on site, commissioning the truck and instructing the drivermust be carried out by personnel trained and authorised by the manufacturer

Connect the hydraulic lines to the basic machine / mast interface and commission thetruck only after having installed the mast as per the instructions.

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Important notes on transporting and mounting load lifting devicesto reach trucks

Transport

Depending on the overall height of the lifting mast and the local conditions transportcan be performed in three different ways

– Standing, with the lifting mast mounted (for trucks with low overall height)– Standing, with martially mounted lifting mast tilted towards the overhead guard (for

trucks with medium overall height). Hydraulic line for the lifting function is interrup-ted.

– Standing, with the lifting mast dismounted (for trucks with large overall height)


f The assembly of the truck on site, commissioning the truck and instructing the drivermust be carried out by personnel trained and authorised by the manufacturer

Connect the hydraulic lines to the basic machine / mast interface and commission thetruck only after having installed the mast as per the instructions.

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ForewordThe present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter. Each chapterstarts with page 1. The page identification consists of a chapter letter and a pagenumber.For example: Page B 2 is the second page in chapter B.

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

ForewordThe present ORIGINAL OPERATING INSTRUCTIONS are designed to providesufficient instruction for the safe operation of the industrial truck. The information isprovided clearly and concisely. The chapters are arranged by letter. Each chapterstarts with page 1. The page identification consists of a chapter letter and a pagenumber.For example: Page B 2 is the second page in chapter B.

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

Safety instructions and important explanations are indicated by the followinggraphics:

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

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

Z Used before notices and explanations.

t Used to indicate standard equipment.

o Used to indicate optional equipment.

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

Copyright

Copyright of these operating instructions remains with JUNGHEINRICH AG.

Jungheinrich Aktiengesellschaft

Am Stadtrand 3522047 Hamburg - GERMANY

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

www.jungheinrich.com

0108

.GB

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IndexA Correct Use and Application

1 General ............................................................................................... A 12 Correct application .............................................................................. A 13 Approved application conditions ......................................................... A 14 Proprietor responsibilities .................................................................... A 25 Adding attachments and/or accessories ............................................. A 2

B Truck Description

1 Application ........................................................................................... B 12 Assemblies and Functional Description .............................................. B 22.1 Truck ................................................................................................... B 32.2 Load handling ...................................................................................... B 63 Standard Version Specifications ......................................................... B 73.1 Performance data ................................................................................ B 73.2 Dimensions ......................................................................................... B 93.3 Standard mast version dimensions ..................................................... B 113.4 Weights ............................................................................................... B 113.5 Wheels/tyres ....................................................................................... B 113.6 Battery ................................................................................................. B 123.7 Hydraulics ........................................................................................... B 123.8 Mast weights ....................................................................................... B 133.9 EN norms ............................................................................................ B 153.10 Conditions of use ................................................................................ B 153.11 Electrical requirements ........................................................................ B 164 Identification points and data plates .................................................... B 174.1 Truck data plate .................................................................................. B 184.2 Truck load chart (capacity) .................................................................. B 194.3 Attachment load chart ......................................................................... B 194.4 Stability ................................................................................................ B 20

C Transport and Commissioning

1 Transport ............................................................................................. C 12 Lifting by crane .................................................................................... C 22.1 Lifting the basic truck by crane ............................................................ C 32.2 Lifting the basic truck and cabin by crane ........................................... C 43 Securing the truck during transport ..................................................... C 54 Using the truck for the first time .......................................................... C 6

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IndexA Correct Use and Application

1 General ............................................................................................... A 12 Correct application .............................................................................. A 13 Approved application conditions ......................................................... A 14 Proprietor responsibilities .................................................................... A 25 Adding attachments and/or accessories ............................................. A 2

B Truck Description

1 Application ........................................................................................... B 12 Assemblies and Functional Description .............................................. B 22.1 Truck ................................................................................................... B 32.2 Load handling ...................................................................................... B 63 Standard Version Specifications ......................................................... B 73.1 Performance data ................................................................................ B 73.2 Dimensions ......................................................................................... B 93.3 Standard mast version dimensions ..................................................... B 113.4 Weights ............................................................................................... B 113.5 Wheels/tyres ....................................................................................... B 113.6 Battery ................................................................................................. B 123.7 Hydraulics ........................................................................................... B 123.8 Mast weights ....................................................................................... B 133.9 EN norms ............................................................................................ B 153.10 Conditions of use ................................................................................ B 153.11 Electrical requirements ........................................................................ B 164 Identification points and data plates .................................................... B 174.1 Truck data plate .................................................................................. B 184.2 Truck load chart (capacity) .................................................................. B 194.3 Attachment load chart ......................................................................... B 194.4 Stability ................................................................................................ B 20

C Transport and Commissioning

1 Transport ............................................................................................. C 12 Lifting by crane .................................................................................... C 22.1 Lifting the basic truck by crane ............................................................ C 32.2 Lifting the basic truck and cabin by crane ........................................... C 43 Securing the truck during transport ..................................................... C 54 Using the truck for the first time .......................................................... C 6

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D Battery Maintenance, Charging & Replacement

1 Safety regulations for handling acid batteries ..................................... D 12 Battery types ....................................................................................... D 23 Exposing the battery ........................................................................... D 34 Charging the battery ............................................................................ D 75 Battery removal and installation .......................................................... D 8

E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 12 Controls and Displays ........................................................................ E 23 Starting up the Truck ........................................................................... E 63.1 Entry and exit ...................................................................................... E 73.2 Setting up the operator position .......................................................... E 73.3 Preparing the truck for operation ......................................................... E 133.4 Emergency stop device ....................................................................... E 143.5 Testing after daily operation ................................................................ E 154 Industrial Truck Operation ................................................................... E 164.1 Safety regulations for truck operation ................................................. E 164.2 Procedure in extraordinary situations .................................................. E 174.3 Emergency Disconnect ....................................................................... E 184.4 Travel, steering, braking ...................................................................... E 194.5 Adjusting the forks ............................................................................... E 234.6 Lifting and depositing loads ................................................................. E 244.7 Mast Support Reach ........................................................................... E 264.8 Emergency lowering ............................................................................ E 294.9 Operating Attachments ....................................................................... E 304.10 Park the truck safely ............................................................................ E 355 Driver’s display .................................................................................... E 365.1 Driver’s Display Luminous Symbols .................................................... E 405.2 Driver Display Switches ...................................................................... E 415.3 Driver’s Display Warning Messages ................................................... E 416 Keypad (CANCODE) (o) .................................................................... E 476.1 Code lock ............................................................................................ E 476.2 Parameters .......................................................................................... E 486.3 Parameter Settings ............................................................................. E 497 ISM (o) ............................................................................................... E 528 Changing truck parameters ................................................................. E 529 Troubleshooting .................................................................................. E 5310 Moving the truck without a battery, recovery ....................................... E 5311 Optional equipment ............................................................................. E 5611.1 Headlights .......................................................................................... E 5611.2 Beacon / strobe ................................................................................. E 5611.3 Limit switch system / electrical lift limit switch ..................................... E 5711.4 Clamp button ...................................................................................... E 5911.5 Seat heating ....................................................................................... E 59

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D Battery Maintenance, Charging & Replacement

1 Safety regulations for handling acid batteries ..................................... D 12 Battery types ....................................................................................... D 23 Exposing the battery ........................................................................... D 34 Charging the battery ............................................................................ D 75 Battery removal and installation .......................................................... D 8

E Operation

1 Safety Regulations for the Operation of Forklift Trucks ...................... E 12 Controls and Displays ........................................................................ E 23 Starting up the Truck ........................................................................... E 63.1 Entry and exit ...................................................................................... E 73.2 Setting up the operator position .......................................................... E 73.3 Preparing the truck for operation ......................................................... E 133.4 Emergency stop device ....................................................................... E 143.5 Testing after daily operation ................................................................ E 154 Industrial Truck Operation ................................................................... E 164.1 Safety regulations for truck operation ................................................. E 164.2 Procedure in extraordinary situations .................................................. E 174.3 Emergency Disconnect ....................................................................... E 184.4 Travel, steering, braking ...................................................................... E 194.5 Adjusting the forks ............................................................................... E 234.6 Lifting and depositing loads ................................................................. E 244.7 Mast Support Reach ........................................................................... E 264.8 Emergency lowering ............................................................................ E 294.9 Operating Attachments ....................................................................... E 304.10 Park the truck safely ............................................................................ E 355 Driver’s display .................................................................................... E 365.1 Driver’s Display Luminous Symbols .................................................... E 405.2 Driver Display Switches ...................................................................... E 415.3 Driver’s Display Warning Messages ................................................... E 416 Keypad (CANCODE) (o) .................................................................... E 476.1 Code lock ............................................................................................ E 476.2 Parameters .......................................................................................... E 486.3 Parameter Settings ............................................................................. E 497 ISM (o) ............................................................................................... E 528 Changing truck parameters ................................................................. E 529 Troubleshooting .................................................................................. E 5310 Moving the truck without a battery, recovery ....................................... E 5311 Optional equipment ............................................................................. E 5611.1 Headlights .......................................................................................... E 5611.2 Beacon / strobe ................................................................................. E 5611.3 Limit switch system / electrical lift limit switch ..................................... E 5711.4 Clamp button ...................................................................................... E 5911.5 Seat heating ....................................................................................... E 59

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11.6 12 V DC / 24 V DC transformer .......................................................... E 5911.7 Weatherproof cab ............................................................................... E 6011.8 Parabolic mirror ................................................................................... E 6111.9 Removable load backrest .................................................................... E 6211.10 ISM access module ............................................................................. E 6311.11 Assembly and hydraulic ports of additional attachments .................... E 64

F Forklift Truck Maintenance

1 Operational safety and environmental protection ................................ F 12 Maintenance safety regulations .......................................................... F 23 Servicing and inspection ..................................................................... F 64 ETV 110-116 maintenance checklist ................................................... F 75 ETV 110-116 maintenance schedule .................................................. F 95.1 Lubricants and Lubrication Schedule .................................................. F 105.2 Consumables ..................................................................................... F 115.3 Tank Capacities .................................................................................. F 126 Maintenance Instructions .................................................................... F 136.1 Preparing the truck for maintenance and repairs ................................ F 136.2 Check fixing of the wheels .................................................................. F 136.3 Removing the seat panel .................................................................... F 146.4 Checking the hydraulic oil level ........................................................... F 146.5 Opening the fuse cover ....................................................................... F 156.6 Opening the instrument panel ............................................................. F 156.7 Checking electrical fuses .................................................................... F 166.8 Recommissioning ................................................................................ F 177 Decommissioning the industrial truck .................................................. F 177.1 Prior to decommissioning .................................................................... F 177.2 During decommissioning ..................................................................... F 177.3 Restoring the truck to operation after decommissioning ..................... F 188 Safety tests to be performed at intervals and after unusual incidents . F 189 Final de-commissioning, disposal ....................................................... F 1910 Human vibration measurement ........................................................... F 19

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11.6 12 V DC / 24 V DC transformer .......................................................... E 5911.7 Weatherproof cab ............................................................................... E 6011.8 Parabolic mirror ................................................................................... E 6111.9 Removable load backrest .................................................................... E 6211.10 ISM access module ............................................................................. E 6311.11 Assembly and hydraulic ports of additional attachments .................... E 64

F Forklift Truck Maintenance

1 Operational safety and environmental protection ................................ F 12 Maintenance safety regulations .......................................................... F 23 Servicing and inspection ..................................................................... F 64 ETV 110-116 maintenance checklist ................................................... F 75 ETV 110-116 maintenance schedule .................................................. F 95.1 Lubricants and Lubrication Schedule .................................................. F 105.2 Consumables ..................................................................................... F 115.3 Tank Capacities .................................................................................. F 126 Maintenance Instructions .................................................................... F 136.1 Preparing the truck for maintenance and repairs ................................ F 136.2 Check fixing of the wheels .................................................................. F 136.3 Removing the seat panel .................................................................... F 146.4 Checking the hydraulic oil level ........................................................... F 146.5 Opening the fuse cover ....................................................................... F 156.6 Opening the instrument panel ............................................................. F 156.7 Checking electrical fuses .................................................................... F 166.8 Recommissioning ................................................................................ F 177 Decommissioning the industrial truck .................................................. F 177.1 Prior to decommissioning .................................................................... F 177.2 During decommissioning ..................................................................... F 177.3 Restoring the truck to operation after decommissioning ..................... F 188 Safety tests to be performed at intervals and after unusual incidents . F 189 Final de-commissioning, disposal ....................................................... F 1910 Human vibration measurement ........................................................... F 19

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Appendix

JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If usinganother brand, refer to the manufacturer's operating instructions.

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Appendix

JH Traction Battery Operating Instructions

Z These operating instructions apply only to Jungheinrich battery models. If usinganother brand, refer to the manufacturer's operating instructions.

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A Correct Use and Application1 General

The industrial truck described in the present operating instructions is designed forlifting, lowering and transporting load units.It must be used, operated and serviced in accordance with the present instructions.All other types of use lie beyond the scope of application and can result in damage topersonnel, the truck or property.

2 Correct application

F The maximum load and load distance are indicated on the load chart and must not beexceeded.The load must rest on the load handler or be lifted by an attachment approved by themanufacturer. The load must rest on the back of the fork carriage and centrallybetween the forks.

The following operations are permitted:

– Lifting and lowering of loads.– Transporting lowered loads.

The following operations are prohibited:

– Travelling with a raised load (>30 cm).– Transporting hanging loads. If the truck is to be operated with hanging loads, proof

of sufficient safety distance under local operating conditions must be obtained froma specialist assessor.

– Carrying and lifting passengers.– Pushing or pulling load units.

3 Approved application conditions

F Do not exceed the permissible surface and spot load limits on the travel routes.At blind spots get a second person to assist.The driver must ensure that the loading ramp / bridge cannot move or come looseduring loading / unloading.

– Operation in industrial and commercial environments.– Permissible temperature range -20 °C to 40 °C.– Operation only on secure, level surfaces with sufficient capacity.– Operation only on routes that are visible and approved by the proprietor.– Negotiating inclines up to a maximum of 15 %.– Do not negotiate inclines crosswise or at an angle. Loads must always be carried

on the end of the truck facing uphill.– Operation in partially public traffic.

Z Special equipment and authorisation are required if the truck is to be constantly usedin extreme conditions.The truck is not authorised for use in areas at risk of explosion.

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A Correct Use and Application1 General

The industrial truck described in the present operating instructions is designed forlifting, lowering and transporting load units.It must be used, operated and serviced in accordance with the present instructions.All other types of use lie beyond the scope of application and can result in damage topersonnel, the truck or property.

2 Correct application

F The maximum load and load distance are indicated on the load chart and must not beexceeded.The load must rest on the load handler or be lifted by an attachment approved by themanufacturer. The load must rest on the back of the fork carriage and centrallybetween the forks.

The following operations are permitted:

– Lifting and lowering of loads.– Transporting lowered loads.

The following operations are prohibited:

– Travelling with a raised load (>30 cm).– Transporting hanging loads. If the truck is to be operated with hanging loads, proof

of sufficient safety distance under local operating conditions must be obtained froma specialist assessor.

– Carrying and lifting passengers.– Pushing or pulling load units.

3 Approved application conditions

F Do not exceed the permissible surface and spot load limits on the travel routes.At blind spots get a second person to assist.The driver must ensure that the loading ramp / bridge cannot move or come looseduring loading / unloading.

– Operation in industrial and commercial environments.– Permissible temperature range -20 °C to 40 °C.– Operation only on secure, level surfaces with sufficient capacity.– Operation only on routes that are visible and approved by the proprietor.– Negotiating inclines up to a maximum of 15 %.– Do not negotiate inclines crosswise or at an angle. Loads must always be carried

on the end of the truck facing uphill.– Operation in partially public traffic.

Z Special equipment and authorisation are required if the truck is to be constantly usedin extreme conditions.The truck is not authorised for use in areas at risk of explosion.

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4 Proprietor responsibilities

For the purposes of the present operating instructions the “proprietor” is defined asany natural or legal person who either uses the industrial truck himself, or on whosebehalf it is used. In special cases (e.g. leasing or renting) the proprietor is consideredthe person who, in accordance with existing contractual agreements between theowner and user of the industrial truck, is charged with operational duties.The proprietor must ensure that the industrial truck is used only for the purpose it isintended for and that danger to life and limb of the user and third parties are excluded.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The attachment must only be operated by trained and authorised personnel.The proprietor must ensure that all users have read and understood these operatinginstructions.

M Failure to comply with the operating instructions shall invalidate the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer’s customer service department.

5 Adding attachments and/or accessories

The mounting or installation of additional equipment which affects or enhances theperformance of the forklift truck requires the written permission of the manufacturer.Local authority approval may also need to be obtained. Local authority approval doesnot however constitute the manufacturer’s approval.

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4 Proprietor responsibilities

For the purposes of the present operating instructions the “proprietor” is defined asany natural or legal person who either uses the industrial truck himself, or on whosebehalf it is used. In special cases (e.g. leasing or renting) the proprietor is consideredthe person who, in accordance with existing contractual agreements between theowner and user of the industrial truck, is charged with operational duties.The proprietor must ensure that the industrial truck is used only for the purpose it isintended for and that danger to life and limb of the user and third parties are excluded.Furthermore, accident prevention regulations, safety regulations and operating,servicing and repair guidelines must be followed. The attachment must only be operated by trained and authorised personnel.The proprietor must ensure that all users have read and understood these operatinginstructions.

M Failure to comply with the operating instructions shall invalidate the warranty. The sameapplies if improper work is carried out on the truck by the customer or third partieswithout the permission of the manufacturer’s customer service department.

5 Adding attachments and/or accessories

The mounting or installation of additional equipment which affects or enhances theperformance of the forklift truck requires the written permission of the manufacturer.Local authority approval may also need to be obtained. Local authority approval doesnot however constitute the manufacturer’s approval.

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B Truck Description1 Application

The ETV 110-116 is a three wheel electric side seat, clear view reach truck. It isdesigned for use on level floors to lift and transport goods. Open bottom pallets orpallets with transverse boards can be lifted inside or outside the area of the loadwheels or roll cage. Loads can be stacked or unstacked and transported over longdistances. The capacity can be obtained from the data plate.

Type Capacity Load centre of gravity

ETV 110 1,000 kg 600 mmETV 112 1,200 kg 600 mmETV 114 1,400 kg 600 mmETV 116 1,600 kg 600 mm

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B Truck Description1 Application

The ETV 110-116 is a three wheel electric side seat, clear view reach truck. It isdesigned for use on level floors to lift and transport goods. Open bottom pallets orpallets with transverse boards can be lifted inside or outside the area of the loadwheels or roll cage. Loads can be stacked or unstacked and transported over longdistances. The capacity can be obtained from the data plate.

Type Capacity Load centre of gravity

ETV 110 1,000 kg 600 mmETV 112 1,200 kg 600 mmETV 114 1,400 kg 600 mmETV 116 1,600 kg 600 mm

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2 Assemblies and Functional Description

Item Description Item Description1 t Clearview mast 9 t Brake pedal2 t Overhead guard 10 t Accelerator pedal3 t Free lift cylinder

(not with ZT mast)11 t Battery trolley lock pedal

4 t Solo Pilot 12 t Driver’s displayo Multi Pilot 13 t Two stage switch key with

spare key (service).5 t Load wheels o CANCODE6 t Outriggers o ISM Access Module7 t Drive wheel 14 t EMERGENCY DISCONNECT

switch8 t Deadman button

t Standard Equipment o Optional Equipment

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2.1 Truck

F The truck can only be moved with or without a load when the mast support isretracted, the mast tilted back and the load handler lowered.

Safety mechanisms: An enclosed truck geometry with rounded edges facilitatessafe handling of the ETV 110-116. The driver is protected by the overhead guard (2).The drive wheel (7) and the load wheels (5) are protected by a solid ram protection.

M A slight danger remains for third parties, even when a drive wheel cover is used.

Pressing the EMERGENCY DISCONNECT switch (14) disconnects all electricalfunctions in hazardous situations.

Line brake safety devices in the lift cylinders limit the load lowering speed in the eventof a hydraulic system failure.

Displays: Driver’s display (12) with widescreen LCD display (t) including residualtime display, battery discharge indicator, lift and travel profile settings and steer anglemode display. The battery discharge indicator and hourmeter are combined on thedriver’s display (12). The discharge indicator is designed as a monitor which disableslifting when the battery is discharged, in order to avoid depletion.

Drive: The complete drive unit is enclosed in the vehicle chassis. A fixed, 6.9 kWthreephase motor governs the drive wheel (7) via a a bevel spur gearbox.The electrical drive current control ensures the smooth rotation of the drive motor andas a result smooth driving, powerful acceleration and electrically controlled brakingwith energy recovery.

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2.1 Truck


Safety mechanisms: An enclosed truck geometry with rounded edges facilitatessafe handling of the ETV 110-116. The driver is protected by the overhead guard (2).The drive wheel (7) and the load wheels (5) are protected by a solid ram protection.

M A slight danger remains for third parties, even when a drive wheel cover is used.

Pressing the EMERGENCY DISCONNECT switch (14) disconnects all electricalfunctions in hazardous situations.

Line brake safety devices in the lift cylinders limit the load lowering speed in the eventof a hydraulic system failure.

Displays: Driver’s display (12) with widescreen LCD display (t) including residualtime display, battery discharge indicator, lift and travel profile settings and steer anglemode display. The battery discharge indicator and hourmeter are combined on thedriver’s display (12). The discharge indicator is designed as a monitor which disableslifting when the battery is discharged, in order to avoid depletion.

Drive: The complete drive unit is enclosed in the vehicle chassis. A fixed, 6.9 kWthreephase motor governs the drive wheel (7) via a a bevel spur gearbox.The electrical drive current control ensures the smooth rotation of the drive motor andas a result smooth driving, powerful acceleration and electrically controlled brakingwith energy recovery.

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Brake system: The electric brake system consists of independent brake systems.Applying the brake pedal results in inversion braking (plugging) in the traction motor.The parking brake is electrically operated and acts mechanically (compressionspring) on a magnet brake mounted on the drive unit. This brake is also used foremergency braking. A warning light appears when the brake is applied. Faults in the steering and brake systems (which trigger an emergency stop) areshown on the driver’s display or the on board computer.Applying the brake pedal activates the parking brake when the truck is idle.

Emergency stop safety feature: The emergency stop is controlled by the traction orsteering controller.If an error is detected the truck automatically brakes to a halt. Control displays on thedriver’s display indicate the emergency stop. Every time the truck is switched on, thesystem performs a self-diagnosis which only releases the parking brake (emergencystop) if the functionality test is positive.

Steering: Electrical steering system which turns the drive unit via a spur gear. Choiceof 2 operating modes in service mode on the driver’s display:

– 180° (t)– 360° (o, endless)

The adjustable steering wheel acts as a steering transmitter.

Driver’s position: The driver’s position is ergonomically designed with ample leg-room. The driver's seat, steering arm and Solo Pilot / Multi Pilot (o) can be adjustedto suit the driver.The accelerator pedal and brake pedal are of “automotive” design.

Curve Control: Automatic speed reduction for cornering. Curve Control limits thespeed and acceleration when cornering.This reduces the risk of oscillations or tipovers.

Deadman button: The deadman button in the left foot compartment must bedepressed to allow the driver to operate the truck. Lifting and travel are inhibited if thedriver takes his foot off the foot switch. Steering and braking remain enabled. Thedeadman button can be adjusted so that when the foot switch is released the parkingbrake applies after a set time. (prevents the truck from accidentally rolling away)

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Brake system: The electric brake system consists of independent brake systems.Applying the brake pedal results in inversion braking (plugging) in the traction motor.The parking brake is electrically operated and acts mechanically (compressionspring) on a magnet brake mounted on the drive unit. This brake is also used foremergency braking. A warning light appears when the brake is applied. Faults in the steering and brake systems (which trigger an emergency stop) areshown on the driver’s display or the on board computer.Applying the brake pedal activates the parking brake when the truck is idle.

Emergency stop safety feature: The emergency stop is controlled by the traction orsteering controller.If an error is detected the truck automatically brakes to a halt. Control displays on thedriver’s display indicate the emergency stop. Every time the truck is switched on, thesystem performs a self-diagnosis which only releases the parking brake (emergencystop) if the functionality test is positive.

Steering: Electrical steering system which turns the drive unit via a spur gear. Choiceof 2 operating modes in service mode on the driver’s display:

– 180° (t)– 360° (o, endless)

The adjustable steering wheel acts as a steering transmitter.

Driver’s position: The driver’s position is ergonomically designed with ample leg-room. The driver's seat, steering arm and Solo Pilot / Multi Pilot (o) can be adjustedto suit the driver.The accelerator pedal and brake pedal are of “automotive” design.

Curve Control: Automatic speed reduction for cornering. Curve Control limits thespeed and acceleration when cornering.This reduces the risk of oscillations or tipovers.

Deadman button: The deadman button in the left foot compartment must bedepressed to allow the driver to operate the truck. Lifting and travel are inhibited if thedriver takes his foot off the foot switch. Steering and braking remain enabled. Thedeadman button can be adjusted so that when the foot switch is released the parkingbrake applies after a set time. (prevents the truck from accidentally rolling away)

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Controls and Displays: Controls and displays are clearly arranged in the driver’scab. The logically arranged controls (4) enable single handed operation of traveldirection, lift / lower, mast reach/retract, mast tilt, sideshift left and right in sideshiftmode (auxiliary hydraulics HF5 (o)) and horn.

Hydraulic system: Pump unit with AC motor and low-noise precision high pressurepump. The system is controlled by the Solo Pilot (t) or the Multi Pilot (o) (4).

Electrical system: 48 volt, twin cable system. Standard electronic drive, lift andsteering control system.The electronic drive control provides infinite travel speed control and enablesplugging when changing direction.Travel and lift parameters can be set as required via the driver’s display (12). Warningdisplays, operator error messages and service functions can also be shown on thedriver’s display.

2.2 Load handling

Mast support: The mast support is mounted on support rollers. A single telescopicreach cylinder extends and retracts the support. The mast support rails for theETV 114/116 are screwed onto the outriggers (6). For the ETV 110/112 the rails arehoused within the outriggers (6).

Mast: The trucks are equipped with tilting telescopic clearview masts positioned inthe mast support. Adjustable side rollers take up the lateral pressure exerted on thefork carriage if the load is positioned on one side. The forks are fitted to the forkcarriage and are adjustable. With the two stage Triplex mast (DZ) a short, offset freelift cylinder (3) initially lifts the load carriage (free lift) without changing the overallheight of the truck. With the telescopic mast (ZT) the free lift is limited to 80 mm.

Attachments: The truck can be optionally fitted with mechanical and hydraulicattachments.

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Controls and Displays: Controls and displays are clearly arranged in the driver’scab. The logically arranged controls (4) enable single handed operation of traveldirection, lift / lower, mast reach/retract, mast tilt, sideshift left and right in sideshiftmode (auxiliary hydraulics HF5 (o)) and horn.

Hydraulic system: Pump unit with AC motor and low-noise precision high pressurepump. The system is controlled by the Solo Pilot (t) or the Multi Pilot (o) (4).

Electrical system: 48 volt, twin cable system. Standard electronic drive, lift andsteering control system.The electronic drive control provides infinite travel speed control and enablesplugging when changing direction.Travel and lift parameters can be set as required via the driver’s display (12). Warningdisplays, operator error messages and service functions can also be shown on thedriver’s display.

2.2 Load handling

Mast support: The mast support is mounted on support rollers. A single telescopicreach cylinder extends and retracts the support. The mast support rails for theETV 114/116 are screwed onto the outriggers (6). For the ETV 110/112 the rails arehoused within the outriggers (6).

Mast: The trucks are equipped with tilting telescopic clearview masts positioned inthe mast support. Adjustable side rollers take up the lateral pressure exerted on thefork carriage if the load is positioned on one side. The forks are fitted to the forkcarriage and are adjustable. With the two stage Triplex mast (DZ) a short, offset freelift cylinder (3) initially lifts the load carriage (free lift) without changing the overallheight of the truck. With the telescopic mast (ZT) the free lift is limited to 80 mm.

Attachments: The truck can be optionally fitted with mechanical and hydraulicattachments.

B 7

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3 Standard Version Specifications

Z Technical data specified in accordance with VDI 2198.Technical modifications and additions reserved.

3.1 Performance data

ETV 110/112

1)Lift height up to 6,500 mm 0.15 m/sLift height up to 7,700 mm 0.10 m/s

Description ETV 110 ETV 112Q Capacity (where C = 600 mm) 1000 1200 kgc Load centre of gravity 600 600 mm

Travel speedDrive, fork direction

11.0 / 10.0 11.0 / 10.0 km/h

Lift speedw / w.o. load

0.48 / 0.70 0.43 / 0.70 m/s(±10%)

Lowering speedw / w.o. load

0.50 / 0.50 0.50 / 0.50 m/s(-15%)

Reach speedw / w.o. load

0.21)

up to 5,600 mm

0.21)

up to 5,600 mm

m/s

Gradeability w / w.o. load 7 / 10 7 / 10 %Max. gradeability (5 min rating)w / w.o. load

10 / 15 10 / 15 %

Acceleration with / without load 4.8/4.4 4.9/4.4 s

Drive motor, output S2 = 60min 6.9 6.9 kW

Lift motor, output at S3 15% 10 10 kW

B 7

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3 Standard Version Specifications

Z Technical data specified in accordance with VDI 2198.Technical modifications and additions reserved.

3.1 Performance data

ETV 110/112

1)Lift height up to 6,500 mm 0.15 m/sLift height up to 7,700 mm 0.10 m/s



11.0 / 10.0 11.0 / 10.0 km/h


0.48 / 0.70 0.43 / 0.70 m/s(±10%)


0.50 / 0.50 0.50 / 0.50 m/s(-15%)


0.21)

up to 5,600 mm

0.21)

up to 5,600 mm

m/s


10 / 15 10 / 15 %




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ETV 114/116

1) Lift height up to 6,500 mm 0.15 m/sLift height up to 7,700 mm 0.10 m/s



10.0 / 9.0 10.0 / 9.0 km/h


0.37 / 0.65 0.33 / 0.65 m/s(±10%)


0.50 / 0.50 0.50 / 0.50 m/s(-15%)


0.21)

up to 5,600 mm

0.21)

up to 5,600 mm

m/s


10 / 15 10 / 15 %




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ETV 114/116

1) Lift height up to 6,500 mm 0.15 m/sLift height up to 7,700 mm 0.10 m/s



10.0 / 9.0 10.0 / 9.0 km/h


0.37 / 0.65 0.33 / 0.65 m/s(±10%)


0.50 / 0.50 0.50 / 0.50 m/s(-15%)


0.21)

up to 5,600 mm

0.21)

up to 5,600 mm

m/s


10 / 15 10 / 15 %




B 9

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3.2 Dimensions

(all distances in mm)

ETV 110/112 (280Ah) DZ-GE

a) Fork length 800 mmb) Applies to 280 Ah battery. Other battery sizes will change this reading.

ETV 114/116 (420Ah) DZ-GE


Description ETV 110 ETV 112s Lowered fork height 40 40 mmh6 Height above overhead guard 2150 2150 mml1 Overall length 1965 a) 1965 a) mml4 Reach 515 b) 600 b) mml7 Length over outriggers 1640 1725 mm

b1/ b2

Overall width 1120 1120 mm

Wa Turning radius 1515 1595 mmAst Working aisle width

800 x 1200 longitudinal pallets2659 / 2570 2663 / 2565 mm

Ast Working aisle width 1000 x 1200 traverse pallets

2603 / 2370 2623 / 2365 mm

Net weight See truck data plate

Description ETV 114 ETV 116s Lowered fork height 40 40 mmh6 Overhead guard head 2150 2150 mml1 Overall length 1996 2068 mml4 Reach 622 600 mml7 Length over outriggers 1722 1842 mm

b1/ b2




Ast Working aisle width for pallets 1000 x 1200 traverse

2650 / 2396) 2715 / 2468 mm


B 9

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3.2 Dimensions

(all distances in mm)

ETV 110/112 (280Ah) DZ-GE


ETV 114/116 (420Ah) DZ-GE


Description ETV 110 ETV 112s Lowered fork height 40 40 mmh6 Height above overhead guard 2150 2150 mml1 Overall length 1965 a) 1965 a) mml4 Reach 515 b) 600 b) mml7 Length over outriggers 1640 1725 mm

b1/ b2




Ast Working aisle width 1000 x 1200 traverse pallets

2603 / 2370 2623 / 2365 mm


Description ETV 114 ETV 116s Lowered fork height 40 40 mmh6 Overhead guard head 2150 2150 mml1 Overall length 1996 2068 mml4 Reach 622 600 mml7 Length over outriggers 1722 1842 mm

b1/ b2




Ast Working aisle width for pallets 1000 x 1200 traverse

2650 / 2396) 2715 / 2468 mm


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B 10

Ast

b5 b4 b11 b1b2

e

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Ast

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e

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α

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3.3 Standard mast version dimensions

ETV 110/112

ETV 114/116

3.4 Weights

(All dimensions in kg)

a)Applies to ETV 110/112 with 280 Ah battery and ETV 114/116 with 420 Ah battery.Other battery sizes will change this reading.

3.5 Wheels/tyres

Description Telescopic mast (ZT)

Two stageTriplex mast (DZ)

h1 Height 2050-2400 2050-2900 mm h2 Free lift 80 1415-2265 mm h3 Lift 3090-3790 4550-7100 mm h4 Max. height 3660-4360 5185-7735 mm




Description ETV 110 ETV 112 ETV 114 ETV 116

Net weight incl. batterya) 2560 2580 2950 3070

Axle load, w.o. load front/rear

1587 /973 1587 /993 1770 /1180 1842 /1228

Axle loading forks fwd. w. load front/rear

634 /2926 516 /3264 522 /3828 560 /4110

Axle loading forks back w. load front/rear

1282 /2278 1361 /2419 1566 /2784 1681 /2989

Description ETV 110 ETV 112 ETV 114 ETV 116Tyre size, front 343x114 343x114 343x114 343x114

Tyre size, rear 230x85 230x85 285x100 285x100

Wheels, number front / rear (x = driven)

1x/2 1x/2 1x/2 1x/2

Tyres (full rubber, super elastic, pneumatic, polyurethane)

Vulkollan® Vulkollan® Vulkollan® Vulkollan®

B 11

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3.3 Standard mast version dimensions

ETV 110/112

ETV 114/116

3.4 Weights

(All dimensions in kg)

a)Applies to ETV 110/112 with 280 Ah battery and ETV 114/116 with 420 Ah battery.Other battery sizes will change this reading.

3.5 Wheels/tyres







Description ETV 110 ETV 112 ETV 114 ETV 116

Net weight incl. batterya) 2560 2580 2950 3070

Axle load, w.o. load front/rear

1587 /973 1587 /993 1770 /1180 1842 /1228

Axle loading forks fwd. w. load front/rear

634 /2926 516 /3264 522 /3828 560 /4110

Axle loading forks back w. load front/rear

1282 /2278 1361 /2419 1566 /2784 1681 /2989

Description ETV 110 ETV 112 ETV 114 ETV 116Tyre size, front 343x114 343x114 343x114 343x114

Tyre size, rear 230x85 230x85 285x100 285x100

Wheels, number front / rear (x = driven)

1x/2 1x/2 1x/2 1x/2

Tyres (full rubber, super elastic, pneumatic, polyurethane)

Vulkollan® Vulkollan® Vulkollan® Vulkollan®

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3.6 Battery

See battery types in chapter D.

3.7 Hydraulics

Description ETV 110/112 ETV 114/116Available working pressure for attachments 150 bar 150 bar

Oil flow for attachments 20 l/min 20 l/min

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3.6 Battery

See battery types in chapter D.

3.7 Hydraulics

Description ETV 110/112 ETV 114/116Available working pressure for attachments 150 bar 150 bar

Oil flow for attachments 20 l/min 20 l/min

B 13

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3.8 Mast weights

The weight of the mast can be calculated using the formulae given below.The necessary details such as truck name, model and length of the extended mast(lift height) can be taken from the data plate. The weight of the truck and the batterycan be found on the data plate.

3.8.1 Mast weight calculation example

Truck name (31): ETV1160

Mast (42): Section reinforcement, fork tilt

Mast weight = 0.63 x lift height (42) + 325 kg

Mast weight = 0.63 x 740 + 325 kg = 1304 kg

3.8.2 Overview of formulae to be applied (table depending on operating instructionsor truck)

Truck series Design CalculationETV/ETM-110/112 ZT Weight = 0.90 x lift height + 112 kg

DZ Weight = 0.81 x lift height + 200 kgETV/ETM-114/116 ZT Weight = 0.65 x lift height + 266 kg

DZ hot rolled Weight = 0.63 x lift height + 325 kgDZ; large lift heights cold rolled

Weight = 0.74 x lift height + 370 kg

xxx kg

ETV 116

xxx kg

GNE 160 740 DZ

31 42

38

35

B 13

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3.8 Mast weights

The weight of the mast can be calculated using the formulae given below.The necessary details such as truck name, model and length of the extended mast(lift height) can be taken from the data plate. The weight of the truck and the batterycan be found on the data plate.

3.8.1 Mast weight calculation example

Truck name (31): ETV1160

Mast (42): Section reinforcement, fork tilt

Mast weight = 0.63 x lift height (42) + 325 kg

Mast weight = 0.63 x 740 + 325 kg = 1304 kg

3.8.2 Overview of formulae to be applied (table depending on operating instructionsor truck)

Truck series Design CalculationETV/ETM-110/112 ZT Weight = 0.90 x lift height + 112 kg

DZ Weight = 0.81 x lift height + 200 kgETV/ETM-114/116 ZT Weight = 0.65 x lift height + 266 kg

DZ hot rolled Weight = 0.63 x lift height + 325 kgDZ; large lift heights cold rolled

Weight = 0.74 x lift height + 370 kg

xxx kg

ETV 116

xxx kg

GNE 160 740 DZ

31 42

38

35

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Ast

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a2

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α

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h3

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210 yl2 x

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B 14

Ast

b5 b4 b11 b1b2

e

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a2

a2

Wa

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α

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h6

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210 yl2 x

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B 15

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3.9 EN norms

Noise emission: 68 dB(A)

in accordance with EN 12053 as harmonised withISO 4871.

Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the driver’s ear.

Vibration: 0.66 m/s2

In accordance with EN 13059.

The internal accuracy of the measuring chain at 21°C is ± 0.02 m/s². Furtherdeviations may occur in particular through the positioning of the sensor and differentdriver weights.

Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weighted accelerationin the vertical direction. It is calculated when travelling over bumps at constant speed.These recordings were taken uniquely on the truck and must not be confused with thehuman vibrations of the "2002/44/EC/Vibrations" operator directive. To measurehuman vibrations the manufacturer offers a separate service (see chapter F "10.Human vibration measurement").

Electromagnetic compatibility (EMC)

The manufacturer confirms the truck adheres to the limitsfor electromagnetic emissions and resistance as well asthe static electricity discharge test in accordance withEN 12895 as well as the standardised instructionscontained therein.

Z No changes to electric or electronic components or their arrangement may be madewithout the written agreement of the manufacturer.

Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless datatransmission) can affect operators' medical equipment (pacemakers, hearing aidsetc.) and result in malfunctions. Consult with a doctor or the manufacturer of themedical equipment to clarify whether it can be used near the industrial truck.

3.10 Conditions of use

Ambient temperature- operating at -20 °C to +40 °C

with constant use 0 °C or. where there are extreme changes in temperatures andhumidity special equipment for forklift trucks is available for which permission isrequired.

B 15

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3.9 EN norms

Noise emission: 68 dB(A)

in accordance with EN 12053 as harmonised withISO 4871.

Z The noise emission level is calculated in accordance with standard procedures andtakes into account the noise level when travelling, lifting and when idle. The noiselevel is measured at the driver’s ear.

Vibration: 0.66 m/s2

In accordance with EN 13059.

The internal accuracy of the measuring chain at 21°C is ± 0.02 m/s². Furtherdeviations may occur in particular through the positioning of the sensor and differentdriver weights.

Z The vibration acceleration acting on the body in the operating position is, inaccordance with standard procedures, the linearly integrated, weighted accelerationin the vertical direction. It is calculated when travelling over bumps at constant speed.These recordings were taken uniquely on the truck and must not be confused with thehuman vibrations of the "2002/44/EC/Vibrations" operator directive. To measurehuman vibrations the manufacturer offers a separate service (see chapter F "10.Human vibration measurement").

Electromagnetic compatibility (EMC)

The manufacturer confirms the truck adheres to the limitsfor electromagnetic emissions and resistance as well asthe static electricity discharge test in accordance withEN 12895 as well as the standardised instructionscontained therein.

Z No changes to electric or electronic components or their arrangement may be madewithout the written agreement of the manufacturer.

Electrical equipment on the truck emitting non-ionised radiation (e.g. wireless datatransmission) can affect operators' medical equipment (pacemakers, hearing aidsetc.) and result in malfunctions. Consult with a doctor or the manufacturer of themedical equipment to clarify whether it can be used near the industrial truck.

3.10 Conditions of use

Ambient temperature- operating at -20 °C to +40 °C

with constant use 0 °C or. where there are extreme changes in temperatures andhumidity special equipment for forklift trucks is available for which permission isrequired.

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B 16

3.11 Electrical requirements

The manufacturer certifies compliance with the requirements for the design andmanufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -Electrical Requirements", provided the truck is used according to its purpose.

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B 16

3.11 Electrical requirements

The manufacturer certifies compliance with the requirements for the design andmanufacture of electrical equipment, according to EN 1175 "Industrial Truck Safety -Electrical Requirements", provided the truck is used according to its purpose.

B 17

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4 Identification points and data plates

Item Description16 Decal: “Caution: Low voltage electronics system"17 Truck data plate18 Test plaque (o) 19 Travel direction for steering angle (o) 20 Capacity plate, capacity / sideshift21 Capacity plate, Capacity / Load Centre of Gravity, Forks22 Capacity plate, Capacity / Load Centre of Gravity/ Lift Height23 Notice "No standing under the load carriage"24 “Final inspection completed” label25 Strap points for crane lifting26 "Do not reach through the mast" warning27 Serial no. (engraved on truck chassis)28 Jack contact points29 “Hydraulic oil filler neck” label30 Attention: Read operator manual.31 Truck name

20, 21, 22 25

24

17

18

28 25

mV1,5 V

28

30

16

26

19

23

29

27

B 17

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4 Identification points and data plates

Item Description16 Decal: “Caution: Low voltage electronics system"17 Truck data plate18 Test plaque (o) 19 Travel direction for steering angle (o) 20 Capacity plate, capacity / sideshift21 Capacity plate, Capacity / Load Centre of Gravity, Forks22 Capacity plate, Capacity / Load Centre of Gravity/ Lift Height23 Notice "No standing under the load carriage"24 “Final inspection completed” label25 Strap points for crane lifting26 "Do not reach through the mast" warning27 Serial no. (engraved on truck chassis)28 Jack contact points29 “Hydraulic oil filler neck” label30 Attention: Read operator manual.31 Truck name

20, 21, 22 25

24

17

18

28 25

mV1,5 V

28

30

16

26

19

23

29

27

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B 18

4.1 Truck data plate

Z For queries regarding the truck or ordering spare parts please quote the truck serialnumber (32) which is engraved in the chassis.

Item Description Item Description31 Type 37 Manufacturer32 Serial no. 38 Min./max. battery weight (kg)33 Rated capacity (kg) 39 Output34 Battery voltage V 40 Load centre of gravity (mm)35 Net weight w.o. battery (kg) 41 Year of manufacture36 Manufacturer’s logo 42 Option

37

36

3835

3934

4033

4132

4231

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4.1 Truck data plate

Z For queries regarding the truck or ordering spare parts please quote the truck serialnumber (32) which is engraved in the chassis.

Item Description Item Description31 Type 37 Manufacturer32 Serial no. 38 Min./max. battery weight (kg)33 Rated capacity (kg) 39 Output34 Battery voltage V 40 Load centre of gravity (mm)35 Net weight w.o. battery (kg) 41 Year of manufacture36 Manufacturer’s logo 42 Option

37

36

3835

3934

4033

4132

4231

B 19

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4.2 Truck load chart (capacity)

F Loss of stability can cause accidentsThe stability as indicated in the load chart can only be guaranteed with thecomponents (battery, mast) as shown on the data plate. Only manufacturer-approvedbatteries may be used. Batteries that are pushed forward or unlocked can alter thestability.

Z The capacity plate (22) gives the capacity (Q) of the truck in kg for a vertical mast.The maximum capacity is shown as a table with a standard load centre of gravitydistance * C (in mm) and the required lift height H (in mm). The arrow shape markings(42 and 43) on the inner and outer masts show the driver when the specified lift limitshave been reached.

*) The standard load centre of gravity distance takes into account the width as wellas the height of the load.

Example of how to calculate the maximum capacity:With a load centre of gravity distance C of 600 mm and a maximum lift height H of3600 mm. the max. capacity Q is 1105 kg.

4.3 Attachment load chart

The attachment load chart gives the truck capacity Q in conjunction with therespective attachment in kg. The serial number specified in the load chart must matchthe data plate of the attachment, as the capacity for each truck is specifically indicatedby the manufacturer. It is shown in the same way as the truck capacity and can bedetermined accordingly.

4222 43

500 600 700

850850600

X.XXXX.XX.XX

12501105850

12501105850

290036004250

B 19

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4.2 Truck load chart (capacity)

F Loss of stability can cause accidentsThe stability as indicated in the load chart can only be guaranteed with thecomponents (battery, mast) as shown on the data plate. Only manufacturer-approvedbatteries may be used. Batteries that are pushed forward or unlocked can alter thestability.

Z The capacity plate (22) gives the capacity (Q) of the truck in kg for a vertical mast.The maximum capacity is shown as a table with a standard load centre of gravitydistance * C (in mm) and the required lift height H (in mm). The arrow shape markings(42 and 43) on the inner and outer masts show the driver when the specified lift limitshave been reached.

*) The standard load centre of gravity distance takes into account the width as wellas the height of the load.

Example of how to calculate the maximum capacity:With a load centre of gravity distance C of 600 mm and a maximum lift height H of3600 mm. the max. capacity Q is 1105 kg.

4.3 Attachment load chart

The attachment load chart gives the truck capacity Q in conjunction with therespective attachment in kg. The serial number specified in the load chart must matchthe data plate of the attachment, as the capacity for each truck is specifically indicatedby the manufacturer. It is shown in the same way as the truck capacity and can bedetermined accordingly.

4222 43

500 600 700

850850600

X.XXXX.XX.XX

12501105850

12501105850

290036004250

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4.4 Stability

The truck's stability has been tested according to latest technological standards.These take into account the dynamic and static tipover forces that can occur if usedcorrectly.

Stability can also be affected by the following factors:

– Battery size and weight,– Tyres,– Mast,– Attachment,– Transported load (size, weight and centre of gravity),– Ground clearance, e.g. modification of the support columns– Position of the mast holder stops.

Changing the components can alter the stability.

4.4.1 Wind loads

Wind forces can affect the stability of a truck when lifting, lowering and transportingloads with large surface areas.

Light loads must be especially secured when they are subjected to wind forces. Thiswill prevent them from sliding or falling.

Stop the truck in both cases.

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4.4 Stability

The truck's stability has been tested according to latest technological standards.These take into account the dynamic and static tipover forces that can occur if usedcorrectly.

Stability can also be affected by the following factors:

– Battery size and weight,– Tyres,– Mast,– Attachment,– Transported load (size, weight and centre of gravity),– Ground clearance, e.g. modification of the support columns– Position of the mast holder stops.

Changing the components can alter the stability.

4.4.1 Wind loads

Wind forces can affect the stability of a truck when lifting, lowering and transportingloads with large surface areas.

Light loads must be especially secured when they are subjected to wind forces. Thiswill prevent them from sliding or falling.

Stop the truck in both cases.

C 1

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C Transport and Commissioning1 Transport

Depending on the height of the mast and local conditions, the truck can betransported in three different ways:

– Vertically, with the mast assembled (for low heights).– Vertically, with the mast partially assembled and leaning against the overhead

guard (for medium heights), lifting hydraulic line disconnected.– Vertically, with the mast dismantled (for large heights), all hydraulic lines between

the basic truck and the mast separated.


F On site assembly of the truck, commissioning and driver instruction may only becarried out by personnel trained and authorised by the manufacturer.

The hydraulic lines may only be connected to the basic truck / mast interface and thetruck commissioned when the mast has been properly assembled.

If several trucks have been delivered, make sure that the serial numbers of the loadhandlers, masts and basic truck always match.

C 1

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C Transport and Commissioning1 Transport

Depending on the height of the mast and local conditions, the truck can betransported in three different ways:

– Vertically, with the mast assembled (for low heights).– Vertically, with the mast partially assembled and leaning against the overhead

guard (for medium heights), lifting hydraulic line disconnected.– Vertically, with the mast dismantled (for large heights), all hydraulic lines between

the basic truck and the mast separated.


F On site assembly of the truck, commissioning and driver instruction may only becarried out by personnel trained and authorised by the manufacturer.

The hydraulic lines may only be connected to the basic truck / mast interface and thetruck commissioned when the mast has been properly assembled.

If several trucks have been delivered, make sure that the serial numbers of the loadhandlers, masts and basic truck always match.

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C 2

2 Lifting by crane

M Loading by crane is only intended for when the truck is being transported for thefirst time.

F Improper lifting by crane can result in accidentsThe use of unsuitable lifting gear can cause the truck to crash when being liftedby crane.

– Prevent the truck and mast from striking other objects when they are being raised,and avoid any uncontrolled movement. If necessary, secure the truck and mast withguide ropes.

– The truck and mast should only be laden by people who are trained in handling lift-ing slings and tools.

– Wear safety shoes when lifting the truck by crane.– Do not stand under a swaying load.– Do not walk into or stand in a hazardous area.– Always use lifting gear with sufficient capacity (for truck weight see truck data plate).– Always attach the crane slings to the prescribed strap points and prevent them

from slipping.– Use the lifting gear only in the prescribed load direction.

Crane slings should be fastened in such a way that they do not come into contact withany attachments when lifting.

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C 2

2 Lifting by crane

M Loading by crane is only intended for when the truck is being transported for thefirst time.

F Improper lifting by crane can result in accidentsThe use of unsuitable lifting gear can cause the truck to crash when being liftedby crane.

– Prevent the truck and mast from striking other objects when they are being raised,and avoid any uncontrolled movement. If necessary, secure the truck and mast withguide ropes.

– The truck and mast should only be laden by people who are trained in handling lift-ing slings and tools.

– Wear safety shoes when lifting the truck by crane.– Do not stand under a swaying load.– Do not walk into or stand in a hazardous area.– Always use lifting gear with sufficient capacity (for truck weight see truck data plate).– Always attach the crane slings to the prescribed strap points and prevent them

from slipping.– Use the lifting gear only in the prescribed load direction.

Crane slings should be fastened in such a way that they do not come into contact withany attachments when lifting.

C 3

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2.1 Lifting the basic truck by crane

M Only use lifting gear with sufficient capacity. (Loading weight = net weight + battery weight; see truck data plate).

– In order to lift the truck with a harness wrap rope slings around the strut of theoverhead guard (1). Two strap points (2) are provided on the outriggers.

– Park the truck securely (see Chapter E).– Secure the truck with wedges to prevent it from rolling away.

M Attach the crane slings to the strap points so that the truck cannot slip. Lifting slingsshould be fastened in such a way that they do not come into contact with any parts ofthe truck when it is being raised.

2

1

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1009

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2.1 Lifting the basic truck by crane

M Only use lifting gear with sufficient capacity. (Loading weight = net weight + battery weight; see truck data plate).

– In order to lift the truck with a harness wrap rope slings around the strut of theoverhead guard (1). Two strap points (2) are provided on the outriggers.

– Park the truck securely (see Chapter E).– Secure the truck with wedges to prevent it from rolling away.

M Attach the crane slings to the strap points so that the truck cannot slip. Lifting slingsshould be fastened in such a way that they do not come into contact with any parts ofthe truck when it is being raised.

2

1

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C 4

2.2 Lifting the basic truck and cabin by crane

M If the truck is equipped with a weatherproof cab (o) or a cold store cab (o), theoptions for lifting by crane are restricted. Because of the risk to the window, the cranelifting gear and rope slings must not pass over the front door.

Z Always use crane lifting gear with sufficiently wide cross members and attachmentslings with hooks to lift the truck with a weather-proof cab or a cold store cab.

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C 4

2.2 Lifting the basic truck and cabin by crane

M If the truck is equipped with a weatherproof cab (o) or a cold store cab (o), theoptions for lifting by crane are restricted. Because of the risk to the window, the cranelifting gear and rope slings must not pass over the front door.

Z Always use crane lifting gear with sufficiently wide cross members and attachmentslings with hooks to lift the truck with a weather-proof cab or a cold store cab.

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3 Securing the truck during transport

F The truck must be securely fastened when transported on a lorry or a trailer. Thelorry / trailer must have fastening rings.

– To fasten the truck pull the tensioning belt (3) through the guide on the overheadguard brace (1) and attach it to the fastening rings.

– Tighten the tensioning belt with the tensioner (4).

M Loading must be carried out by specially trained staff in accordance withrecommendations contained in Guidelines VDI 2700. In each case correctmeasurements must be taken and appropriate safety measures adopted.

3

1

4

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3 Securing the truck during transport

F The truck must be securely fastened when transported on a lorry or a trailer. Thelorry / trailer must have fastening rings.

– To fasten the truck pull the tensioning belt (3) through the guide on the overheadguard brace (1) and attach it to the fastening rings.

– Tighten the tensioning belt with the tensioner (4).

M Loading must be carried out by specially trained staff in accordance withrecommendations contained in Guidelines VDI 2700. In each case correctmeasurements must be taken and appropriate safety measures adopted.

3

1

4

1009

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C 6

4 Using the truck for the first time

F Before commissioning the truck ensure that the mast is correctly assembled and thehydraulic hoses have been connected to the basic truck / mast interface.

M Only operate the truck with battery current. Rectified AC current will damage theelectronic components. The battery leads (tow cable) must be less than 6m long.

To prepare the truck after delivery or transport the following tasks must be carried out:

– Install battery (where required). Do not damage battery cable.– Charge the battery (see Chapter D).– If necessary, remove the transport lock from the parking brake.– Visually inspect the truck, see "Checks Before Starting Daily Operation" in Chapter E.– Commission the truck in accordance with instructions (see Chapter E).– Test the truck, see "Testing After Daily Operation" in Chapter E.

Z If supplied without a battery, the truck can only be steered with the steering crank(see Chapter E, “Truck Recovery”).

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C 6

4 Using the truck for the first time

F Before commissioning the truck ensure that the mast is correctly assembled and thehydraulic hoses have been connected to the basic truck / mast interface.

M Only operate the truck with battery current. Rectified AC current will damage theelectronic components. The battery leads (tow cable) must be less than 6m long.

To prepare the truck after delivery or transport the following tasks must be carried out:

– Install battery (where required). Do not damage battery cable.– Charge the battery (see Chapter D).– If necessary, remove the transport lock from the parking brake.– Visually inspect the truck, see "Checks Before Starting Daily Operation" in Chapter E.– Commission the truck in accordance with instructions (see Chapter E).– Test the truck, see "Testing After Daily Operation" in Chapter E.

Z If supplied without a battery, the truck can only be steered with the steering crank(see Chapter E, “Truck Recovery”).

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BD Battery Maintenance, Charging &

Replacement1 Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries (see Chapter E).

Maintenance personnel: Batteries may only be charged, serviced or replaced bytrained personnel. The present operator manual and the manufacturer’s instructionsconcerning batteries and charging stations must be observed when carrying out thework.

Fire protection: Smoking and naked flames must be avoided when working withbatteries Wherever a truck is parked for charging there shall be no inflammablematerial or operating fluids capable of creating sparks within 2 metres around thetruck. The area must be well ventilated. Fire protection equipment must be provided.

Battery maintenance: The battery cell covers must be kept dry and clean. Theterminals and cable shoes must be clean, secure and have a light coating of dielectricgrease. Batteries with non insulated terminals must be covered with a non slipinsulation mat.

M Before closing the battery cover make sure that the battery lead cannot be damaged.

Battery Disposal: Batteries may only be disposed of in accordance with nationalenvironmental protection regulations or disposal laws. The manufacturer’s disposalinstructions must be followed.

F Batteries contain an acid solution which is poisonous and corrosive. Therefore,always wear protective clothing and eye protection when carrying out work onbatteries. Above all avoid any contact with battery acid.Nevertheless, should clothing, skin or eyes come in contact with acid the affectedparts should be rinsed with plenty of clean water - where the skin or eyes are affectedcall a doctor immediately. Immediately neutralise any spilled battery acid.

M Only batteries with a sealed battery container may be used.

F The weight and dimensions of the battery have considerable affect on the operationalsafety of the truck. Battery equipment may only be replaced with the agreement of themanufacturer.

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D Battery Maintenance, Charging &Replacement

1 Safety regulations for handling acid batteries

Park the truck securely before carrying out any work on the batteries (see Chapter E).

Maintenance personnel: Batteries may only be charged, serviced or replaced bytrained personnel. The present operator manual and the manufacturer’s instructionsconcerning batteries and charging stations must be observed when carrying out thework.

Fire protection: Smoking and naked flames must be avoided when working withbatteries Wherever a truck is parked for charging there shall be no inflammablematerial or operating fluids capable of creating sparks within 2 metres around thetruck. The area must be well ventilated. Fire protection equipment must be provided.

Battery maintenance: The battery cell covers must be kept dry and clean. Theterminals and cable shoes must be clean, secure and have a light coating of dielectricgrease. Batteries with non insulated terminals must be covered with a non slipinsulation mat.

M Before closing the battery cover make sure that the battery lead cannot be damaged.

Battery Disposal: Batteries may only be disposed of in accordance with nationalenvironmental protection regulations or disposal laws. The manufacturer’s disposalinstructions must be followed.

F Batteries contain an acid solution which is poisonous and corrosive. Therefore,always wear protective clothing and eye protection when carrying out work onbatteries. Above all avoid any contact with battery acid.Nevertheless, should clothing, skin or eyes come in contact with acid the affectedparts should be rinsed with plenty of clean water - where the skin or eyes are affectedcall a doctor immediately. Immediately neutralise any spilled battery acid.

M Only batteries with a sealed battery container may be used.

F The weight and dimensions of the battery have considerable affect on the operationalsafety of the truck. Battery equipment may only be replaced with the agreement of themanufacturer.

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D 2

F WARNING!Unsuitable batteries that have not been approved by Jungheinrich for the truck canbe hazardous. The design, weight and dimensions of the battery have a considerableeffect on the operational safety of the truck, in particular its stability and capacity. Theuse of unsuitable batteries that have not been approved by Jungheinrich for the truckcan lead to a deterioration of the braking system during energy recovery operationsand also cause considerable damage to the electrical control system. The use ofbatteries that have not been approved by Jungheinrich can therefore affect the healthand safety of personnel.

– Only manufacturer-approved batteries may be used on the truck.– Battery equipment may only be replaced with the agreement of the manufacturer.– When replacing/installing the battery make sure the battery is securely located in

the battery compartment of the truck.– Do not use batteries that have not been approved by the manufacturer.

2 Battery types

The truck will be equipped with different battery types, depending on the application. The following table shows which combinations can be included as standard:

The battery weight is indicated on the battery data plate.

F When replacing/installing the battery make sure the battery is securely located in thebattery compartment of the truck.

Capacitance Standard (L) High Performance HX)48 V - 2PzS battery 280 Ah 280L 310H48 V - 3PzS battery 420 Ah 420L 450H48 V - 4PzS battery 560 Ah 560L 600H48 V - 5PzS battery 700 Ah 700L 775H

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D 2

F WARNING!Unsuitable batteries that have not been approved by Jungheinrich for the truck canbe hazardous. The design, weight and dimensions of the battery have a considerableeffect on the operational safety of the truck, in particular its stability and capacity. Theuse of unsuitable batteries that have not been approved by Jungheinrich for the truckcan lead to a deterioration of the braking system during energy recovery operationsand also cause considerable damage to the electrical control system. The use ofbatteries that have not been approved by Jungheinrich can therefore affect the healthand safety of personnel.

– Only manufacturer-approved batteries may be used on the truck.– Battery equipment may only be replaced with the agreement of the manufacturer.– When replacing/installing the battery make sure the battery is securely located in

the battery compartment of the truck.– Do not use batteries that have not been approved by the manufacturer.

2 Battery types

The truck will be equipped with different battery types, depending on the application. The following table shows which combinations can be included as standard:

The battery weight is indicated on the battery data plate.

F When replacing/installing the battery make sure the battery is securely located in thebattery compartment of the truck.

Capacitance Standard (L) High Performance HX)48 V - 2PzS battery 280 Ah 280L 310H48 V - 3PzS battery 420 Ah 420L 450H48 V - 4PzS battery 560 Ah 560L 600H48 V - 5PzS battery 700 Ah 700L 775H

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B3 Exposing the battery

F Accident riskTrapping hazard when exposing the battery.

– Instruct any persons to leave the hazardous area.– Make sure there is nothing between the battery and the mast holder when you

move the mast holder.

Procedure

– Preparing for Operation (see Chapter E).

Solo Pilot:

– Move the Solo Pilot (1) in the arrow direction. (U). Move the mast holder as far asthe stop in the battery direction and release the Solo Pilot (the mast is now in itslimit position).

T

3

U

1

2

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B

3 Exposing the battery

F Accident riskTrapping hazard when exposing the battery.

– Instruct any persons to leave the hazardous area.– Make sure there is nothing between the battery and the mast holder when you

move the mast holder.

Procedure

– Preparing for Operation (see Chapter E).

Solo Pilot:

– Move the Solo Pilot (1) in the arrow direction. (U). Move the mast holder as far asthe stop in the battery direction and release the Solo Pilot (the mast is now in itslimit position).

T

3

U

1

2

03.1

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D 4

– Again move the Solo Pilot (1) in the direction of arrow (U) and move the mastsupport further towards the battery as far as the stop position (preparation forunlatching the battery) and hold it in this position.

– Maintain the Solo Pilot (1) in the arrow direction (U) (second lever) and depress thebattery unlocking device (2) with your right foot.

The “battery unlocked” button (red graphic symbol) (3) lights up on the driver’sdisplay.

– Move the Solo Pilot (1) towards arrow (T) and extend the mast holder with thecoupled battery trolley until the battery is exposed for maintenance.

– Release the battery unlatch pedal (2).– Turn the EMERGENCY DISCONNECT switch and key switch off.

Z The battery unlatch safety switch only allows for travel at crawl speed if the batterytrolley is unlocked and the control light (3) is still on. Before starting up the truck again,the battery trolley must be restored to its initial position in order to uncouple thebattery trolley and the mast holder. Control display (3) must be off.

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D 4

– Again move the Solo Pilot (1) in the direction of arrow (U) and move the mastsupport further towards the battery as far as the stop position (preparation forunlatching the battery) and hold it in this position.

– Maintain the Solo Pilot (1) in the arrow direction (U) (second lever) and depress thebattery unlocking device (2) with your right foot.


– Move the Solo Pilot (1) towards arrow (T) and extend the mast holder with thecoupled battery trolley until the battery is exposed for maintenance.



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BMulti Pilot:

– Move the Multi Pilot (4) in the arrow direction. (U). Move the mast holder as far asthe stop in the battery direction and release the Multi Pilot (the mast is now in itslimit position).

– Again move the Multi Pilot (4) in the direction of arrow (U) and move the mastsupport further towards the battery as far as the stop position (preparation forunlatching the battery) and hold it in this position.

– Maintain the Multi Pilot (4) in the arrow direction (U) (second lever) and depress thebattery unlocking device (2) with your right foot.

U

T4

3

2

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B

Multi Pilot:

– Move the Multi Pilot (4) in the arrow direction. (U). Move the mast holder as far asthe stop in the battery direction and release the Multi Pilot (the mast is now in itslimit position).

– Again move the Multi Pilot (4) in the direction of arrow (U) and move the mastsupport further towards the battery as far as the stop position (preparation forunlatching the battery) and hold it in this position.

– Maintain the Multi Pilot (4) in the arrow direction (U) (second lever) and depress thebattery unlocking device (2) with your right foot.

U

T4

3

2

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D 6


– Move Multi Pilot (1) towards arrow (T) and extend the mast holder with the coupledbattery trolley until the battery is exposed for maintenance.



03.1

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B

D 6


– Move Multi Pilot (1) towards arrow (T) and extend the mast holder with the coupledbattery trolley until the battery is exposed for maintenance.



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B4 Charging the battery

M The gases produced during charging can cause explosions

The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.

– Switch the charging station and truck off first before connecting/disconnecting thecharging cable of the battery charging station to/from the battery connector.

– The charger must be adapted to the battery in terms of voltage and charge capacity.– Before charging, check all cables and plug connections for visible signs of damage.– Ventilate the room in which the truck is being charged.– The battery cover must be open and the battery cell surfaces must be exposed dur-

ing charging to ensure adequate ventilation.– Do not smoke and avoid naked flames when handling batteries.– Wherever an industrial truck is parked for charging there shall be no inflammable

material or lubricants capable of creating sparks within 2 metres around the truck.– Fire protection equipment must be on hand.– Do not lay any metallic objects on battery.– It is essential to follow the safety regulations of the battery and charger station

manufacturers.– Expose the battery (see Section 3).

Procedure

– Expose the battery (see Section 3).

F When charging, the tops of the battery cells must be exposed to provide sufficientventilation. Do not place any metal objects on the battery. Before charging, check allcables and plug connections for visible signs of damage.

– Where necessary remove the insulating mat from the battery.– Connect the battery charging station cable to the battery plug.– Charge the battery in accordance with the battery and charging station manu-

facturers’ instructions.

F It is essential to follow the safety regulations of the battery and charging stationmanufacturers.

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B

4 Charging the battery

M The gases produced during charging can cause explosions

The battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.

– Switch the charging station and truck off first before connecting/disconnecting thecharging cable of the battery charging station to/from the battery connector.

– The charger must be adapted to the battery in terms of voltage and charge capacity.– Before charging, check all cables and plug connections for visible signs of damage.– Ventilate the room in which the truck is being charged.– The battery cover must be open and the battery cell surfaces must be exposed dur-

ing charging to ensure adequate ventilation.– Do not smoke and avoid naked flames when handling batteries.– Wherever an industrial truck is parked for charging there shall be no inflammable

material or lubricants capable of creating sparks within 2 metres around the truck.– Fire protection equipment must be on hand.– Do not lay any metallic objects on battery.– It is essential to follow the safety regulations of the battery and charger station

manufacturers.– Expose the battery (see Section 3).

Procedure


F When charging, the tops of the battery cells must be exposed to provide sufficientventilation. Do not place any metal objects on the battery. Before charging, check allcables and plug connections for visible signs of damage.

– Where necessary remove the insulating mat from the battery.– Connect the battery charging station cable to the battery plug.– Charge the battery in accordance with the battery and charging station manu-

facturers’ instructions.

F It is essential to follow the safety regulations of the battery and charging stationmanufacturers.

03.1

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B

D 8

5 Battery removal and installation

F Always install the battery with a cable guide

When a battery is installed a cable guide (5) must be fitted with the appropriate batterycable. The battery cable length depends on the battery type.

– Contact the manufacturer's service department when replacing the factory-fittedbattery.

M Accident risk during battery removal and installation

Due to the battery weight and acid there is a risk of trapping or scalding when the bat-tery is removed and installed.

– Note the "Safety regulations for handling acid batteries" section in this chapter.– Wear safety shoes when removing and installing the battery.– Do not reach between the battery and the truck.– Use only batteries with insulated cells and terminal connectors.– Cover batteries with open terminals or connectors with a rubber mat.– Park the truck on a level surface to prevent the battery from sliding out.– Make sure the crane lifting gear has sufficient capacity to replace the battery.– The crane lifting gear must exert a vertical pull so that the battery container is not

compressed.– Hooks must be fitted in such a way that when the crane lifting gear is slackened,

it does not fall onto the battery cells.– Use only approved battery replacement devices (battery roller stand, replacement

trolley etc.)– Make sure the battery is securely located in the truck's battery compartment.

Procedure


F To prevent short circuits, batteries with exposed terminals or connectors must becovered with a rubber mat. When replacing a battery with a crane, make sure thecrane has sufficient capacity (see battery weight on the battery data plate on thecontainer). The lifting gear must exert a vertical pull so that the battery container isnot compressed. Hooks must be fitted in such a way that when the crane liftingharness is slackened, they do not fall onto the battery cells.

5

03.1

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B

D 8

5 Battery removal and installation

F Always install the battery with a cable guide

When a battery is installed a cable guide (5) must be fitted with the appropriate batterycable. The battery cable length depends on the battery type.

– Contact the manufacturer's service department when replacing the factory-fittedbattery.

M Accident risk during battery removal and installation

Due to the battery weight and acid there is a risk of trapping or scalding when the bat-tery is removed and installed.

– Note the "Safety regulations for handling acid batteries" section in this chapter.– Wear safety shoes when removing and installing the battery.– Do not reach between the battery and the truck.– Use only batteries with insulated cells and terminal connectors.– Cover batteries with open terminals or connectors with a rubber mat.– Park the truck on a level surface to prevent the battery from sliding out.– Make sure the crane lifting gear has sufficient capacity to replace the battery.– The crane lifting gear must exert a vertical pull so that the battery container is not

compressed.– Hooks must be fitted in such a way that when the crane lifting gear is slackened,

it does not fall onto the battery cells.– Use only approved battery replacement devices (battery roller stand, replacement

trolley etc.)– Make sure the battery is securely located in the truck's battery compartment.

Procedure


F To prevent short circuits, batteries with exposed terminals or connectors must becovered with a rubber mat. When replacing a battery with a crane, make sure thecrane has sufficient capacity (see battery weight on the battery data plate on thecontainer). The lifting gear must exert a vertical pull so that the battery container isnot compressed. Hooks must be fitted in such a way that when the crane liftingharness is slackened, they do not fall onto the battery cells.

5

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BRemoval and Installation using a Crane Lifting Harness

– Loosen and remove the retaining screw (8) from the battery lock (7).– Remove the battery lock (7).– If necessary, remove the battery cover.– Strap the crane lifting harness to both sides of the battery container (6).– Lift the battery clear and move out to the side.

Removal and Installation using a Battery Trolley (o)

F The truck be horizontal to prevent the battery itself from rolling out when removing thebattery retaining bracket.

– Loosen and remove the retaining screw (8) from the battery lock (7).– Remove the battery lock (7).– If necessary, remove the battery cover.– Lift the battery to the side on to the battery trolley

Assembly is the reverse order.

F When replacing a battery always use the same battery type. After installing thebattery again, check all cables and plug connections for visible signs of damage. Thecovers must be tightly shut.

6

8

7

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B

Removal and Installation using a Crane Lifting Harness

– Loosen and remove the retaining screw (8) from the battery lock (7).– Remove the battery lock (7).– If necessary, remove the battery cover.– Strap the crane lifting harness to both sides of the battery container (6).– Lift the battery clear and move out to the side.

Removal and Installation using a Battery Trolley (o)

F The truck be horizontal to prevent the battery itself from rolling out when removing thebattery retaining bracket.

– Loosen and remove the retaining screw (8) from the battery lock (7).– Remove the battery lock (7).– If necessary, remove the battery cover.– Lift the battery to the side on to the battery trolley

Assembly is the reverse order.

F When replacing a battery always use the same battery type. After installing thebattery again, check all cables and plug connections for visible signs of damage. Thecovers must be tightly shut.

6

8

7

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E 1

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E Operation1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation: The forklift truck may only be used by suitably trainedpersonnel, who have demonstrated to the proprietor or his representative that theycan drive and handle loads and have been authorised to operate the truck by theproprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.

Do not lean out or reach beyond the working and operating area. The driver mustremain within the geometry of the overhead guard during operation.

Unauthorised use of truck: The driver is responsible for the truck during the time itis in use. The driver must prevent unauthorised persons from driving or operating thetruck. Do not carry passengers or lift other people.

Damage and faults: The supervisor must be immediately informed of any damageor faults to the forklift truck or attachment. Trucks which are unsafe for operation(e.g. wheel or brake problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the industrial truckwithout the necessary training and authorisation to do so. The driver must neverdisable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at riskdue 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 orlowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there isdanger to personnel, a warning must be sounded with sufficient notice. Ifunauthorised personnel are still within the hazardous area the truck shall be broughtto a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warninginstructions shall be strictly observed.


E 1

0812

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E Operation1 Safety Regulations for the Operation of Forklift Trucks

Driver authorisation: The forklift truck may only be used by suitably trainedpersonnel, who have demonstrated to the proprietor or his representative that theycan drive and handle loads and have been authorised to operate the truck by theproprietor or his representative.

Driver’s rights, obligations and responsibilities: The driver must be informed ofhis duties and responsibilities and be instructed in the operation of the truck and shallbe familiar with the operator manual. The driver shall be afforded all due rights. Safety shoes must be worn for pedestrian operated trucks.

Do not lean out or reach beyond the working and operating area. The driver mustremain within the geometry of the overhead guard during operation.

Unauthorised use of truck: The driver is responsible for the truck during the time itis in use. The driver must prevent unauthorised persons from driving or operating thetruck. Do not carry passengers or lift other people.

Damage and faults: The supervisor must be immediately informed of any damageor faults to the forklift truck or attachment. Trucks which are unsafe for operation(e.g. wheel or brake problems) must not be used until they have been rectified.

Repairs: The driver must not carry out any repairs or alterations to the industrial truckwithout the necessary training and authorisation to do so. The driver must neverdisable or adjust safety mechanisms or switches.

Hazardous area: A hazardous area is defined as the area in which a person is at riskdue 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 orlowering operating equipment.

F Unauthorised persons must be kept away from the hazardous area. Where there isdanger to personnel, a warning must be sounded with sufficient notice. Ifunauthorised personnel are still within the hazardous area the truck shall be broughtto a halt immediately.

Safety devices and warning signs: Safety devices, warning signs and warninginstructions shall be strictly observed.


0812

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E 2

2 Controls and Displays

Item Control / Display Function1 Key switch t Switches control current on and off.

Removing the key prevents the truck from being switched on by unauthorised personnel.

Keypad(CANCODE)

o Used to set codes and to switch on the truck

ISM Access Module o Used to set codes and to switch on the truck2 EMERGENCY

DISCONNECTt Disconnects the supply current, deactivates

all electrical functions, causing the truck to brake automatically.

3a3b

Solo PilotMulti Pilot

to

Operating the functions:– Forward / reverse travel direction – Load handler lift/lower – Mast support extend / retract– Mast forward or backward tilt / fork tilt– Sideshift left / right – Horn button– Aux. hydraulics (HF5) (o)

4 Armrest lock t Armrest longitudinal adjuster5 Driver's seat lock t The driver’s seat can be horizontally

adjusted.6 Weight adjustment -

driver’s seatt Adjusts driver’s weight for optimal seat

cushioning7 Backrest adjuster t The backrest on the driver’s seat can be

adjusted.8 Accelerator pedal t Provides infinite control of travel speed.9 Brake pedal t Brakes the truck.10 Deadman button t – Not applied: Travel inhibited, truck

decelerates.– Applied: Travel released.

t = Standard equipment o= Optional equipment

0812

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E 2

2 Controls and Displays

Item Control / Display Function1 Key switch t Switches control current on and off.

Removing the key prevents the truck from being switched on by unauthorised personnel.

Keypad(CANCODE)

o Used to set codes and to switch on the truck

ISM Access Module o Used to set codes and to switch on the truck2 EMERGENCY

DISCONNECTt Disconnects the supply current, deactivates

all electrical functions, causing the truck to brake automatically.

3a3b

Solo PilotMulti Pilot

to

Operating the functions:– Forward / reverse travel direction – Load handler lift/lower – Mast support extend / retract– Mast forward or backward tilt / fork tilt– Sideshift left / right – Horn button– Aux. hydraulics (HF5) (o)

4 Armrest lock t Armrest longitudinal adjuster5 Driver's seat lock t The driver’s seat can be horizontally

adjusted.6 Weight adjustment -

driver’s seatt Adjusts driver’s weight for optimal seat

cushioning7 Backrest adjuster t The backrest on the driver’s seat can be

adjusted.8 Accelerator pedal t Provides infinite control of travel speed.9 Brake pedal t Brakes the truck.10 Deadman button t – Not applied: Travel inhibited, truck

decelerates.– Applied: Travel released.

t = Standard equipment o= Optional equipment

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311

4

568910 7

12

13

1 2

14

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12

13

1 2

14

0812

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E 4

Item Control / Display Function11 Override switch

Limit switch system and lift height display

o Prevents damage to the truck and the load.

12 Steering column adjustment

t Sets steering column distance and height.

13 Driver’s display t Displays important travel and lift parameters, selection and display of steering modes, warnings, incorrect operation notes and service displays (see Section 6).

14 Battery trolley unlatch pedal

t Unlatches the battery trolley.

t = Standard equipment o = Optional equipment

0812

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E 4

Item Control / Display Function11 Override switch

Limit switch system and lift height display

o Prevents damage to the truck and the load.

12 Steering column adjustment

t Sets steering column distance and height.

13 Driver’s display t Displays important travel and lift parameters, selection and display of steering modes, warnings, incorrect operation notes and service displays (see Section 6).

14 Battery trolley unlatch pedal

t Unlatches the battery trolley.

t = Standard equipment o = Optional equipment

E 5

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3 Starting up the Truck

F Before the truck can be started, operated or a load lifted, the driver must ensure thatthere is nobody within the hazardous area.

Checks and operations to be performed before starting daily work

– Inspect the entire truck (in particular wheels, wheel bolts and load handler)for damage.

– Visually inspect the hydraulic system in the visible area for damage and leaks.Damaged hoses must be replaced immediately.

– Check the battery attachment and wire connections for damage and make surethey are secure.

– Check the battery connector is secure.– Check the load handler for visible signs of damage such as cracks, bent or severely

worn forks.– Check the forks.– Check the drive wheel and load wheels for damage.– Check that the lift chains are evenly tensioned and damage-free.– Check that the load chart and warning labels are legible.– Check the fork tine retaining screw.– Integrated sideshifter (o): Check the screws on the restraint system (B) and

the fork locking system (A) are secure, tighten if necessary. Torque: 190 Nm.

Sideshifter with roller guide Sideshifter with slip-in guide

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3 Starting up the Truck

F Before the truck can be started, operated or a load lifted, the driver must ensure thatthere is nobody within the hazardous area.


– Inspect the entire truck (in particular wheels, wheel bolts and load handler)for damage.

– Visually inspect the hydraulic system in the visible area for damage and leaks.Damaged hoses must be replaced immediately.

– Check the battery attachment and wire connections for damage and make surethey are secure.

– Check the battery connector is secure.– Check the load handler for visible signs of damage such as cracks, bent or severely

worn forks.– Check the forks.– Check the drive wheel and load wheels for damage.– Check that the lift chains are evenly tensioned and damage-free.– Check that the load chart and warning labels are legible.– Check the fork tine retaining screw.– Integrated sideshifter (o): Check the screws on the restraint system (B) and

the fork locking system (A) are secure, tighten if necessary. Torque: 190 Nm.

Sideshifter with roller guide Sideshifter with slip-in guide

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3.1 Entry and exit

– To enter and exit the cab, hold onto the handle (13a).– Enter or leave the truck.

3.2 Setting up the operator position

M An operator position that is unsecured or has not been set up can cause injury

An unsecured driver's seat can slide out of its guide during travel, resultingin accidents. An operator position that has not been, or is incorrectly, set up cancause accidents.

– The driver's seat must be locked in position.– Do not adjust the driver’s seat, steering column or armrest while travelling.– Before starting to travel, adjust the driver’s seat, steering column and armrest so

that all the controls are within reach and can be applied without having to strain.

Adjusting the driver’s seat

Z To achieve optimal seat cushioning the driver’s seat must be adapted to the driver’sweight. The driver’s seat must be vacant when adapting it to the driver's weight.

Setting the driver's weight:

– Pull the lever (6) in the direction of thearrow as far as the stop and thenreturn it.

Z The previous weight setting is reset tothe minimum value.Seat suspension setting ranges from50 to 130 kg

– Move lever (6) again in the direction ofthe arrow until the correspondingweight marking on the scale (15) isreached. Then finally return the lever.

– Sit on the driver’s seat.

F Do not reach between the seat and theside wall / overhead guard.

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3.1 Entry and exit

– To enter and exit the cab, hold onto the handle (13a).– Enter or leave the truck.

3.2 Setting up the operator position

M An operator position that is unsecured or has not been set up can cause injury

An unsecured driver's seat can slide out of its guide during travel, resultingin accidents. An operator position that has not been, or is incorrectly, set up cancause accidents.

– The driver's seat must be locked in position.– Do not adjust the driver’s seat, steering column or armrest while travelling.– Before starting to travel, adjust the driver’s seat, steering column and armrest so

that all the controls are within reach and can be applied without having to strain.

Adjusting the driver’s seat

Z To achieve optimal seat cushioning the driver’s seat must be adapted to the driver’sweight. The driver’s seat must be vacant when adapting it to the driver's weight.

Setting the driver's weight:

– Pull the lever (6) in the direction of thearrow as far as the stop and thenreturn it.

Z The previous weight setting is reset tothe minimum value.Seat suspension setting ranges from50 to 130 kg

– Move lever (6) again in the direction ofthe arrow until the correspondingweight marking on the scale (15) isreached. Then finally return the lever.

– Sit on the driver’s seat.

F Do not reach between the seat and theside wall / overhead guard.

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To adjust the backrest:

– Lift up locking lever (7) and adjust the incline of the backrest (16).– Release locking lever to lock the backrest in position.

To adjust the seat position:

– Pull up the locking lever (5) of the driver’s seat lock in the direction of the arrow andpush the seat forwards or backwards to the desired position.

– Engage the locking lever (5) in position again.

Z The procedure for adjusting the driver’s seat applies to standard models. For othermodels, follow the manufacturer’s adjustment instructions. When adjusting, ensurethat all controls are within easy reach.

Set the seat heating

M Avoid prolonged contact of uncovered / unprotected skin with the heated seat.

Procedure

– Press the seat heating button (C) once.The heating changes to heat mode level 3 (highest level), all LEDs (D) arepermanently lit.

– Press the seat heating button (C) again.The heating changes to heat mode level 2.


– Press the seat heating button (C) again.The heating changes to operational (Off).

Seat heating set.

M In the event of an error one or more LEDs (D) next to the switch light up. Switch offthe truck. Switch the truck on again. Call the service department if necessary.

Z The cold store version (o) contains seat heating which is controlled via the switch (8)in the overhead guard.

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Z The procedure for adjusting the driver’s seat applies to standard models. For othermodels, follow the manufacturer’s adjustment instructions. When adjusting, ensurethat all controls are within easy reach.

Set the seat heating

M Avoid prolonged contact of uncovered / unprotected skin with the heated seat.

Procedure

– Press the seat heating button (C) once.The heating changes to heat mode level 3 (highest level), all LEDs (D) arepermanently lit.



– Press the seat heating button (C) again.The heating changes to operational (Off).

Seat heating set.

M In the event of an error one or more LEDs (D) next to the switch light up. Switch offthe truck. Switch the truck on again. Call the service department if necessary.

Z The cold store version (o) contains seat heating which is controlled via the switch (8)in the overhead guard.

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Adjusting the driver’s seat (comfort seat, o)

Z To avoid risk to health and property, check and adjust the individual driver’s seatsetting before starting up the truck.The driver’s seat must be occupied in order to adjust to the driver’s weight.

Adjusting the driver's weight:

– Move the lever (9) as far asit will go in the arrowdirection. To adjust, movethe lever up or down andthen restore it to its homeposition.

– Move the lever up anddown to set the seat to ahigher weight.

– Move the lever down andup to set the seat to a lowerweight.

Z The driver's weight is correctif the arrow is in the middle ofthe display window (18).The min. or max. weight setting is reached when you can feel a return stroke on thelever.

– After adjusting the weight, move the lever back fully until it engages.


F The backrest must be securely engaged in the set position. The backrest setting mustnot be changed during travel!



F Hold the locking lever (8) only the recess, do not reach through underneath the lever.The driver’s seat must be securely engaged in the set position. The driver’s seatsetting must not be changed during travel.Do not lift the locking lever with your leg or calves.



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Adjusting the driver’s seat (comfort seat, o)

Z To avoid risk to health and property, check and adjust the individual driver’s seatsetting before starting up the truck.The driver’s seat must be occupied in order to adjust to the driver’s weight.

Adjusting the driver's weight:

– Move the lever (9) as far asit will go in the arrowdirection. To adjust, movethe lever up or down andthen restore it to its homeposition.

– Move the lever up anddown to set the seat to ahigher weight.

– Move the lever down andup to set the seat to a lowerweight.

Z The driver's weight is correctif the arrow is in the middle ofthe display window (18).The min. or max. weight setting is reached when you can feel a return stroke on thelever.

– After adjusting the weight, move the lever back fully until it engages.


F The backrest must be securely engaged in the set position. The backrest setting mustnot be changed during travel!



F Hold the locking lever (8) only the recess, do not reach through underneath the lever.The driver’s seat must be securely engaged in the set position. The driver’s seatsetting must not be changed during travel.Do not lift the locking lever with your leg or calves.



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Seat heating:

Apply the switch (6): 1 = seat heating ON; 0 = seat heating OFF

Lumbar vertebrae support:

Hand wheel (7) in position 0 = no bending in lumbar vertebrae area.

Turn hand wheel (7) to position 1 = Increased bending in upper lumbar vertebrae area.

Turn hand wheel (7) to position 2 = Increased bending in lower lumbar vertebrae area.

3.2.1 Using the seat belt o

– Put on the seat belt each time beforestarting the industrial truck.

– Change the belt height setting (22)according to your body size.

– Do not alter the belt setting.– Frozen belt locks (20) or pulleys must

be thawed out and dried.– The warm air temperature must not

exceed +60 °C.– The seat belt and seat cover must be

checked for damage after an accidentand replaced if necessary.

– Damaged or non-functional belts to bereplaced only by contracted dealers orbranches.

– Only original spare parts to be used forretrofits or repairs.

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Seat heating:

Apply the switch (6): 1 = seat heating ON; 0 = seat heating OFF

Lumbar vertebrae support:

Hand wheel (7) in position 0 = no bending in lumbar vertebrae area.

Turn hand wheel (7) to position 1 = Increased bending in upper lumbar vertebrae area.

Turn hand wheel (7) to position 2 = Increased bending in lower lumbar vertebrae area.

3.2.1 Using the seat belt o

– Put on the seat belt each time beforestarting the industrial truck.

– Change the belt height setting (22)according to your body size.

– Do not alter the belt setting.– Frozen belt locks (20) or pulleys must

be thawed out and dried.– The warm air temperature must not

exceed +60 °C.– The seat belt and seat cover must be

checked for damage after an accidentand replaced if necessary.

– Damaged or non-functional belts to bereplaced only by contracted dealers orbranches.

– Only original spare parts to be used forretrofits or repairs.

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3.2.2 Seat belt operating instructions

Before starting the truck pull the belt out of its the retractor, tight against your bodyand engage it in the lock (20).

F The belt must not be twisted when fastened.

When operating the industrial truck (e.g. travelling, lifting,lowering, etc.), sit back as far as possible so that your back isagainst the backrest.

The automatic lock on the take up pulley permits sufficientmovement in the seat.

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

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

– After using the belt press the red button and manually passthe lock tongue (21) to the retractor.

Starting the industrial truck on steep slopes

The automatic blocking system locks the belt in the retractor when the truck ispositioned on a steep slope. The belt cannot be removed further from the retractor.Carefully drive the truck off the slope and then put on the belt.

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3.2.2 Seat belt operating instructions

Before starting the truck pull the belt out of its the retractor, tight against your bodyand engage it in the lock (20).

F The belt must not be twisted when fastened.

When operating the industrial truck (e.g. travelling, lifting,lowering, etc.), sit back as far as possible so that your back isagainst the backrest.

The automatic lock on the take up pulley permits sufficientmovement in the seat.

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

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

– After using the belt press the red button and manually passthe lock tongue (21) to the retractor.

Starting the industrial truck on steep slopes

The automatic blocking system locks the belt in the retractor when the truck ispositioned on a steep slope. The belt cannot be removed further from the retractor.Carefully drive the truck off the slope and then put on the belt.

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Adjusting the steering column

– Undo the steering column lock (12)and adjust the steering head (17)vertically and horizontally to therequired position.

Now fix the steering column lock again.

Adjusting the armrest

– Raise the armrest lock (4) and set thearmrest (18) to the required position(longitudinally).

– Release the armrest bar (4) again.

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Adjusting the steering column

– Undo the steering column lock (12)and adjust the steering head (17)vertically and horizontally to therequired position.

Now fix the steering column lock again.

Adjusting the armrest

– Raise the armrest lock (4) and set thearmrest (18) to the required position(longitudinally).

– Release the armrest bar (4) again.

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3.3 Preparing the truck for operation

– Pull up the EMERGENCYDISCONNECT switch (2).

– Insert the key in the key switch (1) andturn it clockwise to the “I” position or:

– for trucks without a key switch, enterthe release code via CANCODE (1a), or

For the CANCODE (o), enter thestarting PIN 2580 via the keypad (1a).

– Test horn.

The truck is now operational. The batterydischarge monitor shows the availablebattery capacity.

– Check the operation of the brake andhandbrake(see Section 4.4).

– When you start up the truck thedeadman switch must be applied.

– Selects the travel direction.– Release the parking brake with the

brake switch (19).

The truck is operational.

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3.3 Preparing the truck for operation

– Pull up the EMERGENCYDISCONNECT switch (2).

– Insert the key in the key switch (1) andturn it clockwise to the “I” position or:

– for trucks without a key switch, enterthe release code via CANCODE (1a), or

For the CANCODE (o), enter thestarting PIN 2580 via the keypad (1a).

– Test horn.

The truck is now operational. The batterydischarge monitor shows the availablebattery capacity.

– Check the operation of the brake andhandbrake(see Section 4.4).

– When you start up the truck thedeadman switch must be applied.

– Selects the travel direction.– Release the parking brake with the

brake switch (19).

The truck is operational.

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3.4 Emergency stop device

Z The truck is fitted with an emergency stop device. After switching on theEMERGENCY DISCONNECT switch (2) and the key switch (1) or entering thePin code there follows an automatic safety prompt.

Emergency stop display

If a fault is detected in the steering or brake systems, it will be shown on the driver’sdisplay (13).

Emergency stop activation

If a fault occurs in the steering system while travelling which affects the safety of theoperator, the truck will brake in a controlled manner until it comes to a halt.

Emergency stop reset

– Turn the EMERGENCY DISCONNECT switch and the key switch off and on again.

Z If the emergency stop is shown on the driver’s display after repeatedly activating theemergency stop reset button, notify the manufacturer’s service department.

M If, after the emergency stop has been activated, the truck is in a hazardous areaor aisle, it can only be operated with the steering crank for recovery purposes(see "Moving the truck without a battery, recovery" in chapter E).

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3.4 Emergency stop device

Z The truck is fitted with an emergency stop device. After switching on theEMERGENCY DISCONNECT switch (2) and the key switch (1) or entering thePin code there follows an automatic safety prompt.

Emergency stop display

If a fault is detected in the steering or brake systems, it will be shown on the driver’sdisplay (13).

Emergency stop activation

If a fault occurs in the steering system while travelling which affects the safety of theoperator, the truck will brake in a controlled manner until it comes to a halt.

Emergency stop reset

– Turn the EMERGENCY DISCONNECT switch and the key switch off and on again.

Z If the emergency stop is shown on the driver’s display after repeatedly activating theemergency stop reset button, notify the manufacturer’s service department.

M If, after the emergency stop has been activated, the truck is in a hazardous areaor aisle, it can only be operated with the steering crank for recovery purposes(see "Moving the truck without a battery, recovery" in chapter E).

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3.5 Testing after daily operation

– Make sure the driver’s seat is locked in position.– Test the seat belt. (The belt should block if extracted suddenly.)– Test the horn.– Test the controls and displays.– Test the steering.– Check the steer angle display; turn the steering wheel in both directions as far as

the stop and check that the wheel position is displayed on the control panel.– Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.

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3.5 Testing after daily operation

– Make sure the driver’s seat is locked in position.– Test the seat belt. (The belt should block if extracted suddenly.)– Test the horn.– Test the controls and displays.– Test the steering.– Check the steer angle display; turn the steering wheel in both directions as far as

the stop and check that the wheel position is displayed on the control panel.– Test the lift/lower, tilt and if applicable the attachment hydraulic control functions.

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4 Industrial Truck Operation

4.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorised third parties must stay away from work areas. Loads mustonly be stored in places specially designated for this purpose. Loads must not bedeposited on travel or escape routes, in front of safety mechanisms or operatingequipment that must be accessible at all times.

The truck must only be operated in work areas with sufficient lighting to avoid dangerto personnel and materials.

Driving conduct: The driver must adapt the travel speed to local conditions.The truck must be driven at slow speed when negotiating bends or narrowpassageways, when passing through swing doors and at blind spots. The driver mustalways observe an adequate braking distance between the forklift truck and thevehicle in front and must be in control of the truck at all times. Abrupt stopping (exceptin emergencies), rapid U turns and overtaking at dangerous or blind spots are notpermitted. Do not lean out or reach beyond the working and operating area. Do notuse a mobile phone or walkie-talkie without a handsfree device while operatingthe truck.

Travel visibility: The driver must look in the direction of travel and must always havea clear view of the route ahead. Loads that affect visibility must be positioned at therear of the truck. If this is not possible, a second person must walk in front of the truckas a lookout.

Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted ifsuch roads are clean and have a non-slip surface and providing such journeys aresafely undertaken in accordance with the technical specifications for the truck inquestion. The truck must always be driven with the load unit facing uphill. Theindustrial truck must not be turned, operated at an angle or parked on inclines orslopes. Inclines must only be negotiated at slow speed, with the driver ready to brakeat any moment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficientcapacity, 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 truckcan only be moved with or without a load when the mast support is retracted, the masttilted back and the load handler lowered. The truck must enter lifts with the load infront and must take up a position which does not allow it to come into contact with thewalls of the lift shaft.Persons riding in the lift with the forklift truck must only enter the lift after the truck hascome to a rest and must leave the lift before the truck.

Work platforms: The use of work platforms is governed by national law: In somemember states the use of work platforms is prohibited on industrial trucks. Observethe applicable law. Work platforms can only be used in the country of application ifthe law permits it. Contact the national authorities before using a work platform.

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4 Industrial Truck Operation

4.1 Safety regulations for truck operation

Travel routes and work areas: Only use lanes and routes specifically designated fortruck traffic. Unauthorised third parties must stay away from work areas. Loads mustonly be stored in places specially designated for this purpose. Loads must not bedeposited on travel or escape routes, in front of safety mechanisms or operatingequipment that must be accessible at all times.

The truck must only be operated in work areas with sufficient lighting to avoid dangerto personnel and materials.

Driving conduct: The driver must adapt the travel speed to local conditions.The truck must be driven at slow speed when negotiating bends or narrowpassageways, when passing through swing doors and at blind spots. The driver mustalways observe an adequate braking distance between the forklift truck and thevehicle in front and must be in control of the truck at all times. Abrupt stopping (exceptin emergencies), rapid U turns and overtaking at dangerous or blind spots are notpermitted. Do not lean out or reach beyond the working and operating area. Do notuse a mobile phone or walkie-talkie without a handsfree device while operatingthe truck.

Travel visibility: The driver must look in the direction of travel and must always havea clear view of the route ahead. Loads that affect visibility must be positioned at therear of the truck. If this is not possible, a second person must walk in front of the truckas a lookout.

Negotiating slopes and inclines: Negotiating slopes or inclines is only permitted ifsuch roads are clean and have a non-slip surface and providing such journeys aresafely undertaken in accordance with the technical specifications for the truck inquestion. The truck must always be driven with the load unit facing uphill. Theindustrial truck must not be turned, operated at an angle or parked on inclines orslopes. Inclines must only be negotiated at slow speed, with the driver ready to brakeat any moment.

Negotiating lifts and docks: Lifts and docks must only be used if they have sufficientcapacity, 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 truckcan only be moved with or without a load when the mast support is retracted, the masttilted back and the load handler lowered. The truck must enter lifts with the load infront and must take up a position which does not allow it to come into contact with thewalls of the lift shaft.Persons riding in the lift with the forklift truck must only enter the lift after the truck hascome to a rest and must leave the lift before the truck.

Work platforms: The use of work platforms is governed by national law: In somemember states the use of work platforms is prohibited on industrial trucks. Observethe applicable law. Work platforms can only be used in the country of application ifthe law permits it. Contact the national authorities before using a work platform.

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Nature of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Loads must always be positioned safely and carefully. Usesuitable precautions, e.g. a load guard, to prevent parts of the load from tipping orfalling down. Prevent liquid loads from sloshing out.


F Electromagnetic faults can cause accidentsStrong magnets can cause electronic components such as Hall sensors to becomedamaged, resulting in accidents.

– Do not use magnets in the operating area of the truck. Exceptions to this rule arecommercial, weak clamping magnets for attaching notices.

4.2 Procedure in extraordinary situations

M If the truck is in danger of tipping over, proceed as follows:

– Press your upper body against back of seat.

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

– Tilt your body in the opposite direction of fall.

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Nature of loads to be carried: The operator must make sure that the load is in asatisfactory condition. Loads must always be positioned safely and carefully. Usesuitable precautions, e.g. a load guard, to prevent parts of the load from tipping orfalling down. Prevent liquid loads from sloshing out.


F Electromagnetic faults can cause accidentsStrong magnets can cause electronic components such as Hall sensors to becomedamaged, resulting in accidents.

– Do not use magnets in the operating area of the truck. Exceptions to this rule arecommercial, weak clamping magnets for attaching notices.

4.2 Procedure in extraordinary situations

M If the truck is in danger of tipping over, proceed as follows:

– Press your upper body against back of seat.

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

– Tilt your body in the opposite direction of fall.

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4.3 Emergency Disconnect

F Accident riskApplying the Emergency Disconnect switch during travel will cause the truck todecelerate to a halt at maximum force. This may cause the load to slide off the forks.There is an increased risk of accidents and injuryThe operation of the Emergency Disconnect switch must not be affected by anyobjects placed in its way.

4.3.1 Applying the Emergency Disconnect

Procedure

Do not use the Emergency Disconnect (2) as a service brake.

– In hazardous situations press the Emergency Disconnect switch (2) down.

All electrical functions are deactivated.

The truck brakes to a halt.

4.3.2 Release the Emergency Disconnect

Procedure

– Turn the Emergency Disconnect switch to unlock it.– All electrical functions are switched on, the truck is operational again. (Provided the

truck was operational before the Emergency Disconnect was pressed).

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4.3 Emergency Disconnect

F Accident riskApplying the Emergency Disconnect switch during travel will cause the truck todecelerate to a halt at maximum force. This may cause the load to slide off the forks.There is an increased risk of accidents and injuryThe operation of the Emergency Disconnect switch must not be affected by anyobjects placed in its way.

4.3.1 Applying the Emergency Disconnect

Procedure

Do not use the Emergency Disconnect (2) as a service brake.

– In hazardous situations press the Emergency Disconnect switch (2) down.

All electrical functions are deactivated.

The truck brakes to a halt.

4.3.2 Release the Emergency Disconnect

Procedure

– Turn the Emergency Disconnect switch to unlock it.– All electrical functions are switched on, the truck is operational again. (Provided the

truck was operational before the Emergency Disconnect was pressed).

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4.4 Travel, steering, braking

Travel

F Do not drive the truck unless the panels are closed and properly locked.The main travel direction is the drive direction (V). Extra caution is required whentravelling in the load direction (R).

Z You should only travel in the load direction (R) for shunting and lifting or depositing aload.

– Prepare the truck for operation (see Section 3.3).– Release the parking brake with the brake switch (19).

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4.4 Travel, steering, braking

Travel

F Do not drive the truck unless the panels are closed and properly locked.The main travel direction is the drive direction (V). Extra caution is required whentravelling in the load direction (R).

Z You should only travel in the load direction (R) for shunting and lifting or depositing aload.

– Prepare the truck for operation (see Section 3.3).– Release the parking brake with the brake switch (19).

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Z When the truck has been prepared for operation, no travel direction is selected. Thetruck can only be driven when the required direction has been selected.

– When the truck is ready for operation press the travel switch (20/20a) in thedirection of the arrow to select the required direction (R). Keep pressing the travelswitch to change direction.

– Apply the deadman switch (10) and the accelerator pedal (8).The truck will start in the desired direction.

F The deadman switch (10) ensures that the driver’s feet do not jut out over theperimeter of the truck. If it is not pressed, all electric functions are inhibited with theexception of steering, the driver’s display panel and the horn. The truck coasts to astop according to the “coasting brake” parameter setting.

Z The travel speed is governed by the accelerator (8).

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Z When the truck has been prepared for operation, no travel direction is selected. Thetruck can only be driven when the required direction has been selected.

– When the truck is ready for operation press the travel switch (20/20a) in thedirection of the arrow to select the required direction (R). Keep pressing the travelswitch to change direction.

– Apply the deadman switch (10) and the accelerator pedal (8).The truck will start in the desired direction.

F The deadman switch (10) ensures that the driver’s feet do not jut out over theperimeter of the truck. If it is not pressed, all electric functions are inhibited with theexception of steering, the driver’s display panel and the horn. The truck coasts to astop according to the “coasting brake” parameter setting.

Z The travel speed is governed by the accelerator (8).

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Steering

Reverse steering (t)

When traveling forward (travel in direction of entry = drive direction) steer left to turninto a left hand bend and right into a right hand bend. The drive wheel position isindicated on the driver’s display.

Synchronised steering (o)

– When travelling forward (travel indirection of entry = drive direction)steer left to turn into a right hand bendand right into a left hand bend. Thedrive wheel position is indicated in thedriver’s display.

Brakes

Z The truck’s brake pattern depends largely on the ground conditions. The driver musttake this into consideration when handling the truck.

The truck can brake in three different ways:

– with the reversing brake– with the coasting brake– with the service brake

F If the truck is operated by several drivers (e.g. multi-shift operation) and theparameters are individually set, pay attention to the different braking and travellingpatterns. When you start the truck again, test how it responds.

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Steering

Reverse steering (t)

When traveling forward (travel in direction of entry = drive direction) steer left to turninto a left hand bend and right into a right hand bend. The drive wheel position isindicated on the driver’s display.

Synchronised steering (o)

– When travelling forward (travel indirection of entry = drive direction)steer left to turn into a right hand bendand right into a left hand bend. Thedrive wheel position is indicated in thedriver’s display.

Brakes

Z The truck’s brake pattern depends largely on the ground conditions. The driver musttake this into consideration when handling the truck.

The truck can brake in three different ways:

– with the reversing brake– with the coasting brake– with the service brake

F If the truck is operated by several drivers (e.g. multi-shift operation) and theparameters are individually set, pay attention to the different braking and travellingpatterns. When you start the truck again, test how it responds.

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Braking with the reversing brake:

– Press the travel direction switch (20 / 20a) while travelling. This changes to theopposite travel direction; the truck decelerates via the traction current controlleruntil it starts to move in the opposite direction.

Z This method reduces energy consumption. Energy is recovered, which is controlledby the traction current controller. The energy recovery is indicated on the driver’sdisplay.

20

20a

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Braking with the reversing brake:

– Press the travel direction switch (20 / 20a) while travelling. This changes to theopposite travel direction; the truck decelerates via the traction current controlleruntil it starts to move in the opposite direction.

Z This method reduces energy consumption. Energy is recovered, which is controlledby the traction current controller. The energy recovery is indicated on the driver’sdisplay.

20

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Braking with the coasting brake:

– Release accelerator while travelling.The truck decelerates through thetraction current controller dependingon the accelerator position.

Braking with the service brake:

– Depress the brake pedal (9) the fullstroke.

The truck decelerates through thecontrolled counter-current via thetraction motor until it comes to a stop.Just before the truck comes to rest, themechanical brake applies anddisengages after being released.

4.5 Adjusting the forks

F In order to safely raise a load the forksshould be set as far apart from eachother as possible and centrally to thetruck. The load centre of gravity must bein the centre between the forks.

– Raise the locking lever (21).– Push the forks (22) into the correct

position on the fork carriage (23).

F Turn the locking lever down and movethe forks until the locking pin engages ina slot. The forks must be prevent from fallingwith the retaining screw (23a).

– Ensure the retaining screw (23a)is secure, tighten if necessary.

9

8

2221

23

23a

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Braking with the coasting brake:

– Release accelerator while travelling.The truck decelerates through thetraction current controller dependingon the accelerator position.

Braking with the service brake:

– Depress the brake pedal (9) the fullstroke.

The truck decelerates through thecontrolled counter-current via thetraction motor until it comes to a stop.Just before the truck comes to rest, themechanical brake applies anddisengages after being released.

4.5 Adjusting the forks

F In order to safely raise a load the forksshould be set as far apart from eachother as possible and centrally to thetruck. The load centre of gravity must bein the centre between the forks.

– Raise the locking lever (21).– Push the forks (22) into the correct

position on the fork carriage (23).

F Turn the locking lever down and movethe forks until the locking pin engages ina slot. The forks must be prevent from fallingwith the retaining screw (23a).

– Ensure the retaining screw (23a)is secure, tighten if necessary.

9

8

2221

23

23a

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4.6 Lifting and depositing loads

M Before raising a load, the driver must ensure that it is correctly palletised and that thecapacity of the truck is not exceeded.

– Insert the forks as far as possible underneath the load.

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4.6 Lifting and depositing loads

M Before raising a load, the driver must ensure that it is correctly palletised and that thecapacity of the truck is not exceeded.

– Insert the forks as far as possible underneath the load.

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Lifting

F Do not allow anyone to stand underneath a raised load.

– Pull the Solo Pilot (3) lever (24) indirection (H) or pull the Multi Pilot (3a)in direction (H).

Z The lift speed is determined by theinclination of the control lever.

– Press the Solo Pilot (3) lever (24) orMulti Pilot (3a) until you reach thedesired lift height.

Z When you reach the lock (there will be anoise from the pressure relief valve)restore the control lever immediately toits initial position.

Mast lift speed reduction o

The safety switch is an active accidentprevention device operating outside thefree lift range, which prevents the truckfrom accidentally accelerating with araised load.

Z When the safety switch has beenactivated, the truck can only operate atcrawl speed.

– Lower the load handler and set the accelerator pedal to the zero (home) position.

This deactivates the safety switch and restores normal travel.

Lowering

– Push the Solo Pilot (3) lever (24) or the Multi Pilot (3a) towards direction (S).

Z The lowering speed is determined by the inclination of the Solo Pilot or Multi Pilot.

M Avoid dropping the load abruptly, in order to protect the load and the rack surface.

24

H

S

3

3a

H

S

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T

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Lifting

F Do not allow anyone to stand underneath a raised load.

– Pull the Solo Pilot (3) lever (24) indirection (H) or pull the Multi Pilot (3a)in direction (H).

Z The lift speed is determined by theinclination of the control lever.

– Press the Solo Pilot (3) lever (24) orMulti Pilot (3a) until you reach thedesired lift height.

Z When you reach the lock (there will be anoise from the pressure relief valve)restore the control lever immediately toits initial position.

Mast lift speed reduction o

The safety switch is an active accidentprevention device operating outside thefree lift range, which prevents the truckfrom accidentally accelerating with araised load.

Z When the safety switch has beenactivated, the truck can only operate atcrawl speed.

– Lower the load handler and set the accelerator pedal to the zero (home) position.

This deactivates the safety switch and restores normal travel.

Lowering

– Push the Solo Pilot (3) lever (24) or the Multi Pilot (3a) towards direction (S).

Z The lowering speed is determined by the inclination of the Solo Pilot or Multi Pilot.

M Avoid dropping the load abruptly, in order to protect the load and the rack surface.

24

H

S

3

3a

H

S

U

T

28

U

T

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4.7 Mast Support Reach

F Do not reach between the mast and the batterycover.

– Move the Solo Pilot (3) lever (26) or the MultiPilot (3a) in direction (T) to extend the mastsupport forward and in direction (U) to retract it.

Z The reach speed is determined by theinclination of the Solo Pilot or Multi Pilot.

Mast tilt

Solo Pilot t:

– To tilt forward, push the Solo Pilot (3) lever (27).– To tilt back, pull the Solo Pilot (3) lever (27).

Multi Pilot o:

– To tilt forward, press rocker (28) (V).

– To tilt back, press rocker (28) (R).

26

U

T

3

3a

U

T

27

R

V

3

3a

R V

28

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4.7 Mast Support Reach

F Do not reach between the mast and the batterycover.

– Move the Solo Pilot (3) lever (26) or the MultiPilot (3a) in direction (T) to extend the mastsupport forward and in direction (U) to retract it.

Z The reach speed is determined by theinclination of the Solo Pilot or Multi Pilot.

Mast tilt

Solo Pilot t:

– To tilt forward, push the Solo Pilot (3) lever (27).– To tilt back, pull the Solo Pilot (3) lever (27).

Multi Pilot o:

– To tilt forward, press rocker (28) (V).

– To tilt back, press rocker (28) (R).

26

U

T

3

3a

U

T

27

R

V

3

3a

R V

28

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Collecting, Lifting and Transporting Loads

Solo Pilot t:

– Place fork prongs in the horizontalposition: Set the Solo Pilot (3) lever(27) to neutral.

– Approach the load.– Extend the mast support forward:

Push the Solo Pilot (3) lever (26).– Raise the forks to the correct height:

Pull the Solo Pilot lever (24).– Insert the forks under the load– Lift the load clear: Pull the Solo Pilot

lever (24).– To retract the mast support: Pull the

Solo Pilot (3) lever (26).

F The truck can only be moved with orwithout a load when the mast support is retracted, the mast tilted back and the loadhandler lowered.

– To lower the load in the transport position: Push the Solo Pilot (3) lever (24).– To position the load in the tilt back position: Pull the Solo Pilot (3) lever (27).– Transport load.– To place the load in a horizontal position: Push the Solo Pilot (3) lever (27).– To position the load at the correct height: Pull the Solo Pilot lever (24) and if

necessary push the Solo Pilot (3) lever (26) to extend the mast support.– To lower the load: Push the Solo Pilot (3) lever (24).– To retract the mast support: Pull the Solo Pilot (3) lever (26).

Multi Pilot o:

– Place fork prongs in the horizontalposition: Press rocker switch (28),rocker (V) or (R).

– Approach the load.– Extend the mast support forward: Set

Multi Pilot (3a) to direction (T).– Raise the forks to the correct height:

Pull Multi Pilot (3a) in direction (H).– Insert the forks under the load– Lift the load clear: Pull Multi Pilot (3a)

in direction (H).– To retract the mast support: Set Multi

Pilot (3a) to direction (U).

24 26 27

3

3a

H

S

U

T

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U

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Collecting, Lifting and Transporting Loads

Solo Pilot t:

– Place fork prongs in the horizontalposition: Set the Solo Pilot (3) lever(27) to neutral.

– Approach the load.– Extend the mast support forward:

Push the Solo Pilot (3) lever (26).– Raise the forks to the correct height:

Pull the Solo Pilot lever (24).– Insert the forks under the load– Lift the load clear: Pull the Solo Pilot

lever (24).– To retract the mast support: Pull the

Solo Pilot (3) lever (26).

F The truck can only be moved with orwithout a load when the mast support is retracted, the mast tilted back and the loadhandler lowered.

– To lower the load in the transport position: Push the Solo Pilot (3) lever (24).– To position the load in the tilt back position: Pull the Solo Pilot (3) lever (27).– Transport load.– To place the load in a horizontal position: Push the Solo Pilot (3) lever (27).– To position the load at the correct height: Pull the Solo Pilot lever (24) and if

necessary push the Solo Pilot (3) lever (26) to extend the mast support.– To lower the load: Push the Solo Pilot (3) lever (24).– To retract the mast support: Pull the Solo Pilot (3) lever (26).

Multi Pilot o:

– Place fork prongs in the horizontalposition: Press rocker switch (28),rocker (V) or (R).

– Approach the load.– Extend the mast support forward: Set

Multi Pilot (3a) to direction (T).– Raise the forks to the correct height:

Pull Multi Pilot (3a) in direction (H).– Insert the forks under the load– Lift the load clear: Pull Multi Pilot (3a)

in direction (H).– To retract the mast support: Set Multi

Pilot (3a) to direction (U).

24 26 27

3

3a

H

S

U

T

28

U

T

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– To lower the load in the transport position: Press Multi Pilot (3a) in direction (S).– To position the load in the tilt back position: Press rocker switch (28), rocker (R).– Transport load.– To place the load in a horizontal position: Press rocker switch (28) rocker (V).– To position the load at the correct height: Pull Multi Pilot (3a) in direction (H) and if

necessary extend the mast support forward by setting the Multi Pilot (3a) todirection (T).

– To lower the load: Push Multi Pilot (3) in direction (S).– To retract the mast support: Tilt Multi Pilot (3) in direction (U).

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– To lower the load in the transport position: Press Multi Pilot (3a) in direction (S).– To position the load in the tilt back position: Press rocker switch (28), rocker (R).– Transport load.– To place the load in a horizontal position: Press rocker switch (28) rocker (V).– To position the load at the correct height: Pull Multi Pilot (3a) in direction (H) and if

necessary extend the mast support forward by setting the Multi Pilot (3a) todirection (T).

– To lower the load: Push Multi Pilot (3) in direction (S).– To retract the mast support: Tilt Multi Pilot (3) in direction (U).

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4.8 Emergency lowering

F Keep all personnel out of the hazardous area when applying emergency lowering.

If the mast does not lower due to a fault in the lift controller, apply the emergencylowering valve (25) on the back of the mast support.

F Only operate the emergency loweringvalve when standing next to the truck.Never reach through the mast!Do not stand underneath the load.

– Turn the EMERGENCY DISCONNECTswitch and key switch off.

– Disconnect the battery connector.– Undo the rotary shaft bolt (25, 6 mm

hex.bolt) max. ½ turns if necessarywith a suitable extension. The mastand load handler will lower slowly. Ifnecessary the lowering speed can bereduced by turning clockwise or theload can be stopped. When the load has been lowered, close the emergencylowering valve on the rotary shaft with a torque of 4.5 Nm.

– Do not operate the truck until the fault has been rectified.

25

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4.8 Emergency lowering

F Keep all personnel out of the hazardous area when applying emergency lowering.

If the mast does not lower due to a fault in the lift controller, apply the emergencylowering valve (25) on the back of the mast support.

F Only operate the emergency loweringvalve when standing next to the truck.Never reach through the mast!Do not stand underneath the load.

– Turn the EMERGENCY DISCONNECTswitch and key switch off.

– Disconnect the battery connector.– Undo the rotary shaft bolt (25, 6 mm

hex.bolt) max. ½ turns if necessarywith a suitable extension. The mastand load handler will lower slowly. Ifnecessary the lowering speed can bereduced by turning clockwise or theload can be stopped. When the load has been lowered, close the emergencylowering valve on the rotary shaft with a torque of 4.5 Nm.

– Do not operate the truck until the fault has been rectified.

25

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4.9 Operating Attachments

4.9.1 Safety instructions for operating additional attachments

Z Optionally, trucks can be fitted with one or more auxiliary hydraulic functions tooperate attachments. The auxiliary hydraulic functions are referenced HF4 and HF5.Auxiliary hydraulic functions for exchangeable equipment are fitted with replacementcouplings on the fork carriage. To assemble exchangeable equipment, see "Assembly and hydraulic ports of additional attachments” in chapter E.

F Attaching exchangeable equipment can result in accidents.Other people can be damaged by attaching exchangeable equipment. Use onlyexchangeable equipment which has been deemed safe after a risk analysis carriedout by the owner.

– Only use attachments with a CE mark.– Only use attachments that have been designed by the attachment manufacturer for

use with the respective industrial truck.– Only use attachments that have been fitted for the purpose by the owner.– Make sure the operator has been instructed in the use of the attachment and that

he uses it for its correct purpose.– Re-assess the residual capacity of the truck and if it has been altered, attach an

additional capacity plate to the truck.– Note the attachment manufacturer’s operating instructions.– Only use attachments that do not restrict visibility in the travel direction.

Z If visibility in the travel direction is impaired, the owner must carry out a risk analysisto assess whether the truck needs to be fitted with auxiliary equipment such as acamera system or mirrors. If such equipment is used, spend sufficient time practicingtravelling with them.

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4.9 Operating Attachments

4.9.1 Safety instructions for operating additional attachments

Z Optionally, trucks can be fitted with one or more auxiliary hydraulic functions tooperate attachments. The auxiliary hydraulic functions are referenced HF4 and HF5.Auxiliary hydraulic functions for exchangeable equipment are fitted with replacementcouplings on the fork carriage. To assemble exchangeable equipment, see "Assembly and hydraulic ports of additional attachments” in chapter E.

F Attaching exchangeable equipment can result in accidents.Other people can be damaged by attaching exchangeable equipment. Use onlyexchangeable equipment which has been deemed safe after a risk analysis carriedout by the owner.

– Only use attachments with a CE mark.– Only use attachments that have been designed by the attachment manufacturer for

use with the respective industrial truck.– Only use attachments that have been fitted for the purpose by the owner.– Make sure the operator has been instructed in the use of the attachment and that

he uses it for its correct purpose.– Re-assess the residual capacity of the truck and if it has been altered, attach an

additional capacity plate to the truck.– Note the attachment manufacturer’s operating instructions.– Only use attachments that do not restrict visibility in the travel direction.

Z If visibility in the travel direction is impaired, the owner must carry out a risk analysisto assess whether the truck needs to be fitted with auxiliary equipment such as acamera system or mirrors. If such equipment is used, spend sufficient time practicingtravelling with them.

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Safety instructions for sideshifter and fork adjuster attachments

M When using multi fork adjusters (multi pallet clamps), restricted visibility and reducedlateral tilt resistance can result in accidents.

– Adapt the travel speeds to the visibility and load.– Make sure you have enough visibility when travelling in the forks direction.

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

M Falling loads can cause accidentsThis can result in malfunctions and the load can fall accidentally.

– Clamping attachments must only be operated on trucks will auxiliary hydraulicsHF4 or HF5.

– When connecting the attachment make sure that the hydraulic lines of theattachment are connected to the right ports, see "Assembly and hydraulic ports ofadditional attachments” in chapter E.

– An auxiliary button for releasing the clamp opening must be used.

Safety instructions for rotary attachments

M A non-centred centre of gravity can result in accidents

M When using rotary devices and non-centred loads, the centre of gravity can bedisplaced from the centre with a high risk of accidents.

– Adapt the travel speed to the load.– Lift the load from the centre.

Safety instructions for telescopic attachments

M Accident risk from increased tipover hazard and reduced residual capacityThere is a greater tipover risk with extended telescopic attachments (e.g. reachcarriages, telescopic forks, telescopic crane booms).

– Only use the telescopic function for stacking and retrieving.– Always retract the attachment fully during transport.– Adapt the travel speed to changed load centre of gravity.

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Safety instructions for sideshifter and fork adjuster attachments

M When using multi fork adjusters (multi pallet clamps), restricted visibility and reducedlateral tilt resistance can result in accidents.

– Adapt the travel speeds to the visibility and load.– Make sure you have enough visibility when travelling in the forks direction.

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

M Falling loads can cause accidentsThis can result in malfunctions and the load can fall accidentally.

– Clamping attachments must only be operated on trucks will auxiliary hydraulicsHF4 or HF5.

– When connecting the attachment make sure that the hydraulic lines of theattachment are connected to the right ports, see "Assembly and hydraulic ports ofadditional attachments” in chapter E.

– An auxiliary button for releasing the clamp opening must be used.

Safety instructions for rotary attachments

M A non-centred centre of gravity can result in accidents

M When using rotary devices and non-centred loads, the centre of gravity can bedisplaced from the centre with a high risk of accidents.

– Adapt the travel speed to the load.– Lift the load from the centre.

Safety instructions for telescopic attachments

M Accident risk from increased tipover hazard and reduced residual capacityThere is a greater tipover risk with extended telescopic attachments (e.g. reachcarriages, telescopic forks, telescopic crane booms).

– Only use the telescopic function for stacking and retrieving.– Always retract the attachment fully during transport.– Adapt the travel speed to changed load centre of gravity.

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Safety notices for fork extensions:

M Unsecured and excessive fork extensions can cause accidents.

– For fork extensions with an open cross sectional area, only carry loads that areresting along the entire length of the fork extension.

– Only use fork extensions with the same fork cross section and minimum fork lengthof the truck and which comply with the details on the fork extension data plate.

– The basic fork length must be at least 60% of the length of the fork extension.– Lock the fork extensions onto the basic forks.– When carrying out the daily checks and operations before starting , see "Checks

and operations to be performed before starting daily operation" in chapter E, alsocheck the fork extension lock.

– Mark any fork extensions with an incomplete or faulty lock and take them out ofservice.

– Do not use trucks with an incomplete or faulty fork extension lock. Replace the forkextension.

– Only restore the fork extension to service when the fault has been rectified.

F Observe load chart for the truck with attachment and the truck and attachmentoperator manuals.

– The attachment must only be operated by trained and authorised personnel.– Any operation that could affect safety must be prohibited.– The attachment must only be operated when fully functional.– Check the attachment for visible signs of damage at least once a shift.

Report any signs of damage immediately.

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Safety notices for fork extensions:

M Unsecured and excessive fork extensions can cause accidents.

– For fork extensions with an open cross sectional area, only carry loads that areresting along the entire length of the fork extension.

– Only use fork extensions with the same fork cross section and minimum fork lengthof the truck and which comply with the details on the fork extension data plate.

– The basic fork length must be at least 60% of the length of the fork extension.– Lock the fork extensions onto the basic forks.– When carrying out the daily checks and operations before starting , see "Checks

and operations to be performed before starting daily operation" in chapter E, alsocheck the fork extension lock.

– Mark any fork extensions with an incomplete or faulty lock and take them out ofservice.

– Do not use trucks with an incomplete or faulty fork extension lock. Replace the forkextension.

– Only restore the fork extension to service when the fault has been rectified.



Report any signs of damage immediately.

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4.9.2 Integrated sideshift (Solo Pilot) t

Z The references to left and right arebased on the load handler as viewedfrom the operator’s position.

Sideshift left (from driver’s position):

– Press switch (30) in direction (X1)

Sideshift right (from driver’s position):

– Press switch (30) in direction (Y1).

F Note reduced capacity for extending(see Chapter B).

o Hydraulic attachments

The control lever (29) of the Solo Pilot (3) has functions (X2) and (Y2) to operatehydraulic attachments (HF5) (see manufacturer’s operator manual).

F Note the capacity of the attachment.



F Report any signs of damage immediately.

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X2

Y1

Y2

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4.9.2 Integrated sideshift (Solo Pilot) t



– Press switch (30) in direction (X1)



F Note reduced capacity for extending(see Chapter B).


The control lever (29) of the Solo Pilot (3) has functions (X2) and (Y2) to operatehydraulic attachments (HF5) (see manufacturer’s operator manual).





32930

X1

X2

Y1

Y2

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4.9.3 Integrated sideshift (Multi Pilot) o



– Press switch (33) in direction (X1).



F When extending, note reduced capacity(see Chapter B).


The control lever (34) has functions (X2) and (Y2) to operate hydraulic attachments(HF5) (note manufacturer’s operator manual).





333

34Y2X2

Y1X1

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4.9.3 Integrated sideshift (Multi Pilot) o



– Press switch (33) in direction (X1).



F When extending, note reduced capacity(see Chapter B).


The control lever (34) has functions (X2) and (Y2) to operate hydraulic attachments(HF5) (note manufacturer’s operator manual).





333

34Y2X2

Y1X1

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4.10 Park the truck safely

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

F Do not park the truck on a slope. The load must always be lowered to the ground.

– Activate the parking brake by pressingthe parking key (19).

– Retract the mast support fully.– Lower the load completely and

position it horizontally.– Set the EMERGENCY DISCONNECT

switch (2) OFF.– Set the key switch (1) to the "0"

position and remove the key.

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4.10 Park the truck safely

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

F Do not park the truck on a slope. The load must always be lowered to the ground.

– Activate the parking brake by pressingthe parking key (19).

– Retract the mast support fully.– Lower the load completely and

position it horizontally.– Set the EMERGENCY DISCONNECT

switch (2) OFF.– Set the key switch (1) to the "0"

position and remove the key.

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5 Driver’s display

The driver’s display represents the operator interface to the truck. It is both a displayand control unit for the operator and the service engineer.

Press the four keys (55, 56, 57, 58) to operate the driver's display and hence thetruck. The LEDs of the 11 buttons (36 - 44, 59, 60) can show 3 conditions: active andflashing and off.

All displays are shown as text or as symbols. The meaning of the various symbols isexplained in section 6.

A colour contrasting display gives information on the travel direction, steering angle,battery charge condition and other selected truck parameters.

Set time:

– Press the shift key (56) for 3 seconds.

The display (48) via the battery shows the current time. This allows you to toggle thedisplay between the time and the residual time.

– Press the shift key another 5 seconds (8 in total) until the “Set Time” menu isdisplayed.

– Set the hours with the “Up” (58) & “Down” (57) keys.– Confirm with the shift key.– Set the minutes with the “Up” (58) & “Down” (57) keys.– Confirm with the shift (56) or profile key (55) to return to normal operating mode.

Z Keep pressing the Up and Down keys to set the time and to change between 24 hourand 12 display (SET HOUR 24 H <-> SET HOUR 12 H).

43 49 50

59 58 57 56 5560

44 45 46 47 4842

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52

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39

38

37

36

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5 Driver’s display

The driver’s display represents the operator interface to the truck. It is both a displayand control unit for the operator and the service engineer.

Press the four keys (55, 56, 57, 58) to operate the driver's display and hence thetruck. The LEDs of the 11 buttons (36 - 44, 59, 60) can show 3 conditions: active andflashing and off.

All displays are shown as text or as symbols. The meaning of the various symbols isexplained in section 6.

A colour contrasting display gives information on the travel direction, steering angle,battery charge condition and other selected truck parameters.

Set time:

– Press the shift key (56) for 3 seconds.

The display (48) via the battery shows the current time. This allows you to toggle thedisplay between the time and the residual time.

– Press the shift key another 5 seconds (8 in total) until the “Set Time” menu isdisplayed.

– Set the hours with the “Up” (58) & “Down” (57) keys.– Confirm with the shift key.– Set the minutes with the “Up” (58) & “Down” (57) keys.– Confirm with the shift (56) or profile key (55) to return to normal operating mode.

Z Keep pressing the Up and Down keys to set the time and to change between 24 hourand 12 display (SET HOUR 24 H <-> SET HOUR 12 H).

43 49 50

59 58 57 56 5560

44 45 46 47 4842

4151

54

52

53

40

39

38

37

36

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Item Description36 Lift limit reached (yellow graphic symbol) (o) 37 Service mode is active (yellow spanner icon), Service interval expired

(icon flashing)38 deadman switch not pressed (yellow icon)39 Forks horizontal (green graphic symbol)(o) 40 Sideshift horizontal (green graphic symbol)(o) 41 Slow travel (green icon),42 Error STOP sign (red icon)43 Parking brake applied (red icon)44 Warning, warning triangle (red icon),45 Steering angle display in 30° increments in arrow form46 180 or 360° steering mode through display of 2 or 4 circle segments47 Residual time display with on-board battery (hours : minutes)48 Time display (hours : minutes)49 Battery discharge status and energy recovery display50 Discharge indicator51 Set speed (drive direction) for current profile (in bars from 1 to 5)52 Set speed (lifting) for current profile (in bar form 1 to 5)53 Profile number (travel / lift profile 1, 2 or 3)54 Warning and fault indication as text (14 segment display) and data

registration55 Profile key for selecting travel and lift modes56 Shift key for changing display and accessing service mode57 Brake switch for applying / releasing the handbrake58 Slow travel switch for derating the travel speed59 Battery unlocked (red icon),60 Overtemperature (red icon)

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Item Description36 Lift limit reached (yellow graphic symbol) (o) 37 Service mode is active (yellow spanner icon), Service interval expired

(icon flashing)38 deadman switch not pressed (yellow icon)39 Forks horizontal (green graphic symbol)(o) 40 Sideshift horizontal (green graphic symbol)(o) 41 Slow travel (green icon),42 Error STOP sign (red icon)43 Parking brake applied (red icon)44 Warning, warning triangle (red icon),45 Steering angle display in 30° increments in arrow form46 180 or 360° steering mode through display of 2 or 4 circle segments47 Residual time display with on-board battery (hours : minutes)48 Time display (hours : minutes)49 Battery discharge status and energy recovery display50 Discharge indicator51 Set speed (drive direction) for current profile (in bars from 1 to 5)52 Set speed (lifting) for current profile (in bar form 1 to 5)53 Profile number (travel / lift profile 1, 2 or 3)54 Warning and fault indication as text (14 segment display) and data

registration55 Profile key for selecting travel and lift modes56 Shift key for changing display and accessing service mode57 Brake switch for applying / releasing the handbrake58 Slow travel switch for derating the travel speed59 Battery unlocked (red icon),60 Overtemperature (red icon)

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Battery Discharge Indicator: The charge status of the battery (49) is shown on thedriver’s display. The lower section of the battery symbol is shown as being empty. Itindicates the residual capacity of the battery which is protected and cannot be usedto avoid damaging the battery.

M The standard setting for the battery discharge indicator / discharge monitor is basedon standard batteries.

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

Battery Discharge Monitor: If the residual capacity falls below the required level,lifting is inhibited. A message will be indicated on the driver’s display unit.

Z Lifting is only released when the battery connected is at least 70% charged.

Residual time display: The time remaining to reach the residual capacity isdisplayed.

To display the residual time, the display (48) can be switched by holding down theShift key (56) for three seconds.

Z This allows you to toggle the display between the time and the residual time.

49 50

62 56

48

61

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Battery Discharge Indicator: The charge status of the battery (49) is shown on thedriver’s display. The lower section of the battery symbol is shown as being empty. Itindicates the residual capacity of the battery which is protected and cannot be usedto avoid damaging the battery.

M The standard setting for the battery discharge indicator / discharge monitor is basedon standard batteries.

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

Battery Discharge Monitor: If the residual capacity falls below the required level,lifting is inhibited. A message will be indicated on the driver’s display unit.

Z Lifting is only released when the battery connected is at least 70% charged.

Residual time display: The time remaining to reach the residual capacity isdisplayed.

To display the residual time, the display (48) can be switched by holding down theShift key (56) for three seconds.

Z This allows you to toggle the display between the time and the residual time.

49 50

62 56

48

61

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Hourmeter: Service hours are counted if the truck is released for operation via thekey switch, keypad or transponder card and the deadman switch is applied.

Press the Shift key (56) briefly to change the layout of the display fields (61 and 62).If no lift height (o) or load weight (o) are available, the corresponding line will bebypassed.

Z If neither the lift height, the max. lift height or the load weight are available, displayfield 2 remains empty.

“Energy recovery” display during regenerative braking

During the “energy recovery” stage, the discharge indicator on the driver’s displaychanges so that the bars in the battery container fill from bottom to top.

This takes place cyclically and irrespective of the battery’s charge status (full or partially discharged).

Z The display goes out once energy recovery is complete.

Display field 1 (62) Display field 2 (61)Service hours Load weightService hours Lift height

Lift height Load weightLoad weight Lift height

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Hourmeter: Service hours are counted if the truck is released for operation via thekey switch, keypad or transponder card and the deadman switch is applied.

Press the Shift key (56) briefly to change the layout of the display fields (61 and 62).If no lift height (o) or load weight (o) are available, the corresponding line will bebypassed.

Z If neither the lift height, the max. lift height or the load weight are available, displayfield 2 remains empty.

“Energy recovery” display during regenerative braking

During the “energy recovery” stage, the discharge indicator on the driver’s displaychanges so that the bars in the battery container fill from bottom to top.

This takes place cyclically and irrespective of the battery’s charge status (full or partially discharged).

Z The display goes out once energy recovery is complete.

Display field 1 (62) Display field 2 (61)Service hours Load weightService hours Lift height

Lift height Load weightLoad weight Lift height

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5.1 Driver’s Display Luminous Symbols

SYMBOLForks horizontal (green icon),

SYMBOLSideshift centre position (green graphic symbol)

SYMBOLLift limit reached (yellow icon),

SYMBOLSlow travel (green icon),

SYMBOLDeadman switch not applied (yellow icon),

SYMBOLService mode active (yellow spanner icon)

SYMBOLOvertemperature (red icon),

SYMBOLBattery unlocked (red icon),

SYMBOLParking brake applied (red icon),

SYMBOLWarning, warning triangle (red icon),

SYMBOLError STOP sign (red icon)

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5.1 Driver’s Display Luminous Symbols

SYMBOLForks horizontal (green icon),

SYMBOLSideshift centre position (green graphic symbol)

SYMBOLLift limit reached (yellow icon),

SYMBOLSlow travel (green icon),

SYMBOLDeadman switch not applied (yellow icon),

SYMBOLService mode active (yellow spanner icon)

SYMBOLOvertemperature (red icon),

SYMBOLBattery unlocked (red icon),

SYMBOLParking brake applied (red icon),

SYMBOLWarning, warning triangle (red icon),

SYMBOLError STOP sign (red icon)

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5.2 Driver Display Switches

5.3 Driver’s Display Warning Messages

Travel speed derated (slow travel switch),

Handbrake applied / release (brake switch),

Change display to service mode (Shift key)

Select travel and lift modes

Display Symbol Meaning

INFO 02 No travel direction selected

INFO 03 No travel release

INFO 04 No setpoint

Battery empty, main lift cutout

Safety switch not pressed

INFO 07 Flashing symbolAt least 1 control not in home position when system starts

INFO 08 Flashing symbolHandbrake applied

Crawl speed applied or forced by battery locking

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5.2 Driver Display Switches

5.3 Driver’s Display Warning Messages

Travel speed derated (slow travel switch),

Handbrake applied / release (brake switch),

Change display to service mode (Shift key)

Select travel and lift modes


INFO 02 No travel direction selected

INFO 03 No travel release

INFO 04 No setpoint

Battery empty, main lift cutout

Safety switch not pressed

INFO 07 Flashing symbolAt least 1 control not in home position when system starts

INFO 08 Flashing symbolHandbrake applied

Crawl speed applied or forced by battery locking

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INFO 10 Drive motor overtemperature

INFO 11 Lift motor overtemperature

INFO 12 Steer motor overtemperature

INFO 16 Traction current cutout activated

Lift limit reached

INFO 18 Flashing symbolSafety height not reached

INFO 22 Traction controller does not recognise electric steering

INFO 23 Controller set to diagnostic mode

INFO 24 Switch truck voltage off/on

INFO 25 Flashing symbolTraction controller overtemperature

INFO 26 Flashing symbolLift controller overtemperature

INFO 27 Flashing symbolSteering controller overtemperature

INFO 31 No accelerator pedal zero position detected on power up

INFO 32 No traverse distance reference on power up


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INFO 10 Drive motor overtemperature

INFO 11 Lift motor overtemperature

INFO 12 Steer motor overtemperature

INFO 16 Traction current cutout activated

Lift limit reached

INFO 18 Flashing symbolSafety height not reached

INFO 22 Traction controller does not recognise electric steering

INFO 23 Controller set to diagnostic mode

INFO 24 Switch truck voltage off/on

INFO 25 Flashing symbolTraction controller overtemperature

INFO 26 Flashing symbolLift controller overtemperature

INFO 27 Flashing symbolSteering controller overtemperature

INFO 31 No accelerator pedal zero position detected on power up

INFO 32 No traverse distance reference on power up


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Driver’s display error messages

INFO 54 Set truck type

INFO 55 No deadman switch zero position detected on power up

HEATING Driver display warm-up phase, as the LCD cannot be read at excessively low temperatures.

Error Error text Explanation Remedy

1 LOW VOLTAGE Low voltage Check battery voltage, charge battery

2 HIGH VOLTAGE Overvoltage Check battery voltage.

3 TEMPERAT CONTR

Controller temperature Allow the controllers to cool

5 ELECTR SYSTEM Overvoltage Switch off and on again, call service department

6 ACCELERATOR Analog reading out of range or incompatible with digital signal

Switch off and on again, call service department

7 TURN OFF KEY Key switch Switch off and on again, call service department

10 MAIN CONTACTOR Main contactor faulty Switch off and on again, call service department

11-19 CONTROLLER Controller Failure Switch off and on again, call service department


23 CONTROLLER Controller Failure Switch off and on again

24 CONTROLLER Controller Failure Switch off and on again, call service department

25 INTERFACE / CAN No communication from interface

Switch off and on again

26 LIFT SENSOR Lift sensor wire breakage Switch off and on again, call service department

27 STEER ANGLE Steering actual value sensor faulty


30 TILT SENSOR Tilt sensor wire breakage Switch off and on again, call service department


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Driver’s display error messages

INFO 54 Set truck type

INFO 55 No deadman switch zero position detected on power up

HEATING Driver display warm-up phase, as the LCD cannot be read at excessively low temperatures.


1 LOW VOLTAGE Low voltage Check battery voltage, charge battery

2 HIGH VOLTAGE Overvoltage Check battery voltage.

3 TEMPERAT CONTR

Controller temperature Allow the controllers to cool

5 ELECTR SYSTEM Overvoltage Switch off and on again, call service department

6 ACCELERATOR Analog reading out of range or incompatible with digital signal


7 TURN OFF KEY Key switch Switch off and on again, call service department

10 MAIN CONTACTOR Main contactor faulty Switch off and on again, call service department



23 CONTROLLER Controller Failure Switch off and on again

24 CONTROLLER Controller Failure Switch off and on again, call service department

25 INTERFACE / CAN No communication from interface

Switch off and on again

26 LIFT SENSOR Lift sensor wire breakage Switch off and on again, call service department

27 STEER ANGLE Steering actual value sensor faulty


30 TILT SENSOR Tilt sensor wire breakage Switch off and on again, call service department


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31 SIDESHIFT SENS ZH1 sensor wire breakageHF 4


32 MULTIP SENSOR ZH2 sensor wire breakageHF 5




34 CAN-BUS CANBus damaged Switch off and on again, call service department

39 TRUCK TYPE Improbable truck type Switch off and on again, call service department

40 TEMPERAT MOTOR

Motor overtemperature Allow the motor to cool down

43 ADJUST BRAKE Adjust brake Call service department

44 BRAKE DEFECT Brake controller error Call service department

45 STEERING WHEEL Too many pulses from steering setpoint device

Call service department

46 STEERING WHEEL Steering setpoint device incorrectly connected


47 STEERING WHEEL Processor setpoints do not match


48 STEERING TYPE Processor setpoints do not match


49 CAN-BUS CAN supply interrupted; Switch off and on again, call service department

50 SENSOR HORIZON Multipilot wire breakage horizontal tilter


54 CABLE MOTOR Motor wire breakage Switch off and on again, call service department

56 CONNECTION MOTO

Motor reverse polarity Switch off and on again, call service department

57 STEER CONTROL Motor does not turn Switch off and on again, call service department

58 STEER ANGLE Steering modulation Switch off and on again, call service department

60 STEER CONTROL Swivelling bolster does not follow steering wheel directions



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31 SIDESHIFT SENS ZH1 sensor wire breakageHF 4






34 CAN-BUS CANBus damaged Switch off and on again, call service department

39 TRUCK TYPE Improbable truck type Switch off and on again, call service department

40 TEMPERAT MOTOR

Motor overtemperature Allow the motor to cool down

43 ADJUST BRAKE Adjust brake Call service department

44 BRAKE DEFECT Brake controller error Call service department

45 STEERING WHEEL Too many pulses from steering setpoint device


46 STEERING WHEEL Steering setpoint device incorrectly connected


47 STEERING WHEEL Processor setpoints do not match


48 STEERING TYPE Processor setpoints do not match


49 CAN-BUS CAN supply interrupted; Switch off and on again, call service department

50 SENSOR HORIZON Multipilot wire breakage horizontal tilter


54 CABLE MOTOR Motor wire breakage Switch off and on again, call service department

56 CONNECTION MOTO

Motor reverse polarity Switch off and on again, call service department

57 STEER CONTROL Motor does not turn Switch off and on again, call service department

58 STEER ANGLE Steering modulation Switch off and on again, call service department

60 STEER CONTROL Swivelling bolster does not follow steering wheel directions



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63 CONTROLLER Sensor power supply out of range


65 SWITCH MIDDLE Multipilot wire breakage centre shifter


66 SWITCH 180-360 Multipilot wire breakage 180°/360° steering change


67 DRIVEDIRECTION Multipilot travel direction switch setpoint device jams


68 DEADMAN KEY Safety switch wire breakage


83 ELECTR SYSTEM 2 identical components Switch off and on again, call service department

84 RPM SENSOR Faulty speed sensor Switch off and on again, call service department

85 ELECTRIC DRIVE Power release low voltage


86 RPM INPLAUS Improbable speed Switch off and on again, call service department

87 ELECTR SYSTEM Sensor wire interrupted, load wheel speed sensing affected


97 STEER CONTROL Segment beyond tolerance limits


98 STEER CONTROL Sensor bearing and proximity switch (segment) positions differ


100 MULTIP SOFTW Software versions in Multipilot not compatible


105 CABLE TEMP MOT Motor temperature gauge provides incorrect values


106 CABLE TEMP CON Controller temperature gauge provides incorrect values


107 ELECTR SYSTEM Key switch voltage outside range

Check battery voltage, charge battery

109 BRAKE PEDAL Brake pedal faulty Switch off and on again, call service department

110 CONTROLLER Current output multifunction controller faulty



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63 CONTROLLER Sensor power supply out of range


65 SWITCH MIDDLE Multipilot wire breakage centre shifter


66 SWITCH 180-360 Multipilot wire breakage 180°/360° steering change


67 DRIVEDIRECTION Multipilot travel direction switch setpoint device jams


68 DEADMAN KEY Safety switch wire breakage


83 ELECTR SYSTEM 2 identical components Switch off and on again, call service department

84 RPM SENSOR Faulty speed sensor Switch off and on again, call service department

85 ELECTRIC DRIVE Power release low voltage


86 RPM INPLAUS Improbable speed Switch off and on again, call service department

87 ELECTR SYSTEM Sensor wire interrupted, load wheel speed sensing affected


97 STEER CONTROL Segment beyond tolerance limits


98 STEER CONTROL Sensor bearing and proximity switch (segment) positions differ


100 MULTIP SOFTW Software versions in Multipilot not compatible


105 CABLE TEMP MOT Motor temperature gauge provides incorrect values


106 CABLE TEMP CON Controller temperature gauge provides incorrect values


107 ELECTR SYSTEM Key switch voltage outside range

Check battery voltage, charge battery

109 BRAKE PEDAL Brake pedal faulty Switch off and on again, call service department

110 CONTROLLER Current output multifunction controller faulty



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111 CHECK STEER Traction controller does not receive telegrams from steering controller


113 CHECK LIFT Lift controller does not send lift telegrams


115 CONTACTOR INPL Main contactor improbable


116 INIT SUCCESS After software flashing (field operation), the item number of the software is improbable and parameters may also be implausible.


118 CONTROLLER Steering reports emergency stop


119 WEIGHT SWITCH Weigher button faulty Switch off and on again, call service department

120 WEIGHT SENSOR Weigher pressure sensor faulty


121 CONTROLLER Brake modulation Switch off and on again, call service department

122 BRAKE CONFIG Brake incorrectly connected


201 SENSOR Height sensor faulty Switch off and on again, call service department

203 SENSOR Height sensor evaluation improbable


204 CONTROLLER Error when reading EEPROM height select


240 CONTROLLER No height actual value on job entry


250 The height is invalid for the warehouse level entered

Make correct entry

252 Wrong height select entry Make correct entry


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111 CHECK STEER Traction controller does not receive telegrams from steering controller


113 CHECK LIFT Lift controller does not send lift telegrams


115 CONTACTOR INPL Main contactor improbable


116 INIT SUCCESS After software flashing (field operation), the item number of the software is improbable and parameters may also be implausible.


118 CONTROLLER Steering reports emergency stop


119 WEIGHT SWITCH Weigher button faulty Switch off and on again, call service department

120 WEIGHT SENSOR Weigher pressure sensor faulty


121 CONTROLLER Brake modulation Switch off and on again, call service department

122 BRAKE CONFIG Brake incorrectly connected


201 SENSOR Height sensor faulty Switch off and on again, call service department

203 SENSOR Height sensor evaluation improbable


204 CONTROLLER Error when reading EEPROM height select


240 CONTROLLER No height actual value on job entry


250 The height is invalid for the warehouse level entered

Make correct entry

252 Wrong height select entry Make correct entry


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6 Keypad (CANCODE) (o)

The keypad consists of 10 digit keys, a Set keyand a o key.

The o key indicates operating statuses via a red/green LED.

It contains the following functions:

– Code lock function (starting up the truck).

6.1 Code lock

When the correct code has been entered, the machine is ready for use. You canallocate an individual code to each truck, driver or group of drivers.

Z On delivery of the truck from the factory the operator code for the driver display andCANCODE (o) (factory setting 2-5-8-0) is indicated by a sticker.

M When starting the truck for the first time, change the master and operating codes.

1 2 3

4 5 6

7 8 9

0Set

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6 Keypad (CANCODE) (o)

The keypad consists of 10 digit keys, a Set keyand a o key.

The o key indicates operating statuses via a red/green LED.

It contains the following functions:

– Code lock function (starting up the truck).

6.1 Code lock

When the correct code has been entered, the machine is ready for use. You canallocate an individual code to each truck, driver or group of drivers.

Z On delivery of the truck from the factory the operator code for the driver display andCANCODE (o) (factory setting 2-5-8-0) is indicated by a sticker.

M When starting the truck for the first time, change the master and operating codes.

1 2 3

4 5 6

7 8 9

0Set

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Commissioning

After switching on the EMERGENCY DISCONNECT switch and if necessary the keyswitch, the LED (67) goes red.

When you enter the correct operator code the LED (67) turns green.

If the wrong code is entered LED (67) flashes red for two seconds. The correct codecan then be entered.

Z The Set key (68) has no function in operating mode

Switching off

Press the o key (72) to switch off the truck.

Z The truck can switch off automatically after apre-determined time. To do this theappropriate code lock parameters must beentered.(see Section 6.3).

6.2 Parameters

In programming mode you can set the codelock functions via the keypad.

Parameter Groups

The parameter number is composed of three digits. The first digit refers to theparameter group as shown in Table 1. The second and third digits are numbered insequence from 00 to 99.

No. Parameter Group0xx Code Lock Settings

(Codes, travel program release, automatic cutout, etc.)

1 2 3

4 5 6

7 8 9

0Set

69

68

67

72

7170

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Commissioning

After switching on the EMERGENCY DISCONNECT switch and if necessary the keyswitch, the LED (67) goes red.

When you enter the correct operator code the LED (67) turns green.

If the wrong code is entered LED (67) flashes red for two seconds. The correct codecan then be entered.

Z The Set key (68) has no function in operating mode

Switching off

Press the o key (72) to switch off the truck.

Z The truck can switch off automatically after apre-determined time. To do this theappropriate code lock parameters must beentered.(see Section 6.3).

6.2 Parameters

In programming mode you can set the codelock functions via the keypad.

Parameter Groups

The parameter number is composed of three digits. The first digit refers to theparameter group as shown in Table 1. The second and third digits are numbered insequence from 00 to 99.

No. Parameter Group0xx Code Lock Settings

(Codes, travel program release, automatic cutout, etc.)

1 2 3

4 5 6

7 8 9

0Set

69

68

67

72

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6.3 Parameter Settings

To change the truck setting you must enter the master code.

Z The factory setting for the master code is 7-2-9-5.

M When starting the truck for the first time change the master code.

To enter the master code:

– Press the o key– Enter master code

Code Lock Parameters

Truck setting procedure:

– Enter the three digit parameter number, confirm with the Set key (68).– Enter the setting according to the parameter list or change and confirm with the Set

key (68).

Z If the entry is incorrect, the LED (67) of the o key (72) flashes red. If you enter theparameter number again the setting can be entered or changed.

To enter more parameters, repeat the procedure. To finish entering, press the o key (72).

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6.3 Parameter Settings

To change the truck setting you must enter the master code.

Z The factory setting for the master code is 7-2-9-5.

M When starting the truck for the first time change the master code.

To enter the master code:

– Press the o key– Enter master code

Code Lock Parameters

Truck setting procedure:

– Enter the three digit parameter number, confirm with the Set key (68).– Enter the setting according to the parameter list or change and confirm with the Set

key (68).

Z If the entry is incorrect, the LED (67) of the o key (72) flashes red. If you enter theparameter number again the setting can be entered or changed.

To enter more parameters, repeat the procedure. To finish entering, press the o key (72).

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The following parameters may be entered.

Code Lock Parameter List

No. Function Settingsetting

Standardsetting

CommentsProcedure

Code lock000 Change master code

The length (4-6 digits) of the master code also pre-determines the length of the operator code (4-6 digits). Provided the operator codes are programmed, only news codes of the same length can be entered. If the code length is to be changed, all operator codes must first be deleted.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 69 flashes)Enter the current

code

Confirm (Set)

(LED 70 flashes)Enter a new code

Confirm (Set)

(LED 71 flashes)Repeat new code

Confirm (Set)001 Add operator code (max.

600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 70 flashes)Enter a code

Confirm (Set)

(LED 71 flashes)Re-enter the code

Confirm (Set)

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The following parameters may be entered.

Code Lock Parameter List


Standardsetting

CommentsProcedure

Code lock000 Change master code

The length (4-6 digits) of the master code also pre-determines the length of the operator code (4-6 digits). Provided the operator codes are programmed, only news codes of the same length can be entered. If the code length is to be changed, all operator codes must first be deleted.

0000 - 9999or

00000 - 99999or

000000 - 999999

7295 (LED 69 flashes)Enter the current

code

Confirm (Set)


Confirm (Set)

(LED 71 flashes)Repeat new code

Confirm (Set)001 Add operator code (max.

600)0000 - 9999

or00000 - 99999

or000000 - 999999

2580 (LED 70 flashes)Enter a code

Confirm (Set)


Confirm (Set)

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LEDs 69-71 are located in keypads 1-3.


Standardsetting

CommentsProcedure

Code lock002 Change user code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 69 flashes)Enter the current

code

Confirm (Set)


Confirm (Set)


confirm003 Delete user code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 70 flashes)Enter a code

Confirm (Set)


Confirm (Set)004 Delete code memory

(Deletes all user codes )3265 3265 = delete

other inputs= do not delete

010 Automatic timeout 00 - 31 00 00 = No cutout

01 to 30 =Cutout time in

minutes

31 = Cutout after 10 seconds

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LEDs 69-71 are located in keypads 1-3.


Standardsetting

CommentsProcedure

Code lock002 Change user code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 69 flashes)Enter the current

code

Confirm (Set)


Confirm (Set)


confirm003 Delete user code 0000 - 9999

or00000 - 99999

or000000 - 999999

(LED 70 flashes)Enter a code

Confirm (Set)


Confirm (Set)004 Delete code memory

(Deletes all user codes )3265 3265 = delete

other inputs= do not delete

010 Automatic timeout 00 - 31 00 00 = No cutout

01 to 30 =Cutout time in

minutes

31 = Cutout after 10 seconds

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Error messages on keypad

LED (67) flashes red to indicate the following errors:

– New master code is already an operator code.– New operator code is already a master code.– Operator code to be changed does not exist.– Tried to change the operator code to another user code that already exists.– Tried to delete an operator code that does not exist.– Code memory full

7 ISM (o)

Z If the truck is equipped with an ISM access module see “ISM Access Module”operating instructions.

8 Changing truck parameters

F Changing the truck parameters will affect the behaviour of the truck. This must betaken into account when starting up the truck. Parameters may only be changed when the truck is idle and not lifting.

With the driver’s display it is also possible to change some truck parameters(acceleration, coasting brake, reverse braking, drive direction speed, fork directionspeed and lift speed) and hence the truck’s characteristics.

t Trucks with driver’s display and key switch

For trucks with a key switch, use the grey service spanner to access the travel and liftparameters.

o Trucks with driver’s display and CANCODE

Z Before entering the SERVICE MENU / PARAMETER MENU you will be asked foryour pin. The factory setting for trucks with CANCODE is (o) PIN 7295.

To switch on the truck, enter your Pin. Before entering the SERVICE MENU /PARAMETER MENU you will then no longer be asked for your PIN. The parametersettings are saved under your PIN.You can set 15 different parameters (change of driver or change of program). Toselect other parameter settings, the truck must log off and on again or be switched offand on again. Enter the next PIN.

M Changes to the service mode may only be made by the manufacturer’s servicedepartment.

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Error messages on keypad

LED (67) flashes red to indicate the following errors:

– New master code is already an operator code.– New operator code is already a master code.– Operator code to be changed does not exist.– Tried to change the operator code to another user code that already exists.– Tried to delete an operator code that does not exist.– Code memory full

7 ISM (o)

Z If the truck is equipped with an ISM access module see “ISM Access Module”operating instructions.

8 Changing truck parameters

F Changing the truck parameters will affect the behaviour of the truck. This must betaken into account when starting up the truck. Parameters may only be changed when the truck is idle and not lifting.

With the driver’s display it is also possible to change some truck parameters(acceleration, coasting brake, reverse braking, drive direction speed, fork directionspeed and lift speed) and hence the truck’s characteristics.

t Trucks with driver’s display and key switch

For trucks with a key switch, use the grey service spanner to access the travel and liftparameters.

o Trucks with driver’s display and CANCODE

Z Before entering the SERVICE MENU / PARAMETER MENU you will be asked foryour pin. The factory setting for trucks with CANCODE is (o) PIN 7295.

To switch on the truck, enter your Pin. Before entering the SERVICE MENU /PARAMETER MENU you will then no longer be asked for your PIN. The parametersettings are saved under your PIN.You can set 15 different parameters (change of driver or change of program). Toselect other parameter settings, the truck must log off and on again or be switched offand on again. Enter the next PIN.

M Changes to the service mode may only be made by the manufacturer’s servicedepartment.

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9 Troubleshooting

All faults or results of operating sequence errors are shown on the driver’s display.Follow the instructions shown on the display.

It may be necessary to start up the truck again. Turn the EMERGENCYDISCONNECT switch off and on again.

If the truck does not start consider the following:

Z If, after having carried out the instructions on the driver’s display and “Action”remedies, the fault persists, inform the manufacturer’s service department as the faultcan only be corrected by trained and qualified service engineers.

10 Moving the truck without a battery, recovery

F This operation must only be performed by a suitably trained maintenance engineer.When the brakes are de-activated the truck must be parked on a level surface, sincethe brakes are no longer effective.

Preparing the truck for recovery

– Turn the Emergency Disconnectswitch and key switch off.

– Prevent the truck from rolling away.– Push the driver’s seat out of the guide

towards the steering wheel.– Disconnect the plug connection.– Remove the seat panel (the seat

panel can be removed once the3 mounting screws have beenunscrewed).

Ventilate the magnetic brake

F Uncontrolled truck movementWhen the brakes are de-activated the truck must be parked on a level surface, sincethe brakes are no longer effective. A de-energised truck with a released magneticbrake cannot be stopped with the truck's own braking system.

– Do not release the brake on slopes or inclines.– Apply the brake again when you reach your destination.– Do not park the truck with the brake released.

Fault Probable Cause ActionTruck cannot be switched on

Battery not connected / battery cable severed

Check battery connector, insert if necessary / check cable

EMERGENCY DISCONNECT switch pressed.

Unlock the EMERGENCY DISCONNECT switch.

Key switch set to "0" Set key switch to “I”.Faulty fuse. Check fuses.

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9 Troubleshooting

All faults or results of operating sequence errors are shown on the driver’s display.Follow the instructions shown on the display.

It may be necessary to start up the truck again. Turn the EMERGENCYDISCONNECT switch off and on again.

If the truck does not start consider the following:

Z If, after having carried out the instructions on the driver’s display and “Action”remedies, the fault persists, inform the manufacturer’s service department as the faultcan only be corrected by trained and qualified service engineers.

10 Moving the truck without a battery, recovery

F This operation must only be performed by a suitably trained maintenance engineer.When the brakes are de-activated the truck must be parked on a level surface, sincethe brakes are no longer effective.

Preparing the truck for recovery

– Turn the Emergency Disconnectswitch and key switch off.

– Prevent the truck from rolling away.– Push the driver’s seat out of the guide

towards the steering wheel.– Disconnect the plug connection.– Remove the seat panel (the seat

panel can be removed once the3 mounting screws have beenunscrewed).

Ventilate the magnetic brake

F Uncontrolled truck movementWhen the brakes are de-activated the truck must be parked on a level surface, sincethe brakes are no longer effective. A de-energised truck with a released magneticbrake cannot be stopped with the truck's own braking system.

– Do not release the brake on slopes or inclines.– Apply the brake again when you reach your destination.– Do not park the truck with the brake released.

Fault Probable Cause ActionTruck cannot be switched on

Battery not connected / battery cable severed

Check battery connector, insert if necessary / check cable

EMERGENCY DISCONNECT switch pressed.

Unlock the EMERGENCY DISCONNECT switch.

Key switch set to "0" Set key switch to “I”.Faulty fuse. Check fuses.

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Procedure:

– Disconnect the two-pin connector from the magnetic brake.– Unscrew the brake release screws from the drive plate and insert them in the

magnetic brake holes.

Align the drive wheel

F Steering the truck at idle tensions thedrive wheel tyre. Releasing the crank canresult in a correcting moment.

Procedure

Set the drive wheel to the requiredposition, to do this:

– Remove the protective cap from overthe centre screw on the steer motor(see arrow).

– Assemble the steering crank inaccordance with the tool set table.

– Place the steering crank on the steeringtransmission.

Turn the drive to the required steeringposition.

Recovering the truck

F The required steering wheel position can only be adjusted when the truck is stationary.

F Only use vehicles to tow the truck which have sufficient tow and brake forces for thetrailer load without its own braking system. Always tow the truck at walking pace.

F An unsecured truck can cause accidentsParking the truck on an incline or with a raised load / load handler is dangerous andis strictly prohibited.

– Always park the truck on a level surface. In special cases the truck may need to besecured with wedges.

– Always fully lower the mast and forks.– Select a place to park where no other people are at risk of injury from lowering forks.

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Procedure:

– Disconnect the two-pin connector from the magnetic brake.– Unscrew the brake release screws from the drive plate and insert them in the

magnetic brake holes.

Align the drive wheel

F Steering the truck at idle tensions thedrive wheel tyre. Releasing the crank canresult in a correcting moment.

Procedure

Set the drive wheel to the requiredposition, to do this:

– Remove the protective cap from overthe centre screw on the steer motor(see arrow).

– Assemble the steering crank inaccordance with the tool set table.

– Place the steering crank on the steeringtransmission.

Turn the drive to the required steeringposition.

Recovering the truck

F The required steering wheel position can only be adjusted when the truck is stationary.

F Only use vehicles to tow the truck which have sufficient tow and brake forces for thetrailer load without its own braking system. Always tow the truck at walking pace.

F An unsecured truck can cause accidentsParking the truck on an incline or with a raised load / load handler is dangerous andis strictly prohibited.

– Always park the truck on a level surface. In special cases the truck may need to besecured with wedges.

– Always fully lower the mast and forks.– Select a place to park where no other people are at risk of injury from lowering forks.

35

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Procedure

– Recovering the truck in the drivedirection: Guide the tow rope, towforce > 5 tonnes, around the entrygrips on the overhead guard,as indicated in the diagram.

– Recovering the truck in the forksdirection: Guide the tow rope, towforce > 5 tonnes, around the mast,as indicated in the diagram.

– Recover the truck carefully andslowly.

– When the truck reaches itsdestination, restore the brakesystem to its operating condition.

Bleed the magnetic brake

F The truck must not be parked withthe brakes released. The magneticbrake release must be removed.If the brake is not working, placewedges underneath the wheels ofthe truck to prevent it from moving.

Procedure

– Restore the protective cap over the centre screw on the steer motor (see arrow).– Unscrew the brake release screws from the magnetic brake and insert them in the

drive plate holes.– Attach the two-pin connector back onto the magnetic brake.

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Procedure

– Recovering the truck in the drivedirection: Guide the tow rope, towforce > 5 tonnes, around the entrygrips on the overhead guard,as indicated in the diagram.

– Recovering the truck in the forksdirection: Guide the tow rope, towforce > 5 tonnes, around the mast,as indicated in the diagram.

– Recover the truck carefully andslowly.

– When the truck reaches itsdestination, restore the brakesystem to its operating condition.

Bleed the magnetic brake

F The truck must not be parked withthe brakes released. The magneticbrake release must be removed.If the brake is not working, placewedges underneath the wheels ofthe truck to prevent it from moving.

Procedure

– Restore the protective cap over the centre screw on the steer motor (see arrow).– Unscrew the brake release screws from the magnetic brake and insert them in the

drive plate holes.– Attach the two-pin connector back onto the magnetic brake.

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11 Optional equipment

11.1 Headlights

Z The work lights are fitted with a 360º swivel link.

11.2 Beacon / strobe

Item Description73 o Work lights74 o Work lights75 o Headlights ON/OFF switch for (item 73)76 o Headlights ON/OFF switch for (item 74)

Item Description77 o Beacon78 o Beacon switch ON/OFF

7675

73

74

7877

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11 Optional equipment

11.1 Headlights

Z The work lights are fitted with a 360º swivel link.

11.2 Beacon / strobe

Item Description73 o Work lights74 o Work lights75 o Headlights ON/OFF switch for (item 73)76 o Headlights ON/OFF switch for (item 74)

Item Description77 o Beacon78 o Beacon switch ON/OFF

7675

73

74

7877

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11.3 Limit switch system / electrical lift limit switch

o ESA 1

ESA stands for End-Schalter-Anlage / 1 (Limit Switch System)

The task of ESA 1 is to prevent damage to the truck and / or the load near theoutriggers caused by incorrect operation.ESA 1 is only available for trucks with integrated sideshift. It operates as follows:

– Only when the mast is fully extended or the fork carriage above the outriggers areall functions released.

– Sideshift and lowering are deactivated if the mast is not fully extended and the loadis near the outriggers. (Outrigger area = 500...600 mm)

Automatic centring release allows,

– when the sideshift is centrally positioned, the mast reach to move automatically inthe outrigger area.

– when the sideshift is centrally positioned, the load to be lowered to the ground.– the central position on the driver’s display to be shown via a control display (79).

Item Description15 o Override switch79 o Symbol display sideshift in central position

15 79

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11.3 Limit switch system / electrical lift limit switch

o ESA 1


The task of ESA 1 is to prevent damage to the truck and / or the load near theoutriggers caused by incorrect operation.ESA 1 is only available for trucks with integrated sideshift. It operates as follows:

– Only when the mast is fully extended or the fork carriage above the outriggers areall functions released.

– Sideshift and lowering are deactivated if the mast is not fully extended and the loadis near the outriggers. (Outrigger area = 500...600 mm)

Automatic centring release allows,

– when the sideshift is centrally positioned, the mast reach to move automatically inthe outrigger area.

– when the sideshift is centrally positioned, the load to be lowered to the ground.– the central position on the driver’s display to be shown via a control display (79).

Item Description15 o Override switch79 o Symbol display sideshift in central position

15 79

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o ESA 2 with override switch


The task of the ESA 2 is to prevent damage to the truck and / or the load near theoutriggers caused by incorrect operation.

This also applies to trucks with features such as:

– various attachments such as fork adjusters, baling clamps,– masts with integrated sideshift– particularly sensitive loads

Only when the mast is extended or the fork carriage above the outriggers are allfunctions released.

At outrigger height level (i.e. below a lift height of approx 500 – 600 mm) the sideshiftand other hydraulic functions except for lifting and tilting (forward / backward) aredisabled if the mast is not extended.

Override switch

The override switch (15) is located above the steering arm and enables all functionswhen activated.

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o ESA 2 with override switch


The task of the ESA 2 is to prevent damage to the truck and / or the load near theoutriggers caused by incorrect operation.

This also applies to trucks with features such as:

– various attachments such as fork adjusters, baling clamps,– masts with integrated sideshift– particularly sensitive loads

Only when the mast is extended or the fork carriage above the outriggers are allfunctions released.

At outrigger height level (i.e. below a lift height of approx 500 – 600 mm) the sideshiftand other hydraulic functions except for lifting and tilting (forward / backward) aredisabled if the mast is not extended.

Override switch

The override switch (15) is located above the steering arm and enables all functionswhen activated.

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11.4 Clamp button

When the "Clamp function release" button (81a) is pressed and the correspondinghydraulic function applied simultaneously, the clamp function is activated.

11.5 Seat heating

11.6 12 V DC / 24 V DC transformer

The transformers (O) can be operated via theswitches to connect a radio system or an externaldevice that requires a 12 / 24 volt supply.

Item Description81a o “Clamp function release” button

Item Description80 o Seat heating switch81 o Seat heating display

Item Description85 o 24 volt transformer switch86 o 12 volt transformer switch

81a

kg

81 80

85 86

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11.4 Clamp button

When the "Clamp function release" button (81a) is pressed and the correspondinghydraulic function applied simultaneously, the clamp function is activated.

11.5 Seat heating

11.6 12 V DC / 24 V DC transformer

The transformers (O) can be operated via theswitches to connect a radio system or an externaldevice that requires a 12 / 24 volt supply.

Item Description81a o “Clamp function release” button

Item Description80 o Seat heating switch81 o Seat heating display

Item Description85 o 24 volt transformer switch86 o 12 volt transformer switch

81a

kg

81 80

85 86

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11.7 Weatherproof cab

Item Description87 o Weather-proof cab Comfort 1 (without entry door)88 o Weather-proof cab Comfort 2 (with entry door)89 o Spray water reservoir (behind driver’s seat)90 o Emergency hammer91 o Load side work lights92 o Not used93 o Heating94 o Seat heating indicator95 o Not used96 o Windscreen spray water pump97 o Seat heating switch98 o Fan99 o Beacon

100 o Drive side work lights101 o Windscreen wiper switch

87, 88

91

89

101

90

92

93

94

95

100

99

98

97

96

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11.7 Weatherproof cab

Item Description87 o Weather-proof cab Comfort 1 (without entry door)88 o Weather-proof cab Comfort 2 (with entry door)89 o Spray water reservoir (behind driver’s seat)90 o Emergency hammer91 o Load side work lights92 o Not used93 o Heating94 o Seat heating indicator95 o Not used96 o Windscreen spray water pump97 o Seat heating switch98 o Fan99 o Beacon

100 o Drive side work lights101 o Windscreen wiper switch

87, 88

91

89

101

90

92

93

94

95

100

99

98

97

96

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11.8 Parabolic mirror

The parabolic mirror is fitted with a side swivel link.

Item Description102 o Parabolic mirror (adjustable)

102

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11.8 Parabolic mirror

The parabolic mirror is fitted with a side swivel link.

Item Description102 o Parabolic mirror (adjustable)

102

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11.9 Removable load backrest

M Trapping hazardWear safety gloves and safety shoes when carrying out this operation.

Z The load backrest is heavyTwo people are required to remove and attach the load backrest.

Load backrest disassembly

– Loosen the screws (104)– Remove the load backrest from the fork carriage and put it down securely.

Load backrest assembly

– Attach the load backrest to the top rail of the fork carriage (103).– Fit the bolts and tighten them with a torque wrench.

Z Torque = 85 Nm

103

104

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11.9 Removable load backrest

M Trapping hazardWear safety gloves and safety shoes when carrying out this operation.

Z The load backrest is heavyTwo people are required to remove and attach the load backrest.

Load backrest disassembly

– Loosen the screws (104)– Remove the load backrest from the fork carriage and put it down securely.

Load backrest assembly

– Attach the load backrest to the top rail of the fork carriage (103).– Fit the bolts and tighten them with a torque wrench.

Z Torque = 85 Nm

103

104

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11.10 ISM access module

The access module replaces the key switch on a truck. The transponders replace thekey and are held in front of the access module to log on. When you leave the truckpress the red button to log off. The truck can only be used again if an authorisedtransponder is held again in front of the access module.

Z If the truck is equipped with an ISM access module see the “ISM Access Module”operating instructions.

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11.10 ISM access module

The access module replaces the key switch on a truck. The transponders replace thekey and are held in front of the access module to log on. When you leave the truckpress the red button to log off. The truck can only be used again if an authorisedtransponder is held again in front of the access module.

Z If the truck is equipped with an ISM access module see the “ISM Access Module”operating instructions.

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11.11 Assembly and hydraulic ports of additional attachments

M Incorrectly connected attachments can cause accidents.Attachments with incorrectly connected hydraulic attachments can result in accidents.

– Attachments must only be assembled and commissioned by trained, specialistpersonnel.

– Note the attachment manufacturer’s operating instructions.– Before commissioning, check the fasteners are positioned correctly and securely

and make sure they are complete.– Before commissioning, make sure the attachment is working correctly.

Hydraulic ports

Requirements

– Non-pressurised hydraulic hoses.– The attachment directions of movement must match the controls’ direction of

movement.

Procedure

– Depressurise the hydraulic hoses by switching off the truck and waiting a few minutes.– Attach the plug connector and engage it in position.– Mark the controls with symbols that indicate their function.

The attachment is now hydraulically connected.

Z Spilled hydraulic oil must be set using a suitable agent and disposed of in accordancewith environmental regulations. If hydraulic oil comes into contact with the skin, washit off immediately with soap and water. If it comes into contact with the eyes rinsethem immediately with flowing water and call for a doctor.

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11.11 Assembly and hydraulic ports of additional attachments

M Incorrectly connected attachments can cause accidents.Attachments with incorrectly connected hydraulic attachments can result in accidents.

– Attachments must only be assembled and commissioned by trained, specialistpersonnel.

– Note the attachment manufacturer’s operating instructions.– Before commissioning, check the fasteners are positioned correctly and securely

and make sure they are complete.– Before commissioning, make sure the attachment is working correctly.

Hydraulic ports

Requirements

– Non-pressurised hydraulic hoses.– The attachment directions of movement must match the controls’ direction of

movement.

Procedure

– Depressurise the hydraulic hoses by switching off the truck and waiting a few minutes.– Attach the plug connector and engage it in position.– Mark the controls with symbols that indicate their function.

The attachment is now hydraulically connected.

Z Spilled hydraulic oil must be set using a suitable agent and disposed of in accordancewith environmental regulations. If hydraulic oil comes into contact with the skin, washit off immediately with soap and water. If it comes into contact with the eyes rinsethem immediately with flowing water and call for a doctor.

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F Forklift Truck Maintenance1 Operational safety and environmental protection

The servicing and inspection duties contained in this chapter must be performed inaccordance with the intervals indicated in the maintenance checklists.

F Risk of accidents and damage to componentsAny modification to the forklift truck assemblies, in particular the safety mechanisms,is prohibited. The operational speeds of the truck must not be changed under anycircumstances.

Exception: Owners should only make changes or have changes made to poweredindustrial trucks if the truck manufacturer is no longer operating in the field and thereis no successor to the business; owners must however:

– Ensure that the changes to be made are planned, tested and performed by a spe-cialist engineer in industrial trucks taking safety into account.

– Keep permanent graphic records of the plans, tests and completion of the changes– carry out and have authorised the respective changes to the capacity data plates,

decals and stickers as well as the operator and service manuals.– Attach permanent and clearly visible marking to the truck indicating the types of

changes made, the date of the changes and the name and address of theorganisation responsible for the work.

M Only original spare parts have been certified by our quality assurance department. Toensure safe and reliable operation of the forklift truck, use only the manufacturer'sspare parts. Used parts, oils and fuels must be disposed of in accordance with therelevant environmental protection regulations. For oil changes, contact the manu-facturer’s specialist department.

Upon completion of inspection and servicing, the tasks contained in the“Recommissioning” section must be performed (see chapter F).

F 1

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F Forklift Truck Maintenance1 Operational safety and environmental protection

The servicing and inspection duties contained in this chapter must be performed inaccordance with the intervals indicated in the maintenance checklists.

F Risk of accidents and damage to componentsAny modification to the forklift truck assemblies, in particular the safety mechanisms,is prohibited. The operational speeds of the truck must not be changed under anycircumstances.

Exception: Owners should only make changes or have changes made to poweredindustrial trucks if the truck manufacturer is no longer operating in the field and thereis no successor to the business; owners must however:

– Ensure that the changes to be made are planned, tested and performed by a spe-cialist engineer in industrial trucks taking safety into account.

– Keep permanent graphic records of the plans, tests and completion of the changes– carry out and have authorised the respective changes to the capacity data plates,

decals and stickers as well as the operator and service manuals.– Attach permanent and clearly visible marking to the truck indicating the types of

changes made, the date of the changes and the name and address of theorganisation responsible for the work.

M Only original spare parts have been certified by our quality assurance department. Toensure safe and reliable operation of the forklift truck, use only the manufacturer'sspare parts. Used parts, oils and fuels must be disposed of in accordance with therelevant environmental protection regulations. For oil changes, contact the manu-facturer’s specialist department.

Upon completion of inspection and servicing, the tasks contained in the“Recommissioning” section must be performed (see chapter F).

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F 2

2 Maintenance safety regulations

Maintenance personnel

Industrial trucks must only be serviced and maintained by the manufacturer’s trainedpersonnel. The manufacturer’s service department has field technicians speciallytrained for these tasks.We therefore recommend that you enter into a maintenance contract with the manu-facturer’s local service centre.

Lifting and jacking up

Lifting and jacking up the truck safely

In order to raise the truck, the lifting gear must only be secured to the points speciallyprovided for this purpose.You may only work under a raised load handler / raised cab if they have been securedwith a sufficiently strong chain or the fastening bolt. In order to raise and jack up thetruck safely, proceed as follows:

– Jack up the truck only on a level surface and prevent it from moving accidentally.– Always use a jack with sufficient capacity. When jacking up the truck, take appropriate

measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).– In order to raise the truck, the lifting gear must only be secured to the points spe-

cially provided for this purpose, see "Identification points" in chapter B.

Cleaning

Fire hazard

Do not use flammable liquids to clean the industrial truck.

– Always disconnect the battery before starting cleaning work.– Carry out all necessary safety measures to prevent sparking before cleaning (e.g.

by short-circuiting).

Risk of electrical system damage

The electrical system can be damaged if it is cleaned with water. Do not wet-cleanthe electrical system.

– Do not clean the electrical system with water.– Clean the electrical system with weak suction or compressed air (use a compressor

with a water trap) and not a conductive, anti-static brush.

Risk of component damage when cleaning the truck

If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfunctions. Do not clean with pressurised water.

After cleaning the truck, carry out the operations detailed in the “Recommissioning”section.

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F 2

2 Maintenance safety regulations

Maintenance personnel

Industrial trucks must only be serviced and maintained by the manufacturer’s trainedpersonnel. The manufacturer’s service department has field technicians speciallytrained for these tasks.We therefore recommend that you enter into a maintenance contract with the manu-facturer’s local service centre.

Lifting and jacking up

Lifting and jacking up the truck safely

In order to raise the truck, the lifting gear must only be secured to the points speciallyprovided for this purpose.You may only work under a raised load handler / raised cab if they have been securedwith a sufficiently strong chain or the fastening bolt. In order to raise and jack up thetruck safely, proceed as follows:

– Jack up the truck only on a level surface and prevent it from moving accidentally.– Always use a jack with sufficient capacity. When jacking up the truck, take appropriate

measures to prevent it from slipping or tipping over (e.g. wedges, wooden blocks).– In order to raise the truck, the lifting gear must only be secured to the points spe-

cially provided for this purpose, see "Identification points" in chapter B.

Cleaning

Fire hazard

Do not use flammable liquids to clean the industrial truck.

– Always disconnect the battery before starting cleaning work.– Carry out all necessary safety measures to prevent sparking before cleaning (e.g.

by short-circuiting).

Risk of electrical system damage

The electrical system can be damaged if it is cleaned with water. Do not wet-cleanthe electrical system.

– Do not clean the electrical system with water.– Clean the electrical system with weak suction or compressed air (use a compressor

with a water trap) and not a conductive, anti-static brush.

Risk of component damage when cleaning the truck

If the truck is to be cleaned with a water jet or a high-pressure cleaner, all electricaland electronic components must be carefully covered beforehand as moisture cancause malfunctions. Do not clean with pressurised water.

After cleaning the truck, carry out the operations detailed in the “Recommissioning”section.

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Electrical system

M Accident risk

– Only suitably trained electricians may operate on the truck's electrical system.– Before working on the electrical system, take all precautionary measures to avoid

electric shocks.– Always disconnect the battery before starting cleaning operations.

M Electric currents can cause accidents

Make sure the electrical system is voltage-free before starting work on it.Before starting maintenance on the electrical system:

– Park the truck securely (see “Parking the Truck Securely” in Chapter E).– Press the Emergency Disconnect.– Disconnect the battery.– Remove any rings or metal bracelets etc. before working on electrical components.

Consumables and used parts

Consumables and use parts must be disposed of in accordance with the applicableenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.

– Note the safety regulations when handling these materials.

Welding

To avoid damaging electric or electronic components, remove these from the truckbefore performing welding operations.

Settings

When repairing or replacing hydraulic, electric or electronic components or assem-blies, always note the truck-specific settings.

F 3

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Electrical system

M Accident risk

– Only suitably trained electricians may operate on the truck's electrical system.– Before working on the electrical system, take all precautionary measures to avoid

electric shocks.– Always disconnect the battery before starting cleaning operations.

M Electric currents can cause accidents

Make sure the electrical system is voltage-free before starting work on it.Before starting maintenance on the electrical system:

– Park the truck securely (see “Parking the Truck Securely” in Chapter E).– Press the Emergency Disconnect.– Disconnect the battery.– Remove any rings or metal bracelets etc. before working on electrical components.

Consumables and used parts

Consumables and use parts must be disposed of in accordance with the applicableenvironmental protection regulations. To change the oil contact the manufacturer'scustomer service department, who have been specially trained for this task.

– Note the safety regulations when handling these materials.

Welding

To avoid damaging electric or electronic components, remove these from the truckbefore performing welding operations.

Settings

When repairing or replacing hydraulic, electric or electronic components or assem-blies, always note the truck-specific settings.

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F 4

Tyre type

M The use of wheels that do not match the manufacturer's specifications can re-sult in accidents. The quality of wheels affects the stability and performance of the truck.Uneven wear affects the truck's stability and increases the stopping distance.

– When replacing wheels make sure the truck is not skewed.– Always replace wheels in pairs, i.e. left and right at the same time.– When replacing wheels fitted at the factory, only use the manufacturer’s original

spare parts. Otherwise the truck's rated performance cannot be ensured.

Lift chains

M Non-lubricated and incorrectly cleaned lift chains can cause accidents

Lift chains are safety-critical parts. They must not contain any serious contamination.Lift chains and pivot pins must always be clean and well lubricated.

– Lift chains should only be cleaned with paraffin derivatives e.g. petroleum ordiesel fuels.

– Never clean chains with steam jet high pressure cleaners, cold or chemicalcleaning agents.

– Immediately after cleaning, dry the lift chain with compressed air and applya chain spray.

– Always lubricate a chain when it is discharged.– Lubricate a lift chain with particular care around the pulleys.

Hydraulic hoses

M Brittle hydraulic hose lines can cause accidents

The hoses must be replaced every six years. The manufacturer's customer servicedepartment is specially trained to carry out these operations.

– Comply with the safety regulations for hydraulic hose lines in accordance withZH 1/74.

M Hydraulic line leaks can cause accidents

Hydraulic oil can escape from leaky and faulty hydraulic lines.

– Report any defects immediately to your supervisor.– Tag out and decommission a faulty lift truck.– Only return the truck to service when you have identified and rectified the fault.– Spilled fluids must be removed immediately with an appropriate bonding agent.

The bonding agent / consumable mixture must be disposed of in accordance withregulations.

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F 4

Tyre type

M The use of wheels that do not match the manufacturer's specifications can re-sult in accidents. The quality of wheels affects the stability and performance of the truck.Uneven wear affects the truck's stability and increases the stopping distance.

– When replacing wheels make sure the truck is not skewed.– Always replace wheels in pairs, i.e. left and right at the same time.– When replacing wheels fitted at the factory, only use the manufacturer’s original

spare parts. Otherwise the truck's rated performance cannot be ensured.

Lift chains

M Non-lubricated and incorrectly cleaned lift chains can cause accidents

Lift chains are safety-critical parts. They must not contain any serious contamination.Lift chains and pivot pins must always be clean and well lubricated.

– Lift chains should only be cleaned with paraffin derivatives e.g. petroleum ordiesel fuels.

– Never clean chains with steam jet high pressure cleaners, cold or chemicalcleaning agents.

– Immediately after cleaning, dry the lift chain with compressed air and applya chain spray.

– Always lubricate a chain when it is discharged.– Lubricate a lift chain with particular care around the pulleys.

Hydraulic hoses

M Brittle hydraulic hose lines can cause accidents

The hoses must be replaced every six years. The manufacturer's customer servicedepartment is specially trained to carry out these operations.

– Comply with the safety regulations for hydraulic hose lines in accordance withZH 1/74.

M Hydraulic line leaks can cause accidents

Hydraulic oil can escape from leaky and faulty hydraulic lines.

– Report any defects immediately to your supervisor.– Tag out and decommission a faulty lift truck.– Only return the truck to service when you have identified and rectified the fault.– Spilled fluids must be removed immediately with an appropriate bonding agent.


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M Hairline cracks in the hydraulic lines can cause injury and infection

Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracksin the hydraulic lines, causing severe injury.

– Call for a doctor immediately if you are injured.– Do not touch pressurised hydraulic lines.– Report any defects immediately to your supervisor.– Tag out and decommission a faulty lift truck.– Only return the truck to service when you have identified and rectified the fault.– Spilled fluids must be removed immediately with an appropriate bonding agent.


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M Hairline cracks in the hydraulic lines can cause injury and infection

Pressurised hydraulic oil can penetrate the skin through fine holes or hairline cracksin the hydraulic lines, causing severe injury.

– Call for a doctor immediately if you are injured.– Do not touch pressurised hydraulic lines.– Report any defects immediately to your supervisor.– Tag out and decommission a faulty lift truck.– Only return the truck to service when you have identified and rectified the fault.– Spilled fluids must be removed immediately with an appropriate bonding agent.


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F 6

3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safeoperation of the industrial truck. Failure to perform regular servicing can lead to truckfailure and poses a potential hazard to personnel and equipment.

M The application conditions of an industrial truck have a considerable impact on thewear of the service components. We recommend that a Jungheinrich customer adviser carries out an applicationanalysis on site to work out specific service intervals to prevent damage due to wear.The service intervals stated are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which theyshould be carried out. Maintenance intervals are defined as:

W = Every 50 operating hours, at least weeklyA = Every 500 operating hoursB = Every 1000 operating hours, or at least annuallyC = Every 2000 operating hours, or at least annually

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

– In the run-in period - after approx. 100 operating hours - or after repair work, theowner must check the wheel nuts/bolts and re-tighten if necessary.

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3 Servicing and inspection

Thorough and expert servicing is one of the most important requirements for the safeoperation of the industrial truck. Failure to perform regular servicing can lead to truckfailure and poses a potential hazard to personnel and equipment.

M The application conditions of an industrial truck have a considerable impact on thewear of the service components. We recommend that a Jungheinrich customer adviser carries out an applicationanalysis on site to work out specific service intervals to prevent damage due to wear.The service intervals stated are based on single shift operation under normaloperating conditions. They must be reduced accordingly if the truck is to be used inconditions of extreme dust, temperature fluctuations or multiple shifts.

The following maintenance checklist states the tasks and intervals after which theyshould be carried out. Maintenance intervals are defined as:

W = Every 50 operating hours, at least weeklyA = Every 500 operating hoursB = Every 1000 operating hours, or at least annuallyC = Every 2000 operating hours, or at least annually

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

– In the run-in period - after approx. 100 operating hours - or after repair work, theowner must check the wheel nuts/bolts and re-tighten if necessary.

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4 ETV 110-116 maintenance checklistMaintenance intervals

Standard = t W A B CCold Store = k

Chassis/Super-structure:

1.1 Check all load bearing components for damage t1.2 Check screw connections t1.3 Check overhead guard for damage and test attachment k t1.4 Check driver position mounting bolts k t

Drive: 2.1 Check transmission for noise and leakage t2.2 Check drive plate and bolts are secure t2.3 Check transmission oil level t2.4 Check pedal mechanism t2.5 Change transmission oil k t

Wheels: 3.1 Check wheels for wear and damage t3.2 Check suspension and attachment k t

Steering: 4.1 Check steering toothing for wear and lubricate k t4.2 Check mechanical parts of steering head t4.3 Test steering t

Brakesystem:

5.1 Test operation and settings k t5.2 Check brake mechanism k t5.3 Check brake lines are insulated and mechanical damage t5.4 Check brake lining wear limit and air gap setting and

adjust if necessaryt

HydraulicSystem:

6.1 Test operation t6.2 Check unions and connections for leaks and damage t6.3 Check hydraulic cylinder for leaks and damage and make

sure it is securek t

6.4 Check oil level k t6.5 Change hydraulic oil, filter cartridge and breather k t6.6 Test hose guide and check for damage k t6.7 Test pressure relief valve k t6.8 Test emergency lowering valve t

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4 ETV 110-116 maintenance checklistMaintenance intervals

Standard = t W A B CCold Store = k

Chassis/Super-structure:

1.1 Check all load bearing components for damage t1.2 Check screw connections t1.3 Check overhead guard for damage and test attachment k t1.4 Check driver position mounting bolts k t

Drive: 2.1 Check transmission for noise and leakage t2.2 Check drive plate and bolts are secure t2.3 Check transmission oil level t2.4 Check pedal mechanism t2.5 Change transmission oil k t

Wheels: 3.1 Check wheels for wear and damage t3.2 Check suspension and attachment k t

Steering: 4.1 Check steering toothing for wear and lubricate k t4.2 Check mechanical parts of steering head t4.3 Test steering t

Brakesystem:

5.1 Test operation and settings k t5.2 Check brake mechanism k t5.3 Check brake lines are insulated and mechanical damage t5.4 Check brake lining wear limit and air gap setting and

adjust if necessaryt

HydraulicSystem:

6.1 Test operation t6.2 Check unions and connections for leaks and damage t6.3 Check hydraulic cylinder for leaks and damage and make

sure it is securek t

6.4 Check oil level k t6.5 Change hydraulic oil, filter cartridge and breather k t6.6 Test hose guide and check for damage k t6.7 Test pressure relief valve k t6.8 Test emergency lowering valve t

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Maintenance intervalsStandard = t W A B CCold Store = k

ElectricalSystem:

7.1 Test operation t7.2 Make sure wire connections are secure and check for

damaget

7.3 Check fuse ratings t7.4 Make sure switches are secure and are operating

correctlyt

7.5 Test operation of warning devices and safety switches k t7.6 Check contactors, replace any worn parts t7.7 Make sure electronic components are secure and clean t

Electric Motors:

8.1 Check motor attachment t

Battery: 9.1 Check battery cables for damage, replace if necessary t9.2 Check battery trolley lock, setting and operation t9.3 Check acid density, acid level and cell voltage k t9.4 Check terminals are securely attached, and apply

greasek t

9.5 Clean battery connections, make sure they are tight k tMast: 10.1 Check mast attachment t

10.2 Check lift chains and guides for wear, adjust and lubricate

k t

10.3 Check tilt cylinder suspension and attachment t10.4 Check mast tilt angle t10.5 Visually inspect rollers, slide pieces and stops k t10.6 Check mast suspension t10.7 Check reach mechanism for wear and damage; if

necessary adjust lateral play, adjust rollers and lubricate the tracks

t

10.8 Check forks and fork carriage for wear and damage k t10.9 Check free lift cylinder displacement k t10.10 Integrated sideshifter (o): Check the screws on the

restraint system and the fork locking system are secure.t

Attach-ment:

11.1 Test operation k t11.2 Check attachment on truck and load bearing

componentsk t

11.3 Check bearing points, guides and stops for wear and damage, grease these components

t

GeneralMeasure-ments:

12.1 Check electrical system for frame leakage t12.2 Test travel speed and braking distance t12.3 Test lift and lowering speeds t12.4 Test safety devices and cutouts t

Lubrica-tion:

13.1 Lubricate truck in accordance with Lubrication Schedule k t

Demon-stration:

14.1 Test run with rated load t14.2 After carrying out maintenance, present the truck to the

supervisork t

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Maintenance intervalsStandard = t W A B CCold Store = k

ElectricalSystem:

7.1 Test operation t7.2 Make sure wire connections are secure and check for

damaget

7.3 Check fuse ratings t7.4 Make sure switches are secure and are operating

correctlyt

7.5 Test operation of warning devices and safety switches k t7.6 Check contactors, replace any worn parts t7.7 Make sure electronic components are secure and clean t

Electric Motors:

8.1 Check motor attachment t

Battery: 9.1 Check battery cables for damage, replace if necessary t9.2 Check battery trolley lock, setting and operation t9.3 Check acid density, acid level and cell voltage k t9.4 Check terminals are securely attached, and apply

greasek t

9.5 Clean battery connections, make sure they are tight k tMast: 10.1 Check mast attachment t

10.2 Check lift chains and guides for wear, adjust and lubricate

k t

10.3 Check tilt cylinder suspension and attachment t10.4 Check mast tilt angle t10.5 Visually inspect rollers, slide pieces and stops k t10.6 Check mast suspension t10.7 Check reach mechanism for wear and damage; if

necessary adjust lateral play, adjust rollers and lubricate the tracks

t

10.8 Check forks and fork carriage for wear and damage k t10.9 Check free lift cylinder displacement k t10.10 Integrated sideshifter (o): Check the screws on the

restraint system and the fork locking system are secure.t

Attach-ment:

11.1 Test operation k t11.2 Check attachment on truck and load bearing

componentsk t

11.3 Check bearing points, guides and stops for wear and damage, grease these components

t

GeneralMeasure-ments:

12.1 Check electrical system for frame leakage t12.2 Test travel speed and braking distance t12.3 Test lift and lowering speeds t12.4 Test safety devices and cutouts t

Lubrica-tion:

13.1 Lubricate truck in accordance with Lubrication Schedule k t

Demon-stration:

14.1 Test run with rated load t14.2 After carrying out maintenance, present the truck to the

supervisork t

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5 ETV 110-116 maintenance schedule

A

G

EF

EF

EF

J

Min. = 16lMax.= 29l

BB+C1)

2,9 l

E F

195 Ð10 Nm

75 Ð5 Nm

2)

g Contact surfaces

s Grease nipples

Hydraulic oil filler plug

c Hydraulic oil drain plug

b Transmission oil filler neck

a Transmission oil drain plug

Cold Store Application1) Cold store mix ratio 1:12) For capacity see section 5.2 “Tank Capacity”

F 9

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5 ETV 110-116 maintenance schedule

A

G

EF

EF

EF

J

Min. = 16lMax.= 29l

BB+C1)

2,9 l

E F

195 Ð10 Nm

75 Ð5 Nm

2)

g Contact surfaces

s Grease nipples

Hydraulic oil filler plug

c Hydraulic oil drain plug

b Transmission oil filler neck

a Transmission oil drain plug

Cold Store Application1) Cold store mix ratio 1:12) For capacity see section 5.2 “Tank Capacity”

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5.1 Lubricants and Lubrication Schedule

5.1.1 Handling consumables safely

Handling consumables: Consumables must always be handled correctly.Follow the manufacturer’s instructions.

M Improper handling is hazardous to health, life and the environment

Consumables can be flammable.

– Keep consumables away from hot components and naked flames.– Always keep consumables in prescribed containers.– Always fill consumables in clean containers.– Do not mix up different grades of consumable. The only exception to this is when

mixing is expressly stipulated in the Operating Instructions.

M Spilled liquids can cause slipping and endanger the environment

Risk of slipping from spilled liquids. The risk is greater when combined with water.

– Do not spill liquids.– Spilled liquids must be removed immediately with an appropriate bonding agent.– The bonding agent / consumable mixture must be disposed of in accordance with

regulations.

M Oils (chain spray / hydraulic oil) are flammable and poisonous.

– Dispose of used oils in accordance with regulations. Store used oil safely until it canbe disposed of in accordance with regulations

– Do not spill oil.– Spilled fluids must be removed immediately with an appropriate bonding agent.– The bonding agent / consumable mixture must be disposed of in accordance with

regulations.– Observe national regulations when handling oils.– Wear safety gloves when handling oils.– Prevent oil from coming into contact with hot motor parts.– Do not smoke when handling oil.– Avoid contact and digestion. If you swallow oil do not induce vomiting but call for

a doctor immediately.– Seek fresh air after breathing in oil fumes or vapours.– If oil has come into contact with your skin, rinse your skin with water.– If oil has come into contact with your eyes, rinse them with water and call for a doc-

tor immediately.– Replace oil-soaked clothing and shoes immediately.

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F 10

5.1 Lubricants and Lubrication Schedule

5.1.1 Handling consumables safely

Handling consumables: Consumables must always be handled correctly.Follow the manufacturer’s instructions.

M Improper handling is hazardous to health, life and the environment

Consumables can be flammable.

– Keep consumables away from hot components and naked flames.– Always keep consumables in prescribed containers.– Always fill consumables in clean containers.– Do not mix up different grades of consumable. The only exception to this is when

mixing is expressly stipulated in the Operating Instructions.

M Spilled liquids can cause slipping and endanger the environment

Risk of slipping from spilled liquids. The risk is greater when combined with water.

– Do not spill liquids.– Spilled liquids must be removed immediately with an appropriate bonding agent.– The bonding agent / consumable mixture must be disposed of in accordance with

regulations.

M Oils (chain spray / hydraulic oil) are flammable and poisonous.

– Dispose of used oils in accordance with regulations. Store used oil safely until it canbe disposed of in accordance with regulations

– Do not spill oil.– Spilled fluids must be removed immediately with an appropriate bonding agent.– The bonding agent / consumable mixture must be disposed of in accordance with

regulations.– Observe national regulations when handling oils.– Wear safety gloves when handling oils.– Prevent oil from coming into contact with hot motor parts.– Do not smoke when handling oil.– Avoid contact and digestion. If you swallow oil do not induce vomiting but call for

a doctor immediately.– Seek fresh air after breathing in oil fumes or vapours.– If oil has come into contact with your skin, rinse your skin with water.– If oil has come into contact with your eyes, rinse them with water and call for a doc-

tor immediately.– Replace oil-soaked clothing and shoes immediately.

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5.2 Consumables

M * The trucks are factory-equipped with a special hydraulic oil (the Jungheinrichhydraulic oil with a blue colouration) or the cold store hydraulic oil (red colouration).The Jungheinrich hydraulic oil can only be obtained from the Jungheinrich servicedepartment. The use of named alternative hydraulic oils is not prohibited but may leadto a decline in functionality. It is possible to mix the Jungheinrich hydraulic oil with oneof the named alternative hydraulic oils.

Grease guidelines

Code Order no. Quantity Description Used for

A51 132 827* 5,0 l Jungheinrich

Hydraulic OilHydraulic system

50 449 669 5,0 l HLP-D 46,DIN 51524

B 29 200 680 5,0 l CLP 100,DIN 51517 Transmission

C 29 200 810 5,0 l HLP 10,DIN 51524

Transmission, Hydraulic System

E 29 201 430 1,0 kg Grease, DIN 51825 LubricationF 50 430 702 1,0 kg Grease, TTF52 LubricationG 29 201 280 400 ml Chain spray ChainsJ 51 081875 5 l Renolin MR 310 Hydraulic System

Code Saponification Dew point °C

Worked penetration at 25°C

NLG1 class

Application-temperature °C

E Lithium 185 265 - 295 2 -35 / +120F — — 310 - 340 1 -52 / +100

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5.2 Consumables

M * The trucks are factory-equipped with a special hydraulic oil (the Jungheinrichhydraulic oil with a blue colouration) or the cold store hydraulic oil (red colouration).The Jungheinrich hydraulic oil can only be obtained from the Jungheinrich servicedepartment. The use of named alternative hydraulic oils is not prohibited but may leadto a decline in functionality. It is possible to mix the Jungheinrich hydraulic oil with oneof the named alternative hydraulic oils.

Grease guidelines

Code Order no. Quantity Description Used for

A51 132 827* 5,0 l Jungheinrich

Hydraulic OilHydraulic system

50 449 669 5,0 l HLP-D 46,DIN 51524

B 29 200 680 5,0 l CLP 100,DIN 51517 Transmission

C 29 200 810 5,0 l HLP 10,DIN 51524

Transmission, Hydraulic System

E 29 201 430 1,0 kg Grease, DIN 51825 LubricationF 50 430 702 1,0 kg Grease, TTF52 LubricationG 29 201 280 400 ml Chain spray ChainsJ 51 081875 5 l Renolin MR 310 Hydraulic System

Code Saponification Dew point °C

Worked penetration at 25°C

NLG1 class

Application-temperature °C

E Lithium 185 265 - 295 2 -35 / +120F — — 310 - 340 1 -52 / +100

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5.3 Tank Capacities

ETV 110-112

ETV 114-116

Marking LitresETV 110-112

Lift heights (h3)ZT DZ

Max (low air cushion) 25 - -

V 23.5 - up to 7100IV 21 - up to 6200III 18.5 - up to 4550II 16 up to 3790 -I 13 - -



Max (low air cushion) 31.6 - -

V 30 - -IV 28 - up to 9020III 25 up to 4400 up to 8420II 21 - up to 6200I 17 - -

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5.3 Tank Capacities

ETV 110-112

ETV 114-116



Max (low air cushion) 25 - -

V 23.5 - up to 7100IV 21 - up to 6200III 18.5 - up to 4550II 16 up to 3790 -I 13 - -



Max (low air cushion) 31.6 - -

V 30 - -IV 28 - up to 9020III 25 up to 4400 up to 8420II 21 - up to 6200I 17 - -

F 13

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6 Maintenance Instructions

6.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying outmaintenance and repairs. The following preparations must be made:

– Park the truck securely (see Chapter E).– Disconnect the battery (1) to prevent the truck from accidentally starting.

F When working under a raised load fork or a raised truck, secure them to prevent themfrom lowering, tipping or sliding away. When raising the truck also refer to theinstructions in the “Transport and Commissioning” section.When working on the parking brake, prevent the truck from rolling away.

6.2 Check fixing of the wheels

F Accident risk from incorrect wheel disassembly/assembly

The load / drive wheels can only be disassembled or assembled by themanufacturer's customer service department which has been trained to do this.Exceptionally, this task may be performed by a customer service organisationauthorised by the manufacturer.

– Park the truck and render it safe (see chapter E).– Tighten wheel bolts cross-wise with a torque wrench.

TorqueDriven wheels ETV 110/116 MA = 90 Nm

Driven wheels ETV 114/116 MA = 120 Nm

Rear wheels MA = 195-10 Nm

1

F 13

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6 Maintenance Instructions

6.1 Preparing the truck for maintenance and repairs

All necessary safety measures must be taken to avoid accidents when carrying outmaintenance and repairs. The following preparations must be made:

– Park the truck securely (see Chapter E).– Disconnect the battery (1) to prevent the truck from accidentally starting.

F When working under a raised load fork or a raised truck, secure them to prevent themfrom lowering, tipping or sliding away. When raising the truck also refer to theinstructions in the “Transport and Commissioning” section.When working on the parking brake, prevent the truck from rolling away.

6.2 Check fixing of the wheels

F Accident risk from incorrect wheel disassembly/assembly

The load / drive wheels can only be disassembled or assembled by themanufacturer's customer service department which has been trained to do this.Exceptionally, this task may be performed by a customer service organisationauthorised by the manufacturer.

– Park the truck and render it safe (see chapter E).– Tighten wheel bolts cross-wise with a torque wrench.

TorqueDriven wheels ETV 110/116 MA = 90 Nm

Driven wheels ETV 114/116 MA = 120 Nm

Rear wheels MA = 195-10 Nm

1

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F 14

6.3 Removing the seat panel

– Pull seat locking lever (2) up and push seat (3) towards the steering wheel.– Disconnect the system.– Slacken collar screws (4) and remove panel (5).

Z The drive unit and hydraulic unit are now exposed for maintenance.

6.4 Checking the hydraulic oil level

– Preparing the truck for maintenanceand repairs (see Section 6.1 and 6.3).

– Check oil level in hydraulic tank.

Z The oil level should be checked in thehydraulic tank when the load is lowered.

– If necessary replenish at the filler neck(6) using the correct oil grade (forhydraulic oil specification, see section 5.1).

– Replace seat panel and secure withcollar screws (4).

– Connect fan.– Push seat into position and engage

locking lever (2).

3

5

42

6

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F 14

6.3 Removing the seat panel

– Pull seat locking lever (2) up and push seat (3) towards the steering wheel.– Disconnect the system.– Slacken collar screws (4) and remove panel (5).

Z The drive unit and hydraulic unit are now exposed for maintenance.

6.4 Checking the hydraulic oil level

– Preparing the truck for maintenanceand repairs (see Section 6.1 and 6.3).

– Check oil level in hydraulic tank.

Z The oil level should be checked in thehydraulic tank when the load is lowered.

– If necessary replenish at the filler neck(6) using the correct oil grade (forhydraulic oil specification, see section 5.1).

– Replace seat panel and secure withcollar screws (4).

– Connect fan.– Push seat into position and engage

locking lever (2).

3

5

42

6

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6.5 Opening the fuse cover

– Grip onto the handle recess in thepanel (7), pull it off with force and putit to one side.

Z Fuses are located under the panel.

6.6 Opening the instrument panel

– Slacken the collar screws in mastguard. Push the steering wheeltowards the seat (most extremeposition) Remove the panel (8).

Z The main fuses are located under thepanel (8).

7

8

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6.5 Opening the fuse cover

– Grip onto the handle recess in thepanel (7), pull it off with force and putit to one side.

Z Fuses are located under the panel.

6.6 Opening the instrument panel

– Slacken the collar screws in mastguard. Push the steering wheeltowards the seat (most extremeposition) Remove the panel (8).

Z The main fuses are located under thepanel (8).

7

8

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F 16

6.7 Checking electrical fuses

– Preparing the truck for maintenance and repairs (see Section 6.5 and 6.6). – Check rating of all fuses in accordance with table, replace if necessary.

a) 13 Nm, b) 10 Nm, c) 4.5 Nm

Item Description Rating / type9a) F8 Main fuse 355 A10b) 2F1 Pump motor fuse 250 A11b) 1F1 Drive motor fuse 250 A12c) F1 Overall control fuse 30 A13c) F13 Valve / brake fuse 30 A14c) 3F1 Steering fuse 30 A15c) 5F6 Cabin fuse 30 A16 F17 Radio fuse 7.5 A17 4F11 Driver’s display fuse 5 A18 5F7 Overhead guard option fuse 10 A19 2F17 Hydraulics MFC control fuse 2 A20 4F12 Aux. MFC control fuse 2 A21 1F13 Travel / brake MFC control fuse 7.5 A22 2F16 Lift controller control fuse 2 A23 4F10 Fan control fuse 3 A24 1F12 Traction controller control fuse 2 A25 3F2 Power steering control fuse 3 A26 9F2 Seat heating control fuse 7.5 A27 4F13 Aux. fuse 7.5 A28 2F18 Hydraulics MFC fuse 10 A29 1F14 Travel / brake MFC control fuse 10 A

16 17 18 1920 21 22

23 24 25 26 27 28 29

9

10

1112 13

1415-06/2006

11

14

10

13

12 15

06/2006-

9

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F 16

6.7 Checking electrical fuses

– Preparing the truck for maintenance and repairs (see Section 6.5 and 6.6). – Check rating of all fuses in accordance with table, replace if necessary.

a) 13 Nm, b) 10 Nm, c) 4.5 Nm

Item Description Rating / type9a) F8 Main fuse 355 A10b) 2F1 Pump motor fuse 250 A11b) 1F1 Drive motor fuse 250 A12c) F1 Overall control fuse 30 A13c) F13 Valve / brake fuse 30 A14c) 3F1 Steering fuse 30 A15c) 5F6 Cabin fuse 30 A16 F17 Radio fuse 7.5 A17 4F11 Driver’s display fuse 5 A18 5F7 Overhead guard option fuse 10 A19 2F17 Hydraulics MFC control fuse 2 A20 4F12 Aux. MFC control fuse 2 A21 1F13 Travel / brake MFC control fuse 7.5 A22 2F16 Lift controller control fuse 2 A23 4F10 Fan control fuse 3 A24 1F12 Traction controller control fuse 2 A25 3F2 Power steering control fuse 3 A26 9F2 Seat heating control fuse 7.5 A27 4F13 Aux. fuse 7.5 A28 2F18 Hydraulics MFC fuse 10 A29 1F14 Travel / brake MFC control fuse 10 A

16 17 18 1920 21 22

23 24 25 26 27 28 29

9

10

1112 13

1415-06/2006

11

14

10

13

12 15

06/2006-

9

F 17

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6.8 Recommissioning

The truck may only be restored to service after cleaning or repair work, once thefollowing operations have been performed.

– Test horn.– Test main switch operation.– Test brakes.– Lubricate the truck in accordance with the maintenance schedule.

7 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. foroperational reasons, it must be parked in a frost-free and dry location and allnecessary measures must be taken before, during and after decommissioning asdescribed.

M On decommissioning the truck must be jacked up so that all the wheels are clear ofthe ground. This is the only way of ensuring that the wheels and wheel bearings arenot damaged.

If the truck is to be out of service for more than 6 months, further measures must betaken in consultation with the manufacturer’s service department.

7.1 Prior to decommissioning

– Thoroughly clean the truck.– Check the brakes.– Check the hydraulic oil level and replenish as necessary (see Chapter F).– Apply a thin layer of oil or grease to any non-painted mechanical components.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Charge the battery (see Chapter D).– Disconnect the battery, clean it and grease the terminals.

Z In addition, follow the battery manufacturer’s instructions.

– Spay all exposed electrical contacts with a suitable contact spray.

7.2 During decommissioning

Every 2 months:

– Charge the battery (see Chapter D).

M Battery powered trucks:The battery must be charged at regular intervals to avoid depletion of the batterythrough self-discharge. The sulfatisation would destroy the battery.

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6.8 Recommissioning

The truck may only be restored to service after cleaning or repair work, once thefollowing operations have been performed.

– Test horn.– Test main switch operation.– Test brakes.– Lubricate the truck in accordance with the maintenance schedule.

7 Decommissioning the industrial truck

If the industrial truck is to be decommissioned for more than two months, e.g. foroperational reasons, it must be parked in a frost-free and dry location and allnecessary measures must be taken before, during and after decommissioning asdescribed.

M On decommissioning the truck must be jacked up so that all the wheels are clear ofthe ground. This is the only way of ensuring that the wheels and wheel bearings arenot damaged.

If the truck is to be out of service for more than 6 months, further measures must betaken in consultation with the manufacturer’s service department.

7.1 Prior to decommissioning

– Thoroughly clean the truck.– Check the brakes.– Check the hydraulic oil level and replenish as necessary (see Chapter F).– Apply a thin layer of oil or grease to any non-painted mechanical components.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Charge the battery (see Chapter D).– Disconnect the battery, clean it and grease the terminals.

Z In addition, follow the battery manufacturer’s instructions.

– Spay all exposed electrical contacts with a suitable contact spray.

7.2 During decommissioning

Every 2 months:

– Charge the battery (see Chapter D).

M Battery powered trucks:The battery must be charged at regular intervals to avoid depletion of the batterythrough self-discharge. The sulfatisation would destroy the battery.

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7.3 Restoring the truck to operation after decommissioning

– Thoroughly clean the truck.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Clean the battery, grease the terminals and connect the battery.– Charge the battery (see Chapter D).– Check transmission oil for condensed water and replace if necessary.– Check hydraulic oil for condensed water and replace if necessary.– Start up the truck (see Chapter E).

Z Battery powered trucks:If there are switching problems in the electrical system, apply contact spray to theexposed contacts and remove any oxide layers on the contacts of the operatingcontrols by applying them repeatedly.

F Perform several brake tests immediately after re-commissioning the truck.

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

Z Perform a safety check in accordance with national regulations. Jungheinrichrecommends the truck be checked to FEM guideline 4.004. Jungheinrich has a safetydepartment with trained personnel, able to carry out inspections.

The truck must be inspected at least annually or after any unusual event by a qualifiedinspector (be sure to comply with national regulations). The inspector shall assess thecondition of the truck from purely a safety viewpoint, without regard to operational oreconomic circumstances. The inspector shall be sufficiently instructed andexperienced to be able to assess the condition of the truck and the effectiveness ofthe safety mechanisms based on the technical regulations and principles governingthe inspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical conditionfrom a safety aspect. The truck must also be examined for damage caused bypossible improper use. A test report shall be provided. The test results must be keptfor 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.

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F 18

7.3 Restoring the truck to operation after decommissioning

– Thoroughly clean the truck.– Lubricate the truck in accordance with the maintenance schedule (see Chapter F).– Clean the battery, grease the terminals and connect the battery.– Charge the battery (see Chapter D).– Check transmission oil for condensed water and replace if necessary.– Check hydraulic oil for condensed water and replace if necessary.– Start up the truck (see Chapter E).

Z Battery powered trucks:If there are switching problems in the electrical system, apply contact spray to theexposed contacts and remove any oxide layers on the contacts of the operatingcontrols by applying them repeatedly.

F Perform several brake tests immediately after re-commissioning the truck.

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

Z Perform a safety check in accordance with national regulations. Jungheinrichrecommends the truck be checked to FEM guideline 4.004. Jungheinrich has a safetydepartment with trained personnel, able to carry out inspections.

The truck must be inspected at least annually or after any unusual event by a qualifiedinspector (be sure to comply with national regulations). The inspector shall assess thecondition of the truck from purely a safety viewpoint, without regard to operational oreconomic circumstances. The inspector shall be sufficiently instructed andexperienced to be able to assess the condition of the truck and the effectiveness ofthe safety mechanisms based on the technical regulations and principles governingthe inspection of forklift trucks.

A thorough test of the truck must be undertaken with regard to its technical conditionfrom a safety aspect. The truck must also be examined for damage caused bypossible improper use. A test report shall be provided. The test results must be keptfor 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.

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9 Final de-commissioning, disposal

Z Final, correct de-commissioning or disposal of the truck must be performed inaccordance with the regulations of the country of use. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

10 Human vibration measurement

Z Vibrations that affect the driver during operation over the course of the day are knownas human vibrations. Excessive human vibrations will cause the driver long termhealth problems. The European "2002/44/EC/Vibration" operator directive hastherefore been established to protect drivers. To help operators to assess the application situation, the manufacturer offers aservice of measuring these human vibrations.

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9 Final de-commissioning, disposal

Z Final, correct de-commissioning or disposal of the truck must be performed inaccordance with the regulations of the country of use. In particular, regulationsgoverning the disposal of batteries, fuels and electronic and electrical systems mustbe observed.

10 Human vibration measurement

Z Vibrations that affect the driver during operation over the course of the day are knownas human vibrations. Excessive human vibrations will cause the driver long termhealth problems. The European "2002/44/EC/Vibration" operator directive hastherefore been established to protect drivers. To help operators to assess the application situation, the manufacturer offers aservice of measuring these human vibrations.

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Traction Battery Appendix
Contents

A Traction Battery Appendix....................................................... 1

1 Correct Use and Application.................................................................... 22 Data plate ................................................................................................ 23 Safety Instructions, Warning Indications and other Notes....................... 34 Lead acid batteries with armour plated cells and liquid electrolyte.......... 44.1 Description............................................................................................... 44.2 Operation................................................................................................. 54.3 Servicing lead-acid batteries with armour plated cells............................. 85 PzV and PzV-BS lead-acid batteries with sealed armour plated cells..... 95.1 Description............................................................................................... 95.2 Operation................................................................................................. 105.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated

cells ......................................................................................................... 136 Aquamatik water replenishment system.................................................. 146.1 Water replenishment system design ....................................................... 146.2 Functional Description ............................................................................. 156.3 Adding water............................................................................................ 156.4 Water pressure ........................................................................................ 156.5 Filling time ............................................................................................... 166.6 Water quality............................................................................................ 166.7 Battery tubing .......................................................................................... 166.8 Operating temperature ............................................................................ 166.9 Cleaning measures.................................................................................. 176.10 Service mobile vehicle............................................................................. 177 Electrolyte circulation............................................................................... 187.1 Functional Description ............................................................................. 188 Cleaning batteries.................................................................................... 209 Storing the battery ................................................................................... 2210 Troubleshooting....................................................................................... 2211 Disposal................................................................................................... 22

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Correct Use and Application

Failure to observe the operating instructions, carrying out repairs with non-originalspare parts, tampering with the battery or using electrolyte additives will invalidate thewarranty.

Observe the instructions for maintaining the safety rating during operation forbatteries in accordance with Ex I and Ex II (see relevant certification).

Data plate

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1 Battery name2 Battery type3 Production week/year manf.4 Serial number5 Supplier number6 Rated voltage7 Rated capacity9 Battery weight in kg8 Number of cells15 Electrolyte volume in litres10 Battery number11 Manufacturer13 Manufacturer's logo12 CE mark only for batteries beyond 75 volts14 Safety instructions and warning information

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Safety Instructions, Warning Indications and other Notes
Used batteries must be treated as hazardous waste.

These batteries are marked with the recycling symbol and the sign showing a crossed-out rubbish bin, and should not be disposed of with ordinary household waste. waste.

Buy-back terms and type of recycling are to be agreed with the manufacturer as described in § 8 of the battery legislation.

Do not smoke!

No naked flames, glowing embers or sparks near the battery - fire and explosion hazard!

Avoid fire and explosion hazards and short circuits due to overheating!

Keep away from naked flames and strong heat sources.

Always wear protective clothing (e.g. safety goggles and safety gloves) when working on cells and batteries. batteries. Always wash your hands after completing the work. Use insulated tools only. Do not physically alter the battery, strike, crush, compress, notch, dent or modify it in any way. Hazardous electric voltage! The metal parts of the battery cells are permanently live. Therefore do not place any foreign objects or tools on the battery.Observe national health and safety regulations.

If the materials leak, do not inhale the fumes. Wear safety gloves.

Follow the user instructions and keep them in a visible position in the charging area.

Work on the batteries should be performed only as instructed by specialist personnel.

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Lead acid batteries with armour plated cells and liquid electrolyte

.1 Description

Jungheinrich traction batteries are lead acid batteries with armour plated cells andliquid electrolyte. The names of the traction batteries are PzS, PzB, PzS Lib and PzM.

Electrolyte

The rated density of the electrolyte assumes a temperature of 30°C and the ratedelectrolyte level is fully charged. Higher temperatures will reduce, lower temperatureswill increase the electrolyte density. The adjustment factor is ± 0.0007 kg/l per K, e.g.electrolyte density 1.28 kg/l at 45°C corresponds to a density of 1.29 kg/l at 30°C.

The electrolyte must conform to DIN 43530 Part 2 purity regulations.

1.1 Battery nominal data

1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells

3. Rated capacity C5 See data plate

4. Discharge current C5/5h

5. Nominal electrolyte density1

1. Reached within the first 10 cycles.

1.29 kg/l

6. Nominal temperature2

2. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

30 °C

7. System rated electrolyte level up to "Max" electrolyte level marking

Limit temperature3

3. Not permissible as operating temperature.

55°C

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.2 Operation

2.1 Commissioning unfilled batteries

Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.

2.2 Commissioning filled and charged batteries


Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)

and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and

connectors. • Charge up the battery.• Check the electrolyte level.

Z The electrolyte level must be above the cell baffle or the top of the separator.• Add electrolyte with distilled water up to the nominal level.

Checks completed.

2.3 Discharging the battery

Z To achieve an optimum useful life avoid operational discharge of more than 80% ofnominal capacity (full discharge). This corresponds to a minimum electrolytedensity of 1.13 kg/l at the end of the discharge. Recharge a discharged batteryimmediately.

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2.4 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the

charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity

and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure

sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.

Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of2 m from the truck.

Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station

manufacturers.

NOTE

The battery must only be charged with DC current. All charging processes inaccordance with DIN 41773 and DIN 41774 are permissible.

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Z The electrolyte temperature rises by approx. 10 K during charging. Charging shouldtherefore only begin when the electrolyte temperature is below 45°C. Theelectrolyte temperature of batteries must be at least +10°C before charging.Otherwise the battery will not charge correctly. Below 10°C the battery isinsufficiently charged with standard charging systems.

Charging the battery

Requirements– Electrolyte temperature min. 10°C to max. 45°C

Procedure• Open or take off the tray lid or covers from the battery compartment.

Z Deviations are outlined in the truck's operating instructions. The plugs remain onthe cells or remain closed.

• Connect the battery to the switched off charger, ensuring the terminals are connect(positive to positive and negative to negative).

• Switch on the charger.

Battery charged

Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging. The maximum compensationcharge current is 5 A/100 Ah rated capacity.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which reduce the usefullife of the batteries.

Z Trickle charges should only be performed when the charge level is below 60 %. Usereplacement batteries instead of regular trickle charging.

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.3 Servicing lead-acid batteries with armour plated cells

Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

3.1 Daily

– Charge the battery after each discharge.– After charging, check the electrolyte level.– If necessary, add purified water up to the rated level after charging.

Z The height of the electrolyte level should not be below the cell baffle or above thetop of the separator, or the "Min" and "Max" electrolyte markings respectively.

3.2 Weekly

– After re-charging, carry out a visual inspection for dirt and physical damage.– If the battery is charged regularly according to the IU characteristic, carry out a

compensation charge.

3.3 Monthly

– Towards the end of the charging process measure and record the voltages of allthe cells with the charger switched on.

– After charging measure and record the electrolyte density and the electrolytetemperature in all the cells.

– Compare the results with the previous ones.

Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.

3.4 Annually

– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.

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PzV and PzV-BS lead-acid batteries with sealed armour plated cells

.1 Description

PzV batteries are sealed batteries with fixed electrolytes, to which no water can beadded over the entire lifespan of the battery. Relief valves are used as plugs whichare destroyed when opened. During operation the same safety requirements apply tothe sealed batteries as for batteries with liquid electrolyte. This is to avoid electricshock, explosion of the electrolyte charging gases or hazardous electrolyte burns ifthe cell vessels are destroyed.

Z PzV batteries are low gassing, but not gassing-free.

Electrolyte

The electrolyte is sulphuric acid which is fixed in gel. The density of the electrolytecannot be measured.

1.1 Battery nominal data

1. Product Traction battery

2. Nominal voltage 2.0 V x no. of cells

3. Rated capacity C5 See data plate

4. Discharge current C5/5h

5. Rated temperature 30 °C

Limit temperature1

1. Higher temperatures shorten the useful life, lower temperatures reduce the available capacity.

45°C, not permissible as operating temperature.

6. Rated density of the electrolyte Cannot be measured

7. System rated electrolyte level Cannot be measured

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.2 Operation

2.1 Commissioning


Procedure• Make sure the battery is in physically good condition. • Make sure the terminals are correct (positive to positive and negative to negative)

and check that contacts on the battery terminal conducting system are secure.• Check the terminal screw torques (M10 = 23 ±1 Nm) of the terminal conductors and

connectors. • Re-charge the battery.• Charge the battery.

Check completed.

2.2 Discharging the battery

Z To achieve an optimum useful life avoid operational discharges of more than 60%of nominal capacity.

Z If the battery is discharged during operation by more than 80% of rated capacity theuseful life of the battery will reduce significantly. Fully or partially dischargedbatteries must be re-charged immediately and not left unattended.

2.3 Charging the battery

WARNING!

The gases produced during charging can cause explosionsThe battery gives off a mixture of oxygen and hydrogen (electrolytic gas) duringcharging. Gassing is a chemical process. This gas mixture is highly explosive andmust not be ignited.Always disconnect the charger and truck before connecting or disconnecting the

charger and battery.The charger must be adapted to the battery in terms of voltage, charge capacity

and battery technology.Before charging, check all cables and plug connections for visible signs of damage.Ventilate the room in which the truck is being charged.Battery cell surfaces must remain exposed during charging in order to ensure

sufficient ventilation, see truck operating instructions, chapter D, Charging theBattery.

Do not smoke and avoid naked flames when handling batteries.Wherever an industrial truck is parked for charging there must be no inflammable

material or consumables capable of creating sparks within a minimum distance of2 m from the truck.

Fire protection equipment must be available.Do not place any metallic objects on the battery.Always follow the safety regulations of the battery and charger station

manufacturers.

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NOTE

Charging the battery incorrectly can result in material damage.Incorrect battery charging can result in overloading of the electric wires and contacts,hazardous gas formation and electrolyte leakage from the cells.Always charge the battery with DC current.All DIN 41773 charging procedures are permitted in the format approved by the

manufacturer.Always connect the battery to a charger that is appropriate to the size and type of

the battery.If necessary have the charger checked by the manufacturer's customer service

department for suitability.Do not exceed limit currents in the gassing area in accordance with DIN EN 50272-

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Charging the battery

Requirements– Electrolyte temperature between +15°C and 35°C

Procedure• Open or take off the tray lid or covers from the battery compartment.• Connect the battery to the switched off charger, ensuring the terminals are connect

(positive to positive and negative to negative). • Switch on the charger.

Z The electrolyte temperature rises by approx. 10 K during charging. If thetemperatures are permanently higher than 40°C or lower than 15°C, a temperature-dependent constant voltage control of the charger is required. The adjustmentfactor must be applied with -0.004 V/C per K.

Battery charged

Z Charging is considered to be complete when the electrolyte density and batteryvoltage remain constant for more than 2 hours.

Compensation charging

Compensation charging is used to ensure the useful life and maintain capacity afterfull discharge and repeated insufficient charging.

Z Compensation charging should be carried out weekly.

Trickle charging

Battery trickle charging is partial charging that extends the daily application time.Higher average temperatures occur during trickle charging which can reduce theuseful life of the batteries.

Z Trickle charges should only be performed when the charge level is below 50%. Usereplacement batteries instead of regular trickle charging.

Z Avoid trickle charging with PzV batteries.
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.3 Servicing PzV and PzV-BS lead-acid batteries with sealed armour plated cells

Z Do not add water!

3.1 Daily

– Charge the battery after each discharge.

3.2 Weekly

– Visually inspect for dirt and physical damage.

3.3 Every three months

– Measure and record the overall voltage.– Measure and record the individual voltages.– Compare the results with the previous ones.

Z Carry out the measurements after full charging and subsequent resting for at least5 hours.

Z If you find significant differences compared with the previous measurements ordifferences between the cells, contact the manufacturer's customer servicedepartment.

3.4 Annually

– Measure the truck insulation resistance in accordance with EN 1175-1.– Measure the battery insulation resistance in accordance with EN 1987-1.

Z In accordance with DIN EN 50272-3 the battery insulation resistance should not beless than 50 Ω per volt of rated voltage.

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Aquamatik water replenishment system

.1 Water replenishment system design

15 Water container16 Tap connection with ball cock17 Flow indicator18 Shut-off cock19 Locking coupling 20 Battery lock connector

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.2 Functional Description

The Aquamatik water replenishment system is used to adjust the rated electrolytelevel automatically on traction batteries for industrial trucks.

The battery cells are interconnected through hoses and are attached to the watersupply (e.g. water container) through a plug connection. When the shut-off cock isopened all the cells are filled with water. The Aquamatik plug controls the amount ofwater required and, at the relevant water pressures, ensures the water supply is shutoff and the valve is closed securely.

The plug systems have an optical level indicator, a diagnostic port to measure thetemperature and electrolyte density and a degassing port.

.3 Adding water

Water should be added to the batteries just before the battery is fully charged. Thisensures that the amount of water added is mixed with the electrolyte.

.4 Water pressure

The water replenishment system must be operated with a water pressure in the waterline of 0.3 bar - 1.8 bar. Any deviations from the permissible pressure ranges willaffect the operation of the systems.

Water drop

Assembly height above battery surface is between 3 - 18 m. 1 m corresponds to 0.1bar

Pressure water

The pressure regulating valve is adjusted to suit the system and must lie between 0.3- 1.8 bar.

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.5 Filling time

The filling time for a battery depends on the electrolyte level, the ambient temperatureand the filling pressure. Filling ends automatically. The water supply line must bedisconnected from the battery when the water has been filled.

.6 Water quality

Z The quality of the water used to fill up electrolyte must correspond to purified ordistilled water. Purified water can be produced through distillation or ionexchangers and is then suitable for the production of electrolyte.

.7 Battery tubing

The tubing of the individual plugs is in accordance with the existing electric circuit. Nochanges should be made.

.8 Operating temperature

Batteries with automatic water replenishment systems should only be stored in roomswith temperatures > 0°C, as otherwise the systems could freeze.

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.9 Cleaning measures

The plug systems must only be cleaned with purified water in accordance with DIN43530-4. No parts of the plugs must come into contact with solvent-based materialsor soap.

.10 Service mobile vehicle

Mobile water filling vehicle with pump and filling gun to fill individual cells. Theimmersion pump in the container generates the necessary filling pressure. Theservice mobile must be at exactly the same height as the battery base.

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Electrolyte circulation

.1 Functional Description

Electrolyte circulation ensures the supply of air during charging to mix the electrolyte,thereby preventing any acid layer, shortening the charge time (charge factor approx.1.07) and reducing the formation of gas during charging. The charger must besuitable for the battery and electrolyte circulation.

A pump in the charger produces the necessary compressed air which is introducedto the battery cells via a hose system. The electrolyte is circulated via the inlet air andthe electrolyte density level is constant over the entire length of the electrode.

Pump

In the event of a fault, e.g. if the pressure control system responds for an unknownreason, the filters must be checked and replaced if necessary.

Battery connection

A hose is attached to the pump module which together with the charge leads is routedfrom the charger to the charging connector. The air is passed on to the battery via theelectrolyte circulation coupling ducts in the connector. When routing make sure thehose is not bent.

Pressure monitoring module

The electrolyte circulation pump is activated when charging begins. The pressuremonitoring module monitors the build up of pressure during charging. This ensuresthat the required air pressure is provided for electrolyte circulation charging.

In the event of malfunctions such as:– Battery air coupling not connected to circulation module (if coupling is separate) or

faulty.– Leaky or faulty hose connections on battery or– Intake filter contaminated

a visual error message appears on the charger.
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NOTE

If an installed electrolyte circulation system is seldom used or not used at all,or if the battery is subjected to severe temperature fluctuations, the electrolytemay flow back into the hose system.Attach a separate coupling system to the air inlet line, such as: locking coupling on

the battery side and through-coupling on the air supply side.

Schematic illustration

Electrolyte circulation on the battery and air supply via the charger.

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Cleaning batteries

Batteries and trays must be cleaned in order to – maintain cell insulation and protect cells from ground or external conductive parts.– Avoid damage from corrosion and stray currents.– Avoid excessive and varying automatic discharge of the individual cells or block

batteries due to stray currents.– Avoid electric sparking due to stray currents.

When cleaning the batteries make sure that:– The assembly site chosen for cleaning is close to a drainage system for processing

the electrolytic rinsing water.– All health and safety as well as water and waste disposal regulations are observed

when disposing of used electrolyte or rinsing water.– Protective goggles and clothing are worn.– Cell plugs are not removed or opened.– Clean the plastic components of the battery, in particular the cell containers, only

with water or water-based cloths without any additives.– After cleaning, the top of the battery is dried with suitable equipment, e.g.

compressed air or cloths.– Any fluid that has entered the battery box must be suctioned off and disposed of in

accordance with the above-mentioned regulations.

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Cleaning the battery with a high pressure cleaner

Requirements– Cell connectors tight, plugged in securely– Cell plugs closed

Procedure• Follow the high pressure cleaner's user instructions.• Do not use any cleaning additives.• Observe the permissible cleaning device temperature setting of 140°C.

Z This generally ensures that the temperature does not exceed 60°C at a distance of30cm behind the outlet nozzle.

• Observe the maximum operating pressure of 50 bar.• Observe a minimum distance of 30 cm from the top of the battery.• The battery should be sprayed over its entire surface to avoid localised

overheating.Z Do not clean one spot for more than 3 seconds with the jet to avoid exceeding the

maximum battery surface temperature of 60°C.• After cleaning dry the battery surface with suitable materials e.g. compressed air or

cleaning cloths.

Battery cleaned.

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Storing the battery

NOTE

The battery should not be stored for longer than 3 months without charging asotherwise it will no longer be functional.

If the battery is to be taken out of service for a long period, it should be stored fullycharged in a dry room protected from frost. To ensure the availability of the batterythe following charges can be selected:

– Monthly compensation charge for PzS and PzB batteries or 3-monthly full chargefor PzV batteries.

– Trickle charge for a charge voltage of 2.23 volts x no. of cells for PzS, PzM and PzBbatteries or 2.25 volts x no. of cells for PzV batteries.

If the battery is to be taken out of service for a long period ( > 3 months), it should, asfar as possible, be charged to 50% of its charge level and stored in a dry roomprotected from frost.

0 Troubleshooting

If any faults are found on the battery or charger, contact the manufacturer's customerservice department immediately.

Z The operations required must be carried out by the manufacturer's customerservice department or a customer service organisation authorised by themanufacturer.

1 Disposal

Batteries marked with the recycling symbol and the sign showing acrossed-out rubbish bin should not be disposed of with ordinaryhousehold waste.

Buy-back terms and type of recycling are to be agreed with themanufacturer as described in § 8 of the battery legislation.

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